Bevel Helical Gearbox Repairs - Highfield Gears

Bevel Helical Gearbox Repairs

The experts here at Highfield Gears are well-versed in repairing, reconditioning and upgrading a series of different heavy-duty gearboxes, one of which is the bevel helical gearbox.

These units have plenty of characteristics and features, all of which can help businesses and organisations achieve their goals. However, when this range of gearboxes falters, reaches the end of its service life or becomes worn down after years of use, the effects of this by way of downtime can be catastrophic for a business if it isn't repaired quickly enough.

Furthermore, there is a wide range of intricacies associated with this gear type making precision and care during the repair process even more important.

Thankfully, we understand this and more here at Highfield Gears and our series of industrial gearbox repair experts will be on hand to offer a cost-effective, efficient solution that reduces downtime and ensures you and your business can get on with the job at hand.

Our in-house machining capabilities mean we’re able to manufacture virtually any part of your bevel helical gearbox there and then, rather than waiting days for the part to arrive. Furthermore, it doesn’t matter what brand of gearbox it is, we have the capabilities and experience to fix a range of competitor gearboxes such as DB Santasalo, Flender, Radicon, Sumitomo, Renold, Chemineer, Siemens and Hansen.

As well as these types of industrial gearboxes we can repair other types including worm gearboxes, extruder gearboxes, planetary gearboxes, spur gearboxes and bevel gearboxes.

We are based in Huddersfield but work with businesses across the country in places such as Birmingham, Cardiff, Aberdeen and Liverpool, we can also help you if you’re further afield in Europe. If you work in an industry where this type of gearbox is prevalent and you need gearbox repairs or gearbox refurbishment then be sure to get in touch with Highfield Gears today by phone on 01484 531 010, or email us at sales@hgi-uk.co.uk.

What Is A Bevel Helical Gearbox?

A bevel helical gearbox, or a helical bevel gearbox, is an angular gearbox where the gear unit output shaft rotates 90 degrees in relation to the motor shaft. They tend to have either a solid or hollow shaft. For drive tasks that need an angular geared motor that can produce high power density and output torques, bevel helical gearboxes are the ideal solution and are often available as foot, flange or shaft gearboxes.

Found in baggage conveyors, rope lifters and industrial mixers, bevel helical gearboxes can be used in narrow construction spaces and offer fluid high power density. In geared motors such as these, the noise and vibration are greatly reduced while operating at high speed and the number of teeth on the helical gear can be reduced, this results in a larger gear ratio and more compact structure. When the teeth are engaged the load is slowly added and removed so the energy and power transmission is stable which reduces impacts, vibrations and noise.

At Highfield Gears, we have the in-house knowledge and capabilities to help your business with its gearbox repairs and gear manufacturing. We’re just as comfortable repairing and upgrading individual elements of the gearbox as we are completely stripping it, up to 18 tonnes, and reconditioning it back to its original specifications – we have the gearbox repair solutions for it all.

The Different Versions And Design Options Of This Unit

The range of helical bevel gearbox designs is just one of the reasons why these industrial gear units are the chosen option for an extensive range of businesses. Here, we're laying out the three main versions of this gearbox. You may not have heard of these design options but, after discovering more about them, you may feel that these are more suited for your industrial applications. 

Skew

These bevel helical gear units are suitable for a range of high powered applications. Similar to a standard gearbox, where the axes of the two shafts intersect, a skewed version has a corresponding crown and the gear teeth are straight.

This design will perform at a consistent gear ratio between two locations on the shaft that don’t lie on the same plane. If this sounds complex, it’s because it is and, as a result, skew bevel gearboxes are rarely used for modern-day industrial applications. The reason these industrial gear units aren’t used is because of their difficulty to manufacture and maintain.

Right Angle

A common type of bevel helical unit. Right-angle gearboxes will have an input and output shaft that is positioned at a right angle. The components can help transmit power from one unit, via a right angle, and then move that force to the desired applications. The right-angled nature of the unit means that it can be installed in small areas, or in areas where there can’t be any speed reductions. These versatile mounting positions, and the option to choose hollow bore or output shaft versions, make right-angle gear units very popular for people with bespoke transmission needs.

High Torque

If high output torque is needed to power heavy machinery then a high torque gearbox unit, with bevel helical gears, is the ideal solution. Very often, these units will have low ratios too. This means that they can be used for a variety of applications and still retain the necessary pulling power (i.e. torque) to complete a range of jobs.

At Highfield Gears, we’ve been lucky enough to work with all types of bevel helical products that power a range of machines. Whether it’s an angular gearbox, a skewed one, or the high torque gear unit design, we can help no matter what. This is a brief description of the three main versions, there are a lot of specific features, statistics, and components that we’ve not touched on. Suffice to say that our team has a great deal of knowledge about all these units and can advise you on what is best for your needs.

