Distributor / authorized representative that deals with supply & delivery of gearboxes 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.Contents:
We are interested in cooperation with the manufacturers of gearboxes (also referred to as reducers, gear reducers, 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 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 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 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 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 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 gearboxes. They will also provide necessary training and guidance for the customer’s personnel
Gearboxes. A brief description
A gearboxes is a mechanism, used as a component of a working machine’s drive and transmitting rotation from the electric motor shaft to the machine’s working shaft.
A gearboxes can be made as a separate device or combined with a motor. This assembly is denoted as a gear motor. A multiplier is a mechanism which is similar in terms of design but opposite in terms of its purpose. Moreover, there are gearboxes that can change rotational speed both stepwise (gearboxes) and continuously (variable-speed drive).
In terms of their design, the types of gearboxes can greatly differ. The main element of a gearboxes is a gear; it is a mechanism used directly to transmit rotation from the motor shaft to the shaft of a working machine. Also, a lubrication system for movable parts, shaft-fastening bearing assemblies, cooling system and other components can be built in. All these components are located in a gear housing and presents a separate assembly; couplings can be used to connect it to a motor shaft and a shaft of a working machine.
The need to use gearboxes is mainly caused by the fact that the frequency of rotation, required for a shaft of a working machine, is often much lower than the frequency of rotation delivered by motors (electric, gasoline motors etc.); and generation of rotation with necessary parameters directly at a motor’s driving shaft is often either impossible or fails to achieve optimum effect.
In early and later stages of development of the humankind, angular speeds, generated in motors, were low. This was caused by the fact that were the sources of rotating force were draught animals or slaves, pressure of water running or falling on blades, etc. The generated angular speeds were comparable with the speeds necessary for operation of related machines, and the transmitted torques were low, thus providing for use of gearboxes of a relatively simple design (made predominantly of wood) to transmit rotation.
Wood, as the material, completely satisfied the requirements set in those times: it withstood the exerted loads well and was more suitable as a material for parts of mechanisms than metal, which required more advanced technologies and tools for work. However, the development of metallurgy and invention of new sources of energy, such as the steam engine, necessitated the improvement of mechanisms for transmission of rotary motion. The development of gasoline and electric motors only confirmed the fact that it was necessary to design standardized gearboxes made of metal.
Current improvement efforts, related to gearboxes, are aimed not only at the increase of efficiency, reliability, durability and other major operating characteristics but also for miniaturization of gearboxes (thus making them operable in extreme conditions), reduction of operating costs, improvement of such parameters as noiseless, compatibility with other equipment, and etc.
Common use of gearboxes is a background for their multidivisional classification that can be based on design-, mounting-, operation-related and other specific features of mechanisms. Systematic description of types of gearboxes, both existing and those under development, is necessary for effective design of sophisticated installations, equipped with driving mechanisms, and for correct selection of equipment.
Depending on the scope of application
In the most general case, the following types are considered:
- general-purpose machinery-building gearboxes
- special gearboxes.
The first type of gearboxes is the most universal. These gearboxes are standardized and made as separate units; moreover, couplings can be used to connect them to other equipment. Irrespective of different designs, general-purpose machinery-building gearboxes are similar in terms of their technical and economic characteristics. The second type of gearboxes is designed for a specific, often quite narrowly specialized industry (gearboxes for ships, aircrafts, cranes etc.). That imposes several restrictions and requirements for the design and characteristics of such a gearboxes that can make it inapplicable beyond the target industry.
Depending on a gear type
With regard to the major function implemented, a gear is the main component of a gearboxes; based on this, the following types are specified:
- worm gear;
- bevel gear;
- harmonic gear;
The name of the gear used usually defines the gearboxes’s type. Corresponding gearboxes have similar advantages and disadvantages and, therefore, their scopes of application differ. According to this classification, both general-purpose machinery-building gearboxes and special gearboxes can be considered. The advantages and disadvantages of various types of gears also predefine, to a great extent, the advantages and disadvantages of corresponding gearboxes, defining their operating conditions and reasonability of usage in one or another area.
Depending on a number of stages
In accordance with this classification, gearboxes are subdivided into the following types:
Each gear is limited by the gear ratio. If the gear ratio required exceeds the maximum gear ratio, possible for a particular gear type, a multi-stage gearboxes is used.
As for the combined gearboxes, additional stages can be added to provide the gearboxes with the properties inherent to various types of gears. For example, if it is necessary to place an output shaft and an input shaft angularly to each other, a bevel gear can be added into a parallel-shaft gearboxes without any variations of the torque.
In parallel-shaft gearboxes, multi-stage configuration is predominantly caused by structural requirements. In a gear pair, the gear ratio is defined mainly by the dimensions of the last gear wheel. An attempt to implement a high gear ratio in a single stage can result in disproportionally large dimensions of a slow gear wheel; thus leading to higher metal consumption of a gearboxes and increase in its overall dimensions. In such a case, a multiple-reduction configuration is reasonable.
