MARCH 2023

Fluid Power:
IFPE Preview
Off-Highway
Smart Systems

TECHNICAL
Ball Bearing Inner Ring Creep and Fit
Weight-Optimized Wheel Bodies in Gear Drives

Power Transmission
Engineering is POWERED
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Manufacturers Association
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 CONTENTS

MARCH 2023

A Publication of
The American Gear

[24]
Manufacturers Association

FEATURE ARTICLES [42]

[16] Making the Move to Digitalization
and Electrification
Fluid power and motion control take center
stage at IFPE 2023. TECHNICAL ARTICLES
[24] Peering into the Crystal Ball on
Condition Monitoring Technology [38] Ball Bearing Inner Ring Fits and
The future of smart components for motion Creep
control systems looks bright. The ball bearing design process starts with
inner ring fits, and if you mess this part up
[32] The High Demands of Off- early, it can be difficult to fix later.
Highway Drive Systems
Customization takes center stage in the push [42] A Model for Considering Wheel
for more efficient motor, brake, and drive Body Deformation in Tooth
concepts. Contact Load Distribution
Reducing the wheel body mass reduces
energy consumption but also has an effect
on load bearing capacity and noise
performance.

Stay Connected

Connect with us on LinkedIn

Follow us on Twitter Subscribe Online
linkedin.com/groups/Power-Transmission-
twitter.com/PowerTransMag powertransmission.com/subscriptions
Engineering-PTE-2950055

Vol. 17, No. 2. POWER TRANSMISSION ENGINEERING (ISSN 2331-2483) is published monthly except in January, May, July and November by The American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, VA 22314, (847) 437-6604. Cover price $7.00. U.S.
Periodicals Postage Paid at Elk Grove Village IL and at additional mailing offices.
The American Gear Manufacturers Association makes every effort to ensure that the processes described in POWER TRANSMISSION ENGINEERING conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the
procedures described. Postmaster: Send address changes to POWER TRANSMISSION ENGINEERING, 1001 N. Fairfax Street, Suite 500, Alexandria, VA 22314. ©2023 Contents copyrighted by THE AMERICAN GEAR MANUFACTURERS ASSOCIATION. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. Contents of ads are subject to Publisher’s approval.

MARCH 2023 Power Transmission Engineering 1

 CONTENTS

KEEP TURBINES
IN MOTION
VOL. 17, NO. 2

[04] PTExtras
Revolutions blog on heat dissipation
through e-drives and an early look at
Automate 2023; Training spotlight:
Elgeti Engineering offers online
bearing seminar.
[06] Publisher’s Page
Thanks, Team!
[08] Product News
Force Control eliminates downtime at
a lumber mill; SKF streamlines bearing
analysis in ANSYS; Kollmorgen
launches new stepper drives; Thomson
releases compact linear drive system;
Bosch Rexroth software for mobile
robotics; and more.
[36] Engineering sMart
Products and services marketplace.

Extend Turbine Service Life and Output. [52] Industry News

IMTS and SPS organizers join forces on
Enduring immense and dynamic mechanical stress, NSK automation trade shows.
Super-TF bearings for main shafts are built to outlast and
outperform conventional solutions. Through advanced [53] Calendar
materials and process controls, STF bearings withstand
Upcoming events in the power transmission
industry.
wear to deliver a longer and more reliable operating life.

Nine of the world’s top ten wind turbine manufacturers

[54] Advertiser Index
Contact information for every advertiser in this
use NSK bearings. Find out why. Visit NSKAmericas.com
issue.
[55] Subscriptions
Renew your free subscription today.
WWW.NSKAMERICAS.COM
[56] Power Play
Metaphor: An Object in Motion.

2 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 .r, ....
Jl ltlt

- ,•�
Solut�ons
Podcast
Series

-
Listen any time
to ABB Solutions Podcast

Do you have challenges? We have solutions.

Listen and subscribe to the ABB Solutions Podcast as we discuss solutions to your everyday
motors and drives challenges.

ABB Solutions Podcast is available on your favorite streaming service.

abbsolutionspodcast.buzzsprout.com
 PTExtras

AGMA MEDIA
1840 Jarvis Avenue
Elk Grove Village, IL 60007
Phone: (847) 437-6604
Fax: (847) 437-6618
®

PTE Revolutions
A Look at Heat Dissipation Through EDITORIAL
E-Drives Publisher & Editor-in-Chief
Randy Stott
Heat is also generated in an e-motor, sometimes quite a bit. [email protected]
In demanding applications, the motor electronics cause Senior Editor
the power to be throttled or even shut down completely. Matthew Jaster
[email protected]
But there is another clever way
to protect an electric motor from Senior Editor
Aaron Fagan
overheating without losing power: [email protected]
using a thermally conductive GRAPHIC DESIGN
casting resin as a heat transfer Graphic Designer
medium. The principle can also be Jess Oglesby
called a static solid cooling system. [email protected]

powertransmission.com/blogs/1-revolutions/post/9060-a- ADVERTISING
Advertising Sales Manager
look-at-heat-dissipation-through-e-drives & Associate Publisher
An Early Look at Automate 2023 Dave Friedman
[email protected]
The leading automation showcase in North America, Materials Coordinator
Automate, is back in Detroit May 22-25, 2023, with the latest Dorothy Fiandaca
in cutting-edge robotics, vision, [email protected]
artificial intelligence, motion CIRCULATION
control and more. Produced by Circulation Manager
the Association for Advancing Carol Tratar
[email protected]
Automation (A3), Automate
delivers the latest innovations MANAGEMENT
President
in manufacturing automation Matthew Croson
technology from more than 600 [email protected]
leading exhibitors.
FOUNDER
powertransmission.com/blogs/1-revolutions/post/9077-an- Michael Goldstein founded Gear Technology in 1984 and Power
early-look-at-automate-2023 Transmission Engineering in 2007, and he served as Publisher and
Editor-in-Chief from 1984 through 2019. Michael continues work-
Training Spotlight ing with both magazines in a consulting role and can be reached
via e-mail at [email protected].
Elgeti Engineering Offers Online Bearing
Seminar
Elgeti Engineering once again is
offering its online bearing seminars
for Spring 2023. Special packages
are available for online 90-minute
sessions. Topics include basics of
bearing technology, application
engineering, bearing supplier
development, and failure analysis.
powertransmission.com/articles/9088-elgeti-engineering-
offers-online-bearing-seminar-spring-2023

powertransmission.com

Cover photo courtesy of Danfoss

4 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 EDITORIAL
Randy Stott
Publisher & Editor-in-Chief

Thanks, Team!
As I read through this issue of Power Transmission Engineering, I’m reminded
of exactly how much hard work goes into producing this publication eight times
per year. I thought it would be a great idea for you to get to know a little bit more
about the team whose work, too often, goes unrecognized.

Dave Friedman, Associate Publisher. In addition to happen to have photos showing power transmission devices
being a talented veteran of trade magazine publishing, Dave being used in great applications, email [email protected].
is one of the most thoughtful marketing minds I know. As Megan Harrold, Digital Content Specialist. Since she
our advertising sales manager, he’s the front-line contact joined our team at the beginning of 2021, Megan has been
with many of the suppliers you read about in every issue. His the engine that drives our digital efforts. If you’ve visited
knowledge of the industry has been indispensable in help- our website or read one of our e-mail newsletters, you can
ing us shape the direction of this magazine since he joined thank her for making sure all the right content is in all the
us in 2009. He’s genuinely interested in helping our advertis- right places and delivered to you in a timely manner. Let her
ers succeed, and his consultative approach, combined with know you appreciate her work at [email protected].
his many years of experience and knowledge, go a long way Carol Tratar, Circulation Manager. Since 2003, Carol has
toward making sure that the ads you see are the ones most been the one to make sure you get the magazine on time and
relevant to what you do. If you’ve ever thought about adver- delivered to the right place. If you have an address change,
tising, email [email protected], and I’m sure he’ll help or if you haven’t renewed your subscription in a while, email
you come up with a plan that makes sense. [email protected], and she’ll help you get it sorted out!
Matt Jaster, Senior Editor. Since we launched PTE in Dorothy Fiandaca, Materials Coordinator. Last but
2007, Matt has been the primary editor responsible for what certainly not least, Dorothy is the glue that holds everything
you read here, as well as online at powertransmission.com, in together. When you call us on the phone, she’s the one who
our newsletters, and on social media. If you’re a subscriber answers. More importantly, she’s the one who manages
and you’ve enjoyed reading our magazine, Matt deserves thousands of pieces of advertising material each year, and in
much of the credit. He’s been to countless trade shows and today’s increasingly digital age, that job becomes more and
industry events, bringing you the latest information about the more complex every day. But if you’ve had the chance to talk
technology of mechanical power transmission and motion with Dorothy, you’ve probably recognized, as I have, that
control. He talks to the people who make gears, gear drives, there couldn’t be anyone more dedicated to getting things
bearings, couplings, clutches, brakes, linear motion, motion right and making sure our customers are taken care of. If you
control and much more. He has his finger on the pulse of need anything from our organization, you can’t go wrong by
the latest trends affecting how those components are used starting with [email protected].
in machines, and his in-depth features keep you informed In my 29 years of publishing, I’ve never been a part of a
about how those trends might affect you in the years to come. stronger team. I thank them for their hard work, and I look
If you have ideas for articles, send them to [email protected]. forward to many more years working with all of them to
Aaron Fagan, Senior Editor. Although he has only been bring you one of the best technical magazines in the world.
with us for a little more than a year, and although he spends

P.S. I’ve listed

most of his time working on our sister publication, Gear
Technology, Aaron is a key member of our editorial team.
His attention to detail and ability to understand complex everyone’s e-mail
engineering subjects are one of the reasons we’re able to
produce some of the best technical content related to power address above. Please
transmission technology. Let him know you appreciate his do me a favor and
work at [email protected].
send each of them
a note to let them
Jess Oglesby, Graphic Designer. Jess joined our team
in August 2022, and I hope you’ve noticed the improvements
in the overall presentation of our magazine. Our feature arti- know that you
cles and technical articles have never looked better. If you
happen to be reading this online, then you can also thank appreciate their
Jess, because she’s the one who makes sure the great expe-
rience you have in print also translates to the websites. Jess
work.
is always looking for great cover art for our magazine. If you

