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Distributor / authorized representative that deals with supply & delivery of parallel-shaft gearbox to industrial enterprises of Russia

Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level. 

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We are interested in cooperation with the manufacturers of parallel-shaft gearboxes, who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.

The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your parallel-shaft gearboxes. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.

Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.

Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for gearboxes, will submit a market overview for gearboxes that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your parallel-shaft gearboxes and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.

Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of parallel-shaft gearboxes in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for parallel-shaft gearboxes as per Russian and other EAEU countries’ requirements.

Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your parallel-shaft gearboxes into the future projects.

The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.

Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of parallel-shaft gearboxes. They will also provide necessary training and guidance for the customer’s personnel.

Parallel-shaft reducers. A brief overview

Parallel-shaft speed reducers

A speed reducer (parallel-shaft speed reducer) is a mechanism, which transforms high angular speed of the input shaft into low speed at the output shaft. Moreover, the torque on the output shaft increases proportionally as the rotation speed decreases.

A speed reducer (parallel-shaft speed reducer) consists of a housing, where gear wheels, shafts, shafts bearings, their lubrication systems etc. are arranged. The housing provides for safety, good lubrication, and therefore ensures high efficiency in comparison to exposed gears, for example.

Parallel-shaft reducers

A parallel-shaft speed reducer is the most widely used type of speed reducers due to the transmission simplicity and maximum efficiency. Gear gears are the basis of the speed reducer (a spur gear, bevel gear or helical gears). The reducer can consist of a single stage or of several ones. The stage number is selected according to required gear ratio. The higher the ratio is, the more stages are required.

Description and principle of operation:

A parallel-shaft speed reducer can be either a single parallel-shaft gear, or it can be several parallel-shaft gears connected in series, which are enclosed in the common housing. The speed reducer is equipped with the input and output shafts. Couplings or other coupling elements connect these shafts to the engine and operating machine respectively. The spur gearing is a pair of meshed gear wheels.

When the torque is applied to the output shaft, it starts to move with the gear wheel fastened to it. The spur gearing transmits the force from the input shaft wheel to the wheel, meshed to it. The wheels come in different sizes and different number of teeth. A wheel with a smaller number of teeth is known as a gear, and the one with more teeth is known as a wheel. The torque is sequentially transmitted from the input shaft to the intermediate shaft, then from the intermediate shaft to the output shaft (in case of the two-stage reducer).

Basic characteristics of speed reducers

Basic characteristics of speed reducers are efficiency, rotation speed of the input and output shafts, gear ratio, transmitted power, quantity of stages and type of gears.

The gear ratio is a ratio between the rotation speed of the input shaft and the rotation speed of the output shaft.

i = win/wout

The efficiency of a speed reducer is determined by the ratio between the power on the input shaft and the power on the output shaft.

n = Pin/Pout

Classification of parallel-shaft speed reducers:

Parallel-shaft speed reducers are classified according to various features including number of stages, types of wheels, types of threads etc. Let’s consider main types of classification.

Depending on the type of wheel teeth:

  • Spur;
  • Helical;
  • Non-linear;
  • Herringbone.
Parallel-shaft reducers

Spur gears are the easiest to manufacture, but they are the noisiest if compared to the helical and herringbone ones. Moreover, regular impacts when the teeth contact each other lead to vibration, which is the reason of increased wear-out.

Helical gears are more complex as compared to spur gears, but their operational characteristics are better, which leads to a lower level of noise, better wear resistance and increased operation smoothness. However, due to this, the axial force occurs, and it is necessary to compensate this negative effect. The wheel with non-linear teeth may be considered a further improvement of the helical gear. The operational characteristics of such wheels are even better, but as the manufacturing complexity of this type of wheels respectively increases, special-purpose equipment is required.

The disadvantage of helical wheels, which is the axial force, can be mitigated: it is necessary to install a second similar wheel on the shaft, but with an opposite inclination of the teeth. This will provide for mutual compensation of axial forces by two halves of the wheel, which is known as a herringbone wheel. This may help to achieve very smooth running. The teeth angle of herringbone wheels is usually higher than of the helical ones.

Depending on positional relationship of shafts:

  • With parallel shaft axes
  • With intersecting shaft axes
Parallel-shaft reducers

Most of the parallel-shaft speed reducers have parallel positioned shafts. If the axes of a speed reducer’s input and output shafts coincide, such speed reducer is referred to as a coaxial speed reducer. The coaxial speed reducer must contain at least two stages so it would be possible to arrange the input and output shafts at the same axis. If it is necessary to combine a parallel-shaft speed reducer with intersecting shaft axis, special spiral wheels are used.

