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We see that the output power Pout equals the input power Pin:
since the ideal gearbox neither adds nor subtracts power. If the speed is measured in radians per second, and the torque is measured in Newton-meters, then the units for power are Watts. In terms of the speed-torque curve above, a gearbox has the effect of reducing the maximum speed and increasing the maximum torque. The figure below shows a speed-torque curve of a motor, and for the same motor with gearboxes of G = 2 and G = 4. Also shown is a desired speed+torque operating point for the motor+gearbox combination, showing that only the G = 4 gearbox meets our specification.
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http://hades.mech.northwestern.edu/index.php/Choosing_a_Motor_and_Ge...
If we have two gearboxes with gear ratios G1 and G2, and the output shaft of gearbox 1 is connected to the input shaft of gearbox 2, the total gear ratio from the input of gearbox 1 to the output of gearbox 2 is Gtotal = G1G2. Gearboxes can achieve gear ratios of several hundred, often by chaining multiple sets of gears. In practice, transmissions are not 100% efficient at transmitting power. Some power is lost due to friction. Gearboxes have an associated efficiency < 1, such that Pout = Pin. Since the gear exactly enforces the speed relationship out = in / G, this means that the torque output of the gearbox is actually out = Gin. The efficiencies of gearboxes attached to each other is obtained by multiplying the individual efficiencies. Gearboxes with large gear ratios are usually obtained by having several gearing stages in series, so the total efficiency of large gear ratio gearboxes are generally lower than those with smaller gear ratios (if the gears are made with the same materials and precision). Below is shown the speed-torque curve for a motor, a motor with . an ideal gearbox with G = 2, and a motor with a gearbox with G = 2 but an efficiency
Another practical issue with gearboxes is backlash. Backlash is defined as the angle the gearbox output shaft can be rotated without the input shaft moving. Backlash can be large (a few degrees) in cheap gears, much lower in precision gears, and nearly zero for certain gear technologies (e.g., harmonic drive gears). See the Gears page. One other issue to keep in mind with gearboxes is backdrivability. A motor+gearbox is backdrivable if it is possible to rotate the output of the gearbox while the motor is off. Some gear types make it nearly impossible to backdrive. Sometimes you want the system to be backdrivable, so a human can physically manipulate it, for example. Other times you don't: for example, you might want the system to hold its position without brakes or power, even under gravity. Backdrivability is a qualitative property. Of two systems using the same type of gearing, the one with the smaller gear ratio is usually more backdrivable.
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Finally, gearboxes usually come with specifications on the maximum speed allowable at the input shaft and the maximum torque allowable at the output shaft.
This is called inertia matching. Again, this is only an issue for more sophisticated designs. To learn more about gears, go to the Gears page. See also an inexpensive modification of a gearmotor to give it an encoder here (http://www.mech.northwestern.edu/courses/433/Writeups/AddEncoderHobbyEngGearMotor/) . Retrieved from "http://hades.mech.northwestern.edu/index.php /Choosing_a_Motor_and_Gearing_Combination"
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