6 Power Transmission Engineering MARCH 2023

 PRODUCT NEWS

Force Control strikes the backstop, at which point

the process repeats itself.
ELIMINATES DOWNTIME FOR The drive motor was originally fit-
INDUSTRIAL LUMBER SAWMILL ted with a dry-friction brake. However,
For nearly 50 years, AJD Forest Products continual activation of the brake (1,400
has been producing top quality indus- and 2,400 cycles per day) was creating
trial lumber for the Lake States region. a maintenance nightmare. On average,
Located in Grayling, Mich., the company brake discs were being replaced every
has earned a reputation for supplying three weeks or so. Furthermore, the
high-grade red oak, hard & soft maple, brakes’ heat of engagement was burn-
aspen, ash, and basswood. The mill ing up transformers leading to more
processes 1,700–2,000 logs, or 70,000– failures and unplanned downtime.
90,000 board feet of lumber a day, but “We were burning up the transformer
constant maintenance and adjustment because the brake pads would get so contact with the control voltage, so
on their stacker and chain conveyor hot that the transformer would melt,” that once the motor is engaged, the
brakes were forcing unplanned down- said Electrical/Automation Technician brake is disengaged. It is instanta-
time. And that was cutting into the saw- Damian Fleischmann. “The repetition neous on both.”
mill’s profits. Since retrofitting their dry- and the friction were causing so much Fleischmann recalls that when he first
friction brakes with Magnashear motor heat that it was just burning everything saw the proposal, he was a little worried
brakes featuring Oil Shear Technology, up inside.” about the price. But after six months of
AJD has eliminated brake maintenance Replacing the brake discs was chal- continuous uptime, he was convinced.
and adjustment, and thus unplanned lenging because the discs first needed Although he did not perform a formal
downtime. Now with the mill running to cool-off as to not burn the techni- ROI calculation, he figures “it was a year
smoothly, oil shear brakes are helping cians replacing them. payback at most, probably sooner.” And
AJD Forest Products cut more boards “We’d wait five or 10 minutes at it is still operating, maintenance-free
without slashing profits. least for them to cool down, “recalls three years later.
Fleischmann, “then it was another 10 “If we ever have another project that
A Critical Path Approach or 15 minutes to swap out the pads. If requires repetitive braking, we’ll defi-
A conveyor chain feeds logs into a the transformer that steps down the nitely use Force Control” he said.
sawing station which cuts each side of 480 V from the motor to the 240 V or
the log. The log then continues down 120 V for the brake is damaged, then Stacking Up the Benefits
a conveyor until reaching a backstop, the process takes a lot longer.” The installation that Fleischmann’s
tripping a sensor that engages the After tallying up the cost of brake pads, production manager recalled was a
motor and releases the brake on a sec- the labor to replace them, the inven- stacker. “We have the Force Control
ond conveyor which is perpendicular tory cost of stocking complete brakes in brake on a lift at our stacking station”
to the first. This second chain conveyor case the entire transformer assembly recounted Fleischmann. “Boards are
incorporates lugs. Once engaged, failed, and the unplanned downtime that presented to the stacker individu-
logs travel approximately four feet resulted from brake failures, the team at ally, and the stacker slides six to eight
or so to another conveyor which car- AJD began searching for a better brak- boards onto the lift.”
ries the lumber onto further process- ing mechanism. In addition to the cost of The lift then drops down anywhere
ing. After depositing the log, the lugs brake pads, the labor to replace them, and from an inch and a half to three inches
trip another sensor which engages the the cost of complete spare brakes stocked depending upon the height of the
brake and stops the motor, which in in case of total failures, unplanned down- boards. It drops below the sensor to
turn stops the chain until the next log time meant lost production. Clearly there allow space for the next row of boards
had to be a better way. to slide onto the lift.
When considering their options, Occasionally, the boards are two-
the mill production manager recalled by-fours, sometimes two-by-sixes, or
a Force Control Oil Shear Brake in two-by-eights, but they can also han-
another location of the mill that was dle three-by-sixes and three-by-eights.
operating smoothly without downtime Therefore, the weight of the lift varies,
for maintenance or adjustment. After but the reaction time and position-
conferring with local manufacturer’s ing of the Force Control brake is pre-
representative, Dave Dilworth, they cise each time. Depending on the line
purchased a MSB6 size Magnashear speed, the lift may cycle 75–100 times
which was quite easy to install. an hour.
“We have a mechanical starter on With the old braking system,
ours,” said Fleischmann. “I wired engaging the brake would generate
up the brake through an auxiliary heat, causing the friction material to

8 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

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 PRODUCT NEWS

glaze over. Consequently, this would “Other than changing the fluid every that the best kind of maintenance is
cause variance on the stopping dis- six months, you don’t have to do any- no maintenance.
tance which lead to necessary air gap thing to them,” said Fleischmann. forcecontrol.com
adjustments. Brake pads would also Eliminating maintenance and ajdforestproducts.com
wear out and require replacement. All increasing uptime is important any
of this maintenance and adjustment
meant the stacker was out of com-
time, but it is even more important
when faced with worker shortages. SKF
mission and the mill would remain “The maintenance on the old brakes STREAMLINES BEARING ANALYSIS
FOR ANSYS USERS
shut down until the brake could be was immense and a huge headache,”
repaired or replaced. recalls Fleischmann, “but since we’ve Machine designers increasingly rely
The MSB6 currently installed on the installed the Force Control Brakes, on earlier and more predictively accu-
lift has been in service since June of 2018 we haven’t had to touch them.” That’s rate simulations to accelerate product
and requires virtually no maintenance. high praise from someone who knows development, help eliminate errors
and reduce the need for physical pro-
totypes. In many mechanical systems,
such as gearboxes or electric drive-
trains, bearing performance is a critical

The
driver of overall system performance.
However, simulation of bearings

Power
is challenging since their behav-
ior depends on load characteristics
and fine geometric details that are

of One2
not readily available to designers or
simulation teams. With the new SKF
Bearing App for the Ansys mechani-
cal finite element analysis (FEA) soft-
Your Objective: ware, engineers no longer need to rely
One face in perfect alignment with another. For infinity. on approximations or complex, unre-
liable models in their simulations.
“With this new integration, we are
taking the burden of bearing simula-
tion away from the user’s system and
doing it ourselves” explains Hedzer
Tillema, product manager engineer-
ing software at SKF. “Our calcula-
tions consider the detailed contacts
No problems. No distress. No delays. between the rolling elements and
the raceways of the bearing, and full
That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.
details of the microgeometry.”
“The partnership with SKF is a great
One to 1000 gears example of empowering engineers to
Customer designed or reverse engineered gain detailed insight into the perfor-
mance of their designs early on” says
Gearbox repair, rebuild or redesign Mark Hindsbo, vice president and
OEM or end-users general manager, at Ansys. “No one
ISO 9001:2015 Certified knows bearings better than SKF and
that knowledge is now available to
every Ansys Mechanical user.”
1501 S. 55th Court, Cicero, IL 60804
In the Ansys integration, the user
(800) 637-9335
(708) 652-1000 / Fax: (708) 652-1100
first selects their chosen bearing
[email protected] using a user-friendly wizard. The App
www.circlegear.com

Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
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10 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

then communicates with a SKF cloud operating on 24–75 VDC with up to
server to obtain a predictively accu- 5.5 Arms current per phase (7.8 Arms
rate representation of the stiffness of a peak). It’s an ideal solution for labelers,
real bearing. indexing tables, CNC machines, pack-
The SKF Bearing App for Ansys can aging systems, pumps and other sin-
simulate any of approximately 10,000 gle-or multi-axis systems requiring low-
common bearings in the SKF range, speed, point-to-point motion control for
and its data is continually updated to fixed loads.
ensure that users always have access Building on the success of previous
to the most current, predictively Kollmorgen drives such as the 6410
accurate information. The app sup- and P70530, the new P80630-SDN drive
ports static as well as dynamic analy- delivers improved positional accuracy
ses where harmonics or vibrations are as demonstrated in laboratory tests
important considerations.
SKF cloud services are used to deliver
predictively accurate, up-to-date infor-
mation on bearing performance and
stiffness to a wide range of engineering
design tools. Customers can use these
services to calculate key performance
parameters such as bearing rating life,
friction, grease life and relubrication
intervals, static safety, and minimum
load. In addition to the new Ansys inte-
gration, detailed bearing stiffness mod-
els are also available for the KISSsoft
and FVA Workbench analysis platforms.
SKF software specialists are con-
tinually extending and expanding the
capabilities of these software inte-
grations, as well as extending the
approach to new platforms, including
customers’ proprietary in-house prod-
uct development environments.
skf.com/group/support/
engineering-tools/integrated-
skf-calculation-services
Performance
Kollmorgen Matters.
Powder
LAUNCHES THE ADVANCED P8000
SERIES WITH THE NEW P80630- Sinter-hardened eccentric ring with
SDN STEPPER DRIVE increased performance and wear

Metallurgy.
resistance.
Kollmorgen recently announced the
new P80630-SDN stepper drive. Cus-
tomers can now benefit from fea- Register today and save!
tures such as smoothness, preci- America’s leading
PM and metal AM
sion and torque across the full speed conferences
range in a significantly more com-
pact package that enables smaller,
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Kollmorgen will also be introducing
additional stepper drives and fea- Drive, driven sprockets, pressure
tures in the coming months, build- plate, and sector gear provide critical
ing upon the new, flagship P8000 torque management.
stepper drive platform. PowderMet2023.org / AMPM2023.org
The P80630-SDN stepper drive Learn more at PickPM.com.
© 2023 Metal Powder Industries Federation June 18–21, 2023 • Caesars Palace, Las Vegas
powers and controls stepper motors

MARCH 2023 Power Transmission Engineering 11

 PRODUCT NEWS

using PMX series stepper motors. This

compact, powerful new drive achieves

FORGING
10 percent greater output current in a
60 percent smaller package that is up to
34 mm shorter in height than the 6410,

AHEAD
depending on the model. Moreover, tems that makes it easier for motion
it reduces setup time by delivering designers to implement complex
smooth, precise performance at all applications in small spaces. Design-
speeds without the need for electronic ers needing thrust and bearing sup-
damping control switches. port in a single, compact unit now

OF THE
The P80630-SDN stepper drive sup- have the flexibility to build such appli-
ports conventional single-ended or dif- cations with versatile, time-tested
ferential step and direction interfaces components from Thomson.
(user-provided pulse train required) "As demand for smaller-scale appli-

PACK
or CW/CCW command inputs. Dip- cations grows, so does the challenge
switch selectable settings include motor of packing high functionality into a
phase current, idle current reduction smaller footprint. Our new family of
and step resolution up to 1/128 micro- compact linear motion systems equips
step, all with no programming required. designers to meet those challenges by
Dedicated enable input and fault out- assembling world-renowned Thomson
put provide control of the drive's power linear motion components, with the
stage and error monitoring. Additional added option of real-time collabora-
models with new features are sched- tion with one of our engineers,” said
uled for release in the coming months. Matt Palmer, product line specialist—
Selected drives will also include widely linear motion systems for Thomson.
used fieldbus protocols for integration In building a Thomson compact lin-
with industry-standard motion control- ear system, a designer can configure
lers. All drives in the series are CE, RoHS a unit or combination of units from a
and REACH certified. wide variety of components based on
As with all Kollmorgen products, their specific application details.
customers can count on the support Many features can be custom-
they need to optimize motor/drive ized, including screw diameters and
selection, sizing, setup and perfor- leads, mounting holes and mount-
mance. Worldwide product availabil- ing configurations.
ity and Kollmorgen’s proven heritage To enable engineers to take maxi-
Fast. ensure long-term project success. mum advantage of such flexibility,
No Fine Print. “The P80630-SDN is the highest-per- Thomson offers an innovative new
No Premium. forming, most versatile stepper drive
in our lineup,” said Ross McMillan,
3D modeling tool that optimizes their
solution by revealing design tradeoffs
At McInnes Rolled Rings, we vice president of engineering at in real time. The tool, in collaboration
Kollmorgen. “And it’s just the begin- with a Thomson engineer, guides the
provide quality products,
ning. The new P8000 series will soon designer in tailoring motor size, stroke
shipped fast. And we partner offer an expanded range of drives to length, and other variables to function
that with exceptional power and control Kollmorgen step- most effectively within given load and
customer service to forge the per motors in a wide variety of appli- space parameters.
perfect partnership with our cations where steppers are the best The resulting designs go directly to
customers. choice. It’s always exciting to extend the Thomson product CAD system,
our lead in the motion-control indus- where the information is used to pro-
try and better serve our customers’ duce the prototype sent for testing.
most challenging requirements.” Because of such close user involve-
kollmorgen.com ment during the design process,
the number of design iterations is
Thomson reduced, which, in turn, decreases the
likelihood of mistakes being made.
1.877.736.4409 RELEASES COMPACT LINEAR
MOTION SYSTEM
www.McInnesRolledRings.com Applications
Thomson Industries, Inc. has intro- Thomson compact linear systems are
duced a family of compact linear sys- appropriate for applications requiring

12 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

high-accuracy linear axes in confined evaluate the signals from a laser sen-
spaces, such as 3D printers, microscope sor in the vehicle and convert them
stage managers, medical pipetting sys- into coordinates in space. No perma-
tems and semiconductor manufac- nently installed aids, such as markers
turing. They are available with NEMA or reflectors, are required for orienta-
motor sizes between 14 and 23; stroke tion and position determination. Users
lengths of up to 40 in (1,000 mm); and only need one click to start up the sys-
load capacities up to 2,091 lbs. (9,300 N). tem and familiarize the unit with its
thomsonlinear.com surroundings in a one-time orienta-
tion trip. An intuitive user interface
Bosch Rexroth based on 3D technology is provided
for this purpose. The software maps an
LOCATOR SOFTWARE OFFERS initially unknown environment and
FLEXIBILITY AND USABILITY FOR
automatically creates a map.
MOBILE ROBOTICS
Locator stores this map on the vehi-
With Bosch Rexroth’s ROKIT Locator cle itself, or optionally on an on-site
software, mobile robots can indepen- server component, also offered by
dently determine their position. Users Bosch Rexroth. If several mobile units
no longer need expert knowledge or are used, they all access this map.
additional infrastructure to commission Afterwards, immediate localization is When other manufacturers’
a mobile robot. Locator allows mobile possible without initial knowledge. keep you on hold.
robots to determine their position and
orientation in any environment, sim-
If a vehicle detects a change in the
environment, such as when setting up a We Pick Up.
plifying the automation of intralogistics
tasks in industry and trade. Locator is
new storage location, it sends this infor-
mation to the server, which automati- When You Call.
compatible with various industrial con- cally updates the map accordingly and
trollers and laser sensors on the mar- sends it to all the mobile units in the
ket and is suitable for mobile units of all fleet. Mobile units purchased subse-
sizes and drive types. quently with the Locator take over the
Until now, many users have shied server data when they are put into oper-
away from the effort required to ation and can drive off immediately.
introduce autonomous guided vehi- The Locator can be used in a wide
cles (AGVs) and autonomous mobile variety of vehicle types, industries, and