Depending on the number of stages:

  • Single-stage;
  • Two-stage;
  • Three-stage;
  • Multi-stage.
Parallel-shaft reducers

A required number of stages is determined by the gear ratio to be provided by the parallel-shaft speed reducer. Various arrangements of stage in the speed reducer can be used to achieve different positions of the input and output shafts relative to each other.

Design versions of parallel-shaft gears:

  • Simple;
  • Split;
  • Coaxial.

The simple design is the most commonly used due to rational unification of reducer parts. For example, the same gears and gear wheels can be used in various reducers, which leads to cost reduction during batch production.

The teeth direction is accepted as left for a gear and as right for a wheel for unification purposes. However, in case of single-item production, it is more convenient to accept left direction for the gear’s teeth and right one for the wheel’s teeth. This is necessary to balance axial forces on the intermediate shaft and to decrease axial loads on supports.

The simple design is used with the center-to-center distance up to 800 mm. The shape of simple design speed reducers is elongated, which leads to metal overconsumption up to 20% as compared to a speed reducer with a split design.

Split design is suitable for low-speed and high-speed stages. The version with the high-speed stage is more rational, because in this case, the intermediate shaft can be designed as a pinion-shaft and a floating high-speed shaft.

The split design is “distributed” by means of helical gears, which is actually a herringbone gear.

Coaxial design provides for arrangement of the input and output shafts on the same axis. The weight and overall dimensions of these speed reducers are similar to those of the reducers with a simple design. The high-speed stage is underloaded and the low-speed stage is overloaded in this design.

On the average, two-stage parallel-shaft speed reducers have the gear ratio from 6.3 to 70.

The life of parallel-shaft reducers is 25 thousand hours.

Benefits and disadvantages:

These speed reducers have numerous benefits, which determine their common use:

  • High efficiency

Parallel-shaft reducers allow transmitting the force with high efficiency, thus leading to efficiency of 98-99%. This is mainly caused by negligible frictional forces, occurred during operation. This benefit makes parallel-shaft speed reducers very cost-effective and has led to their wide usage.

  • Low heat emission

High efficiency leads to loss of a very small portion of transferred energy. Consequently, a very small portion of energy is spent for heating of the transmission parts and this causes very low heat emission. This benefit allows operation without any additional cooling systems on the reducer and increases its operational reliability.

  • High power transmission capacity

Due to the structural features, parallel-shaft speed reducers are not susceptible to seizing. Due to high efficiency and negligible heat emission, they are well suited for transmission of high powers. Losses can be neglected in some cases, when using other type of a reducer is more advantageous or it is the only option. However, the energy efficiency factor prevails when it comes to operation of large assemblies.

  • Operational reliability, even during prolonged periods with frequent starts and stops.

This benefit is mainly determined by low sliding friction in a parallel-shaft speed reducer. This provides for low wear-out of operating parts. As opposed to worm-gear speed reducers, parallel-shaft speed reducers are also sufficiently reliable under operational conditions with frequent starts and stops or with intermittent load, since such mode does not lead to excessive increase in a wear rate.

  • Small play of the output shaft.

As opposed to worm-gear speed reducers, parallel-shaft speed reducers have much smaller play of the output shaft. This allows achieving relatively high indexing accuracy as compared to other types of speed reducers. Due to this, the parallel-shaft speed reducers are suitable for systems with increased accuracy requirements such as positioning system drives.

  • Shafts are able to rotate in any direction.

This feature can be both a benefit and a disadvantage. It depends on the speed reducer’s operation conditions. Full reversibility can be useful for cranking the output shaft. On the other side, it can be undesirable in case of a hoisting mechanism, where a brake mechanism might be required to be installed.

The following disadvantages of parallel-shaft reducers are usually emphasized:

  • Gear ratio is limited

It is recommended that the gear ratio should not exceed 6.3 for a single stage of a parallel-shaft speed reducer. Therefore, if a higher gear ratio is required, additional stages should be added. This leads to unreasonable increase of a parallel-shaft speed reducer’s overall dimensions and its metal consumption. Using bulky parallel-shaft speed reducers with a high gear ratio is irrational in most cases.

  • Increased noise

The contact line is irregular during the operation of a parallel-shaft speed reducer. It appears again when the next teeth pair is meshed. This leads to much higher noise values in parallel-shaft speed reducers as compared to similar worm-gear speed reducers.

