OUR PASSION – YOUR BENEFIT
Compared to straight-toothed gears, the advantage of spiral bevel gears is smoother and more gradual tooth engagement. This not only reduces noise but also the impact stress on the teeth. Moreover, spiral bevel gears, unlike straight-toothed gears, don’t break under heavy load or at high speed.
The first ATA spiral bevel gear was manufactured in 1940. Since then, these specially designed, spiral-toothed gears have become renowned for their superior power transmission capability.
Today, ATA spiral bevel gears and bevel gear systems are considered the preferred choice, especially in very demanding use – for example in marine, industrial and heavy engineering applications that must have high-quality, totally trustworthy gears.
With our know-how and the latest technology, ATA can produce gears from 50 mm to up to 3000 mm in diameter – and the optimal unit solution for any requirement. Our products are recognized as the world’s best in quality. We don’t just deliver a single gear solution – we provide you with a fully customized, totally reliable power transmission.
APPLICATION SPECIFIC BEVEL GEAR DESIGN
In bevel gear drives, performance, reliability and robustness are a top priority for ATA Gears, and we take all possible actions to ensure this. To achieve proper tooth contact in all loading conditions, we apply a simulation-based design concept, where tooth geometry is optimized as a part of a system-level analysis, taking into account the effects of the entire driveline environment. To predict the actual gear positions – and possible misalignments – in various loading positions, we use a complete model of the gearbox, simulation based on precise 3D-tooth models. This process gives the designer valuable insights into important tooth mesh properties, such as tooth stress distribution, dynamic behavior, sliding speeds, flank temperatures and tooth backlash. The tooth geometry can then be modified on a targeted basis to ensure optimal tooth contact characteristics in all loading conditions.
Optimization of tooth contact in the design stage can reduce overall costs in the long run, for example through improved reliability, shorter product development time and faster assembly and testing processes. Not to mention the value of customer satisfaction from less noise and higher efficiency.
These analysis and optimization methods are not limited to micro-geometry – the location and size of the contact pattern – but can be applied to the optimization of the entire gear design to achieve its full macro-geometry potential.
This analysis and optimization concept has been extensively verified in full-scale experiments on special research projects, as well as in numerous successful customer applications with gear wheel size ranging from 150 to over 3 000 mm.
In order to break new ground and properly test gears for performance, life and fatigue, extreme loads must be used. Also, testing times must be shortened radically to avoid waiting 20 years to see the damage with test gears designed to last for decades. For that purpose, and loads of new information, ATA works closely with the Tampere University in a large-scale test bench facility.
The test bench helps provide systematic evidence of the long life of ATA’s bevel gears, designed and manufactured using the latest top technologies. Furthermore, scientifically correct conclusions are required to convince classification societies and to get their stamp of approval, and to ensure that ATA’s customers can benefit from these improvements in their demanding applications.
With this successful testing facility, ATA is also keeping up with the global trend for larger machines and the consequent growing interest in the effects for scale. Testing larger gears is a positive reality for us decisively cutting testing times and getting new and accurate information break ground for future progress – both in our own product development and as a service for our customers.
The goal is to develop and test calculation tools to ascertain how much optimizing tooth contact and various product options in tooth finishing improve bevel gear durability. For any demanding application, this must be highly beneficial.
“Our assembly times were greatly reduced!”
Heat treatment is a vital stage in bevel gear production and a core element in ATA’s business strategy. Its purpose is to ensure the required hardness of the surface wear resistance and fatigue strength which are all essential features for a gear’s quality and usability. The treatment itself is far more than just “putting a gear in a furnace”. It’s a complex process in which a gear goes through numerous and different phases before continuing its journey in the machinery process. Since there is no all-encompassing and detailed guidebook for heat treatment, ATA’s specialists are learning and developing the art themselves. And taking it very seriously.
We continuously develop our processes in close cooperation with local and international research institutes. Our own hardening plants include 9 carburizing and hardening furnaces, 4 of them connected to automatic charge handling systems.
Quality control and associated documentation are part of our normal operations. Our in-house heat treatment guarantees flexible and fast deliveries so you can plan your own operations. Any possible deformation from heat treatment is efficiently detected and the relevant data transferred to hard machining. These processes have been optimized for optimal technical quality.
• Capable of handling bevel gears of diameter up to Ø 2500 mm x length up to 2000 mm
• 9 carburizing furnaces
• 4 connected to automatic charge handling systems
ATA Gears cooperates closely with several steel suppliers and customers for innovative development. Procurement with the latest know-how is a part of every component delivery. We have the expertise for material speciﬁcations, you only need to supply the drawings. We ensure high quality components whatever your application is.
ATA has over 10 years of experience with genuine 5-axis machining. We currently use several CAM software packages including the ATA-CAM software which was developed in-house for fine machining. Our production line offers 16 machines capable of 5-axis machining, four of them connected to FMS lines. We make one-off deliveries of components that require absolute accuracy.
• Capable of handling shafts up to
• Diameter: 800 mm
• Length: 4000 mm
• Weight: 3000 kg
• Other shafts up to
• Diameter: 3150 mm
• Width: 1000 mm
• Weight: 10000 kg
• 16 5-axis machines
• 4 machines connected to FMS lines
• Cutting and grinding
Independent of the product or application, ATA has the right machinery to fulfill its needs.
3D MEASURING MACHINES
Gleason GMS 3000
ATOS II Triple Scan
ATOS IIe SO
Danobat HG91 3000 B8
Toyoda G 72A-40
Okuma Multus B750, 3 machines
Okuma Macturn 550
Mazak Integrex eHII 500
Mazak Integrex eHII 650
Mori-Seiki NT 4300 DCG
DMC160FD, 2 machines
DMC160U, 2 machines
FPT Dinomax 2
Pietro Carnaghi AC20TM1600
CLASSIFICATION PROCESS AND QUALITY ASSURANCE
Quality assurance has always been an important part of ATA’s operations. In addition to measuring systems integrated with machine tools, ATA has two large 3D measuring machines. We guarantee the accuracy of our components and our knowhow is in no way dependent on the end product and application. ATA’s own certified inspectors take care of ultrasonic and magnaflux testing. We cooperate with all classification societies and the associated documentation of quality control can be included as part of your delivery.
• Cooperation with all classification societies
• 2 large 3D measuring machines
• All documentation as part of delivery
• Own certified NDT inspectors
CONSULT THE GEAR DOCTORS
Any questions? Ideas you want to share? Our mechanical power transmission experts will be glad to hear about any problem or idea you may have. Just fill in the details below and we will get back to you soon. Together we can achieve the impossible and make it possible.