At ATA Gears, we take pride in delivering not only bevel gears but also intelligent mechanical power transmission services for maximum lifecycle benefits. A result of decades of engineering experience gathered in thousands of mechanical power transmission solutions delivered worldwide, we offer application-specific bevel gear design and tooth contact simulation to achieve tooth geometry optimization. This service includes basic calculations, micro- and macro-geometry optimization as well as damage and root cause analysis.
For spiral bevel gears the significance of meticulous design is especially high due to the sensitivity and complex relations between the tooth contact and the surrounding driveline. Properties of the surrounding driveline such as shaft bending, housing deformation and temperature differences often cause significant gear misalignments, which can have a major influence on gear meshing properties such as tooth stresses, noise excitation, lubrication and backlash. You have probably noticed it, too, that in such conditions the gears may be fully operational, but performance and robustness are clearly not at the level they could be – or what is assumed in design calculations. The remedy we offer, is designing the tooth flank topographies, so that correct tooth contact is maintained in all loading conditions. That’s what we mean by micro-geometry for improved performance and reliability of bevel gear drives.
ATA Gears applies a proven simulation-based design concept in which the tooth geometry can be optimized as a part of a system-level analysis, taking into account the effects of the entire driveline environment. A complete model of the gearbox is used to predict the actual gear positions (misalignments) in various loading conditions. The misalignments are used as input for tooth mesh simulation based on precise 3D-tooth models. This process gives the designer valuable insight on important tooth mesh properties, such as tooth stress distribution, dynamic behaviour, 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.
In my experience, optimization of tooth contact can in the long run reduce the overall costs of mechanical power transmission. For example through improved reliability (by eliminating a known gear problem), shorter product development time (“right first time”) and faster assembly/testing processes. We believe this is important in all industries; for example in maritime, where the driveline can be subject to rough movements, and at the same time classification societies have specific requirements for the loaded contact pattern. In the mining industry, the relative displacements of the gears are also prominent by nature.
We are proud to offer our mechanical power transmission services to our customers for maximum lifecycle benefits. Digital, smart and interactive, these services will boost your operation big time.
The individual services include ATA X-GearTM, which stands for innovative solutions in driveline design for improved safety and performance. Using Best Available Technology – Isotropic Superfinishing, Shot Peening and High-grade material, it helps optimize each bevel gear to suit the situation and targets and facilitates easy installation and troubleshooting. It also promotes smaller equipment with greater power.
ATA MotionLabTM features the test bench facility for product development and joint research projects. It provides exact knowledge about the dynamic loads for improved bevel gear endurance and offers superb support in condition monitoring.
We at ATA Gears are dedicated to continue utilizing the latest technological tools as we move together towards an increasingly digitalized and hopefully brighter future.
Antti Hämäläinen, Technical Service Engineer