New Combined Process Machine out of Rochester, NY

Image courtesy of Gleason.com

A new combined process machine by Gleason is setting the standard for multiple-function machines for gear manufacturers that require drilling, milling, chamfering/deburring, hobbing and turning all in a single operation. As modern gear manufacturers are aware, the industry is propelled forward by developing more intricate and complex gear designs that can handle larger loads with increased durability and efficiency. A machine like the AGILUS® 180TH represents the next generation of gear-manufacturing hardware, allowing several tasks to be completed in unison, saving the user time and resources.

An article on the new machine by Thomasnet News says of the AGILUS 180TH:

"As compared to typical production of cylindrical gears requiring hobbing, the AGILUS 180TH greatly reduces the number of machines, setups and overall through-put times for the complete processing of the gear, thus reducing both the capital investment and cost per workpiece for the user. AGILUS' ability to perform, in a single setup, complete machining of a wide range of shaft- and disc-type cylindrical gears also gives the user a greater degree of flexibility, higher machine availability, and optimized throughput as compared to the typical process where multiple single-purpose machines are used, requiring time-consuming changeover from part to part."

As the gear manufacturing industry continues to evolve, it is likely that machines with similar capabilities to the 180TH will continue to drive the evolution of the gear market. As lower batch sizes, increasingly complex gear applications and reduced inessential setup times become issues that relate to a business' bottom line, more gear manufacturers will be drawn to do-all machines like the AGILUS 180TH. In the next few years, these machines will continue to be instrumental in the development of our industry, meaning more jobs for qualified operators, less money wasted on inefficient operations and more options for gear manufacturers and their clients.

To read the article from Thomasnet News, click the link:

http://news.thomasnet.com/fullstory/Multifunction-System-offers-complete-cylindrical-gear-machining-574577

For more information on complex gear-machining processes, check out Gear Motions:

http://www.gearmotions.com/gearing-news/

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

Kubota's Latest Has Low Horsepower, Lots of Heart

Kubota, a leading Japanese tractor manufacturer, is introducing its latest yardmonster, the M130X. It sports 140 horsepower engine, which doesn't sound like much. However, its torque figure of 570Nm at a miniscule 1,200rpm is pretty impressive. Also impressive is the fact that every component of the tractor is made in-house.

One very interesting feature of the M130X is its proprietary 16 forward/16 reverse Intelli-Shift transmission, which reaches 40kph and includes the option of eight creep speeds. The gearbox offers eight clutchless powershift steps in each of the two ranges, operated with buttons on the single transmission lever. ‘Auto’ mode is activated by a single switch alongside, and this gives two options. ‘Travel’ mode gives the driver three programmable gear changes according to road gradient and acceleration, while ‘Field’ gives a downshift of two gears upon the rear hitch being raised. A basic headland management sequence if you will, to add to the Dual Memory system. Beside its Intelli-Shift transmission the M130X features a bevel gear drive as part of Kubota's 4wd package, which presents the advantage of no differential to get caught and no UV joints to maintain.

Gear Application Friday: Positive Displacement Meters

Engineer Live has a great article about positive displacement meters. Positive displacement meters measure the volume of a fluid or gas by measuring the flow of the fluid or gas as it passes from a chamber, pushing a rotor. Positive displacement meters are also a common application of gearing technology. Depending on the type of gear used, the positive displacement meter will be different. Engineer Live breaks down the differences very well.

- Rotary Piston: As mentioned above these form the basis of domestic water measurement but the design of the rotary piston that oscillates in a circular chamber with a fixed web has been modified and extended to ultra low flows and high flows, as well as high pressures and for food applications. A good all-rounder.

- Spur gear: The fluid rotates two gears and is forced around the outside of the gears and the inside of the chamber. Depending on the location of the sensor these can yield very high pulses per litre values useful in batching and fast acting processes.

- Diaphragm (or bellows meter): These are common in many people's home as their domestic gas meters. When the gas flows through it alternately fills and empties bellows causing levers to crank a shaft providing an output. Very useful for wide-ranging gas totalisation.

- Oval Gear: Quite similar to the spur gear where two oval gears mesh together and sweep the chamber. The volume displaced is much larger than the round gear. Fairly low cost and some designs available in plastic.

- Nutating Disc: This meter is the hardest to understand but is effective. The rotor is a circular disc attached to a ball. The shaft on the ball is inclined. As the disc rotates in a spherically sided chamber the disc and therefore the shaft wobble creating an output.

- Helical Screw: Possibly the most accurate PD: meter two intersecting cylindrical bores are fitted with 2 interlocking helical screws. As the fluid passes through they rotate. On standard applications the author has observed differences of just +/-0.37 per cent of reading over 50:1 turndown over annual recalibrations over 10 years - quite an achievement. Also common nowadays fitted on petrol pumps.

Positive displacement meters are a great application for industrial gear manufacturers. They leverage the force multiplying aspects of gearing with chemical engineering ingenuity.

Some Turbulence for Gear Manufacturers

MIT's Technology Review has a story that is bad news for some gear manufacturers. Two of the largest manufacturers of wind turbines--Siemens and GE--are going away from using gearboxes in their wind turbine offerings. In the face of problems associated with using gearboxes in wind turbine builds, Siemens and GE both are turning to a direct-drive system. Last month, GE announced it would invest $451.8 million in facilities to manufacture direct drive wind turbines rather than gearbox driven ones.

The new Siemens direct drive turbine is supposed to weigh 12 tons less than a gearbox-driven build due in part to developments in the build of the electromagnetic power generating portion of the turbine.

Stiesdal [the Chief Technology Officer of Siemens] says Siemens reduced weight further by inverting its generator's design. Rather than a steel rotor covered with permanent magnets spinning inside a stationary doughnut-shaped stator (the design GE is using in its four-megawatt direct-drive turbine) Siemens's rotor is a steel cylinder with permanent magnets on the inside, and this rotor spins around a column-like stator.

The company expects to have direct-drive turbines commercialized in Norway by 2012. Siemens has not experience any significant failure of its gearbox-driven turbines. The major advantage of the direct-drive turbines seems to be that they have about half as many parts as their gearbox analogues. The only significant downside to the direct-drive turbines is the relative scarcity of the rare earth metals used to make their magnets.