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Excavator Planetary Gears – The Definitive FAQ Guide

Excavator Planetary Gears FAQ Guide is an excellent reference for engineers, designers, and machinists in the manufacturing and construction industries.

It provides detailed information about planetary gears, characteristics of planetary gears, features of planetary gears, application of excavator planetary gears, sun gear, and ring gear role in the planetary gear system.

Planetary gearboxes line up with the transfer systems of the machine. The main structure is what contains all of the operations going on inside.

This FAQ guide will answer your questions about these gears, and we’ll provide you with a few simple explanations.

1.    What is an excavator planetary gear?

Excavator planetary gears are a type of gear utilized in construction, mining, and other industries with hydraulic drive systems.

Excavator planetary gears transmit the engine’s torque to the machine implements through a system of wheels, backpacks, and shafts.

Planets on the gearbox’s carrier rotate at a different speed than the sun gear to reduce the rate by driving rotational motion through the epicycle gears, which turn the axles.

Planetary gears are combined with bevel gear to form a power train and transmission system for heavy off-road equipment.

The planetary gear is the oldest and most reliable internal combustion engine mounts you can find in excavators.

2.    How do excavator planetary gears work?

Excavator planetary gears work by distributing power provided by the engine to the drive wheels.

The sun gear and planet carrier surround a central ring called the pinion, mounted on the motor shaft.

The planetary gears are mounted on an inner annulus that surrounds an outer ring called the carrier.

When the motor spins, power is transferred from the sun gear to each planet gears utilizing spur pins on the outer ring.

As this happens, each planet gear begins spinning concerning its corresponding pair of tooth rings in sequence around the inner and outer rings until all five have left their respective starting positions.

This is how your excavator planetary gears work.

3.    What materials are used in making an excavator planetary gear?

Excavator planetary gears are made of steel, and this steel is composed of several elements, including the base metals.

The most commonly used base metal is iron. Iron is a naturally occurring element found in the earth’s crust. Iron is cheap and abundant, but it fatigues easily when exposed to heat, vibrations, and shocks.

Therefore, manufacturers find it necessary to add other metallic materials such as nickel, manganese, carbon, silicon, and chromium to give the steels higher strength and fatigue resistance.

After the additions of these different materials, the resulting steels are then used in excavator planetary gears.

This steel is used for the planetary gears, outer ring, and sun gear because of its ability to withstand fatigue, stress crack resistance, and high tensile strength.

4.    Is noise associated with excavator planetary gears?

Yes, noise is associated with excavator planetary gears.

Planetary Gears are fitted to excavators and power shovels, and they are involved in a wide range of equipment operations that make some noise.

Noise levels vary depending on the type of operation.

Noise is generated due to an unbalanced rotating machine, or damaged sum and planetary gears, etc.

In high pressure and medium pressure planetary gearboxes, noise is generated due to

• The existence within the planetary system of an overloading part (such as the pinion gear),
• A contacting part with a high coefficient of friction (in high-pressure gearbox: thrust bearing; in medium pressure gearbox: sliding piece-thrust block),
• A clearance part with significant play (round roller bearing in medium pressure gearbox) etc.,

Both of which affect the transmission efficiency of shafts so that the noise will be generated.

The noise of these gears can be reduced by using quality lubricating oil that meets specifications and replacing it regularly as required by manufacturers’ guidelines.

5.    What is the cost associated with excavator planetary gears?

Several factors determine the cost of excavator planetary gears.

The specification of the gears (including the overall number and dimensions) can affect the price.

Planetary gears efficiency, manufacturing material, and warranty associated also play their part in determining excavator planetary gears.

The cost of planetary gear, manufactured from cast steel with forging technique, lies in $30 to $100 per piece.

The price of the ring gear produced from stainless steel with hard tooth surface lies in the range of $30 to $999 per piece.

The cost will increase if you purchase a planetary gear with additional features, including life and strength.

6.    What type of oil goes into the excavator planetary gears?

The primary lubricant for excavator planetary gears is usually a mineral-based oil.

Several types of oils are used in equipment maintenance, and each has properties that make it suitable for specific applications.

The performance of the excavator planetary gears primarily depends on the type of oil used in it.

Mineral-based oils are used because they have good oxidation resistance and antirust properties, and excellent low-temperature fluidity.

The grade of the oil depends upon the operating conditions, but generally, API GL-4 or SAE80W-90 is used.

For freezing weather, synthetic oils such as SAE10W-30 or 50 can also be used.

7.    What is the life associated with excavator planetary gears?

The life of an excavator planetary gear can vary based on several factors, including

• How the machine is operated,
• Frequency of operation,
• How the gearbox is used,
• Material from which it is made of,
• Operating conditions,
• The manufacturer specifications for each excavator planetary gear unit

The life of an excavator planetary gear is not long since the gears are constantly turning throughout their lifespans.

The wear and tear on them are from inside the gearbox by the action of the rotating teeth rubbing against each other.

These causes wear on the teeth until they can no longer mesh together.

