|
|
|
|
|
|
|
|
|
|
|
|
|
|
Direct Gear Design
Service Mark Registration
|
|
|
Direct Gear Design
|
Gear geometry - primary,
tooling parameters - secondary
|
Traditional gear design utilizing rack generation and preselected (primarily standard) tooling parameters
provides universally satisfactory performance for standard gear applications. However, Direct Gear
DesignŽ is an application-driven gear drive development process that mainly emphasizes performance
maximization and cost efficiency without concern for predefined tooling parameters. It optimizes the
gear tooth flank and fillet profiles and works perfectly with any gear application that demands high
technical and market performance.
Modern Direct Gear Design's foundation is the Theory of
Generalized Parameters created by Prof. E.B. Vulgakov. Please visit the Publications page for more
details about the Direct Gear Design method.
|
|
|
Asymmetric Gears
|
|
The two profiles (sides) of a gear tooth are functionally different for most gear drives. The workload on
one tooth profile is significantly higher and is applied for a longer operating time than for the opposite
tooth profile. The asymmetric tooth shape reflects this functional difference to improve the
performance of the drive tooth profiles on account of the performance of the opposite coast tooth
profiles. The coast tooth profiles are typically unloaded or lightly loaded during a relatively short work
period. Direct Gear Design of the asymmetric gears independently defines the drive tooth profile for
maximum load capacity, the cost tooth profile, and the fillet for sufficient gear tooth flexibility. It
provides high gear transmission performance with low noise and vibration.
|
|
|
Tooth Flank and Fillet Profile Optimization
|
 
|
Optimization of the involute gear tooth flank allows for maximum gear mesh efficiency and tooth
surface endurance. The proprietary fillet profile optimization technique evenly distributes the bending
stress along the fillet profile, reducing stress concentration. It significantly reduces the root bending
stress level by comparison with the best currently used tooth root fillet profiles. This bending stress
reduction is also exchangeable for an additional increase in tooth wear resistance, efficiency, and
lifetime of a gear transmission.
|
|
|
High Gear Ratio Planetary Drives
|
  
|
AKGears has developed and implemented high gear ratio planetary arrangements. These arrangements
enable gear ratios from 20:1 to over 200:1 in one gear stage and from 200:1 up to 100,000:1 in two gear
stages. These planetary systems contain a minimum number of components, provide higher load
capacity, and have less tolerance sensitivity than harmonic or orbiting drives.
|
|
|
Self-Locking Gears
|
|
Most gear drives are back-drivable or inertia-drivable. For many gear drives, the back or inertia
drivability is not acceptable. Such gear drives utilize different brake systems. Some self-locking, non-
back-drivable gear drives (with worm gears, for example) do not require brakes. However, such drives
typically have a high gear ratio, low efficiency, and angled or crossed axes. Based on previous studies,
AKGears has developed and implemented the parallel-axis self-locking gears. These gears can utilize any
gear ratio from 1:1 and higher. They prevent either inertia driving, back driving, or both and can be
external, internal, or incorporated into the planetary gear stage. Their gear mesh efficiency is
significantly higher than in existing self-locking gear drives.
|
|
|
Plastic Gears
|
|
Direct Gear DesignŽ works ideally for plastic gears,
providing total design flexibility that is not achievable
using traditional gear design. It compensates for
plastics' low strength and low thermal conductivity by
balancing pinion and gear tooth bending stresses,
reducing the bending stress concentration, and
minimizing and balancing specific sliding velocities,
resulting in maximum efficiency and minimum heat
generation.
|
Regarding expertise in gear molding accuracy,
inspection, and material selection, Gleason
Plastic Gears is AKGears' first choice. With two
Materials Scientists on staff, expertise in
KISSsoft gear and transmission design
software, extensive gear metrology
capabilities, and proprietary "No Weld-Line"
technology, Gleason Plastic Gears can produce
the quietest, most accurate, and longest-
lasting polymer gears on the market.
|
|
|
|
