Couplings are mechanical components used to connect two shafts in the ends to exchange a movement, starting with one element then onto the next. The principal purpose of couplings is to join two pieces of rotating apparatus while allowing some end movement, or degree of misalignment, or both.
Gear couplings are available in a wide range of sizes, designed to pass on torque among two shafts that are not collinear. They are capable of transmitting high torque at high speed. Gear Coupling is very beneficial as it provides high torque density at high speed. It comprises three types of misalignments: angular misalignment, parallel misalignment, and axial misalignment.
According to research conducted by Technavio research on the worldwide gear couplings market, by 2021, the market will see the expansion in increasing utilization of these couplings in high speed and torque applications, creating a positive impact. As gear couplings offer torsional firmness, they are increasingly used in high-speed applications such as oil and gas, mining and metals, and heavy equipment industries. In addition, the torsional stiffness in gear couplings absorbs small shocks and dampens vibrations in high-speed equipment. These features have increased the adoption rates of gear couplings, which will drive market expansion. Our market research analysts predict that this market will grow at a CAGR of 4.67% by 2021.
Gear Coupling Design and Working
Gear couplings consist of the same left and right-hand external toothed elements or joints linked through an internal toothed sleeve having a matching number of teeth, one fixed to each shaft. These joints are repeatedly coupled by a third shaft called the spindle. The meshed teeth transmit high-speed torque between the coupled shafts while allowing some misalignment to exist between them.
Usually, the equipment is made from steel, but nylon is sometimes used for the sleeve portion. Some designs use a split sleeve design, flanged design, which gets bolted jointly at installation. Special coupling bolts pass on power between flanges or, sometimes, affect friction between adjoining flange faces. A coupling guard is generally required because bolt heads are sometimes shrouded or exposed.
Shaft attachment is often done by using a set screw and keyway, splines, or matched tapers. To make it work properly, the coupling must sustain some clearance between the faces of the external tooth elements. The teeth are usually crowned to provide for angular misalignment. For critical applications, an intrusion fit between shaft and hub is generally suggested.
Lubrication
Gear couplings need periodic lubrication, with every one to two years depending on duty and kind of lubrication is used. In shaft seals, usually, O-rings keep lubricant in place. Special coupling grease is necessary to prevent oil and soap from unravelling due to centrifugal effects – high-speed couplings sometimes employ flooded oil lubrication. If the gear couplings are adequately lubricated and proper angular misalignment is maintained, it has a longer working life. Some gear couplings sleeves use plastic (Nylon, high molecular plastic) for their making. These do not need lubrication. They do not have much high-speed torque capacity than steel-made couplings and are used majorly in small.
A benefit of gear couplings designs is they can tolerate axial growth. An essential attribute is their distance between the shaft ends, which specifies the proper distance between shaft faces of the driven and driving gear. Space may be different by exchanging one or both external gear elements on the shafts.
Gear couplings are commonly used in large, industrial machines such as pumps, blowers, compressors, mixers, etc. They are used in smaller motion control systems, made with a polymer sleeve for reducing backlash. Backlash is essential for metal gear couplings as it provides for misalignment compensation besides providing clearance for lubrication to gush between meshing teeth.
There are different kinds of gear couplings used in various types of machines, as:
● Full Gear Couplings
● Half Gear Half Rigid Couplings
● Rigid Couplings
Conclusion
Gear couplings can transmit greater torques than all other various sorts of couplings for the same amount of weight and size. The space for the coupling is limited in gear coupling because of their small size. Proper lubrication in installed equipment in regular intervals can lead to their long-lasting services. The sleeves present in gear coupling are made up of both metal and plastic (Nylon). The oil and gas industry, power plants, mining, and metals industry accounted for the primary usage of the gear couplings market. The increasing use of gear couplings is chiefly due to the absorption of shock loads during power transmission. Harsh environmental conditions will contribute to the expansion of this industry segment in the coming years. This article presents the definition of coupling, the meaning of gear coupling, types of gear coupling, working of gear coupling, and the importance of lubrication in gear coupling and its market demand. Now that we know all about Gear Coupling, we can apply all the knowledge in a practical sense and reap the benefits of Gear Coupling.
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