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(SPONSORED CONTENT)Meeting the Challenge of Gear Noise Analysis
With the surge in Electric Vehicles (EV), gear noise reduction is critically important. Gleasonâ€™s GMSÂ® inspection systems using powerful GAMAâ„˘ applications software apply multiple analysis tools to help identify the root cause of gear noise. These include Fourier analysis, Tooth Contact Analysis, Surface Finish Analysis, KTEPS and Advanced Waviness Analysis. The GMSL system offers the added benefit of laser technology and ultra-fast inspection speeds. Article Courtesy of Gleason Corporation
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With the ongoing push towards electric vehicles (EVs), there is likely to be increasing focus on the noise impact of the gearing required for the transmission of power from the (high-speed) electric motor to the road. Understanding automotive noise, vibration and harshness (NVH) and methodologies for total in-vehicle noise presupposes relatively large, internal combustion (IC) contributions, compared to gear noise. Further, it may be advantageous to run the electric motors at significantly higher rotational speed than conventional automotive IC engines, sending geartrains into yet higher speed ranges. Thus the move to EV or hybrid electric vehicles (HEVs) places greater or different demands on geartrain noise. This work combines both a traditional NVH approach (in-vehicle and rig noise, waterfall plots, Campbell diagrams and Fourier analysis) - with highly detailed transmission error measurement and simulation of the complete drivetrain - to fully understand noise sources within an EV hub drive. A detailed methodology is presented, combining both a full series of tests and advanced simulation to troubleshoot and optimize an EV hub drive for noise reduction.
Over the past decade, the wire electrical discharge machine (EDM) has become an increasingly important tool for machining non-standard shapes. It has even been used to cut gears and gear cavities for plastic molds. While generally accepted as a quick and versatile method for cutting spur gears, the EDM gear has lacked the precision of a mechanically machined or ground gear. We suspected that many of the errors associated with these gears were caused by inexact setup procedures, poor tool path control and improper cutting parameters. We decided to test the potential for the wire EDM to make the most accurate gear possible.
Step right up! Get your U.S. government gravy here! Weâ€™re the U.S. Treasury Departmentâ€™s Troubled Asset Relief Program, and weâ€™re printing money like weâ€™reâ€”wellâ€”the U.S. reasury. If youâ€™ve got trouble, then get your assets in line!
Zero to 125 MPH in five seconds. Maximum speed of 211 MPH. Seven-second pit stops. Formula One racing is a high-adrenalin sport - one which demands peak performance from drivers and machines alike.
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News on the latest products in the industry.
At first, monitoring the energy I use at my plant or the energy for each individual machine seemed trivial. Isn't this just an overhead cost I have to pay? I'm certainly not going to turn off a machine that costs too much to run when I have to get a job out for that month. Then, I realized how much savings there was for monitoring power consumption and the ROI was timely.
The capabilities and limitations of manufacturing gears by conventional means are well-known and thoroughly documented. In the search to enhance or otherwise improve the gear-making process, manufacturing methods have extended beyond chip-cutting - hobbing, broaching, shaping, shaving, grinding, etc. and their inherent limitations based on cutting selection and speed, feed rates, chip thickness per tooth, cutting pressure, cutter deflection, chatter, surface finish, material hardness, machine rigidity, tooling, setup and other items.
There's never been a better time to put the spotlight on e-drive transmissions and electric vehicles. They're obviously not just coming: they're already here. Just check out any auto show or showroom. That's why Gear Technology magazine is pleased to present the first installment in a series of chapters excerpted from Dr. Hermann J. Stadtfeld's newest book, "E-Drive Transmission Guide - New solutions for electric- and hybrid transmission vehicles."
The first chapter from a new book by Dr. Hermann J. Stadtfeld provides an overview of the need for new technologies and approaches when it comes to developing transmissions for electric vehicles.
The usage of modern thrusters allows combining the functions of the drive and the ship rudder in one unit, which are separated in conventional ship propulsion systems. The horizontally oriented propeller is supported in a vertically rotatable nacelle that is mounted underneath the ship's hull. The propeller can directly or indirectly be driven by an electric motor or combustion engine. Direct drive requires the installation of a low-speed electric motor in the nacelle. This present paper concentrates on indirect drives where the driving torque is transferred by bevel gear stages and shafts from the motor to the propeller.
Noise issues from gear and motor excitation whine are commonly faced by many within the EV and HEV industry. In this paper the authors present an advanced CAE methodology for troubleshooting and optimizing such NVH phenomenon.
CTI Symposium Presents Latest Automotive Transmission Developments and Applications.
Gear designers face constant pressure to increase power density in their drivetrains. In the automotive industry, for example, typical engine torque has increased significantly over the last several decades. Meanwhile, the demands for greater fuel efficiency mean designers must accommodate these increased loads in a smaller, more lightweight package than ever before. In addition, electric and hybrid vehicles will feature fewer gears, with fewer transmission speeds, running at higher rpms, meaning the gears in those systems will have to endure life cycles far beyond what is typical with internal combustion engines.