Key Features Of This Industrial Gearbox

Suitable For Heavy Machinery

Bevel helical gearboxes have fewer teeth than the typical gearbox, as we touched on, this means the pressure that is put on them by heavy-duty machinery is dissipated making them ideal for helping power heavy machinery.

Minimum Maintenance

Again, because they have fewer teeth, these types of gearboxes require very little maintenance over their life cycle when compared with spur gearboxes or similar transmission units which often have a higher tooth density.

High Performance

The fact they can deal with high torque output and high power density makes them ideally suited for high-performance machinery and equipment. As well as being able to work at a high capacity these types of gearboxes are extremely energy efficient and often report 96-98% efficiency.

Countless Applications

Their versatility and the fact they can be mounted in a variety of different ways, including vertically and horizontally, means they can be used in an array of applications. From the steel industry, chemical manufacturing plants and the packaging industry to sugar mills, cement plants and the paper industry - bevel helical gearboxes are comfortable operating in all of them.

Where Are They Used?

This gear unit solution is primarily used in heavy-duty applications that are slow-moving and large.

You’ll often find these industrial gear units in demanding scenarios in the medium and heavy-duty sector of the power transmission market. They are used in a lot of different sectors because of their ability to mount both horizontally and vertically, and the fact that the output bores can be connected by shrink discs.

You can expect to see this innovative gearbox in sugar mills, cement plants, chemical manufacturing plants, and in the paper, steel, and packaging industries respectively. Having the bevel helical range in these places manifests as powering baggage conveyors, rope lifters, industrial mixers, and carriage drives.

Does Bevel Increase Torque?

Does Bevel Increase Torque?

Yes, it can also decrease torque too though. They are able to change the direction of shaft rotation and can increase or decrease torque while producing the opposite effect on the angular speed. 

This mechanical advantage, of being able to increase torque, is twinned with the ability to be used as a speed reduction mechanism.

What's The Difference Between Spur Gears And Bevel Helical Gear?

What's The Difference Between Spur Gears And Bevel Helical Gear?

The difference between these two gears is stark and fairly obvious to the naked eye. Spur gears have straight teeth that are parallel to the axis of the gear. They are highly efficient and produce a great deal of power. A bevel helical gear is set on an angle to the gear’s axis.

Unlike a spur gear, a bevel helical gear has a smoother and quieter operation because the teeth will roll across the axis. Spur gears can only transfer between parallel shafts whereas bevel helical gears are able to transmit power between both parallel and non-parallel shafts. 

These are the main differences and each gear will have its own uses and applications. What works for your organisation will all depend on your transmission needs, and each gear will provide different characteristics that may or may not be suited to you.

Which Material Is Best For Helical And Bevel Gears?

For general purpose gears, that are easy to manufacture and are designed to go in all gearbox sizes, a selection of alloys are available to create them. A metal alloy is a combination of metals or nonmetals that are fused together to create something stronger and more resilient. An alloy can feature two metals or a metal and another non-metal element. Brass and steel are two of the most common alloys and are therefore commonly used materials for gearbox manufacturing.

There are alternatives if needs be such as ceramic, metal injection, or even plastic! For helical and bevel gears, they will use a variety of steel, aluminium, bronze, and nylon. If the gears require greater wear resistance than phosphor bronze can be used as this isn’t as resistant to heat or friction.

Our Bevel Helical Gearbox Repair Capabilities

Our capabilities when it comes to gear manufacturing and gearbox reconditioning of this nature is vast and deeply ingrained in everything we have done since we were founded way back in 1927.

Once your heavy-duty gearbox arrives at our Huddersfield-based headquarters our team will undergo a detailed inspection and create an in-depth report to further understand all elements of the gearbox and its issues before getting on with fixing it. Our in-house machinery means we can undergo cost-efficient gearbox services that not only save you money but also reduce downtime for your business.

When it comes to repairing or reconditioning, we’re not just reactive to the problem at hand, we’re also proactive and will look to implement solutions that will prevent future problems from manifesting themselves so you don’t find yourself back at square one anytime soon. Throughout the process, we’ll provide you with up-to-date reports which feature our findings and the things we’re doing to help fix what has gone wrong.

Have A Bevel Helical Gearbox That Needs Repairing? Get In Touch With Us Today

As an established manufacturer of gear parts, gear spares and reconditioned gearboxes from across several brands we’re confident our extensive capabilities can help you. So, if you have a heavy-duty bevel helical gearbox that needs repairing and you’re after an industrial gearbox repair service that offers competitive prices then get in touch with us here at Highfield Gears today by phone on 01484 531 010 or email us at sales@hgi-uk.co.uk. We’re based in Huddersfield but have worked with several businesses and organisations across the UK such as Sheffield, Glasgow and York as well as further afield in Europe.