Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Corrugated boxmaking machine builder saves 50 percent on components, 30 percent on control cabinet footprint with comparable performance
Fred Harrison, president of Hycorr Machine Corporation, a Kalamazoo, Mich. builder of corrugated boxmaking machinery, has always believed in being first. That competitive and can-do spirit meets every visitor to his company’s website, where a number of Hycorr first’s are listed. The company was the first U.S. rotary die-cutter to introduce an integrated stacker, the first U.S. builder to introduce the reverse angle doctor blade on rotary die-cutters and the first builder in the world to offer an automatic cutting-anvil speed compensator, Auto-CompTM, which was later joined by Hycorr inventions of a quick-change anilox roll system and modular dwell section with inter-station dryers. All these innovations to the industry were achieved in the first 15 years of operation for this company, founded by Fred Harrison in 1985.
Never one to rest on his laurels, Harrison recently put his engineering team on the task of improving the overall controls package on the company’s line of rotary die-cutters. In particular, the servo system and total controls package needed upgrading with newer technology. The previous technology functioned properly and to a satisfactory degree to keep the company competitive in the paperboard container industry, but Hycorr engineers were seeking increased cost containment and a reduced footprint, with no loss in performance on their machines.
After considerable research, and based on the direct experience of a recently hired engineer, Hycorr began its investigation of a totally new system, one that would not only reduce servo drive system and related energy costs, but also integrate both the programmable logic controller (PLC) and human-machine interface (HMI) functions.
Hycorr’s electrical engineer, Mike Walter explains, “We have been building servo driven rotary die-cutters for over 10 years. We wanted to look at a new system for a series of machines that were being built for new customers. After the first price pass, we knew we needed to continue our talks with Siemens.” The package under consideration included servo motors, Sinamics® S120 servo drives, and a Simotion® D motion controller with PLC functionality. Walter continues, “At first, we were only considering this new system for the motion platform. We needed a servo system that would eliminate some gears and maintain the tight tolerances our customers expected for printing and diecutting. We really needed a system with built-in rotary motion functionality.”
Siemens provided the Simotion Shaftless Standard to Hycorr, which greatly reduced this customer’s engineering time. The solution reduced Hycorr’s costs in both hardware and engineering time in terms of the product acquisition as well as the operating energy costs associated with these typically high power-consuming machines. Walter and his team determined that the Siemens motors and drives package was an ideal replacement for the previous vendor’s technology, plus the seamless integration of the PLC and HMI afforded Hycorr additional advantages in control and operational flexibility.
In the proposed implementation of the new solution, each technology (motion, PLC and HMI) had built-in connectivity to the others, making assembly time another area for major savings for this machine manufacturer. Overall, the savings for Hycorr was calculated to be approximately 50 percent,
Capping the decision to make the switch to the Siemens solution was a footprint reduction of 30 percent in control cabinet space. As Walter simply puts it, “The components were smaller. With the combination of the active interface module and active line module, we eliminated the need for line reactors or line filters, thereby saving space, plus mounting and hardwiring time.” Complementing these savings, the Siemens servomotors specified for comparable performance levels were considerably smaller and less expensive to operate than the previous units used.
Working under a tight deadline, the first rotary die-cutter was built and commissioned onsite by Hycorr and Siemens at the end user’s plant. Shortly thereafter, the second machine, needed by another Hycorr customer, was built on a production schedule that Fred Harrison would deem another first for the company in its speed. This improvement in engineering, production and assembly time resulted from the Simotion Shaftless Standard provided at no cost by Siemens to its customers. This Shaftless Standard enabled Hycorr engineers to do much more modular implementation of components plus the interfaces of the overall motion system to the controls architecture. By this process, Hycorr saved approximately 80 percent of its engineering time on the machine build. The entire engineering file for the first machine was loaded from a single compact flash drive and, with minimal debugging, the engineering on the second machine was completed quickly. This demonstrated the serial machine benefits of Simotion, according to Mike Walter.