On average, planetary gears last 1,000 – 2,000 hours, depending on their application and what materials are operated on.

8.    What are the problems associated with excavator planetary gears?

The problems associated with excavator planetary gears are often associated with the design and materials used in their construction.

Often, the gears are constructed from cheap, low-quality materials, which is insufficient for the wear and tear that will occur on a construction site.

The wear planetary gear cannot transfer the torque and thus results in a reduction of efficiency of your excavator.

Planetary gearsets commonly fail in full sun mode when an oversize ring gear is subjected to excessive loads.

Planetary failure may occur when operating in half sun position because of excessive backlash between the sun and the pinion.

The most common cause of this type of failure is misalignment during installation.

9.    What characteristics are embedded in excavator planetary gears oil?

Excavator Planetary Gears Oil is one of the most commonly used lubricants to achieve or maintain an improved power transmission performance in an excavator.

These gears are produced by excellent quality, whose properties are as follows:

• Ideal fluidity,
• Excellent antirust performance,
• Good cold-starting ability
• High neutralization resistance
• Thermal stability
• Wear and tear resistance
• Outstanding protection to gear teeth

It also has a loading capacity to be mixed with other types of oil for usage, and it lacks any chemical corrosion.

With our excavator gears oil, you don’t need to worry about your gears wearing out or the environment being polluted.

10.  What are the maintenance requirements of the excavator planetary gears?

The maintenance requirements of the excavator planetary gears are as follows:

The surface of the teeth should be ground once every 200 hours of operation or one time per year, whichever comes first;

The tooth number and spacing should be measured regularly, and the tooth apex angles need to be checked (the maximum permissible angle is 0.1°).

You should inspect and adjust the machine frequently to make sure that everything is running as it should.

A correct lubrication schedule or standard oil change will be sufficient to keep these gears working correctly.

Failure to provide adequate regular service can result in costly repairs and downtime.

11.  What is the role of sun gear in excavator planetary gears?

The sun gear is a small gear that is located at the center of the planet carrier.

The planetary carrier is the giant wheel that meshes with the other smaller gears.

The sun gear transmits the power from the driver to the planet gears. The sun gear meshes with one or more bull gears locate on a spider shaft.

Together, these gears rotate the hydraulic motor input shaft at the speed determined by the rod that connects them.

They are used to turn a shaft at high torque, and low speed and are especially suitable for use on earth moving equipment like Crawler Excavators, Wheel Excavators, and Motor Graders.

Many excavators use several different types of excavator planetary gears depending on their application.

12.  What are the uses of excavator planetary gears?

Excavator Planetary Gears are widely used in construction sites, agriculture machinery, mining machinery, power plants, thermal power stations, steel-making plants, and paper mills.

These planetary gear systems may be named excavator ring gear or equipment gearbox.

Planetary gears are also widely used in the catering & hotel industry for high-speed pumps and fans.

Excavator Planetary Gears are also used in numerous machines drives such as lifting and conveying equipment.

They are mainly composed of six elements: sun, planet Carrier, inner ring, outer ring, friction sleeve, and rollers.

Their features are high power coefficient, high efficiency, low noise, and long lifespan.

13.  What powers excavator planetary gears?

A hydraulically operated mechanism drives excavator planetary gears.

The power for excavator planetary gears comes from a drive motor connected to the excavator by a hydraulic motor and two types of drive mechanisms.

The selector (also called switching) mechanism and the reaction mechanism.

The reaction mechanism consists of a large outer ring gear with crankshaft gear teeth on its inside edge, called the sun gear.

The selector (switching) mechanism has smaller outer ring gears with teeth on their inside edge, called planet gears.

In a planetary system, the ring gears are attached to an assembly (called an annulus) that rotates to make the planets revolve.

14.  How to install an excavator planetary gear?

You can install excavator planetary gear by following the procedure as follows:

First, you need to take the appropriate kit of tools to carry out the installation.

Then isolate the final drive motor from your excavator because it contains your planetary gears inside.

The next thing you need to do is unscrew the bolt on the front cover of the excavator drive motor.

Then you need to carefully take out the excavator planetary gears from the motor and install the new planetary gears inside.

Make sure to apply the lubricant appropriately to improve the working of your excavator.

Then install the isolations using a screwer or spanner and mount them to your excavator.

After this, finally, check your installation that it is working accurately to move on.

15.  Do excavator planetary gears increase speed?

Planets gears increase the torque rather than speed of your engine without any problems. No need to change the engine or invest in high-end equipment.

All you need is a good machine with a planar transmission.

Excavator planetary gears are primarily used to increase the output torque.

Putting the excavator’s planetary gears in front of the output shaft will support a more tremendous amount of power than the regular output shaft gear.

This makes them attractive to users with a high power-to-output ratio for their system – such as fluid power components.

A planetary gearbox is a kind of gearbox with a “planetary” structure, and it has some advantages like high efficiency, ample output torque, good adaptability.

16.  What is the role of teeth in excavator planetary gears?

The teeth of planetary gears have a vital role to play, as they intermesh with one another and help the gears rotate simultaneously.