Call WorldWide
robots (AMRs). Project durations are applications. The software is indepen-
often several months, and the areas dent of the hardware used by a vehi-
of application in the facility must
be equipped with marking strips,
cle manufacturer. As an encapsulated
function block, it fits into numerous
(800) 808-2131
worldwideelectric.com
reflectors, or mirrors. Afterwards, control systems and supports a wide
specialists must manually train the range of laser sensors, including safety
mobile units to effectively navigate lasers. Locator is already being used by
their environment. various AGV and AMR manufacturers, Responsive Service
With Locator, this time-consuming including Bosch Rexroth’s MP1000R
process can be replaced with quick and ACTIVE Shuttle.
and easy commissioning, without boschrexroth.com Quality Products
requiring additional expert knowl-
edge. Locator enables the robots to
Siemens In Stock Availability

Sinamics Drive Fast Shipping

Series
ADDS FRAME SIZES FOR HIGHER
POWER RATINGS

Siemens is extending its Sinamics

G120C-series of drives to include three
new frame sizes for high power output
ranges. The new frame sizes cover the MOTORS | CONTROLS | GEARS
power output range of 22–132 kilo-

MARCH 2023 Power Transmission Engineering 13

PTE-2023.indd 2 2/8/23 10:13 AM
 TECHNICAL

sensorless vector control permits

high torque levels to be achieved at Timken
low speeds. Sinamics G120C drives PROVIDES BEARINGS FOR FORD’S
are ideal for applications such as ELECTRIC F-150 LIGHTNING
conveyor belts, mixers, extruders, The Timken Company recently an-
pumps, fans, compressors, and sim- nounced its packaged wheel bearings
ple handling machines. are being used on Ford Motor Com-
siemens.com pany’s F-150 Lightning, the first main-
stream electric light-duty pickup truck

watts (kW), making the series avail- Haydon Kerk to hit the market. Timken bearings on
the F-150 Lightning represent incre-
able from 0.55 kW–132 kW. Standard
features of the series include a com-
Pittman mental content per vehicle, compared
to its gasoline-powered counterpart.
ONLINE TOOL ENABLES QUICK
pact design with optional filter, long LINEAR ACTUATOR SELECTION “Customers call on us to serve as a
cable lengths, full integration into the trusted technical supplier, utilizing
Totally Integrated Automation (TIA) our application engineering expertise
Portal and simple control and com- to help them improve and differentiate
missioning. The G120C also includes product performance,” said Andreas
the “Safe Torque Off” function (STO) Roellgen, Timken executive vice pres-
which prevents a motor from uninten- ident, president Engineered Bearings.
tionally starting. “We collaborated closely with Ford’s
The three new frame sizes for the team to solve design challenges and
Sinamics G120C series include: FSD support their high standards for safety
(22–45 kW), FSE (55 kW) and FSF and performance.”
(75–132 kW), making this compact Timken was there to support Ford’s
series of drives ideal for applica- timeline and provide an informed per-
tions requiring higher power ratings. Haydon Kerk Pittman, a business unit spective on innovating product and pro-
The Sinamics G120C, with its total of Ametek’s advanced motion solu- cess technologies to address the emerg-
of seven different frame sizes for tions division, is pleased to announce ing electric vehicle (EV) trend. Timken
operation on three-phase line sup- its new Haydon Kerk Express online has been working for many years on
plies, features a particularly com- linear actuator calculator. advanced designs for EVs, evolving its
pact design, as components such The Haydon Kerk Express tool joins technology to create solutions that are
as the DC choke and EMC filter are the Pittman Express tool, released last lighter, smaller and more fuel efficient,
already integrated in the device. year, and allows users to now iden- yet capable of meeting the unique per-
This reduces the space required tify and select the right linear actua- formance demands of EVs, including
in the control cabinet. The design tor for their applications quickly and higher torque and load requirements.
of the drives also allows all of the easily. When a user enters an ideal Timken’s customized bearing designs
frame sizes to be lined up next to one actuator type, force, and speed, the are helping manufacturers like Ford
another without any derating. Express tool returns a list of Haydon switch to EV designs without the need to
The parameter settings of the Kerk linear actuators that fit these rethink their entire supply chain.
Sinamics G120C can easily be cop- specifications. Once the user selects Timken has a long-standing rela-
ied to an SD memory card and trans- a specific linear actuator to explore, tionship with Ford, dating back to the
ferred to other devices. This allows additional details—including per- production of the Model T in 1908.
the drives to be reliably cloned with- formance curves, specifications and Timken began providing the wheel
out additional technical support dimensional drawings—are avail- bearings for the F-150 Lightning in
and facilitates series commission- able. Haydon Kerk Express then pro- April 2022. Ford also uses Timken
ing with minimum associated costs. vides a list of exact and near-match bearings on its Expedition and Lincoln
Sinamics G120C drives can also be actuators available from Haydon Navigator SUVs, as well as other varia-
integrated into the TIA Portal sys- Kerk Pittman’s e-commerce site with tions of the F-150.
tem diagnostics and communi- 24-hour shipment for fast prototyp-
cate with Simatic controllers via ing or proof of concept.
Profinet and Profibus. This means The Express motor calculator is the
the control and drive system can be latest in Haydon Kerk Pittman’s series
intuitively programmed. The TIA of user-guided tools designed to pro-
Portal library concept ensures the vide interactive and enhanced prod-
drives can be easily reused, includ- uct assistance and selection as com-
ing their parameters and hardware pared to a traditional website.
components. The energy-efficient, haydonkerkpittman.com timken.com

14 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

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 FEATURE

Making the Move

to Digitalization and
Electrification
For Related Articles Search

fluid power
at www.powertransmission.com

Fluid Power and Motion Control Center Stage at IFPE 2023

Matthew Jaster, Senior Editor

The International Fluid Power Exposition (IFPE), Las Vegas March 14-18, is where fluid power professionals meet
to discover highly engineered solutions for improving mobile and industrial equipment's efficiency, perfor-
mance and sustainability. Attendees will also learn about the latest technology available to the industry and
network to discuss and combat the most pressing industrial challenges. From sensor technology and data analyt-
ics to robotics, custom software development, and industrial automation, attendees will experience the latest innovations in
fluid power. The show is co-located with CONEXPO-CON/AGG, the largest construction trade show in North America.
“The international audience for IFPE is significant,” said John Rozum, show director for IFPE. “These are the engineers, the
product planners, the executives from OEMs all over the world. The fluid power and motion control technology on display
at IFPE is what makes the construction equipment you see at CONEXPO-CON/AGG work, and that doesn’t change regard-
less of where the product is made.”
The following is a collection of products and technologies that will be on display during the show:

Regal Rexnord Highlights End-to-End Industrial human-ware, Regal Rexnord will be well positioned to deliver
Powertrain Solutions best-in-class solutions optimized for reliability, performance
Regal Rexnord (Booth #C32490) provides complete, end- and efficiency.
to-end and optimized electromechanical powertrains
for a wide range of applications and industries. Products
that have been engineered to meet specific application
requirements for endless potential. Regal Rexnord will
help customers to design, assemble and commission their
powertrains, and then enhance performance with inter-
net of things (IoT) monitoring via their Perceptiv intelli-
gence platform. The Perceptiv intelligence platform is an
interconnected matrix of smart, digital solutions bundled
with the Tag-It program to simplify asset management for
maintenance and procurement teams. It enables users to
reduce maintenance time, streamline the procurement
process and achieve inventory objectives by integrating
data silos. Plus, users can manage everything in one place regalrexnord.com
using the Perceptiv intelligence IoT platform.
This portfolio includes brands from both Regal and JW Winco Offers Coupling Technology
Rexnord PMC, including Regal’s Browning, Grove Gear, Couplings from JW Winco (Booth #S61913) transmit rotary
Hub City, Jaure, Kop-Flex, McGill, ModSort, Sealmaster motions and torques from shaft to shaft. They also even out
and System Plast brands, as well as PMC’s Berg, tolerances and mechanical deflection that would otherwise
Cambridge, Centa, Falk, Rexnord and Stearns brands, result in damage to drive or measurement configurations.
among others. JW Winco recently added couplings of aluminum and stain-
In addition to more robust solutions across the industrial less steel that include designs for positive and non-positive con-
powertrain, Regal Rexnord will have opportunities to provide nections. Multiple bore diameters, various, stiffness and hard-
customers IIoT and digital solutions by harnessing the com- ness levels of the coupling body as well as an optional keyway
bined capabilities of Regal’s Perceptiv and Rexnord’s DiRXN allow very specific customization to the given use case. In gen-
digital platforms. By integrating hardware, software and eral, all couplings compensate for offsets and misalignments,

16 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 PRECISE. ROBUST. AVAILABLE.

CD® Couplings
• Zero-Backlash & High Torsional Stiffness
• Engineered Performance for Reliable 24/7 Operation
• Servo-Rated for Reversing, Positioning & Precision
• Single-Flex, Double-Flex, Floating-Shaft Solutions
• Standard Models / Fully Customizable
• Engineering Assistance / Fast Delivery

www.zero-max.com 800.533.1731
 FEATURE Making the Move to Digitalization and Electrification

accommodate runout error and axial motion, and dampen shaft options, output flanges, motor attachments, and input
vibrations and impacts to varying degrees. options.
At the application level, there is a choice between posi- Maxxdrive XT industrial gear units drastically reduce
tion and motion control or torque and power transmission. spare parts costs and downtime through their univer-
For position and motion control, the rotary motion sal, symmetrical housing design for mirror image instal-
must be transmitted with very high precision and accu- lations. These units were developed for maximum ther-
racy. This requires a coupling type that functions with mal power and mechanical load capacities and due to
zero backlash in the direction of rotation and has high their ribbed housing, optimized axial fans, and air guide
torsional stiffness. Typical applications include servo covers, they can achieve very high thermal ratings with-
and stepper motors for linear axes, industrial robots and out the need for external cooling measures. Modularly
test benches. attached backstops enable easy maintenance access
For torque and power transmission, on the other hand, without costly downtime.
the focus is on pure force transmission. This calls for cou- Nord’s Unicase helical bevel gear units offer a wide per-
plings that can withstand high torques and heavy loads formance range of 0.16 – 268 hp and torque up to 442,537
while functioning reliably in harsh conditions. Typical lb-in. Specialized heavy-duty bearings and spread bearing/
applications include conveyor systems, pumps and agita- flange mount designs enable these units to produce high
tors, packaging machines. load capacity, minimum backlash, and long service life.
They also achieve a low Total Cost of Ownership (TCO) due
to their low maintenance and high efficiency for low operat-
ing costs. With numerous shaft designs, mounting options,
and bearing concepts, these versatile units are adaptable to
countless applications.
Unicase parallel shaft gear units provide reliable opera-
tion in a compact, robust design. Their single piece hous-
ing protects internal components from debris while deliv-
ering quiet operation, a long service life, and requiring very
low maintenance. They feature various VL bearing options
for maximum radial and axial load capacity, extensive shaft
designs, as well as versatile foot, flange, and shaft mounting
options. A wide range of configurable, specialized solutions
are available with 15 case sizes to choose from, performance
jwwinco.com up to 268 hp, and torque up to 885,075 lb-in.
Control cabinet variable frequency drives from Nord offer
Nord Introduces Latest Drive Solutions scalable functionality in a compact, cost-effective design.
Nord Drivesystem’s (Booth #S-85214) construction solutions They are compatible with both synchronous and asyn-
focus on reliability, high-efficiency, and versatility. chronous motors, provide a high degree of performance,
Maxxdrive XD industrial gear units are Nord’s heavy- and include functional safety options. Nordac Pro SK 500E
duty solution designed specifically for crane and hoist VFDs offer performance up to 215 hp and include an inte-
applications. They feature an extended center distance grated Ethernet interface with various optional modules for
to allow for a U-shaped design with the cable drum and extended functionality.
motor on the same side of the gear unit. Compared to Nordac Pro SK 5OOP VFDs are available in five flexible
Nord’s standard, compact Maxxdrive series, the XD frame sizes and feature multiple easy to use interfaces,
center distance has been increased by 35 percent. This high precision regulation and large overload capacities,
includes 3-stage and 4-stage reductions with same over- and full PLC functionality for adaptability to a wide range
all unit dimensions and center distances for a standard- of applications.
ized design, and various input and output shaft and cou-
pling options for easy adaptation to applications.
Maxxdrive industrial gear units deliver output torques
up to 2,495,900 lb-in, high load capacity, and a long ser-
vice life. They feature Nord’s trademarked Unicase hous-
ing design that ensures precise positioning of bearings and
shafts, quiet operation, low maintenance, and increased
safety with all joints and components sealed. Due to their
robust housing, they can withstand a wide variety of ambi-
ent conditions and function both in dusty environments as
well as in environments with high humidity, heat, and larger
temperature differences. These units are highly configurable
and feature a wide range of options including various output

