A Shift in Ford's Transmissions

Ford Motor Company looks to be doing something original with its research and development: It has designed and engineered an automatic transmission that will deliver better fuel economy to a car than a manual transmission would. The gain seems to be about 11%, presently. The company calls its new transmission technology PowerShift.

The dual dry-clutch PowerShift automatic transmission is based on efficient manual transmission technology, eliminating the additional weight and complexity of a torque converter, planetary gears and the fluid pumps employed in traditional automatics. Electronically controlled, twin internal clutches shift gears quickly and smoothly, providing a seamless flow of torque with the refinement and ease customers expect from a premium automatic transmission.

Ford will equip PowerShift in this year's Ford Fiesta. By the end of the year, it expects to have 85% of its automobiles with PowerShift capability. And by 2013, it hopes to offer PowerShift in all its vehicles.

PowerShift is an interesting technology. It's a dual-clutch in order to reap many of the benefits of manual transmissions. And using new technology, it results in better mileage. This is the sort of innovation that's been sorely lacking in American automobile design. We're frankly thrilled to see it developing--finally.

Printed Gears... What?!

RepRap is undertaking a fairly mindblowing project: They're trying to make a self-copying, open-source 3D printer. (And you thought Avatar in 3D was impressive!) Think about that for a moment. They're trying to construct a 3D printer than can reprint itself. Endless self-iterations. Amazing.

RepRap's blog is documenting their progress, and they've just gotten their printer to print gears that it can use:

I have finally managed to print tiny little ball-chain gears that work with 3.3mm and 3.5mm diameter ball-chain and still fit on the NEMA17's 5mm output shaft. The trick is to print the gears in two pieces.

As you can see in the photograph, I print two 4mm thick sections of gear and put them on the shaft with an M5 washer sandwiched in between. Make sure the teeth are lined up on both gears. This gives a channel to guide the ball-chain down the centre of the gear, and grips the sides of the balls adequately. As the gears age, it will also stop the balls grinding their way too far through the PLA, though I must admit that my experience with ball-chain Z axis gears suggests this will not be a major issue.

This is a really cool project that we'll be sure to follow along with. Good luck, guys!

Google Adds Bike Paths to Google Maps

If you've been a reader of the Gear Manufacturer Blog, you know that we love bicycles. They're the most transparent example of gearing application in everyday life. In fact, we think often of the famous HG Wells quote, "Every time I see an adult on a bicycle, I no longer despair for the future." It's true: Bicycling is good exercise, doesn't pollute the environment, and it's just fun.

There's good news, recently, for bicyclists. Google Maps is adding bicycle routes to its great mapping website. Wired reports,

“This has been a top-requested feature from Google Maps users for the last couple years,” says Shannon Guymon, product manager for Google Maps. “There are over 50,000 signatures on a petition.”

The news thrilled bike advocates, who have for years been pushing — and petitioning — the search giant to include bike routes on Google Maps. No longer do they have to rely upon paper maps or open-source DIY map hacking or crazy-cool helmet-mounted heads up iPhones.

“This new tool will open people’s eyes to the possibility and practicality of hopping on a bike and riding,” says Andy Clarke, president of the League of American Bicyclists. “We know people want to ride more, we know it’s good for people and communities when they do ride more — this makes it possible. It is a game-changer, especially for those short trips that are the most polluting.”

It is great news, and we can't wait to get out there and try out the new Google Maps functionality.

Lord of the (Gear) Ring

New York City-based design company Kinekt Design has come up with an ingenious item, that is "complex enough to play with, yet simple enough to wear," as they say. They call it the Gear Ring, and as you can see in the video below, it is something you can both wear and play with.

The Gear Ring is made from high quality matte stainless steel. It has six small gears that turn in unison when the outerparts of the ring are spun (as can be seen in the video). If you have a gearing engineer--or just a gearhead--in your life, this could be a cool gift. (We're almost tempted to give this gift to ourselves!)

New Helical Gear System in the Shimano Alfine 11 Speed

Shimano has released a new iteration of its Alfine 11-speed internal gear hub. I know some of us at here are cyclists, and so we thought we'd share some news about this exceptional new hub (it's lighter than the previous iteration's 8-speed version!) If you think about it, bicycles are really one of the most pure, commonly known examples of gearing.

Singletrack, a mountain bike blog, does a good job breaking down the Alfine 11-speed hub,

This hub gear will run super smooth thanks to the use of a completely new helical gear system. Helical gears feature an angled teeth profile that engage more gradually compared to spur (or straight-cut) profiles, resulting in a more smooth and quiet shift. This hub gear also features an improved durability by the use of an oil lubricant instead of grease.

It's interesting (to say the least) to see helical gears used in bicycle gearing. You're so used to seeing spur gears that it's disorienting. But since there's increased surface area in a helical gear set-up, you would expect a smoother, less slippery shifting profile. I'm excited to see helical gears used more often in bicycles (and everywhere).

Gearing up for Valentine's Day

Just in time for Valentine's Day, build your sweetie something that shows your love (and your love for gears). This admittedly odd video from Japan shows a heart someone has made--out of gears. Whether you enjoy its technical ingenuity or ponder its deeper implications about romance and relationships, it's an undeniably cool creation.

Gear Cutting Machines... in the White House?

When President Obama redecorated the Oval Office, he kept some old things and some new things. He kept the Resolute desk, a gift from Queen Victoria in 1880, which has been used by nearly every president since Rutherford B. Hayes. He has added some things, though. With an eye on the American spirit of invention, he has three mechanical items on his bookshelves, on loan from the National Museum of American History's patent collection. President Obama now has before his eyes models for

• Samuel Morse's 1849 telegraph register
  
• John Peer's 1874 gear-cutting machine
  
• Henry Williams' 1877 feathering paddle wheel for steamboats

We thought it was pretty cool that the President has a (model of a) gear-cutting machine. Let's hope his decorative tastes presage a move to help American manufacturing and technology, industries that could really use some support.