â€śHighway vehicles release about 1.7 billion tons of greenhouse gases (GHGs) into the atmosphere each year â€” mostly in the form of carbon dioxide (CO2) â€” contributing to global climate change. The CO2 emissions of a car are directly proportional to the quantity of fuel consumed by an engine. In 2013, U.S. greenhouse gas emissions from transportation were second only to the electricity sector â€” an increase of about 16% since 1990.â€ť (EPA.GOV).
Having read about an automobile race in France, Kohlsaat decided he'd host America's first auto race in Chicago. The year was 1895 and automobiles were still a great curiosity. Kohlsaat, owner/publisher of the Chicago Times Herald, planned to exploit the growing interest in motoring by sponsoring a 54-mile race from downtown Chicago to nearby suburb Evanston, Illinois, and back. The match was open to all comers, foreign or domestic, whether powered by gas, electricity, or steam. The top prize: $2,000 (that's 50,000 2016 dollars).
According to the U.K.-based WITT Energy website (witt-energy.com), "The WITT is the only device in the world that can capture energy from all movement and turn it into electricity. No other energy system can exploit the full spectrum of movement, enabling it to harvest power from water (sea, river or tidal), wind and human or animal motion."
Gear manufacturers are moving into an era that will see changes in both engineering practices and industry standards as new end-products evolve. Within the traditional automotive industry, carbon emission reduction legislation will drive the need for higher levels of efficiency and growth in electric and hybrid vehicles. Meanwhile, the fast growing market of wind turbines is already opening up a whole new area of potential for gearbox manufacturers, but this industry is one that will demand reliability, high levels of engineering excellence and precision manufacturing.
Tiger stripes on a high-speed pinion made of a carburized SAE 9310 steel were investigated. The morphology of the damage was typical of electric discharge damage. The cause of the stripes and potential damage to the gear tooth were analyzed and are presented in this report.
"Going green" and energy efficiency are goals that all industries -- especially in Europe and the United States -- are working on, in such sectors as electric motors, lubrication, gears and on and on. Drumroll here please for magnetic gearing
It is widely recognized that the reduction of CO2 requires consistent light-weight design of the entire vehicle. Likewise, the trend towards electric cars requires light-weight design to compensate for the additional weight of battery systems. The need for weight reduction is also present regarding vehicle transmissions. Besides the design of the gearbox housing, rotating masses such as gear wheels and shafts have a significant impact on fuel consumption. The current technology shows little potential of gear weight reduction due to the trade-off between mass optimization and the manufacturing process. Gears are usually forged followed or not by teeth cutting operation.
Electrification has already started to have a noticeable impact on the global automotive industry. As a result, the drivetrains of hybrid (HEV) and full electric vehicles (EV) are facing many challenges, like increased requirements for NVH in high speed e-Drives and the need for performance improvements to deal with recuperation requirements. Motivated by the positive validation results of surface densified manual transmission gears which are also applicable for dedicated hybrid transmissions (DHTs) like e-DCTs, GKN engineers have been looking for a more challenging application for PM gears within those areas.
Delta Research upgrades its Gleason Metrology Workhorses to meet the development requirements of the latest electrical drive vehicles.
The DVS gearing specialist Praewema Antriebstechnik continues to expand its technological expertise in order to keep pace with the growing significance of planetary geartrains for automatic and particularly electric vehicles, with the associated need for even higher-precision production of toothed gear components.
Borazon is a superabrasive material originally developed by General Electric in 1969. It is a high performance material for machining of high alloy ferrous and super alloy materials. Borazon CBN - Cubic Born Nitride - is manufactured with a high temperature, high pressure process similar to that utilized with man-made diamond. Borazon is, next to diamond, the hardest abrasive known; it is more than twice as hard as aluminum oxide. It has an extremely high thermal strength compared to diamond. It is also much less chemically reactive with iron, cobalt or nickel alloys.
Bodine Electric Co. of Chicago, IL., has a 97-year history of fine-and medium-pitch gear manufacturing. Like anywhere else, traditions, old systems, and structures can be beneficial, but they can also become paradigms and obstacles to further improvements. We were producing a high quality product, but our goal was to become more cost effective. Carbide hobbing is seen as a technological innovation capable of enabling a dramatic, rather than an incremental, enhancement to productivity and cost savings.
Gear noise is among the issues of greatest concern in today's modern gearboxes. Significant research has resulted in the application of enhancements in all phases of gear manufacturing, and the work is ongoing. With the introduction of Electric Vehicles (EV), research and development in this area has surged in recent years. Most importantly, powerful new noise analysis solutions are fast becoming available.