18 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 FEATURE

Nord supplies a wide range of synchronous and asyn- The 15 Series variable displacement pump is designed for
chronous motors that deliver high efficiency, reliability, machine applications where up to 15 horsepower is required
and significantly reduce energy costs. These motors con- for the propel function, or for auxiliary work functions where
form to global energy guidelines and certifications and the system pressure requirements and the design life can be
are designed for combination with Nord’s full line of gear met within the pump rating. The maximum pump displace-
units and electronic control products for maximum perfor- ment is 0.913 in3/Rev. (15 cc/Rev.).
mance. Explosion protected versions are also available for The 15 Series fixed displacement motor is an axial piston
safe operation in hazardous environments such as dust and unit with a fixed displacement of 0.913 in3/Rev. (15 cc/Rev.).
gas atmospheres. Add on options such as brakes, encoders, The variable displacement motor has a maximum displace-
external cooling fans, and environmental protection fea- ment of 0.913 in3/Rev. (15 cc/Rev.).
tures are also available to meet the needs of specific appli- QCC took over the manufacture of the Dyna/Barber
cation requirements. Colman actuator and sensor product families using the orig-
nord.com inal tooling, assembly and test procedures transferred to us
from Woodward/Barber Colman, the Original Equipment
RBI Bearing Extends Bearing Life with Armor Manufacturers (OEM). These products are exact matches to
Technology the original equipment part numbers and have been in pro-
RBI Bearing (Booth #C30992) offers bearing treatments and duction for many years with QCC.
protection to reduce bearing failure and extend the bearing Dyna Plus actuators can be operated with Woodward
life, which means less downtime and reduced repair costs. controllers to provide engine governing of speed and
Armor Nano Technology is a procedure that fuses calcium power for combustion gas, diesel, steam engines and tur-
molecules into the molecular fabric of the metal. Challeng- bines. The actuators can also be used in remote position-
ing environments involving heat, pressure, or friction acti- ing and load control systems. Dyna Actuators have output
vate the calcium causing the particles to elongate and form work capacities of 1, 4, 6 and 8 ft-Ibs. through output shafts
a protective barrier that reduces the need for lubrication that can be set for clockwise or counterclockwise rotation.
while substantially increasing the lifespan of the bearing – Dyna actuators are also available in standard or marine/
saving you time and money. This isotropic nanotechnology explosion proof models. QCC also makes electrical speed
treatment was shown by Oak Ridge National Laboratories to switches, mechanical speed switches and mini generators
reduce friction up to 99 percent when both pieces of metal to OEM specifications.
are treated. QCC took over the manufacture of the Webster CP pumps
Armor Coated Protection Bearing Shield offers a and motors product families using the original tooling,
UV-resistant thermoplastic polymer bearing shield end assembly and test procedures transferred to us from Danfoss
users install on site or a spray application of the thermoplas- the Original Equipment Manufacturer (OEM). These prod-
tic material applied on site by a trained technician. Armor ucts are exact matches to the original equipment part num-
Coated Protection will immediately prevent contamination bers and have been in production for many years with QCC.
ingress and stop corrosion in the bearing housing and bolts The CP series gear pumps are high pressure, fixed dis-
as well as reducing the need for purging grease. The inhib- placement pumps of pressure balanced, spur gear design.
iting oil allows the shaft to rotate freely within the coating
which prevents the build-up and entry of debris and moisture
into the bearing, providing unrivalled protection. The slow-
release inhibiting oil prevents corrosion in the bearing casing
and fixing bolts as well as lubricating the rotating shaft.
Armor Permanent Lubrication is a solid lubricant with an
oil-filled porous structure fills the space between the roll-
ing elements and races in a bearing, providing constant and
consistent lubrication. There is no need for additional lubri-
cation during the life of the bearing. Because it is a solid,
Armor Bearings Permanent Lubrication can help block
debris and reduce foreign contamination of the bearing.
Reducing the incursion of debris into the bearing can sig-
nificantly extend the bearing’s life.
rbibearing.com

QCC Displays Pump, Motor and Actuator

Technologies
QCC (Booth #S81133) S15 Series pumps and motors are of
axial piston design, utilizing slippered pistons. All 15 Series
variable pumps feature trunnion style swashplates with
direct displacement control.

MARCH 2023 Power Transmission Engineering 19

 FEATURE Making the Move to Digitalization and Electrification

The design has been optimized to provide high efficiency operating pressure, the balance plate relaxes, allowing the
and light weights by using cast aluminum front and rear rotor to turn freely which translates into higher mechan-
housings and compacted graphite gear housings. The pres- ical efficiencies. Transmitting this power to the output
sure plates are steel backed bronze for maximum strength shaft is the most durable drive link in its class. Four bear-
and bearing capability. ing options, combined with standard mounting flanges
The CP series consists of two primary product sizes: and output shafts, allow the motor to be configured to suit
CP222 series and CP 180 series. Single and tandem ver- nearly any application.
sions of both sizes are available, as well as optional aux- improfluidtek.com
iliary pads. These pumps are applied in open center, open
circuit hydraulic systems to provide output flow and pres- Optibelt Offers Power Transmission Belts
sure for hydraulic functions. Optibelt's (Booth #S83659) modular polyurethane synchro-
qccorp.com nous timing belts allows for almost limitless configurations
on site. Have a damaged cleat? Modify the product and
Impro Fluidtek Presents Heavy-, Medium- and need new cleats? That is no problem with Optibelt’s ATC-
Light-Duty Motors System. The ATC-System with tracking guides help keep the
The WS from Impro Fluidtek (Booth #S81957) targets agri- belts in perfect alignment on the production line. Even bet-
cultural equipment, skid steer attachments, and other ter, the track guide(s) do not affect any of ATC’s customiza-
applications that require greater torque under demanding tion options. Tracking guide options on ATC10K6 include
conditions. Additional product features include a three- widths of 50 mm and 100 mm. They are available in linear
zone commutator valve, heavy-duty tapered roller bearings, and spliced/welded endless.
and case drain with integral internal drain. The WS offers The ATC-System is a patented system of modular polyure-
numerous housing, displacement and shaft options to meet thane timing belts offering amazing customization and cost
most common SAE and European requirements. savings. Customers can now order standard stocked belts
The WP motor series is an economical alternative to and cleats that can be assembled and customized on site
more complex roller gerotor designs and still provides offering faster delivery and greater versatility.
high efficiency across a wide performance range. These The ATC-System uses the ATC belt as a customizable plat-
motors are intended for light-duty applications requir- form. Each ATC belt’s tooth has pre-formed insert and hole
ing high torque in a compact package and are suitable punch locations. The insert locations can be “punched”
for industrial and mobile applications including car where an ATC cleat/attachment needs to be added. The
wash brushes, food processing equipment, conveyors, cleat is simply screwed into the topside of the belt into the
machine tools, agricultural equipment, sweepers, skid insert embedded in the tooth.
steer attachments, and more. The ATC cleating system is strong enough to handle
RE Series motors offer the perfect compromise between assembly fixture attachments or be used to convey prod-
price and performance by producing work horsepower at ucts from one location to the next. There are hundreds of
a reasonable cost. Although these motors perform well in cleating options available to handle a variety of manufac-
a wide range of applications, they are especially suited for turing needs. Facilities can have even stock ATC belts and
low flow, high pressure applications. During startup, pres- cleats to replace worn belting or replace individual cleats
sure causes the balance plate to flex toward the rotor, vastly on demand.
improving volumetric efficiency. As the motor reaches optibelt.com

Stiebel Drive Technology Features Pump Drives

and Gearboxes
Stiebel Drive Technology (Booth #S80153) provides stan-
dard and customized solutions for pump drives and trans-
fer case gearboxes. Applications range across any industry
using mobile class machinery and includes roadbuilding,
construction, agricultural, transportation, marine, railway,
mining, forestry and more. The Type 4462 Six Output Pump
Drive is intended for heavy duty applications. It can be
paired with A7V 1000 and A4VG 250 pumps. It features two
output pads on the gearbox input side and four on the out-
put side, this unit also boasts an oil recirculation pump to
assist when this particular machine is operating on slopped
hills and terrain, avoiding starving the upper gears of lubri-
cation. The Type 4384 Four Pad Pump Drive can accommo-
date pump sizes SAE-B, C & D and is available with either
SAE-1, 2 or 3 Bellhousing or Input Flange 150, 180 or SAE
1800.With a rated input power of 720 hp (530 kW) and

20 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

ZERO EXCUSES.
ZERO ROOM FOR
GEAR DRIVE FAILURE.
KEEP CRITICAL EQUIPMENT
RUNNING WITH PHILADELPHIA GEAR.

When communities count on uninterrupted power,

Philadelphia Gear delivers the mission-critical
gear drive support to keep entire cities moving.
Access end-to-end services — including OEM parts
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runs reliably for decades to come.

GET STARTED TODAY AT

PHILAGEAR.COM/MYMISSION
 FEATURE

twelve (12x) ratio options, this versatile gearbox is suitable

for a variety of machine platforms, including forestry, utility,
construction or agricultural to name a few.
stiebel.de/en

Danfoss Highlights Machine Performance

Danfoss (Booth #S80515) will demonstrate how the com-
pany is “Powering the future of machine performance,” dur-
ing IFPE 2023.
“Autonomy, electrification, connectivity, and digitali-
zation aren’t just buzzwords. They’re enabling original
equipment manufacturers to develop machines with bet-
ter productivity, safety, efficiency, precision, and opera-
tor experience,” said Mike Hill, senior vice president, OEM
sales, Danfoss Power Solutions. “At Danfoss, we’re help-
ing OEMs harness these trends and working with them to
design, iterate, and validate their machines faster. It’s how
we’re powering the future of machine performance.” Danfoss Thorx cam lobe motors reduce shock at speed
With dedicated booth areas for autonomy, connectivity, changeover by 70 percent, improving machine handling
and digital tools, plus the company’s Editron electric pow- and operator comfort. With an integral parking brake, the
ertrain systems, Danfoss will highlight how it’s paving the motor is 33 percent shorter in length than other cam lobe
way to autonomous machines and zero-emission construc- motors, reducing space requirements. In addition, the
tion sites as well as delivering next-generation performance motor’s optimized brake technology lasts 20 to 25 times
through smart, connected solutions. Stations showcasing longer than competitive products, extending the motor’s
system solutions for excavators, telehandlers, skid steer load- service life.
ers, and wheel loaders will demonstrate Danfoss’ application Based on Digital Displacement technology, the
expertise and how it helps OEMs increase speed to market. Dextreme system provides a pathway to 50 percent
A variety of the company’s key products will be on display in energy savings by tackling losses in the whole excavator
these areas, including two of its newest releases: Thorx cam hydraulic system. With the most efficient and control-
lobe motors and the Dextreme system for excavators. lable hydraulic pump at its heart, the Dextreme system

22 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

provides unique digital flow control, resulting in vastly
improved system efficiency and faster operator response
times. Through the fast response and digital control of
the hydraulic pump, engine loading can be controlled,
providing significantly reduced fuel consumption with-
out compromising on productivity.
Visitors can also see Danfoss’ fluid conveyance and indus-
trial hydraulics portfolios. The company’s comprehensive
offering of hose, tubing, fittings, and connectors will be
highlighted. In the industrial zone, the Vickers by Danfoss
line of pumps, motors, valves, cylinders, and brakes will be
on display.
danfoss.com