Components used on the machine builds at Hycorr included Siemens Sinamics S120 drives, Simotion D425 motion controller, 1PH7 servomotors and Simatic® S7 PLC for simple Windows-based operator interface. As part of the Shaftless Standard package, Hycorr is able to make custom modifications to the various options offered on its rotary die cutters, without extensive engineering time.
Fred Harrison concludes, “Hycorr will continue to strive to be first on the market with many innovations, always maintaining the highest quality standards of machine performance. No customer will ever be a trial case for us. We deliver productivity to our customers’ bottom line because we’ve invested in maximizing our own.”
For more information on this story, please contact:
Hycorr Machine Corporation
5801 East Kilgore Road
Kalamazoo, MI 49048
Phone: 269-381-5905
Fax: 269-381-5914
Web: www.hycorr.com
Email: info@hycorr.com
Attention: Fred Harrison, President or Mike Walter, Electrical Engineer
Or
SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595 Fax: 847-437-0784
Web: www.usa.siemens.com/motioncontrol
Email: SiemensMTBUMarCom.industry@siemens.com
Attention: John Meyer, Manager, Marketing Communications
Machine Tool Components at IMTS 2010 – Booth W-2405
Advanced Machine & Engineering Co. (AME) Rockford, IL announces their return to IMTS 2010. As in the past, they will have two booths to showcase their products and services.
Visit Booth W-2405 to learn about precision machine components, featuring:
Visit Booth E-5708, for additional AME products such as:
Our sister company, Hennig, Inc., will have their complete line of products in Booth E-5708 and W-2405.
Visit Booth N-7216 to learn about carbide sawing systems, featuring:
Advanced Machine & Engineering Co., is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components, workholding devices, and, through our sister company, Hennig, machine enclosures, chip removal and filtration systems. The Fluid Power – Safety markets are served with cylinder rod locks and safety catcher devises; and the Production Saw market with our Amsaw carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Hennig, Inc. design and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the U.S., Germany, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
For more information, contact:
Tim Waterman
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham St.
Rockford, IL 61103
Phone: 815-316-5277
Fax: 815-962-6483
E-mail: info@ame.com
Connect with AME online: 
No. 967 is an electrically-heated 500°F(~260°C) inert atmosphere oven from Grieve, currently used for various heat treating operations at the customer’s facility. 9 KW are installed in Incoloy sheated tubular heating elements. Workspace dimensions are 24” wide x 24” deep x 24” high. A 400 CFM, 1/3-HP recirculating blower provides horizontal front-to-rear airflow to the workload.
The unit has 4” insulated walls, an aluminized steel exterior and Type 430, 2B finish stainless steel interior. The door is equipped with adjustable positive-latching door hardware and adjustable offset hinges. A 130 CFM blower pulls air through the air jacket on the inner oven for cooling and a solenoid automatically opens the outlet for purging.
On this Grieve inert atmosphere oven, the inner oven walls are sealed directly against a 1/2” thick silicone rubber door seal with an air jacket installed on the inner oven for cooling and a blower shaft seal and outlet with pressure relief also onboard. All the interior seams are welded gas-tight and all wall penetrations are equipped with compression fittings.
Controls onboard No. 967 include a digital programming temperature controller, manual reset excess temperature controller with separate contactors and a recirculating blower airflow safety switch. The critical pressure of the oven chamber is monitored with a pressure regulator, flow meter and pressure gauge.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank Calabrese.
NEWS RELEASE: THE GRIEVE CORPORATION Agency contact: DATE: May 21, 2010 Tim Daro 847-934-4500
Continue readingHennig, Inc., Machesney Park, Ill., announces their return to IMTS 2010.
Visit Booth E-5708 to learn about Hennig’s machine protection products featuring:
Visit Booth W-2405, for additional Hennig products such as:
Other products include roll-up and flexible apron covers, wiper systems, and telescopic springs.
Our sister company, Advanced Machine & Engineering, will have their complete line of products in Booth E-5708 and W-2405.
Tim Waterman
Hennig Inc.
