Introduction of Oilfield Pumping Unit Gear Reducer/Gearbox

A gear reducer, also known as a gearbox or speed reducer, is a device that converts mechanical power from an electric motor or other driver to a driven load. In the world of pumps, gear reducers convert the high speed, low torque input from the motor to a low speed, high torque output at the pump. A gear reducer is made up of one or more pairs of gears, with each pair consisting of a smaller driver gear and a larger driven gear. The reduction ratio of that pair is determined by the ratio of the number of teeth on the driven gear to the number of teeth of the driver. 

 

Gear reducers are often used in oilfield equipment to improve environmental conditions in the oil fields. For example, some gear speed reducers are qualified for use in petroleum exploitation in harsh environments such as deserts, rocky areas, marshes, shoals, oceans, and places with severely cold temperatures. 

 

High-torque, high-reduction gear reducers often require the use of multi-stage gearing, planetary gear systems, or both. Because these systems contain many independent parts, they often become bulky. 

 

 

 

Requirements for Selecting a Gear Reducer

 

When choosing a gear reducer, several factors need to be taken into account. A gear reducer is commonly used to adjust the characteristics, such as torque and speed, of a mechanism's input and output axes. Therefore, it's essential to consider both torque and rotational speed.

 

Firstly, torque should be a primary consideration. A reducer amplifies the torque of your motor, enabling a receiving part to rotate under the influence of a new torque. Manufacturers specify the minimum and maximum torque (measured in newton meters, N.m) that each of their devices can handle. The torque capacity varies depending on the type of gear reducer, with planetary gears typically offering high torque capabilities.

 

Another important aspect is the reduction ratio, which determines the output rotational speed based on the motor's rotation speed. It's crucial to determine the optimal reduction ratio for your specific application, and manufacturers typically provide this information on their product websites. The reduction ratio is measured in rotations per minute.

 

Lastly, consider the type of gear reducer component that best suits your application. The input and output shafts of your gear reducer may be coaxial, parallel-shaft, or orthogonal, depending on your intended usage.

 

The Different Kinds Of Gear Reducers

 

Planetary gear reducers, worm gear reducers, gear train gear reducers, plus bevel gear reducers are the four primary kinds of gear reducers. 

 

When to Use a Planetary Gearbox?

 

The coaxial assembly is one of the most distinctive features of a planetary gearbox, contributing to its compact size. Planetary gearboxes offer several advantages, including small size, high efficiency, minimal clearance, and a high torque-to-weight ratio. However, their intricate and expensive design requires specialized maintenance.

 

Planetary gears are ideal for applications requiring rapid accelerations, such as robotics, as well as those needing low-speed but high torque, such as industrial rotary furnaces. They are also commonly used in machining centers, other machine tools, and mobile gear applications in public and agricultural operations.

 

When to Use a Worm Gear Reducer?

 

Worm gear reducers feature input and output shafts that are perpendicular to each other and are often used in applications requiring an extremely high transmission ratio. They have a non-reversible mechanism, providing enhanced security for the system. Worm gear reducers are more cost-effective and quieter than planetary gearboxes, as they produce minimal vibrations, resulting in quieter operation. They are suitable for applications such as conveyors, winches, and material handling.

 

When to Use a Gear Train Gear Reducer?

 

Gear train gear reducers with parallel shafts are commonly employed in high-power applications like conveyors. Due to their straightforward design, they offer cost savings on maintenance. Additionally, gear train gear reducers exhibit high efficiency, typically close to 1, and each gear train has a low reduction ratio.

 

About our Product:

 

Characteristic Features of Gear Units

 

Design

 

Gear units are a completely new design. Advantages are:

 

more sizes with a reduced variety of parts;

higher operational reliability combined with increased power capacity;

predominantly non-contacting wear-resistant labyrinth seals are possible;

flanged output shafts to facilitate assembly o f gear units in confined spaces (on request).

 

Mounting position

 

Gear units can be supplied for either horizontal or vertical installation. Other  arrangements are also possible on request.

 

The basic gear unit can be optimally adapted to customer requirements by  fitting different add-on pieces like motor bell housings,gear unit swing-bases or backstops.

 

Noise behaviour

 

New concepts were applied to clearly improve the noise emission of the gear units by grinding the bevel gears; designing noise-absorbing housings by means of the MASAK computing program; and achieving exceptionally large contact ratios.

 

Thermal conduction gear units not only have a high efficiency but alsoa favourable thermal conduction through enlarged housing surface areas; because non-contacting labyrinth seals can be used; and because large fans incorporating a new type of air conduction fan cowl are being used.

 

The selection of gear units is based on a lower maximum oil temperature. By that, the operational reliability will be increased and the cost of maintenance reduced due to longer oil change intervals.

 

Storing

 

Gear units have been designed according to a new unit construction principle.

 

Through this, the variety of parts could be reduced. The parts are mainly on stock enabling gear units worldwide to deliver at short term.

 

General Information of Gear Units

 

Attention!

 

The following items are absolutely to be observed!

 

- Illustrations are examples only and are not strictly binding. Dimensions are

subject to change.

 

- The weights are mean values and not strictly binding.

 

- To prevent accidents, all rotating parts should be guarded according to local  and national safety regulations.

 

- Prior to commissioning, the operat ing instructions must be observed.

 

- The gear units are delivered ready for operation but without oil filling.

 

- Oil quantities given are guide values only.

 

- The exact quantity of oil depends on the marks on the oil dipstick.

 

- The oil viscosity has to correspond to the data given on the name plate.

 

- Approved lubricants may be used only.

 

- You will find current operatinginstructions and lubricant selectiontables  on our home page.

 

- The gear units are supplied with radial shaft seals.

 

- Other sealing variants on request.

 

- Directions of rotation referring to output shaft d2.

 

- In case of outdoor installation , insolation is to be avoided.

 

- The customer has to provide adequate protection.

 

Explanation of symbols used in the dimensioned drawings:

 

= Oil dipstick

= Breather

= Oil drain

= Oil filler

 

From size 13 up jack screws in the housing feet, and leveling pads on the upper housing part.

 

Foundation bolts of min. property class 8.8. Tolerance of the clearance holes in the housing acc. to DIN EN 20273 - "coarse" series.

 

The gear housings are protected against corrosion and lacquered.

 

[Explosion-proof asynchronous electric motor. Explosion protection type - Ex d. Power - 15 kW (20HP), quantity poles - 4, frequency - 50/60 Hz, rotation speed - 1462/1755 rpm, voltage 230/460V, rated current 49.2/24.6 A, operating mode - S1 (work without interruption), starting current - 285/143 A, slip - 2.50%, insulation class - F (ability to withstand temperatures up to 155ºС), protection degree - IP55, noise level - 69.0 dB (A), efficiency at 100% loading - 91. Overall dimensions according to Appendix B. GOST 30195-94

 

Electric motor: asynchronous, explosion-proof, power 200 kW, rotation speed not less than 1450 rpm, not more than 1500 rpm, rated voltage 380V, frequency 50Hz, climatic version and placement category not less than U1, degree of protection no less than IP54. Cosf not less than 0.89. Execution on paws.]