MARCH 2023 Power Transmission Engineering 23

 FEATURE

Peering into the Crystal Ball

on Condition Monitoring
Technology
The future of smart components for motion
control systems looks bright For Related Articles Search

condition monitoring
Aaron Fagan, Senior Editor at www.powertransmission.com

Smart components are designed to improve the over- material handling equipment or maritime applications.
all performance of motion control systems by provid- The BCM system can be used to measure bearing wear in
ing advanced features like condition monitoring, real- axial and radial directions as well as tilting clearance. Such
time data tracking, self-diagnosis, and fault detection, diagnostics ensure flexibility in measurement, as well as
to name a few. These features are designed to significantly reduced downtime, lower costs in maintenance, and above
reduce downtime and enhance the safety and reliability of all, higher personal protection.
the system and play an important role in improving the per-
formance and functionality of motion control systems, mak- Safety Measures in the Danger Zone
ing them an increasingly popular choice for industrial auto- The focus of digital clearance maintenance lies in per-
mation applications. sonnel safety. “A distinct disadvantage of all common
There is an increasing trend toward integrating evermore wear measurement methods is the necessity for ser-
compact smart components into larger, more complex vice technicians to mount dial gauges or other measur-
motion control systems, and advances in AI, ML, and IIoT ing devices directly on the slewing bearing in the danger
are helping with the speed and quality of their adoption. zone under the excavator or other machines,” explains
The future looks bright for this sector—as demonstrated by Stefan Milotzke, head of technical sales of the business
the current offerings showcased here from Liebherr, Nord, unit slewing bearings. “The Liebherr BCM system makes
and John Crane—with many exciting advancements and this unnecessary, as the measuring devices are already
improvements expected in the coming years. permanently installed on the bearing.” Another advan-
tage is flexibility in terms of time. Currently, machine
Digital Clearance Monitoring for Slewing operators commission external service providers to mea-
Bearings from Liebherr sure the bearing clearance. This makes them dependent
With the condition monitoring system for slewing bearings, on the experience and schedule of third-party compa-
Liebherr has created a digital monitoring system. The inte- nies. “With digital maintenance for slewing bearings from
grated wear measurement system, bearing clearance mon- Liebherr, measurements can be carried out at any time
itoring (BCM), ensures optimum monitoring of the slew- outside the danger zone, independently of external ser-
ing bearings in various applications, such as mining and vice providers,” explains Stefan Milotzke.

The danger zone of the excavator is located directly at the point, where the This is how Liebherr’s bearing clearance monitoring system works.
service personnel attaches the measuring device during manual measurement.

24 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 High-Quality Products and Services for Your
Motion Control and Power Transmission Applications
Stock and Custom • One Single Source

Gears & Gearboxes

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 FEATURE Peering into the Crystal Ball on Condition Monitoring Technology

Measurement Within Minutes

How does BCM work? The right technology and the right
connection make it happen. The sensor connection box
receives the data from the sensors attached to the slewing
bearing and supplies the entire BCM system with power.
The gateway stores the sensor data and updates for the
BCM. This allows using the system in even autonomously
in regions without a data connection. This is the case in
mines, for example, as these often do not have the necessary
mobile reception. A direct connection via Bluetooth makes
the measurement process possible from a safe distance Nordac Pro SK 500P family of variable frequency drives (VFDs).
and without a network connection. Smart, integrated and
remote, the BCM system is a small helper with great effects. uniform parameterization. Their versatile functionality is
liebherr.com/en/int/products/components/ available in five frame sizes with powers ranging from 0.33–
large-diameter-bearing/smart-bearing-condition- 30 HP with optional modules to extend features.
monitoring/smart-bearing-condition-monitoring.html Ease of operation is achieved via several interfaces
including an integrated multi-protocol ethernet interface
Condition Monitoring for for connectivity to ethernet-based control systems, a USB
Predictive Maintenance from Nord Drivesystems interface that enables parameterization even when the
With condition monitoring for predictive maintenance, main power is disconnected, a Bluetooth interface, and an
drive and status data are recorded at regular intervals or SD memory card slot for storage and transfer of parame-
continuously to optimize the operational safety and effi- ters, firmware, and operating data. Integrated programable
ciency of systems. The results derived from data analysis logic controller (PLC) functionality and Posicon position-
enable machines to be proactively maintained and avoid ing control provide further intelligent control optimized
unplanned downtimes. This status-based maintenance for specific system needs. Functional safety is also imple-
approach prolongs the service life of components and mented with safe torque off (STO) and safe stop 1 (SS1)
machines, increases system availability, and reduces service options for safe shutdown to prevent hazards to people
and material costs. Condition monitoring can even deter- and damage to system components.
mine the optimal time to change oil, ensuring systems are Nordac Pro variable frequency drives (VFDs) are a part
always operating at their highest capacity. of Nord’s modular product system and are compatible with
Nordac Pro variable frequency drives from Nord both synchronous and asynchronous motors. Sensorless
Drivesystems enable dynamic control of gear units, pro- current vector control enables high starting torques and pre-
vide precise control, and can be easily configured to meet cise control of motor speeds. The drives also feature motor
application needs. They are characterized by their compact, brake management, lifting gear functionality, a brake chop-
space-saving design, advanced control characteristics, and per, and extensive monitoring functions. Thanks to their
Nord Drivesystems condition monitoring for predictive maintenance solution.

Aktuelle Spannung Aktuelle Drehzahl

687,5

160 v
0 1375

1282 rpm
P722 P717

System vibration sensor Oil change Integrated PLC Lokal dashboard Higher level PLC
n NORD qualified sensors n Determination of the optimum time for oil change n Pre-processing of drive-specific parameters Aktuelle Spannung Aktuelle Drehzahl
n Display of drive data and system data n Processing of condition monitoring information
n Customer-specific sensors can be connected on the basis of the virtual oil temperature and drive-related sensors by the customer
687,5

160 v
0 1375
1282 rpm
P722 P717

(analogue / digital) n Algorithm is executed in the internal PLC n Evaluation of drive condition n Combination of condition monitoring information
Local data management with process data
Temperature sensor Drive parameters Beacon signal
n Processing of drive data for drive analysis
n Motor temperature sensor on the basis of PT1000 n Read-out of the drive parameters of the drive system n Local display of drive condition and system analysis
n Ambient or system temperature n Basis for virtual sensors n Status display n Condition Monitoring

26 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 FEATURE

high level of performance, safety, and versatility, Nordac Pro high-volume warehousing, parcel distribution systems,
VFDs are used in a wide range of industries such as airport and packaging systems.
baggage handling, intralogistics, bulk material handling,
packaging, and more. Two-Stage Helical Bevel Gear Units
Nord’s answer to supply chain solutions is its modular Two-stage helical bevel gear units deliver efficient opera-
product design that aims to deliver versatility with millions tion in a compact, robust design ideal for conveyor systems.
of unique configurations of gearboxes, electric motors, and They feature a large speed range, quiet operation, and high
variable frequency drives—eliminating the need for costly axial and radial load capacities. Flexible installation options
custom components. are available including various input and output options,
solid and hollow shafts, and foot, flange, or shaft mount-
Nordac On/On+ VFDs ing—making the drives highly adaptable to a wide range of
Nordac On/On+ VFDs offer a compact, flexible design applications and environments.
developed to meet the specific requirements of horizon-
tal conveyor technology. Nordac On VFDs are designed for Nordbloc.1 Helical Inline Gear Units
use with IE3 asynchronous motors while Nordac On+ VFDs Nordbloc.1 helical inline gear units are characterized by
have been optimized for performance with IE5+ synchro- quiet, reliable performance in a smooth, easy-to-clean
nous motors. These VFDs feature an integrated Ethernet design. Their Unicase housing is made from high-strength,
interface, full Plug-&-Play capabilities, and functional safety low-weight aluminum alloy and ensures a long service life
options such as STO and SS1. With precise positioning and with increased stability and safe operation. They offer 13
full PLC functionality for dynamic control of conveyor sys- case sizes to choose from as well as a performance of 0.16–
tems, Nordac On/On+ VFDs provide a reliable, cost-effec- 60 hp, keyless shaft designs with Shrink Disc and Grip-
tive solution for IIoT environments. maxx, and foot or flange mounting. High output torques
paired with efficient operation reduce system costs for a
IE5+ Synchronous Motors lower total cost of ownership (TCO) and a fast return on
IE5+ synchronous motors achieve ultimate efficiency in a investment (ROI).
compact, versatile design that can be installed quickly and nord.com
easily. They are available in two versions—a non-ventilated
variant (N-design) for hygienic wash-down areas and a Seeing Into the Darkness of Seal Health with
ventilated variant (F-design) with high overload capac- John Crane
ity suited for intralogistics. IE5+ motors provide a stan- John Crane, a global leader in rotating equipment solutions,
dardized, high-efficiency solution thanks to their constant supplying engineered technologies and services to process
torque over a wide speed range. This enables them to elim- industries, offers John Crane Sense Turbo, a dry gas seal dig-
inate the need for system variants, minimize operating ital diagnostics solution to monitor conditions at the heart
costs, and increase energy savings. of the compressor.
John Crane Sense Turbo uses a unique set of sensors
DuoDrive Integrated Gear Unit and Motor embedded directly into a compressor’s dry gas seal to deliver
The DuoDrive with an integrated IE5+ motor and sin- continuous, real-time insight to identify potential issues
gle-stage helical gear unit brings a new level of energy and ensure corrective actions are taken to extend the useful
efficiency and easy system maintenance. The compact, life of the seal. Designed to improve reliability, reduce the
modular design features full Plug-&-Play capabilities risk of failures and unplanned downtime, and increase the
for fast commissioning, quick installation, and minimal mean time between repairs (MTBR) while increasing effi-
space requirements. Constant motor torque over a wide ciency and profits, John Crane Sense Turbo monitors condi-
speed range enables system variants to be reduced— tions that impact seal health.
minimizing administrative expenses and optimizing Data from different sensors are combined, processed at the
service processes. The DuoDrive is especially suitable edge, and sent to cloud servers for additional real-time pro-
for supply chain applications due to its high-power den- cessing and archiving, using industrial-grade cybersecurity.
sity, extremely high system efficiency of up to 92%, and Access to secured and actionable information is available on
quiet operation. any device, using enterprise-grade cybersecurity in the cloud
with multifactor-protected data portals.
LogiDrive Complete Drive Solution “Leveraging machine learning, John Crane Sense Turbo
The LogiDrive solution is a service-friendly, modular sys- allows customers to assess the health of dry gas seals
tem designed for standardization and reduction of sys- installed in turbomachinery and understand how to opti-
tem variants. The package combines a gear unit with high mize the reliability and performance of their rotating equip-
overload capacity, a high-efficiency electric motor, and a ment,” said John Crane Product Line Director, Digital, Brian
compact variable frequency drive for a complete solution Boykin. “By understanding the remaining useful life of a
that is flexible, low-maintenance, and Industry 4.0 ready. mechanical seal, our customers can add months, if not
Efficient operation at partial load and low speeds makes years, to the time before repair of their equipment, while
LogiDrive especially suited for a variety of conveyors in significantly reducing maintenance costs at the same time.”

MARCH 2023 Power Transmission Engineering 27

www.diequa.com

When off the shelf

just won’t do.
With our extensive range of standard components and
custom machining capabilities, a custom-designed
and manufactured gearbox for specific applications is
something we do all the time.

