Custom Gearboxes & Gear Design

What We Offer

Covalo Industries offers you a one stop shop from custom gearbox design to prototyping and production volume delivery. If your gears already have an established design we can assist in the manufacturability and offer cost savings advantages.

It is our passion to make your detailed gears or gear reducer efficient and cost effective. We are willing to support you in any step of your process. Our strengths live in the areas of material applications, heat treatment and surface treatments. Economically designed gears need the correct processing requirements based on the application and volume.

Services Offered

• New concept Design Gears, Gearboxes and Actuators
• Re-engineering Gears
• Prototyping
• Gearbox Repair
• Gear Reducer Assembly and Production Volume
• Actuator Assembly and Production Volume
• Gear Manufacturing
• Design for Manufacturing
• Manufacturing Process Design
• Product Catalog
• Actuator Development

Types of Gears

• Spur Gears
• Helical Gears
• Rack and Pinion
• Bevel Gears
• Worms and Worm Gears
• Splines
• Sprockets
• Pump Gears
• 3D Printed Gears

Types of Gearboxes

• Spur Gearboxes
• Right angle Worm Gearboxes
• Epicyclic Gearboxes
• Bevel Gearboxes
• Compound Gear Reducer
• Rotary Actuator
• Linear Actuators
• Gearhead Motors

How do you design a gearbox?

Custom design of a gearbox requires preliminary evaluation of operating conditions for the desired application. Operating conditions such as environmental temperatures, external loads, exposure to moisture, envelope spacing, output torque and output rpm, etc. are some of the requirements that must be understood prior to designing. Once the operating conditions are considered, the next step is what type of gear reducer is best for the application.

The type of gearbox chosen will help layout a basic gear system which would include the number of gears, shaft count, basic housing size and method of mounting. At this point the gear system is well underway with the preliminary design phase and will continue to take shape with selecting the gear reducers bearings, seals, locking hardware, cooling needs, etc. This process comes as second nature to us here at Covalo Industries.

Our team of engineers are experts in gears, from the design to processing procedure. We have extensive knowledge, taking a project from initial concept to manufacturability. Our design process is based upon thorough evaluation of the application and meeting the life expectancy of your product. Take a look at some of the markets we serve to help find a solution to your application.

Epicyclic Gear Systems

Worm Gearbox

Gear & Gearbox Product Catalog

Finding gears for your application can be a challenge. We offer various catalog and custom gears to ease this process. Please browse our Gear Catalog below!

Not only is Covalo Industries able to manufacture custom gears, we also offer a product catalog with hundreds of parts. This catalog contains various gears; spur gear, rack gears, rack and pinions, helical gears, bevel gears, planetary gear reducers, 90 degree reducer and more to come! All standard sized gearboxes are made to order to guarantee high quality control over the internal components. Sizes are suitable for both servo motor and NEMA motor mounting. If your not able to find a specific fit size or ratio, reach out to us so we can retro fit our gear units for your application.

We will continue to grow our gear catalog so that you can find the part just right for your application. We understand the importance of material strengths, surface treatments, material hardness and precision, when it comes to your gear application. It’s very important that we offer multiple options to fit your gear reducer/gear system. If you’re seeking a specific part specification and it’s not within our catalog, we are more than willing to have it made for you with keeping the price competitive.

Gear Catalog

Common Types of Industrial Gearboxes

The five most common kinds of industrial gearboxes are outlined here.

Helical Gearbox

The helical gear systems is a very common gearbox utilized when high load carrying capability and efficiency are of utmost importance. Helical gear reducers can be found in various industrial applications or where low noise transmissions are a requirement. The helical reducer is prevalent in the plastics, cement, and rubber industries and other heavy industrial applications

The key benefit of helical gears are the higher load carrying ability and low noise generation. These two features are possible because of the high contact ratio between the teeth and the angle lead of the tooth. In combination this allows for a lower tangential load acting against the tooth and the load to be distributed amongst multiple teeth at any given time.

Straight Bevel Gear Gearbox

Bevel gearboxes are ideal when power must be transmitted between two shafts aligned on a 90-degree angle. A straight bevel gear tooth gear reducer is recommended when large shaft misalignments are expected, and the design does not require high levels of efficiency. The straight tooth bevel gears offers the ability to transfer load between the 90 degrees but limits the amount of design complexity and cost.

Spiral Bevel Gear Gearbox

Similar to straight bevel gears, spiral bevels gear allows load transmission between two non-parallel shafts. But spiral bevel gear reducers are higher in efficiency and generate less noise. Additionally, spiral bevel gears have larger load carrying capabilities. This is due to the helix angle of the gear teeth. The helix angle disperses the load into radial, axial and tangential vectors.

The helix angle also permits a larger tooth contact ratio, to better share the load amongst multiple teeth. A spiral-bevel gear systems are recommended in demanding applications where high load and speeds will be experienced. Also, if the system has demanding vibration requirements, spiral bevels gears are ideal to transfer loads with minimal losses.

Worm Gearboxes

Worm reduction gearboxes are ideal for large increases in torque or reductions in speed. Worm gears can carry high loads because of the large thickness of the gear teeth. Similar to bevel gears and helical gears, the angle teeth provide less tangential loading of the teeth. This transfers loads in the axial and radial directions making worm gear teeth less vulnerable to bending failures.

The one down fall is worm gear reducers do not experience the same efficiency as other the gear train options mentioned on this page. This is due to the high sliding velocity experienced between the teeth. This results in frictional losses and gearbox heat generation. Worm gear reducers should be evaluated closely when high speeds are of interest.

Epicyclic Gearbox

Epicyclic gear systems are very useful in many applications. These gear reducers provide in-line shaft connections, permit high gear ratio combinations and operate at a high level of efficiency. The gearboxes are arranged with a large outer ring gear, a centered sun gear and multiple planet gears. The system’s advantage comes from the multiple planet gear arrangement. Unlike a single gear on gear mesh where the load is one to one from the first gear to the second. In a multiple planet gear arrangements, the load is divided between the number of planet gears. This allows for an improved load carrying capability. Epicyclic gearboxes also benefit in application with their ability to be in constrained locations. There’s a reason these types of gearbox systems are used in automotive transmissions.