Application:

Parallel-shaft speed reducers are one of the most commonly used types of speed reducers. It is hard to name a single area, where they are not used to some extent. They are implemented in various industries from the construction and machine building to robotics and military industrial sector. Such wide usage is mainly caused by the fact that parallel-shaft speed reducers are used in machinery electric drives or are a part of gear motors. As previously mentioned, one of the main reasons for such wide usage is high efficiency of parallel-shaft speed reducers, which makes their usage the most cost-effective.

Calculation of parallel-shaft reducer:

Generally, some of the speed reducer characteristics are already defined prior to designing. Let’s assume that the gear ratio and torque on the gear are known.

An approximate value of center-to-center distance is predefined:

aw1 = K·(u∓1)·∛(Tg/u)

aw1 – preliminary center-to-center distance, mm
K – correction factor, which depends on the wheel and gear teeth hardness
u – gear ratio of the reducer
Tg – torque on the gear, Nm
∓1 – plus sign corresponds to external engaging, minus sign – internal

Then the peripheral speed is calculated:

v = [2·π·aw1·n1]/[6·104·(u∓1)]

v – peripheral speed, м/с
aw1 – preliminary center-to-center distance, mm
n1 – gear rotation speed, RPM
u – gear ratio of the reducer
∓1 – plus sign corresponds to external engaging, minus sign – internal

The value obtained is checked against the tables, containing allowable peripheral speed, depending on accuracy of transmission.

Then the value of center-to-center distance is improved:

aw = K1·(u∓1)·∛((KL·Tg)/(ψab·u·σL²))

aw -  improved center-to-center distance, mm
K1 – correction factor (spur wheels – 540; helical and herringbone - 410), MPa1/3
u – gear ratio of the reducer
±1 – plus sign corresponds to external engaging, minus sign – internal
KL – correction factor for load
Tg – torque on the gear, Nm
[δ] – allowable stress, MPa
ψab – width factor, which depends on wheels width

The obtained value of center-to-center distance is used for determining the preliminary geometrical dimension of wheels.

Reference diameter:

d2 = (2·aw·u)/(u∓1)

Width:

b2 = ψab·aw

The minimum (depending on strength conditions) and maximum (depending on non-undercutting of teeth) values of transmission module is calculated:

mmin = [Km·KF·Tш·(u∓1)]/[aw·b2·σF]

Km – correction factor (spur wheels – 3400; helical - 2800)
KF – load factor
σF – allowable bending stresses of wheel or gear teeth, MPa

mmax = [2·aw]/[17·(u∓1)]

A desired value of the transmission module is selected out of the range obtained. And a minimum value is selected out of the standard line of normal linear dimensions.

The obtained pitch module value is used for calculating the required inclination angle for teeth (for helical or herringbone wheels).

For helical wheels:

βmin = arcsin⁡((4·m)/b2)

For herringbone wheels:

βmin = 25°

The total number of teeth is also determined using the pitch module:

Ztot = 2·aw·(cosβmin)/m

The value obtained is rounded down and used for determining the actual value of teeth inclination angle:

β = arccos[(ztot·m)/(2·aw)]

and the number of the teeth on the gear and wheel.

For the gear:

Zg = ztot/(u∓1)

The value obtained should not be less than minimum value. For spur wheels, it equals 17. For helical and herringbone wheels it is determined according to the following formula: zmin=17·(cosβ)3. If the value obtained is less than minimum value, the gear should be manufactured with an offset in order to prevent undercut of the teeth during operation. The offset ratio is determined according to following formula:

x = (17-u)/17

Number of wheel teeth:

Zw = ztot-zg

The actual gear ratio shall be determined according to the obtained number of teeth:

UITC = zw/zg

The value obtained should not deviate from the initial value by more than 3% (for single-stage), by 4% (for two-stage), and 5% (for multi-stage).

Final geometrical parameters of gear wheels:

Reference diameter of the gear:

d1 = (ztot·m)/cosβ

Reference diameter of the wheel:

d2 = 2·aw∓d1

+ – for internal teeth
- – for external teeth

In the end, the strength verification calculation is performed.

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Upon becoming the official distributer of parallel-shaft gearboxes, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (parallel-shaft gearboxes) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.

We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.

We are always open for cooperation, so let’s move forward together!

Intech GmbH SARLIntech GmbH SARL