Custom Flanges Custom Paint

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 180 Covington Drive
Bloomingdale, IL 60108 USA
630-980-1133
www.diequa.com

Motion Control and Power Transmission Drive Components

 FEATURE Peering into the Crystal Ball on Condition Monitoring Technology

John Crane Sense Turbo is part of the John Crane Sense reduction targets, future-proof businesses, and protect the
platform and suite of solutions including John Crane Sense world for future generations.
Pumps and John Crane Sense Monitor designed to trans- Digitization will play an essential role in helping the
form industrial equipment to build a better understanding industry to meet these challenges. Today, only one-third
of asset health through the digitization of critical compo- of oil and gas businesses are approaching digital maturity.
nents. Sense is an open platform for a suite of apps that pro- As the industry evolves toward a cleaner, greener, and more
vide actionable information. The pumps are a digital health cost-efficient model, that number must change quickly.
monitoring system that leverages years of experience in
mechanical seal expertise, combined with machine learn- The Power of Digitization
ing technology to provide insight into the health and per- There are clear opportunities for the oil and gas industry
formance of the pump asset. And the monitor is a wireless to adopt the kind of digitized, data-driven approaches that
monitoring solution that enables visibility into asset health have transformed other industries—even if the technology
and performance across the entirety of the plant or site, that drives them is more complex.
including in the most remote locations. Put simply, when you don’t have the right data, you rely
Change is everywhere in our industry and we’re all under on estimates and approximations to make critical business
pressure to spot efficiencies and do more with less while decisions. When you do have the right data, you can move
staying competitive. As the impacts of climate change forward with facts—and confidence.
become clear and the demand for cleaner energy grows, That’s why we developed the John Crane Sense platform—
we all need to find ways to work smarter to hit emission an industry-first technology that allows you to see what’s

The John Crane Sense open platform is designed to allow third parties, component OEMs, and end users to digitize

30 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 FEATURE

going on in the heart of your critical operations and make shutdown. Knowing a seal is healthy can enable you to defer
more informed decisions about maintenance and repair to replacement, saving on both equipment cost and downtime.
reduce downtime and extend the useful life of your assets.
Seeing into the Future
Digitization in Practice Technology like John Crane Sense platform is only the
John Crane Sense Turbo is an excellent example of the way beginning. As the move toward digital accelerates, new
that digitization can drive new benefits. The Turbo solution opportunities will be available to seamlessly connect data
consists of sensors embedded into a dry gas seal that moni- from other parts of your plant and ensure every decision you
tor process conditions and seal health. make is working toward the same goal.
By using John Crane Sense user interface, you can moni- Smart seals are a key component in meeting emission
tor the seal from anywhere and receive alerts about process reduction targets—monitoring leaks that, unless identified
upsets or other operational irregularities. This allows you and fixed proactively, will cost your operation and contami-
to respond immediately before manageable issues become nate soil, water, and air.
more significant failures that require downtime. The future is only going one way—greater digitization
It also ensures you’re getting the most out of your equip- of equipment, processes, and plants. The John Crane
ment. Traditional forms of seal monitoring provide some Sense platform can help you on your digital transforma-
information, but they don’t give a complete picture or suf- tion journey, giving you the intelligence you need to hit
ficient indication of a seal’s health. Understanding health tomorrow’s targets, enhance your brand reputation and
is critical to shortening the duration of an unplanned protect the environment.
johncrane.com

their physical devices with application development support from John Crane.

MARCH 2023 Power Transmission Engineering 31

 FEATURE

The High Demands of Off-

Highway Drive Systems
Customization takes center stage in the push for more
efficient motor, brake and drive concepts.
Matthew Jaster, Senior Editor

Warner Electric Presents

Customized Braking Solutions
The off-highway industry is cur-
rently moving through a significant
transition. The journey started about
10–12 years ago as the forklift truck
industry began converting from
internal combustion engines into
electric drives. Today, construction
equipment, more precisely, compact
construction equipment, has also
begun the transformative conver-
sion to electric drives.
As with the automotive industry,
national and municipal emission reg-
ulations are rapidly becoming more
restrictive for off-highway vehicles and
equipment. In some areas, the use of
gas-powered equipment has already
been completely banned. Some ana-
lysts believe that by 2030, 50 percent
of the construction equipment market
will be electric powered.
As environmental awareness grows,
construction equipment manufactur-
ers have begun to respond with elec-
tric powered equipment that meets
various mandated emission regula-
tions. However, they are also being
driven by voluntary environmen-
tal policies adopted by construction
contractors and large equipment
rental companies. This new genera-
tion of much quieter equipment is
Warner Electric application engineers routinely work with Tier 1 drivetrain OEMs as well as major construction not only environmentally friendly,
equipment manufacturer engineering teams to develop compact, energy efficient braking solutions. but also provides increased operator
comfort, health and safety benefits.
Motor and brake manufacturers in areas like noise, vibration, and Warner Electric offers innovative
are facing increased pressure to harshness (NVH) as well as com- braking solutions designed to reduce
provide off-highway components fort, safety, and health consider- power consumption on a wide vari-
with energy efficient and sus- ations. The following off-highway, ety of battery-powered construc-
tainable benefits. This transition construction and mining solutions tion equipment, including slewing
starts during the design phase as hint at the all-electric transition taking and track drives on excavators, wheel
engineers provide optimization place across each industry. and track motors on compact track

32 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 FEATURE
For Related Articles Search
provide reliable emergency and park-
off-highway ing brake functionality and allow for
at www.powertransmission.com increased maximum vehicle speed
and improved productivity.
Proprietary W134 nonstick dry fric-
tion material, designed and manu-
factured in-house, is available on PK
and CBTB models for increased high-
capacity braking requirements at
very high speeds. The linear speed of
the friction material determines the
speed limit, certain brakes and design
sizes have been functionally tested at
speeds of 12,000 rpm.

Force Control MagnaShear

Brakes Provide Conveyor and
Mining Solutions
Customization of a Warner braking unit includes IP rating, manual release cables, connectors, sensors, and MagnaShear motor brakes, which pro-
friction material. vide a secure, no-maintenance, no-
adjustment, holding brake solution
loaders, skid steers, wheeled excava- IP67-Rated models are available to for mining conveyor applications were
tors, compact dumpers and mobile meet challenging washdown applica- recently featured at Minexchange 2023.
elevating work platforms (MEWPs). tion requirements. In addition to holding brakes, Magna-
Highly experienced Warner Electric The recently launched PK–Low Shear are ideal for mining applica-
application engineers routinely work Noise Design brake features a unique tions where the motor is stopped, or
with Tier 1 drivetrain OEMs as well patent-pending dampening system reversed, each cycle such as loaders/
as major construction equipment that significantly reduces operat- unloaders, conveyors, rail car spot-
manufacturer engineering teams ing (engagement) noise to below 70 ters and dumpers, overland and inter-
to develop compact, energy effi- db. The new brake was developed for nal tripper cars, rotary coal sweep sam-
cient braking solutions to meet the applications where high noise levels plers, and more.
needs of each vehicle requirement, can be annoying such as under-cab These proven motor brakes are
whether it’s for a completely new slewing drives on mini excavators. available to accommodate a wide
design or the electric conversion of The CBTB family of electromagnetic range of applications. Spring set
existing equipment. axle brakes are specifically for use on torque ratings from three to 1,250 foot-
The design process typically starts battery-powered, dual-drive vehicles pounds are available. The MagnaShear
with one of Warner’s existing brak- with capacities generally up to eight motor brakes can be sized to the cor-
ing solutions, including the PK and tons (17,900 lbs.). These advanced rect torque value independent of the
CBTB ranges. Once selected, custom- high-speed, high-torque brakes motor frame size or horsepower by
ization of the unit begins, including
IP rating, manual release cables, con-
nectors, sensors, and friction material.
The result is a “plug and play” product
that the OEM can easily integrate into
a drivetrain.
Warner Electric’s PK (Very Thin)
brakes are used for parking and offer
emergency stop capabilities. The vehi-
cle’s AC motor is used in combina-
tion with the PK brake for regenerative
braking of the vehicle.
The benefits of this cost competi-
tive range include one-piece design
for easy assembly, lower power con-
sumption, longer battery life, and
overall lower maintenance costs.
These brakes are enclosed to with- MagnaShear brakes are ideal for conveyors, rail car spotters and dumpers, overland and internal tripper
stand harsh outdoor environments. cars, rotary coal sweep samplers, and more.

MARCH 2023 Power Transmission Engineering 33

 FEATURE The High Demands of Off-Highway Drive Systems

from driving to braking mode, and the

direction of rotation can be switched
quickly by changing the direction of
the oil flow.
Shock Load Resistance: Shock loads
can damage critical equipment and
lead to major unplanned downtimes.
With direct drive motors applying
power directly to the core of conveyors,
crushers and feeders, the direct drive
offers a solution without mechanical
play and with a low moment of inertia
so it can easily withstand vibrations,
external shock loads and changing
load directions.
Fusion Direct Hydraulic Drive:
Released in 2022, Hägglunds Fusion
won industry recognition two times.
The Fusion is a unique drive system
Magnashear brakes working in a mining application. that puts everything on the torque
arm, from the hydraulic motor and
changing the combination of springs exchange 2023 leverage the unique pumps to the cabinet that houses
and friction discs. characteristics of hydraulic direct them, making high torque and total
MagnaShear motor brakes feature drive technology—delivering power reliability available from a single
a “quick mount” feature for quick directly to the drive shaft with full unit – in a footprint that was previ-
and easy mounting to drive motors in torque from zero speed and protec- ously unthinkable.
NEMA frame sizes 56 to 449 or some tion from shock loads—to maximize Atom Hydraulic Motor: Combining
IEC frame motors. They are shipped the efficiency and uptime of convey- the right size with Hägglunds perfor-
ready to install, with no assembly or ors, feeders, crushers, drums, bucket mance, it offers the right fit for mining
adjustments required. wheel reclaimers, kilns and more. applications where both compact size
MagnaShear motor brakes can be fur- Torque Control: Direct drives with and high-power density are required.
nished as a complete motor and brake low speed and high torque can pro- With a maximum torque of up to 13.6
assembly (assembled brake motor), or vide full torque from standstill, without kNm and a specific torque of 40 Nm/bar,
to mount on a machine frame or other time restrictions. Hägglunds hydraulic the Hägglunds Atom hydraulic motor
special mounting configuration. direct drives can operate continuously can supply maximum power of 394 kW,
These proven motor brakes are throughout their power range up to their outstripping other motors in its class.
totally enclosed from outside contam- rated torque, from zero to full speed. CB Direct Drive Motors: Tough and
inants, with seal integrity for harsh and Start-Stop-Reverse: A Hägglunds rugged with a wide range of sizes
washdown environments. A modu- hydraulic direct drive reacts especially and displacements, the Hägglunds
lar design/assembly allows for ease of quickly due to its very low moment of CB provides the right solution for
servicing and maintenance. inertia. They can switch automatically many heavy-duty applications, such
Hazardous duty units for class II,
Group a, b, c, d, e and f are also avail-
able, as well as low temperature or
Artic duty down to –40 degrees.
The totally enclosed MagnaShear
motor brakes are impervious to mois-
ture, dirt and dust that is common in
mining applications, as well as concrete
block plants, asphalt shingle manufac-
turing, bulk material handling, forest
products manufacturing, and more.
forcecontrol.com

Bosch Rexroth Offers Drive

Solutions from Hägglunds
The products and solutions Häg-
glunds recently displayed at Min- Multiple Hägglunds direct drive systems offer solutions for key mining applications.

34 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 FEATURE

as shredders, feeders and roll mills. It new hydrostatic dropbox functions North American telehandler market
combines space-saving designs with a as a continuously variable transmis- and its modular approach gives custom-
wide range of sizes and displacements. sion without torque interruption and ers the flexibility to make the transition
Rineer Motors: Bosch Rexroth’s Rineer delivers enhanced performance with to a zero-emissions solution."
motors offer the highest power density precise movements at low speeds, In order to support the industry's
with maximum torque, as well as robust- reduced fuel consumption, and an transition to zero-emission vehicles,
ness, even under the most adverse cli- integrated spring applied hydraulic Dana optimized the axles and drive-
matic conditions and high dirt loads. release parking brake. line system for efficiency to support
Rineer motors are frequently used in The transmission is designed to be a variety of architectures, allowing
the mining and construction sectors, on coupled with the field-proven Spicer customers to retain the same drive-
drilling and winch applications. 222 front and rear heavy-duty axles, line solution while choosing between
boschrexroth.com/en/us/ which each feature a limited-slip dif- implementing a hydrostatic dropbox
hagglunds/ ferential and provide the customer or electrically driven design.
with maintenance-free brakes. The From single-and two-speed drop-
Dana Launches Driveline complete driveline system is opti- boxes to shift-on-fly and powersplit
Solutions for Telehandlers mized for efficiency as well as noise, transmissions, Dana offers a complete
Dana Incorporated recently vibration, and harshness. range of hydrostatic transmissions
announced the launch of a hydro- "Dana has more than 40 years of that enable customers to leverage the
static driveline for telehandlers in expertise designing and implementing best solution for their specific vehicle's
North America. The system's modular hydrostatic transmission solutions for duty-cycle requirements.
architecture enables customers to eas- diverse applications across the off-high- In addition, Dana is investing in
ily transition to a hydrogen or battery- way market," said Jeroen Decleer, senior updated drive and motion technolo-
electric vehicle design. vice president of Dana Off-Highway gies for traditional and electrified con-
Developed for telehandler appli- Drive and Motion Systems. "Our new struction machinery, including mini
cations lifting up to 12,000 pounds, hydrostatic driveline offers operators an excavators, mobile elevating work plat-
Dana's new driveline comes equipped easy-to-use solution with increased per- forms (MEWPs), and crawler cranes.
with a compact Spicer 312 dropbox for formance and efficiency at low speeds. dana.com
high-power hydrostatic motors. This This makes it an ideal fit for use in the

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MARCH 2023 Power Transmission Engineering 35

 Engineering sMart

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36 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 Engineering sMart
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MARCH 2023 Power Transmission Engineering 37

 TECHNICAL

Ball Bearing Inner Ring Fits

and Creep
Norm Parker, Technical Fellow, Stellantis

Figure 1—Outer ring creep of differential tapered bearings.