News Items About electric
1 ATI Industrial Automation Develops Radially-Compliant Electric Material Removal Tool (September 25, 2020)
ATI Industrial Automation has developed the RCE-710 Radially-Compliant Electric Material Removal Tool, its first all-in-one, electrically... Read News
2 Grieve Installs Electric Rotary Hearth Oven (February 19, 2015)
Grieve Corporation recently introduced No. 815, a 500°F electric rotary hearth oven, currently in use for preheating gears at a custo... Read News
3 Electrically-Heated Quench Tank Cures Products Post Heat-Treat (April 6, 2009)
The Number 974 insulated quench tank from the Grieve Corporation is electrically-heated to 200 degrees for heating mineral oil to cure me... Read News
4 Sunnen Offers All-Electric Design with Honing System (May 13, 2010)
The new HTA Series actuator hone introduces the first all-electric, lean design, engineered specifically for production of gas-meter tube... Read News
5 Grieve Introduces Electric Rotary Hearth Oven (June 7, 2013)
Grieve Corporation introduces No. 815, a 500°F electric rotary hearth oven, currently in use for preheating gears at a customer&rsquo... Read News
6 Grieve Offers Jumbo Walk-In Electric Oven (January 27, 2020)
No. 976 is a 500ºF (~260ºC) electrically-heated jumbo walk-in oven from Grieve, currently used for heating molds at the custome... Read News
7 Schunk Introduces Servo-Electric Parallel Grippers (January 9, 2015)
Schunk recently introduced the WSG series of servo-electric 2-Finger Parallel Grippers. They are designed for parts handling and assembly... Read News
8 Marposs Electrical Gauge Actuators Provides Increased Control and Reduced Maintenance time for E-Fenar and BlĂş Systems (January 4, 2018)
Marposs has enhanced its gauging solutions for grinding machines with new electrical gauge actuators. As compared to former hydraulic and... Read News
9 MC Machinery Systems Launches Small Electric Press Brake (December 10, 2019)
MC Machinery Systems recently introduced its new ball screw press brake, the BB306, at Fabtech 2019. This fully electric press brake is d... Read News
10 Oven Industries Temperature Controller Features Proportional Integral Control Algorithm for Thermoelectric Modules (February 8, 2017)
Oven Industries offers the 5R9-350 field configurable low cost temperature controller. Accessories available are digital display, k... Read News
11 Cortec CorrLube CpCl Lithium EP Grease Provides Corrosion Resistance for Electrical Connections (June 13, 2016)
When it comes time to lubricate bearings, fans, chassis or other metal areas where grease is applied, Cortec's CorrLube VpCI Lithium ... Read News
12 Power Electric Adds Gearing Products (June 1, 2016)
Power Electric announces the formal addition of gearing products to its product offerings. Custom gears are manufactured to application r... Read News
13 Johnson Electric Expands in Canada (January 12, 2018)
Johnson Electric, Hong Kong, parent company of Stackpole International, Mississauga, Ontario, Canada, will invest $351 million in the dev... Read News
14 Local Motors to Deliver 3-D Printed Electric Vehicle at IMTS 2014 (March 3, 2014)
Local Motors, Inc. recently announced that the Association for Manufacturing Technology (AMT) will be the first customer for its previous... Read News
15 EMO Hannover Preview: Mitsubishi Electric (September 10, 2019)
In an increasingly competitive marketplace smarter machine tools can offer big advantages to production facilities such as increased flex... Read News
16 Renishaw Named Best U.K. Electronic and Electrical Plant (October 22, 2012)
Renishaw's assembly facility at Woodchester in Gloucestershire has been named as the U.K.'s Best Electronics & Electrical Pla... Read News
17 Companies Join up for Electric Vehicle Transmission (November 29, 2011)
Three Swedish companies have brought together their know-how in transmission design, materials and manufacturing to produce a transmissio... Read News
18 Sumitomo Electric Carbide Joins OMIC R&D (December 23, 2019)
The Oregon Manufacturing Innovation Center Research and Development (OMIC R&D) recently welcomed Sumitomo Electric Carbide, Inc. as i... Read News
19 Bodine Electric Doubles Size of Iowa Plant (November 25, 2008)
More than 100 new CNC machining jobs were created as a result of Bodine Electric Company's recent plant consolidation project. The ... Read News
20 Bodine Electric's Low-Voltage Products Counter High Energy Costs (December 19, 2007)
With rising energy costs and environmental concerns, Bodine Electric recently announced the release of a low-voltage product line. Bodine... Read News
21 Schunk Releases New Electrical Miniature High-Speed Parallel Gripper (February 14, 2007)
Schunk Workholding's miniature high-speed parallel gripper (MHP) is the two-finger counterpart to the centric gripper SMG. Accord... Read News
22 Vail Resorts Buys Wind Power to Offset its Electric Power (April 14, 2006)
Vail Resorts announced plans to buy enough wind power credits to offset the power needed for its resorts, retail stores and office buildi... Read News
23 Bison Gear, Armature Electric Partner for Power Transmission Distribution (April 13, 2005)
Bison Gear and Engineering announced the addition of Armature Electric Ltd. as the Bison power transmission distributor for western Canad... Read News