Designing complex material handling and packaging systems is tough, especially when space is tight. Right-angle gearboxes provide a smart solution. They are space-efficient and offer several other valuable advantages for OEMs and in the field.
Comparing Gearbox Types
Gearboxes efficiently transfer rotational motion and power (torque) to change direction, speed, or force. They're often a better, less cumbersome choice than belts or chain-link drivers in industrial applications.
For example, chains and sprockets rotate in the same direction. However, to turn one 90 degrees, you would need multiple chains, sprockets, and shafts.
Instead, a linear gearbox can serve as a reducer to decrease (or increase) in-line rotational speed. And a right angle gearbox can be used to turn a rotation around a corner. Material handling requires both kinds of gearboxes, because products are transported forward and sorted/shifted to different lines.
Advantages of a Right-Angle Gearbox
There are different types of right-angle gearboxes, but all allow gears to turn 90 degrees efficiently, cleanly, and safely. In some cases, right-angle gearboxes are used with an external shaft, with a shiv or sprocket.
- Cleaner operation: Unlike chains, right-angle gearboxes don't involve grease and eliminate the risk of debris from belts or sprockets. Branham gearboxes are fully contained, pre-lubricated, and sealed, preventing lubrication leaks. This is especially important in highly-sanitized food grade or clean room applications.
- Safer performance: Pulleys can create dangerous pinch points and inconsistent rotation, leading to "jumps" that can harm people, products, and equipment. Gearboxes operate smoothly and consistently with no pinch points that cause binding. A right-angle gearbox is more reliable and consistent because it can be precisely calculated for the required number of rotations.
Selecting the Right Gearbox
- Gear ratio: Most Branham right-angle gearboxes have a 1:1 gear ratio (one rotation of the input shaft equals one rotation of the output shaft). This is the most common in industrial applications. However, some applications require greater output speed, and gearboxes can deliver higher torques compared to other methods. So we also manufacture 2:1. 3:2, 10:1, and 20:1 (output:input) gearboxes.
- Torque: Your chosen gearbox must be rated for your equipment's torque. If you have high torque, consider using multiple gearboxes to distribute the load. For example, if you have 1,000 inch-pounds in one piece of equipment, use four gearboxes to distribute the torque so each gearbox is managing 250 inch-pounds.
- Thermal management: Gear rotation and torque generate heat. Right-angle gearboxes are sealed and made from heat-sensitive materials, so excess heat could destroy them and potentially damage other equipment. Confined spaces can worsen this issue. You have a certain envelope within which to work, so you must avoid processing too much torque for that envelope. The solution is balancing appropriate size torque load and RPM so you don’t create too much heat. Also, consider the ambient temperature of your operating environment, as hotter conditions increase overheating risk.
- Washdown: Material handling and packaging systems often require washdown. Branham offers stainless steel right-angle gearboxes designed to withstand this type of environment.
Versatility of Hollow-Core Gearboxes
Some gearboxes are designed with protruding shafts that can be coupled with shafts or equipment. However, Branham manufactures hollow core right-angle gearboxes. Just insert the shaft, and it locks in place.
Our Insert-a-Shaft gearboxes are also adjustable, which makes them perfect for applications that require frequent adjustments to accommodate different processes. Adjustment is simple and quick, with no need to change out equipment shafts. This saves time and labor and avoids costly production delays.
Additionally, mounting holes on our hollow-bore gearboxes allow you to use them as a hanging gearbox. If shafts have bearings on them, you don’t need to mount the gearbox.
How “Compact” Does It Need to Be?
Engineers and OEMs often talk about “compact” gearbox applications in terms of dimension size. But just because you have compact machinery doesn’t necessarily mean you need an extra-small gearbox. The optimal size should depend on the required ratio, equipment torque, and shaft size.
Branham manufactures a full range of gearboxes. Nearly all of them are generally small, but if tiny size is essential, and you don’t need a large amount of torque, our Microgear® gearboxes are ideal. They’ve proven invaluable in material handling, packaging, and even within medical devices.
Make the Right Choice
Here at Branham, we have resources to help engineers solve space and power transmission challenges in material handling equipment design. Our Right-Angle Gearbox Brochure describes all the options available, and our Checklist of Must-Have Specs will describe what information you’ll need to know in order to select the right gearbox product for your application.
We're here to help you make informed decisions, ensuring your systems operate smoothly and efficiently.