I think I spend more time talking with high load demands from the first less. If the turning is substantial, it can
about ball bearings today than at any reduction gearset. The cycle count create heat, wear, and become a real
other time in my career. Ball bear- demands of these bearings are like issue. This annoying reality that we
ings have always had a large place in traditional valvetrain bearings. When- must deal with is referred to as creep.
automotive, but not typically in high ever the vehicle is moving, these bear- There are a few different mechanisms
demand positions—other than a few ings are in motion and taking load. that can cause creep which we will
niche areas. High demand positions, Depending on the gear ratio and type cover in depth another time. Much of
such as axles and planetaries, were of vehicle, cycle counts north of a bil- the literature you will read only talks
typically reserved for tapers, nee- lion are not out of the question. Over about outer ring creep, but inner ring
dles and cylindricals. The landscape the life of a heavily loaded bearing of creep is just as common and can be
is changing quickly. Along the rotor any sort, some amount of turning on more troublesome.
shaft of an electric powertrain, ball the shaft and housing are not uncom- The ball bearing design process
bearings and cylindricals are the most mon. Light indications of turning that starts with inner ring fits and if you
popular choices to handle the high- aren’t plowing and damaging mate- mess this part up in the beginning, it
speed demands, often accompanied rial are generally considered harm- can be difficult to fix later.

38 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 In every bearing catalog, you will start with a table that looks something like this:

Then determine the level of damage.

If the bore is black or heavily scored,
you probably need to revisit your fits. If
it is like the bearing photograph (third
column, bottom), some light turning,
but no damage—cannot feel anything
Figure 2—JTEKT Co. Cat B2001E-3 Ball and Roller Bearings Table 9-1 p.A80
with your fingernail, you may be ok if it
was a severe test and you don’t antici-
If you are not used to the nomen- the outer ring. There are times when pate it getting any worse.
clature, gearboxes of any sort have this still can be an issue, but most of
a rotating inner ring load (the load the time it is not. Inner rings aren’t
is being delivered by the shaft), always so obvious. I have had rings
opposed to a wheel bearing which turn that had no business turning.
has a rotating outer ring load. This The loads were light, the fits were
takes us to the first row of the table substantial. Or other times, the loads
(above) which calls for an interfer- were substantial, but the press fits
ence fit on the inner ring and a clear- were outrageously high. Sometimes
ance fit on the outer ring. I get asked you simply cannot get it to com-
frequently why we have a clearance pletely go away. It is good to have a
fit on the outer ring and won’t it spin pre-established plan for what to call
in the housing? For a non-sealed acceptable and not acceptable. Many
bearing in an oil fed system, the bearing engineers like the crude fin-
answer is, you may see some light gernail test. If you can feel it with
evidence of turning, but not enough your fingernail, it’s not great. First,
to move material and/or create any determine if the bearing has been
type of damage. The reason why this turning. On a ball bearing, there will
is the case is because the bearing is often be some obvious abrasion on
usually loaded, pressing the outer the inner ring or polishing of the sur-
ring into the housing. When we go faces. After test, if the bearing bore,
from drive to coast or regeneration, shaft, or parts of the bearing seem
the bearing load is briefly lifted, and unusually shiny, it likely has been
the bearing may turn a little dur- turning. The photograph (third col- I love having a fit chart on hand at all
ing this transition time, but no load umn, top) is a taper, but was a good times. One easy point to remember is
means no damage. When the bear- example of a bearing that was obvi- that an H fit is a line to line fit for both
ing is loaded, it is only the tractive ously turning, but didn’t damage shaft and housings. As you move up the
force of the rollers trying to move any mating components. alphabet, the fits get tighter. The number

MARCH 2023 Power Transmission Engineering 39

 TECHNICAL

represents the IT (international toler- At this point, you’ll have a decent

ance) band for each fit. A 6 might have a guess for the bearing fit. From the chart
12 µm tolerance where (below left) for a 25 mm shaft with mod-
8 might have a 25 µm erate loads, you will often find yourself in
tolerance—all depend- the k5, k6 area and thinking about the m
ing on the specific size. fits for a hollow shaft. This is where the
important part starts. When we press fit a
bearing on a shaft, the bearing inner ring
is going to expand. We never want the
bearing internal clearance to go to zero
and into radial preload. Ball bearings can
handle a very small amount of radial pre-
load—5–10 µm—but this should not be
built into the operating design. This might
be a consideration for very extreme con-
ditions, such as running a sustained high-
speed test where the inner ring tempera-
ture might be ~ 20°C hotter than the outer
ring and could allow 5 µm of preload for
that specific test. We do not want radial
Figure 3—JTEKT Co. Cat B2001E-3 Ball and Roller Bearings Figure 9-1 p.A80
preload during normal operating condi-
Around this same area in the cat- shaft, the chart is useless. Very gener- tions. It generates huge internal loads to
alog, there will be a more detailed ally, I like to assume a 1 class higher the bearing and increases operating tem-
chart with the most important dis- fit for hollow shafts. If the chart says perature which further increases internal
claimer you are going to see. This a k shaft for instance, I will often start loads. This can develop into a spiral that
chart only applies to solid shafts. with an m fit and seen how the math results in failure. Regardless of our fit,
That is not to say if you have a hollow works out. the bearing internal clearance must be
designed to match at this point. Let’s talk
about nightmare scenario one. You are
purchasing the motor and shaft that you
are pressing your bearing onto. You find
late in testing that the bearing is spin-
ning too hard and needs to have the shaft
fit increased. The motor supplier won’t
cha-nge their dimension without revali-
dating. The bearing supplier will adjust
the clearance, but puts you into a sepa-
rate manufacturing run which increases
the cost. You are in trouble. With this sce-
nario in mind, it might sound tempting
to increase your fit as much as possible,
but there are two roadblocks on that side
as well. First, there is a hoop stress limi-
tation for the bearing inner ring to avoid
risking cracking the ring. The typical
guideline for this 120 MPa for ball bear-
ings—though numbers up to 150 MPa
are not uncommon. The second road-
block is serviceability. Bearings that are
around 150 MPa or more are incredibly
hard to remove without damage (usu-
ally from cutting them off). We find our
design window getting smaller. We need
to know how much fit we really need.
This is based on the operating load and
a simple equation buried in my favorite
catalog, the NSK Technical Report (Fig. 4,
page 41).

40 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 Norm Parker is currently Technical Fellow
at Stellantis. He has contributed articles
for PTE since 2014

Figure 4—NSK Technical Report Cat. No. E728g p. 64

Let’s apply this to a standard 6205

running up to 50 percent of the
dynamic load rating.

Fifty percent load falls under equa- you need to talk to the bearing sup-
tion 2. ∆d ≥ 0.02 (7.7 kN/15 mm) = plier about what your options are and
10.2 µm. This is the interference fit what clearances you should be run-
needed to avoid creep at this load. ning. What is going to cost you pen-
Even though this formula does not nies and what is going to cost you dol-
specify hollow or solid shafts, I have lars? And finally, if you haven’t already
found it sufficient for both and usu- done this, what load do you really
ally higher than the table recommen- need to protect for? Hopefully I have
dations. This is a little higher than an done my job and convinced you that
m5 fit which is 8–17µm for a 6205. The not every micron of turning needs to
very next step from here is calculating be stopped. How do your calculations
the hoop stress for the fits at the upper change if you allow the top 10 percent
end. Most people do this through of the loads go above the creep calcu-
bearing software or FEA analysis, lation? How much time are you really
there are a couple of free online bear- going to spend at 50 percent, etc.?
ing calculators on the bearing manu- In our next post, we will finish out
facturers sites and there is a cumber- this example for completely defining
some manual calculation also found the fit and internal clearance along
in most bearing catalogs. Secondly, with talking about outer ring creep.

For Related Articles Search

bearing creep
at www.powertransmission.com

MARCH 2023 Power Transmission Engineering 41

 TECHNICAL

A Model for Considering

Wheel Body Deformation in
Tooth Contact Load Distribution
Benjamin Abert and Dr. Georg Hammerl
Introduction
Current legislation and customer concerns about climate change demand drives with a special focus on efficiency. General
trends are starting to focus on energy savings, and customers often use total cost of ownership as a deciding factor when
selecting new drives.
In addition to the influences of the gear geometry, for example as described by Wimmer (Ref. 1), lightweight construc-
tion also plays an increasingly important role. Targeted lightweight gear wheel design can reduce the rotating mass, which
directly reduces the energy required by the drive unit during acceleration or braking. The following formula (1) for determin-
ing the rotational energy Erot measured in [J] demonstrates the potential for energy savings:
1 1
Erot = 2 ) J ) ~2 = 2 ) 8r2 dm ) ~2 (1)
J represents the mass moment of inertia in [kg*m²], and ~ describes the angular velocity in [1/s]. For cylindrical wheel
bodies, this results in:
Jcyl = 2 ) m ) r o2 = 2 t ]r ) r o2 ) bg ) r o2 = 2 t ) r ) b ) r o4
1 1 1
(2)
where t represents the density in [kg/m³], b the width in [m], and ro the outer diameter of the wheel body in [m]. The outer
radius ro is factored to the fourth power in the inertia calculation and is therefore particularly suitable for reducing the energy
expended for acceleration or braking. A smaller gear would serve the same purpose, but this is not always possible as the
transmissible torque may no longer be sufficient or the transmission ratio may have specific requirements. However, ro4 can
be substituted with ro4-ri4, where ri4 represents the inner diameter of the wheel body. In other words, the overall amount of
wheel body material can be reduced. This brings both cost savings from lower material consumption and energy savings dur-
ing acceleration and braking. This simple consideration makes it clear that the gear rim thickness should be minimized for
the most efficient acceleration. However, this also presents limitations, as less material under the teeth reduces the stiffness,
which leads to changes in the load and pressure distribution and in the excitation spectrum. For example, holes in the wheel
body have been shown to influence the excitation (Ref. 2).
Therefore, the wheel body must be considered in the design of gear modifications, as it has a significant influence on the
gear modification itself, the noise excitation, and also on the tooth root stress in extreme cases. The following paper will intro-
duce a method that makes it possible to consider the influence of the wheel body geometry on the gear. As the influence of
the wheel body on the tooth root stress only has a significant impact on the product design in extreme cases, such as in avia-
tion, this will not be considered in detail.
Today, complex flexible structures are calculated using the finite element method (FEM). Here, the mechanical equations
are solved (in a weak form, in an integral sense) on powerful computers/clusters using a discretized geometry. The tooth con-
tact is also frequently modeled and calculated with a rolling through of at least one mesh. This method makes it possible to
consider any mechanical effects, such as of the wheel bodies. However, these calculations are very slow (calculation times > 1
hour are not uncommon), especially if the tooth contact is also modeled. Furthermore, identifying solutions for contact prob-
lems is not a trivial task, and the calculation may terminate unexpectedly if the parameters are not selected appropriately.
Fast solutions are preferable, especially in the early design phases. Many calculation tools use an approach based on Weber-
Banaschek (Ref. 3). The results of these simulations have been validated many times and have been used in industrial applications
for decades. Thus, it is obvious that the influence of the wheel body in the stiffness calculation according to Weber-Banaschek
should be considered. The simple modeling of the gear using this analytical approach also does not lead to many errors. Even
inexperienced engineers can produce reliable results, and specialized calculation engineers are not absolutely necessary.
To be commercially successful, new methods must meet the following requirements:
1. The method should be applicable in the gear design phase. This requires calculation times < 10 seconds.
2. The results must be reliable, which presupposes that all relevant influences are considered.
The results of this paper have been simulated in the FVA-Workbench (Ref. 4) and compared with the results of research
projects by the Drive Technology Research Association (“Forschungsvereinigung Antriebstechnik e.V”, or FVA).

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, 5th Floor, Alexandria, Virginia 22314.