9900 N. Alpine Rd.
Machesney Park, IL 61115
(815) 316-5277
info@hennig.ame.com
www.hennigworldwide.com
Connect with Hennig online: 
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Hennig, Inc. designs and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the U.S., Germany, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico; and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
Advanced Machine & Engineering Co., our sister company, is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components and workholding devices. The Fluid Power-Safety markets are served with cylinder rod locks and safety catcher devises; and the Production Saw market with our AmSaw carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Continue readingAdvanced Machine & Engineering Co. (AME) Rockford, IL announces their participation in IMTS 2010. 
Visit the pioneers of carbide sawing systems in North America at Booth N-7216, featuring: Amsaw high-speed production sawing machines for billets, tubes, rails and more Speedcut carbide saw blades.
Amsaw systems are specifically designed for faster cutting speeds, longer tool life and enhanced precision of carbide saw technology. Amsaw systems use carbide-or cermet-tipped blades to provide fast, accurate cutting for ferrous and non-ferrous materials, bars or billets, rails, profiles, pipes and tubes.
AME custom machine services include complete design and build services to go along with Amsaw sawing systems, blades and machine rebuilding services.
Speedcut sells and services saw blades with a variety of styles and tooth configurations. New carbide, cermet and thin-kerf blades are available along with complete in-house facilities for sharpening, re-tipping and repairing older blades. Virtually any size blade can be fully reconditioned, so it’s ready to cut ferrous and non-ferrous materials, bars or billets, rails profiles, pipes and tubes.
Speedcut can build and service blades as large as 80 inches in diameter, so whatever your application, you can make sure your blades are always sharp and ready for the rigors of high-speed, high-volume cutting.
See our other AME and Hennig group products in Booths E-5708 and W-2405.
Advanced Machine & Engineering Co., is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components, workholding devices, and, through our sister company, Hennig, machine enclosures, chip removal and filtration systems. The Fluid Power – Safety markets are served with cylinder rod locks and safety catcher devises; and the Production Saw market with our Amsaw carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Hennig, Inc. design and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the U.S., Germany, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
For more information, contact:
Tim Waterman
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham St.
Rockford, IL 61103
Phone: 815-316-5277
Fax: 815-962-6483
E-mail: info@ame.com
Connect with AME online: 
Denis Bermingham, New Manufacturing Manager
Gear/Gearbox company names new manufacturing and marketing managers as growth continues
Excel Gear, Inc. of Roscoe, Illinois announces the appointment of Denis Bermingham as the manager of manufacturing engineering and special projects, plus William “Bill” Powers as the company’s marketing manager. Both appointments were made by company president N.K. “Chinn” Chinnusamy, who noted these hirings were made as the result of the company’s recent growth and anticipated expansion into new market segments.
Bermingham brings a strong engineering background in metalworking and machine tool building to his new position, as well as an extensive knowledge of metallurgy and heat treatment. He will oversee Excel’s manufacturing engineering and special projects, as well as continue the company’s ongoing implementation of lean manufacturing strategies. Denis brings 30 years of manufacturing and machine tool experience to Excel Gear. He worked the majority of his career at Ingersoll Milling Machine in Rockford, IL in the Manufacturing Engineering, Assembly, Engineering, and Prototyping departments. He has a degree in Industrial Technology and will be responsible for the various manufacturing functions at Excel.
Bill Powers, New Marketing Manager
He notes, “I joined Excel Gear to become part of the technical/manufacturing environment here. We can offer customers innovative solutions, with excellent quality and value. I’m very excited to be part of this team.”
Powers brings 30 years’ experience in the gear and machine tool business to Excel. Formerly an account manager, project manager and supervisor of customer training with Ingersoll, as well as other metalworking/automation systems firms, he has handled various sales, marketing and customer relations functions, giving him a well-rounded perspective on the dynamics of the industry. He has a degree in Business Administration and will oversee all the marketing and business development for Excel.
Bill observes, “Chinn has structured a first-class company at Excel, supplying engineering-based products, brought to market by a very highly-skilled and dedicated team. All customers receive the highest quality possible, backed by service and application assistance that’s second to none. It’s a great working environment and I look forward to the challenges of our changing markets.”
