Winds Continue to Blow in the Favor of Gear Manufacturers...

(Image Courtesy of the Site Selection Energy Report at siteselection.com)

Several of our more recent posts have dealt with developments in gear manufacturing as it relates to renewable energy, most notably in the field of wind energy. It is likely that these two technologies will continue to walk hand-in-hand into the future in which both industries will develop a symbiotic relationship. The Windpower 2010 conference was recently held in Dallas, Texas where several burgeoning new technologies were revealed, and the importance of the evolution of gear technology was evident in the demonstrations that were displayed. Of particular interest is the development of a new lubricant from Kluber Lubrications which can handle the varying lubrication requirements of individual bearing applications within a wind power station. As is quoted in the article from Gear Technology Magazine:

"The Klüberplex BEM 41-141 is a beige grease that features a special blend of base oil and additives to cover the varying lubrication requirements of the individual bearing applications within wind power stations. These include pitch and yaw bearings (high stresses, oscillations, vibrations), main bearings (low rpm, high stresses, vibrations), and generator bearings (high rpm and temperatures). Also on display was the Klüberplex AG 11-462, which is a gear grease that provides adhesion and protection against high loads and corrosion. The white grease lubricates the control gears for pitch and yaw systems while reducing the risk of migration inside the nacelle and onto the tower."

These new developments in lubrication technology will serve as a huge boon to the gear manufacturing industry, in which the varying thresholds and strength requirements for individual applications can sometimes lead to inaccurate calculations regarding the amount of stress a material will have to withstand. By anticipating developments in complimentary technologies, gear manufacturers will be able to assess strength requirements with improved accuracy, as adapting lubricants will allow them to cover a broader spectrum of applications. In an era where gear and wind power technologies are rapidly advancing alongside each other, it is always good news to hear about a new process which can allow all parties involve to achieve their goals in a more fluid manner.

To read the article from Gear Technology Magazine, follow the link:

http://www.geartechnology.com/issues/0610x/windpower.pdf

Poly want a cracker?: Polymer Gears at the PEEK of Gear Technology

By now we've all read the June issue of Gear Technology Magazine, and we've all probably stumbled upon the article by Lindsey Snyder entitled At the "PEEK" of the Polymer Food Chain regarding the latest advancements in polymer gears by Victrex. Will PEEK and related technologies soon become the standard in gear manufacturing technologies? How do the benefits of reduced mass and inertia weigh against the loss of durability when switching from a metal to a polymer?

The following statistics are provided by the article from Gear Technologies Magazine:

“By switching from current iron gear to PEEK, we can save roughly 70 percent reduction in mass and almost 80 percent reduction in inertia. The combination results in a three to nine percent power consumption reduction.”

“PEEK features dynamic fatigue resistance at temperatures above 120 degrees Celsius (248 degrees Fahrenheit). “

Basically, the polymer gears are preferable in low-heat scenarios in which it is unlikely for the gear to endure enough heat that it would lose strength or stiffness. In most balance shaft modules working in tandem with engines, the temperatures can reach in excess of 155 degrees Celsius, or 311 degrees Fahrenheit, making iron gears still more preferable in most of these engine applications. While the range of applications of polymers in gear manufacturing continues to expand, it is unlikely that they will be taking over the industry any time soon. Although reduced mass and inertia make for higher efficiency systems, the costs to repair or replace polymer gears in most higher-temperature applications is still far too great to warrant serious consideration.

To read the article from Gear Technology Magazine, follow the link:

http://www.geartechnology.com/issues/0610x/victrex.pdf

Or, head to the comments section to voice your opinion!

Standards, Practices and the Future of the Gear Industry

The Chief Operations Officer at Romax Technologies, Graeme Walford has recently written an article for Gear Technology Magazine in which he discusses the future of standards and practices in the gear industry. While it rehashes a lot of the information that we are all already aware of (hybrid vehicles will require quieter and more efficient gearboxes, wind turbine technology is evolving with the need for more durable gear mechanisms) he makes several good points regarding the new generation of opportunities awaiting gear manufacturers.

Most notably is his concise (however brief) discussion of prototype efficiency and the need to derive quality and quantity components from the same resources while ensuring that parts manufactured will endure harsher environments. Walford is aware of the challenge that this presents to gear manufacturers, and of these changes on the horizon, he remarks:

"As we move into the future, a new generation of opportunities awaits the gear industry. Going forward, the gear industry will need to utilize and embrace new and developing technologies to ensure that it remains as competitive as possible. The gear industry has a bright future, one that will carve out new practices and standards as we seek to meet the challenges this future brings with it."

As gear technology becomes more essential to the evolution of the automobile and renewable energy industries, it is important for gear manufacturers to focus on optimization and efficiency with their products. This means further educating employees and prepping engineers to do more work with the same, or even less starting materials. As our industry becomes more frequently tapped for innovation and reliability, we must strive to meet the challenges we are faced with head on.

The May issue of Gear Technology Magazine is available as a .pdf here:

http://www.geartechnology.com/issues/0510x/gt0510.pdf