Depending on relative spatial positioning of an input shaft and an output shaft:
- with parallel axes
- with coinciding axes (coaxial)
- with intersecting axes
- with crossed axes
Axes may be located in a horizontal, vertical or inclined area. The choice of a gearboxes in accordance with this classification is defined by mutual positioning of shafts of a motor and a working machine that must be connected by the gearboxes. An additional gear is often included into the gearboxes only to change the necessary position of the output shaft axis relative to the input shaft axis.
The primary purpose of a gearboxes is transmission of rotation from an input shaft to an output shaft, with the rotation characteristics changed in accordance with the specified values. Irrespective of the limited scope of functions, implemented by gearboxes, they are used everywhere, and they are an integral part of any working machine.
Various types of gearboxes make it possible to vary the torque in wide ranges; moreover, they have various characteristics in terms of running smoothness, efficiency, noise level during operation, durability etc. Combination of these characteristics predefines the scopes of application of particular gearboxes types. To reach the desirable characteristics of a gearboxes, various types of mechanical gears can be combined in it, resulting in a tradeoff between the complexity and functionality.
The major characteristics of gearboxes depend on the type; however, several types of gearboxes have their unique properties, distinguishing them from other types of gearboxes and making them irreplaceable or the most effective in situations where some specific characteristics are necessary.
Gearboxes fastening methods
Fastening of a gearboxes on lugs is used quite often. This fastening method is reasonable if a gearboxes is of a large size and heavy. Half-couplings are predominantly used to connect the shafts of a motor or a rotated mechanism with a gearboxes.
Fastening on flanges: a gearboxes and a responding mechanism are connected by flanges on a housing. This fastening type is also widely applied; it is reasonable if the weight and dimensions of a gearboxes are not large.
Put-on fastening: in this configuration, a hollow output shaft of a gearboxes is used; this shaft is put on the shaft of a working mechanism.
Lubrication of gearboxes is used to prevent premature wear-out and to cool the gearboxes parts down.
To lubricate gearboxes with low gearing speed, oil bath lubrication is used. Gear wheels, pinions and spraying device are partially submerged into oil.
To lubricate high-gearboxes, a pump is used to deliver oil to the meshing area.
Separate lubrication (oil or grease) can be provided for bearings.
Requirements for gearboxes housings
Major requirements for gearboxes:
- rigidity, to prevent shaft misalignment
- minimal weight in order to reduce the cost and weight of the structure (for non-fixed)
- convenient maintenance holes
- eye rings for easy mounting
Casting is predominantly used to make gearboxes housings – split or one-piece-cast (solid).
As a rule, split housings consist of two parts: a housing and a removable cover, fastened to each other by bolts or studs. Usually (for easy machining) the parting plane is configured parallel to the parting base plane; to prevent oil leaks, the parting plane is covered by spirit varnish, soluble glass or sealant.
Solid housings are used for light-weight gearboxes. Usually, they are provided with a removable cover; it is used to mount various shafts with gear wheels put on them.
Gray cast iron is predominantly used as a material for gearboxes housings. It has excellent casting properties, low cost and good machinability. Steel is used when the strength of cast iron is insufficient; nevertheless, it is cast iron that is used in most cases. Steel is quite suitable, for example, for simple housing configurations (without thin walls or elements where high accuracy is required) with high impact or transverse loads.
A parallel-shaft gearboxes 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 gearboxes 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).
Worm gear gearboxes
A worm gear consists of a screw with the thread on it and a helical gear wheel. The screw is called a worm; as a result, this name is given to the gear itself and to the gearboxes type. Rotational motion of a worm provides translational motion (along the screw axis) of thread turns that are meshed with the wheel teeth. Wheel teeth and screw turns are meshed along the line. In such a way, force is transmitted between the gear elements. The worm and wheel axes are perpendicular.
Bevel gear gearboxes
Bevel gear gearboxes are very similar to parallel-shaft gearboxes, but there is a principal difference – cylindrical wheels. This type of wheels has a shape of a truncated cone with threads machined on its side surface. Meshed bevel wheels are fastened on shafts, whose axes intersect each other in space. Usually the intersection angle equals 90°, but it is possible to change it by selecting other wheels. The force is transmitted from one wheel to another in the same way as in parallel-shaft gearboxes. There can be only one stage in bevel gear gearboxes.
Planetary gearboxes have a number of features similar to those of the parallel-shaft gearboxes, since the force is also transmitted by a gear train, and gear wheels are used in the design. However, the design and principle of operation of planetary gearboxes is more complex.
