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Reliable rotary motion power can be affixed above or below systems
The lightweight feature of our gearboxes allows them to be installed above or below systems, giving you the most flexibility in meeting the demands of your power needs. And they’re effective at handling demanding applications that require a compact footprint, without sacrificing torque capacity.
Our well-tested and extremely reliable internal roller gear provides a wide range of torque and ratio combinations. The option for gear metrix ranges from 1” to 48”.
Our gearheads can be customized to specify: housing dimension and bolt; patterns; input and output shafts; and size.
Units are available in 5:1, 4:1, and 3:1 ratios for single stage and 9:1 up to 125:1 for double and triple stage. Ratios can reach 1000:1 and higher. Housings are available to fit IEC or NEMA configurations.
The modularity feature of our gearboxes allows for maximum flexibility at all stages. These units:
• Pack more power in less space
• Are lightweight but durable
• Allow for easy and quick maintenance, instead of replacement
• Are ideal for mission critical equipment
We offer short-run quantities at competitive prices, and have many in-stock units from which to choose.
QED Wind Power uses Gearing Solutions’ YAW drives in its wind turbines
When QED Wind Power began looking into redesigning its 20 kW turbine, the components were all made in China. The team wanted American-made parts to ensure quality control and better access to repair parts. QED got its wish, and the Phoenix is a veritable tour of American manufacturing: blades from Texas, meteorological sensors from Oregon, and the yaw drive from Gearing Solutions in Ohio.
In keeping with the Betz limit, wind turbines can’t harness more than 59% of the wind’s kinetic energy. (If a wind turbine was 100% efficient, there would be no wind left to turn the blades). To increase electrical generation and get as close as possible to that 59% limit, wind turbines rely on yaw drives to point the blades in the direction of the wind. Even with the drives, however, utility-sized wind turbines only get to within 75% to 80% of the Betz limit.
QED Wind Power manufactures the Phoenix 20-kW wind turbines which generate up 50,000 kw-hr annually (assuming a 20-knot wind), enough to power a mid-sized farm or up to eight homes. Yaw drives from Gearing Solutions, which keep the blades turned into the wind, are a critical factor in keeping QED’s turbines turning and making as much electricity as they can.
When QED began looking into redesigning its 20 kW turbine, the components were all made in China. The team wanted American-made parts to ensure quality control and better access to repair parts. QED got its wish, and the Phoenix is a veritable tour of American manufacturing: blades from Texas, meteorological sensors from Oregon, and the yaw drive from Gearing Solutions in Ohio.
QED talked with several yaw drive suppliers before choosing Gearing Solutions, but they wanted to sell the team off-the-shelf products which could not take full advantage of the design or supply their specific needs. The engineering staff at Gearing Solutions talked with QED several times before coming up with a custom prototype that would meet its needs.
The prototype had a stronger, more durable shaft and could use a three-phase 1.5-hp motor as the drive motor. The drive was also designed to use grease discs rather than gear oil to simplify maintenance. After several months of testing and revisions in shaft size and material, the new yaw drive was ready.
It combines roller-gear technology with innovative gear construction to optimize the gearbox and minimize size. It is 50% shorter than standard gearboxes and can handle over 30 hp. With the addition of an internal roller gear, driver, and several planetary gears, the new drive handles loads more than three times the size of the earlier drive, and aluminum housings make the drive 50% lighter, lowering the weight-to-torque ratio and increasing the power-to-weight ratio. The lower weight simplifies installation and repairs—both critical when working at height in a tight space. The smaller size also lets the turbine’s nacelle be lighter and more aerodynamic.
Despite their lighter weight, the yaw drives are still durable enough to provide years of trouble-free service. Many have been in continued service for more than five years with no downtime.
To view the full article visit Machine Design.
Investment in new equipment helps advance our CNC services
From prototype through high-volume production, we manufacture machined housings from solid aluminum, giving us the capability to machine a variety of housing designs with minimum tooling. We can provide you with high precision, geometrically complex, milled components with very tight tolerances.
We recently invested in two new CNC lathes to meet the demands of this market.
Product highlights include:
• Machined housings from solids
• Short run capabilities
• High precision, geometrically complex parts
• Milled components with very tight tolerances
The sophisticated CNC programming software eliminates separate routing and gives our operators more control. Our skilled tradespeople are able to inspect completed parts right on the machine, and can even compensate for variables such as atmosphere and temperature, which improves quality.
Contact us with your requirements. We offer quick turn around on precision parts for your most complex applications in the industrial, green energy, medical and aerospace markets.
Take a closer look at our engineering services
To swing the mixer blade on the food-grade equipment, our customer wanted to switch from a 50:1 cone worm gear to a 600:1 drive. With the 50:1 cone worm, the efficiency drops drastically.
The various commercial options included using double worms, which are shown to have poor efficiencies, or undergoing a complete redesign of the equipment. And we all know a complete redesign can be very expensive.
The customer reached out to Gearing Solutions to see what ideas we had to help. Our suggestion was to install a Gearing Solutions 12:1.
The solution saved the company thousands of dollars and many hours of down time.
Our Engineering Services include:
• Reverse Engineering to help with gear replacement or recreation;
• Design for Manufacturability, allowing for early discovery of potential problems;
• Redesign, whether it’s a new gear or improvements to an existing; and
• Digital Transmission Automated Program that sorts through thousands of possible combinations, narrowing the options down to the top 4 or 5.
DTAP (Digital Transmission Automated Program)
Our Digital Transmission Automated Program (DTAP) will save you, the end user, substantial engineering time and expense, by simply sorting through thousands of possible combinations, narrowing the options down to the top 4 or 5. This is a free service offered only by Gearing Solutions.
We’ve helped countless customers create the exact solutions they need, and we’d love the opportunity to do the same for you. Please do not hesitate to contact us at 440-498-9538.
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