For a planetary gear to work efficiently, it must be constructed with precision-cut teeth that intermesh correctly with the sun gear.

The type of teeth required in excavator planetary gears will often depend on the kind of machine for which they are designed.

They also may be cut in different ways depending on the manufacturer or company is making them.

These teeth allow for smooth operations of all moving parts in the gearbox.

Planetary gears are placed inside an aluminum housing with seals around the planetary groove to ensure resistance against high-pressure fluids emitted during power transmission.

17.  Is friction associated with excavator planetary gears?

Friction is one of the leading causes of reduction in the life span of excavator planetary gears.

According to torque calculation, the maximum permissible value of adequate coefficient friction in connection with anti-friction coating should be no more than 0.04.

If machine drive spares are used, this value must be exceeded: 0.09 – 0.15.

The most important reason for such high values of friction is that excavator operators are seldom looking after their gears and lubricating them regularly.

Excessive or incorrect feeding of grease may produce similar results.

There are a few key reasons why you should be concerned about friction involving excavator planetary gears.

Firstly, to deliver a higher power output from the gearbox; and secondly, to transfer an increased load from the motion of the planet carrier to that of the gearbox output shaft.

18.  What is the role of the mounting assembly in excavator planetary gears?

A planetary gearbox with mounting assembly is an essential component of excavators that transfers power.

The mounting assembly is a mechanical part that includes bearings, seals, and others.

Excavator Planetary Gears are a critical component of the gearbox, through which power and motion are transferred to the attached parts.

It is mounted inside the main housing of the gearbox to ensure that it operates with the same tension as all other gears.

A mounting assembly comes with many features, including a plate that supports planetary pinion gears, a part of the assembly that is mounted on one end.

The assembly includes multiple machined surfaces that help it connect to different bearings.

The mounting assembly is designed to absorb the impact and vibration produced by the engine during its operation.

19.  Why do excavator planetary gears fail?

Excavator planetary gears and gearboxes experience regular wear and tear in various applications with heavy-duty construction and high-intensity working conditions.

This causes parts to break down over time, which is inevitable, but wear can be delayed by the correct application of additives to the lubricant.

Wear reduces production output and increases maintenance costs.

There are several reasons why your excavator planetary gears may fail. Some include:

• Excessive heat due to end gear ratio mismatch,
• Improper lubrication or improper assembly of components like intermediate gears,
• The lubrication breaks down,
• Damage or destruction to other parts, including gears, bearings, and seals

Adopting regular maintenance measures may reduce the chances of failure to your excavator planetary gears.

20.  What is the manufacturing process of the excavator planetary gears?

The manufacturing process of the excavator planetary gears mainly includes casting, heat treatment, grinding, lapping, and hardening.

The manufacturing process starts with a blank if it is gear type and pinion type.

It is needed to finish the rough grinding first and then do the precision primary grinding after that.

After that, you need to modify and improve the rough machining parameters to get a better surface finish and polished geometry.

Then you do the secondary grinding to make sure the proper shape, profile finish.

After that, you have to measure the dimension and inspect whether the component dimensions are in the specification or not. If yes, then your product is ready.

21.  What are the things to consider before choosing an excavator planetary gear?

The proper selection process can help eliminate problems as the system ages or when component replacement is required.

The selection of a planetary gearbox for an excavator involves considering the machine, application, products and services, components, equipment, sun gear, connections, and other options.

While selecting, you also need to consider the type and number of planetary gears in the design, speed ratio range, load range, and feedback control that direct torque to move heavy loads.

Other considerations involve:

• Type of material
• Wear and tear resistance
• Working life
• Warranty associated

This will help you having planetary gears with extended life, and you no need to worry about your excavator efficiency and effectiveness.

22.  What is the role of the ring gear in excavator planetary gears assembly?

The ring gear plays a vital role in an excavator’s planetary gear system. This component is uniquely designed to engage the sun gear.

The ring gear’s diameter and tooth profile shape are two specific features that are crucial in this role.

The ring gear is positioned between the center carrier, or rotation axis, and the outer planet carrier (the third piece).

The teeth of the middle carrier rotate into the gaps between the teeth of the ring and planet gears.

This allows for multiple configurations of unit designs, offering machine owners more customization and control.

The role of the ring gear in excavator planetary gears is to transfer the rotation from the pinion. The pinion will be mounted on the driving unit, such as the engine.

The ring gear will be mounted directly on the excavator or attached to a gearbox.

23.  What components are included in excavator planetary gears?

Excavator planetary gears are typically composed of a sun gear, planet carrier, and ring gear. The shape of the teeth and the pattern of the teeth dictate the type of rating borne upon them.

The sun gear is the central member of the system. Its purpose is to transmit power from the motor to a rotating load.

The ring gear is used for this exact purpose, but it also transmits torque from one planetary member to another.

A planet gear set consists of several pinions that rotate a load around an axis that intersects both gears.

The direction in which these gears rotate determines if they are right-handed or left-handed gears.