Generally, a planetary gearboxes consists of the following parts: a crown gear, pinion gears (satellites), pinion cage and sun gear. Like the Sun, which is located in the center of the Solar system, the sun gear is placed in the center of the gearboxes’s operating part. The sun gear is meshed with identical pinion gears, whose axes are positioned on the circle. The circle center is located on the sun gear axis. At the same time, the pinion gears are meshed with the crown gear, which is a gear wheel with internal teeth. The pinion cage rigidly fastens all pinion gears in relation to each other.
Description and operation principle:
As the name suggests, these gearboxes are combinations of basic gearboxes types. Due to the same reason, combined gearboxes must consist of at least two stages, and a different gear must be used in each of them.
Combined gearboxes make it possible to combine advantages of different gearboxes in a single mechanism and to implement tasks, which simple gearboxes will not be able to solve that effectively. Sometimes, only a combination of different gears makes it possible to design a gearboxes capable to implement a specific function.
Two-stage worm gearboxes are widely used; in terms of their noisiness, they are similar to worm gear gearboxes, but they have higher efficiency and are capable to transmit higher powers. Another commonly used type of combined gearboxes is a two-stage bevel gear gearboxes, that combines a parallel-shaft gear and a bevel gear. Combinations of gears in combined gearboxes can vary greatly depending on operating parameters (transferred power, gear ratio, operation mode etc.) of a gearboxes to be designed.
Gearboxes with a flexible element
Description and operation principle:
This type of gearboxes is distinguished by the flexible element used in their configuration. Chains or belts can be used as these elements. In the simplest case, a gearboxes with a flexible element consists of three parts: an input shaft with a wheel (or a pulley, if a belt gear is used), a flexible element and an output shaft with a wheel (or a pulley). If a chain is used as a flexible element, it can be considered as a gear gear; if a flexible element is a belt, it can be considered as a friction gear. Rotation of an input wheel drives a flexible element that, in turn, drives an output wheel.
Classification of gearboxes with a flexible element:
Depending on the type of a flexible element (transmission), the following classes are considered:
- chain gearboxes
- belt gearboxes
Chain and belt gearboxes have their classification, depending on the specific features of a chain (or a belt), their tensioning method, running wheel wrapping etc.
If one compares gearboxes with a flexible link and gearboxes without such a link, the following set of advantages can be noted:
- Large distances between axes
Chain or belt length can be increased within reasonable limits; due to this, torque can be transmitted between the shafts quite distant from each other. If, for example, a parallel-shaft gearboxes is used in such a case, it would be necessary to include an additional stray stage, resulting in additional efficiency losses and higher metal consumption of the gearboxes.
- Distances between axes can be varied with the gearboxes not replaced
Distance between input and output shafts can be varied by tightening the flexible element, without replacing it. Moreover, the flexible element itself can be replaced by the similar one having another length. Even if the distance between axes is not varied, gear mounting errors can be compensated due to this feature.
- Force can be transmitted to several sprockets (pulleys)
A flexible element can be used to connect several output points at the same time, without any additional equipment installed for this purpose.
- Overload protection
This is more relevant for belt gears where the belt slippage effect exists; as a result, damages of gear elements are prevented.
- Low cost
Generally, the flexible gear is cheaper. To a large extent, it is due to a relatively low cost of the flexible element itself and this element can be easily replaced in case of failure.
Disadvantages of this type of gearboxes also result from specific features of the gear in use.
- Short service life of a flexible element
Chains and belts fail and need replacement more frequently than the elements of rigid gears. Their service lives are shorter.
- Increased load on shafts
It appears when the required belt pre-tensioning is carried out. The chain gear is free of this disadvantage.
- Additional accessories are often necessary
For correct operation of a gear, installation of an additional device for flexible element tightening or for compensation of oscillations of this component may be necessary.
- Unstable gear ratio
This disadvantage exists for belt gears only; it results from elasticity of the belt itself and its possible slippage on pulleys.
Due to the specific features of gearboxes with flexible gears, they can be successfully used in transfer mechanisms (such as elevators, conveyors, lifters etc.), machine tool drives, automobile transport and machines with movable members (such as scrapers, sling hooks etc.).
A gear motor is a device where an electric motor and a gearboxes are combined.
Gear motors are widely used in industry due to their high efficiency. They have smaller dimensions than a gearboxes and an electric motor used separately; moreover, maintenance of gear motors is easier. A gear motor configuration can contain any types of gear trains (such as parallel-shaft, bevel, planetary, worm gears) in any combinations.
The most common types of gearboxes in industry are planetary and parallel-shaft gearboxes with mutual positioning of an electric motor and an output shaft.
Gearboxes and polymeric equipment
Casting machines, injection molding machines
Extruders, extrusion lines
Polymer substance press, preforming machines
Roll mills, calenders
- Редукторы: цилиндрические, червячные, конические, планетарные, комбинированные и мотор-редукторы
Upon becoming the official distributer of 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 (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!