For more information on these appointments, please contact:
EXCEL GEAR, INC. 11865 Main Street, Roscoe, IL 61073. Phone: 815-623-3414 Fax: 815-623-3314 Web: www.excelgear.com Email: sales@excelgear.com N.K. Chinnusamy, President
ABOUT EXCEL GEAR
Excel Gear brings over 50 years of machine tool experience to the design, manufacturing and quality analysis of its various gear, gearbox, fluid bearing, spindle, CNC gimbal head, nutator and special equipment production. ANSYS software for FEA on stress, strain, deflection, as well as modal analysis, time and frequence domain, our Spindle Analysis Program, MATLAB/Simulink, AutoCAD/SolidWorks/CADAM and other programs are all utilized to effect the best solutions to customer requirements. Excel also builds two-axis CNC gimbal heads with 20,000RPM motorized spindle, 15,000RPM cartridge type spindle assemblies and CNC rotary tables for major machine tool companies. Our high-accuracy gear grinding equipment produces to AGMA 15 (DIN 2) tolerances for quality that meets or exceeds the increasing customer demands for high-speed and high power transmission with smooth, quiet operation. Recently, the company has entered the emerging wind turbine market to provide various gears and gearbox components.
PR agency: Tim Daro Bernard & Company tdaro@bernardandcompany.com 847-934-4500
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Advanced Machine & Engineering Co., (AME) Rockford, IL offers its line of Amlok® cylinder rod locks for a variety of applications in myriad industries. One recent and innovative installation is on the worker lift platforms at a major RV manufacturer in the Elkhart-Goshen, Indiana area, home to that industry’s leading producers of motor homes, fifth wheel campers, trailers and other vehicles. According to the customer, the results of this installation have included more stability in the platforms, which frequently bear the load of multiple workers, considerable raw materials and all the tools necessary to perform the various assembly operations.
At this manufacturing location, unlike a conventional parallel orientation assembly line, the frame and the axles move perpendicular to the work stations, on rail track-mounted dollies. Owing to the highly customized nature of the RV industry, it is frequently necessary for one-off assembly operations to be performed in sequence, as the content of a day’s quota. Plus, given the height of the units, these work platforms are invaluable assets to the production process at the company. In this case, work platforms were engineered and built to enable faster access from both sides of the unit.
With the work platform concept, the units can now be rolled from one station to the next, allowing the various build-ups to occur in sequence. As each step in the manufacturing process is completed, the entire work platform is raised. Because of the length of the platforms, (up to 30’) and the weight load bearing requirements (typically several hundred lbs. of materials and 1-2 workers per side), stability was a key issue.
One of the engineers at the integrator comments, “We’d seen the cylinder rod lock concept in a trade magazine article and contacted Advanced Machine & Engineering to discuss our needs. On each corner of the lifting system, the rod lock would need to attach to the platform and a separate rod installed for the Amlok.”
The Amlok® design, originated by AME, allows free movement of the cylinder during normal operation. When the lift system is stopped or when air pressure is lost, the locking mechanism secures the load in position until released by the return of air
pressure. The positioning of the work platform is entirely controlled by the workers and is infinitely adjustable to the desired height for their cutting, routing, forming and riveting of the various materials used for construction and assembly of these RV units. Each 1-3/4” diameter rod is mounted to the floor of the factory and the rod lock follows it, riding along a guide mechanism designed by the integrator and AME engineers, in cooperation with the factory workers at the plant. Upon completion of work at each station, the platform is raised to the top park position, where the Amlok is engaged in the locked condition, the RV unit is transported to the next station and the platform is loaded with the next unit’s required materials. Each worker’s complete toolbox remains on the platform throughout the work shift.
The Amlok rod locks used in this application are the company’s fourth generation design and prevent the typical problems encountered with most large scale air movement systems, namely, over-travel, bouncing, drifting and reverse travel. The patented intensifier mechanism of the AME rod lock is spring-operated to lock and is released by normal 60-160psi air lines. These devices were deemed both cost-effective and functionally desirable for the work platform application at the RV builder.
On this project, AME supplied the rod locks, mounting brackets and all hardware, while the integrator supplied the controls, pressure valves and all pneumatic circuitry to match the plant’s existing air lines, which were substantial, given the number of air tools used in the manufacturing process here.
Following the installation, the RV builder commissioned an independent engineering firm to fully certify that the work platforms met all relevant codes. This certification has been received.
Worker satisfaction with the system and the platform stability has been found to be very high, as well.
For technical questions on this story or the Amlok devices, please contact Ken Davis (ken@ame.com) or Shane Hatfield (shane@ame.com), the AME engineers on the project.
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Advanced Machine & Engineering Co., is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components, workholding devices, and, through our sister company, Hennig, machine enclosures, chip removal and filtration systems. The Fluid Power – Safety markets are served with cylinder rod locks and safety catcher devises; and the Production Saw market with our Amsaw carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Hennig, Inc. design and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the U.S., Germany, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
For more information, contact:
Tim Waterman
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham St.
Rockford, IL 61103
Phone: 815-316-5277
Fax: 815-962-6483
E-mail: info@ame.com
Connect with AME online:
Flying optic design with dual shuttle tables, each 26’ x 8’, said to be only laser in industry with cutting head covering entire workspace without repositioning table
Han-Kwang USA announces the introduction of its largest laser model, built to date. The FS8025 is a flying-optic CO2 laser cutting system with dual shuttle tables, each measuring 26’ long by 8’ wide. This laser system is immediately available for sale in the North American market.
Powered by either a 2.5KW, 4KW or 6KW Panasonic laser resonator, the FS8025 is the only laser in industry on which the cutting head can cover the entire 26’ x 8’ worktable area without repositioning the table in process, according to the manufacturer.
All other currently available laser machines must reposition the table to process such a large area, resulting in longer cycle times and severe limitations on the cutting of very long, continuous part surfaces. Also eliminated are the inherent inaccuracies that result from repositioning the table in process.
Other features on this new machine line from Han-Kwang include a Siemens 840D CNC, the builder’s unique Constant Beam Distance System (CBDS), automatic edge detection and sheet axis realignment, quick-piercing cross-jet system, multi-pulse piercing, high-speed cutting head and synchronized twin servo motors on the gantry with auto-focus control.
According to Robert Won, Han-Kwang vice president for North American operations, “Our company has developed this very large laser system, following years of research and testing. The first several units have already been produced and installed at customer sites in Taiwan and Korea. We are now in full production at our factories. Another FS8025 will be installed soon.”
Won also detailed other models of the large table laser systems in this new line from Han-Kwang, including FS8020, FS6025, FS4025 and FS4020. All models are currently in production.
Interested parties should contact the company or their local Han-Kwang dealer for details.
Full machine specifications may be found at http://hankwangus.com/fs8025.html
For more information or to arrange a visit to Han-Kwang, please contact:
HAN-KWANG USA INC. 1120 Garfield Street Lombard, IL 60148 Phone: 630-916-0200 Fax: 630-916-0300 Web: www.hankwangus.com Email: salesusa@hankwang.co.kr Attention: Robert Won, Eric Kim or Jane Lee
Agency contact: Tim Daro Bernard & Company tdaro@bernardandcompany.com 847-934-4500
Release: HAN-KWANG USA INC.
Date: May 1, 2010
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No. 1015 is an electrically-heated 500°F(~260°C) combination airflow walk-in oven from Grieve, currently used for preheating molds to be filled with metal alloy at the customer’s facility. 40 KW are installed in Incoloy sheated tubular heating elements. Workspace dimensions are 48” wide x 48” deep x 120” high. A 3,300 CFM, 2-HP recirculating blower provides combination airflow to the oven.
The unit has a 2” insulated floor with truck wheel guide tracks, an aluminized steel interior and exterior and an interior oven light. The roof has a 4” square access port and a 8” x 10” double pane Pyrex window that is adjacent to the access port.
Controls onboard No. 1015 include a digital indicating temperature controller, an adjustable, thermocouple actuated, manual reset excess temperature controller and 30-hour shut down timer.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank Calabrese.
Gear grinding using special fixturing to support the weight and torque
Q & A with N.K. Chinnusamy, president of Excel Gear, Inc., Roscoe, IL
1. What are the challenges when machining gears for wind turbines?
Gears for wind turbine applications are typically large in diameter and have wide face widths, requiring very exacting material composition and heat treatment processing. The gear design must be optimized to insure low rolling resistance and long life, owing to the extreme costs of maintenance, down time, and repair of the gear box assemblies once they have been commissioned in the field. Every step in the manufacturing phase of these gears must be carefully processed, documented, and controlled to achieve the high quality, consistency, accuracy, and reliability that is demanded for operation in these environments.
The use of carburized steel for these gears is common and the associated heat treatments and stress relief operations have to be exacting to minimize part distortion and growth, as well as to achieve the proper metallurgical properties required. Oftentimes, a preheat treatment of the forging or bar stock is necessitated on these large gears to minimize part distortion. In addition, one of the seemingly small but critical techniques to minimize distortion on gears is the vertical insertion of the gear into the quench tank during the hardening phase.
Heat treatment can cause cracks as well, so careful processing with predetermination of stock allowance for grinding and final case depth must be considered. Inspection for cracks with magnetic particle inspection and for grinding burns utilizing nital etching is an important inspection tool.
Finally, off center crown grinding of the tooth geometry may be needed to properly distribute the load on the gear teeth.
2. What modifications, if any, are needed in the tooling or the machine tool, to make gears for this application?
Helical gear grinding of large wind turbine gearbox components often requires off-center crowning to centerload the gear in operation.
Rigid, heavy-duty hobbing machines are needed for the coarse pitch gears, using roughing hobs or gear milling (gashing) cutters. Likewise, coarse pitch diamond dressing rolls and special grinding wheel abrasives are required for the large, high-accuracy gear grinders to produce efficient, accurate results and to prevent grinding burns and cracks.
The cutting fluids used must have the proper viscosity, the right amount of extreme pressure additives, and must be directed to the exact location of the work piece and cutting tool interface to maximize results. These fluids have to be routinely sampled and adjusted for optimum results.
3. Likewise, in building the gearbox, what special considerations must be taken into account?
Establishing the correct bearing clearances/preloads is critical to long life and proper gearbox operating temperature. Sophisticated measuring techniques with bearing inspection gages can only insure these results. The type and method of lubrication and proper sealing weighs heavily on the performance of a gearbox. The verification of gearbox performance through computerized analysis and testing is a crucial step to insuring long life.
4. What are some of the ancillary requirements in gear prep for wind turbines?
Special work holding and fixturing is an obvious consideration to bear the weight and to reduce the vibration and movement of the gear blank while hobbing or roughing. Careful and uniform torquing of the clamping fasteners during these operations prevents work piece movement and distortion of the gear blank during the roughing operation. The gear blank must have accurate mounting and indicating surfaces to control the pitch line runout to critical features (bearing journals, splines, etc.) and for minimal lead error.
5. Last thoughts?
CMM inspection of the complete gear and spindle must be done to achieve the proper parallelism
The critical factor here, as with all similar power transmission applications, is that the gears are properly designed and manufactured. The other mechanical components that make up the assembly, along with the gearing, must be applied/designed so the overall system performance does not have any shortcomings that could affect the performance and life of the unit. Then if the sub-assembly/assembly is carried out with real precision and care, a favorable outcome is sure to follow.
Excel Gear, Inc. is a total service company, specializing in the design, manufacture and analysis of coaxial gearboxes, custom built gears, helical/bevel gearboxes, internal gears, spur gears, worm gears, gear-driven high-speed machine spindles, CNC gimbal heads and wind turbine gearbox components. The company performs full FEA and vibration analysis, plus complete metallurgical and heat treatment evaluation.
For more information on this interview, please contact:
EXCEL GEAR, INC. 11865 Main Street Roscoe, IL 61073 Phone: 815-623-3414 Fax: 815-623-3314 Web: www.excelgear.com Email: sales@excelgear.com N.K. Chinnusamy, President
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