42 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 Background FEM meshing of the gear, regardless of the complexity of the
shape of the wheel body.
Methods for Determining the Mesh Stiffness Similar to the Weber-Banaschek method, the influence
In the FVA-Workbench, the local load is determined for each factors are determined by applying a single load to discrete
point on the flank using the influence coefficient method, points and recording the deformation of the flank. For the
with which the meshing force is distributed to individual FE calculation, these discrete points are the nodes of the
points for each meshing position along the contact lines. FE mesh. The correct stiffness of the complete geometry,
The local stiffness at these points can be determined using including the wheel body, is determined by superimposing
two different methods: the individual loads. The results show a slightly wavy sur-
face for the pressure distribution. This can be smoothed by
Determination of the Influence Factors According to choosing a finer meshing resolution, but this increases the
Weber-Banaschek/Schmidt calculation effort.
In this approach, the local gear stiffness over the tooth The advantage of this FE-based approach is that the influ-
depth is determined according to the Weber/Banaschek ence of the deformation of the wheel body is automatically
method (Ref. 3). The teeth are modeled as bending considered. However, the calculation time is longer com-
beams, with a cross-section that varies over the height. pared to the analytical approach.
The deformation is influenced by the Hertzian contact,
the shear deformation, and the clamping point of the Gear System Approach
tooth in the wheel body. The wheel body is considered To correctly determine the load distribution in cylindri-
as an elastic half-space. The majority of software pack- cal gear stages and design suitable gear modifications, all
ages use this method as the basic value for the gear stiff- cross-influences between the machine elements of a com-
ness, and it is also the foundation for the determining the plete gear system that are relevant for component defor-
gear stiffness according to DIN 3990 (Ref. 5) and ISO 6336 mation must be considered for the operating state to be
(Ref. 6). The additional change to the gear stiffness over calculated. The deformation behavior of the gearbox is
the face width is considered using a plate model accord- represented in a complete stiffness matrix. The partial stiff-
ing to Schmidt (Ref. 7). This method is also implemented ness matrices of the individual components (casing, shafts,
in the FVA-Workbench in the RIKOR (Ref. 8) and DZP bearings, gears, couplings, etc.) are added to the com-
(Ref. 9) calculation programs, and has been validated by plete stiffness matrix according to the method described
both bench tests (Ref. 10) as well as decades of indus- in (Ref. 12). The deformation vector of the coupling points
trial application for the design of gear modifications. between the machine elements is determined by multiply-
The advantage of this analytical formula-based method ing the inverted complete stiffness matrix by the load vec-
is that it produces reliable results for load distribution, tor of the external loads.
noise excitation, and for the design of gear modifications To determine the partial stiffness matrices of each com-
with minimal calculation time. ponent, methods are used which deliver sufficiently pre-
The problem with previously available software-based cise determination of the deformations with a short calcu-
implementations is that they only deliver precise results lation time. For example, the shafts are modeled in sections
for the influence of cylindrical wheel bodies. The following as classic Timoshenko beams. The bearing stiffnesses are
solution will demonstrate how the analytical calculation of determined according to (Ref. 13) based on the Hertzian
the influence factors can be extended to include detailed contact deformation. FEM calculations are used for com-
wheel body deformation calculated using FE methods, plex structural components such as the casing and planet
without significantly increasing the calculation time. carriers. A reduced stiffness matrix is determined for these
components and then considered in the calculation. An
Determination of the Influence Factors Using an FE example of this procedure is described in (Ref. 14). The sys-
Approach tem must be solved iteratively due to the non-linear behav-
In this approach, the tooth deformation influence factors ior of the tooth contacts, the bearings in the gearbox, etc.
can be calculated using FEM. Here, both the gear and the This is done using the Newton method for iteration control.
wheel body are meshed. The mesh resolution is automati-
cally determined according to a method developed in FVA How to Consider a Wheel Body
Research Project 127 (Ref. 11), which is implemented in the The gear stiffness from ISO 6336 (Ref. 5) is used throughout
FVA STIRAK calculation program and has also been vali- the mechanical system. This gear stiffness cc describes the
dated in test bench trials and practical application. What deformation behavior of two gears in mesh, and the model
is unique about this approach is that the parametric mesh- includes a fully cylindrical wheel body.
ing is done using hexahedra for the tooth area to be evalu- The gear stiffness is linked with the shaft via a rigid lever
ated and tetrahedra for the underlying wheel body. The two arm. The stiffness of the shaft can be modeled as either a
bodies are combined in the calculation process via mesh Timoshenko beam or as an FE structure. This modeling
tying, also known as glued contact. This enables reliable method is shown in Figure 1.

Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association.

MARCH 2023 Power Transmission Engineering 43

 TECHNICAL

To resolve the load distribution, reduction nodes are dis-

tributed at equidistant intervals across the common tooth
width. The lever arms described above are applied at these
reduction nodes. The shear influence in the wheel body is
already fully considered via the static reduction.
The meshing of the surface is essential for the qual-
ity of the results. In particular, the distance between
the nodes of the FE mesh and the reduction points has
been observed to have an influence on the quality of the
results. This imposes strict requirements on the quality
Figure 1—Analytical model using cc from ISO 6336.
and the resolution of the mesh. Special pre-processing of
In an intermediate step, the gear stiffness is initially consid- the CAD geometry of the wheel body makes it possible to
ered using a modified stiffness which does not include the fulfill these requirements.
influence of the wheel body. This is designated as ccmod, and
the reduced stiffness of the wheel body is designated as kred. Results and Discussion
The gear pair stiffness is then linked at the level of the virtual The same model of a two-stage reducer gearbox, as typically
bending diameter of the wheel body according to (Ref. 15). used for electromobility, is used for all of the following anal-
This type of modeling is shown in Figure 2. To link the wheel yses. The overall gear ratio of the gearbox is 1/7.76. The gear-
body with the shaft, rigid rods are added which transmit the box is driven with an input power of 100 kW at 5,000 min^-1.
deflections of the shaft and the torsion of the wheel body. The input torque at a nominal speed is specified as 190 Nm.

Figure 4—The model used for the following studies.

Figure 2—Integration of the reduced stiffness of the wheel body via a All of the following analyses focus on the input stage and
modified meshing stiffness. describe its behavior. The gear data is summarized in Table 1:
In the following, a virtual node is introduced in the center
of the hub and linked to the reduction point of the wheel Input stage [513]
body and the tooth pair stiffness. The connecting elements Sym. Unit
Wheel [516] Pinion [517]
and the connection to the virtual node are rigid. This results
in a system with identical mechanical behavior. Normal pressure angle an 20 °
Helix angle at reference b -30 30 °
diameter
Number of teeth z 43 21 -
Center distance a 75 mm
Normal module mn 2 2 mm
Transverse module mt 2.3094 2.3094 mm
Addendum modification x 0.57179 0 -
Figure 3—Possible deformation types of the model. coeff.
Face width b 25 32 mm
Considering the possible deformation cases shown in Figure
Tip diameter da 105.591 52.497 mm
3, the advantages of this kind of modeling are clear. The com-
mon analytical models are limited to the bending of the tooth Transverse contact ratio fa 1.301 -
and the associated deformation of the cylindrical wheel body. Overlap contact ratio fb 1.989 -
In contrast, this model can represent all degrees of freedom.
Total contact ratio fγ 3.291 -
The radial deformation and its tilting in the drawing plane are
important to consider for thin-walled structures, in particular. Table 1—Gear geometry.

44 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 The geometry of the wheel body is shown in Figure 5. The The applied gear modifications are specified in Table 2:
wheel body is fixed to the shaft via an interference fit. The
geometry is largely determined by the outer diameter of the
Modification to:
hub. The holes are positioned in the center between the
outer diameters of the hub and wheel body to allow for holes Type of modification Symbol Pinion Wheel Unit
with a maximum diameter.
Helix angle CHb 17 - nm

Face modifications
modification
Lead crowning Cb 4 - nm
Circular end relief Cb 3 - nm
Length of circular lC 5 - nm
end relief
Symmetrical profile Ca 5 - nm

modifications
crowning

Profile
Circular tip relief Caf 5 5 nm
Length of circular 3 4 nm
Figure 5—Illustration of the wheel body geometry. root relief

Table 2—Applied modifications.

The gear is modified to achieve uniform load distribu-
tion at nominal load. The full disc wheel body according to This results in the flank and profile lines shown in Figure 7.
the Weber-Banaschek (Ref. 3) model is used as a reference.
The 2D load distribution and the pressure distribution are Normal module: 2.0
Number of teeth: 21

shown in Figure 6. α​n​: 20.0˚

β: 30.0˚
Helix: Right
Scale [2µm]

Left flank Profile lines Right flank

Line load [N/mm] 52.5

Resulting modification: pinion

52
Diameter [mm]

<- Tip Root ->

Scaling 1 : 5

50

350
48.5
48

300
46 45.84
Line load [N/mm]

250
U M D D M U
0.0 16.0 32.0
Flank lines 32.0 16.0 0.0

200 32.0
30
Face width [mm]

150
Scaling 1 : 1

20

<- Up Down ->

16.0

100
10

50
K​Hß​ 1.07 0 0.0

Left flanks in contact Root Pitch circle Tip Tip Pitch circle Root
0 45.84 48.5 52.5 52.5 48.5 45.84
0 5 10 15 20 25
Contact width in u-direction [mm]

Normal module: 2.0

Number of teeth: 43
α​n​: 20.0˚
β: -30.0˚
Helix: Left
x-Axis: Contact width in u-direction[mm] Scale [10µm]
y-Axis: Path of contact [mm]
z-Axis: Pressure distribution [N/mm²]

Left flank Profile lines Right flank

1500
Resulting modification: wheel

106
105.59

104
Hertzian contact stress

Diameter [mm]

<- Tip Root ->

Scaling 1 : 3

102
1000

100
99.3

98 98.08
500

U M D D M U
0.0 12.5 25.0 Flank lines 25.0 12.5 0.0

25 25.0
0
20
Face width [mm]
Scaling 1 : 1

<- Up Down ->

15
12.5
10

ISO � Max. hertzian stress: 1380.91 N/mm²

5

0 0.0

Root Pitch circle Tip Tip Pitch circle Root

98.08 99.3 105.59 105.59 99.3 98.08

Figure 6—Loaded flank; load distribution over the tooth width (top),
pressure distribution over the entire flank (bottom). Figure 7—Resulting modifications for pinion and wheel.

MARCH 2023 Power Transmission Engineering 45

 TECHNICAL

Validation with Existing Models With the FE wheel body, a slight drop in the load (17 N/mm)
First, the results of the cylindrical FE wheel body are com- can be observed at the right edge of the gear. At the left edge,
pared with the results of the wheel body according to Weber- the load increases by 12 N/mm. This indicates additional
Banaschek. The width of the wheel body corresponds to the tilting in the tooth contact. Considering the deformations in
gear width. The diameter of the wheel body ends 3 ) mn the tooth contact, shown in Figure 9, it becomes clear that
below the gear. the additional tilting is caused by the lateral deformation of
In a pre-processing step, the wheel body is meshed with the wheel body.
tetrahedra and the stiffness is determined using static Additional degrees of freedom are available with the FE
reduction. The mesh details are listed in Table 3. wheel body, as shown in Figure 3. Due to the helical gears,
Cylindrical gear wheel Unit an axial force acts on the gear mesh. In the axial direction,
body [556] the wheel body behaves like a one-sided clamped cantile-
ver. This deformation leads to additional tilting, in which
FE mesh element quality All elements meet -
assessment the quality criteria the right side is pressed radially into the gear mesh and the
Element type Tetrahedron -
left side is pulled out of the mesh. This increases the lateral
deformation from 10 µm to 12.5 µm compared to the Weber-
Mesh type Uniform - Banaschek model (Ref. 3).
Element order Quadratic -
Number of elements 103857 -
Lateral deformation
?
Number of nodes 147865 - Lateral deformation + Torsion
Lateral deformation + Torsion + Flank line modification

Allow surface corrections X -

Defeaturing (relative to total size) 0 % Weber-Banaschek wheel body 15
16.92

Amount [μm]
Table 3—Wheel body mesh details. 10
9.92
5

The results of the calculation are shown in Figure 8. The 0

graph on the left shows the result with the wheel body
according to Weber-Banaschek, the reduced FE stiffness is
Amount [μm]

on the right. The results are qualitatively very similar, and

1
there is no difference in the transverse load factor KHb.
0
0 5 10 15 20 25
Line load [N/mm]
Contact width in u-direction [mm]
Weber-Banaschek wheel body

350 Lateral deformation

Lateral deformation + Torsion
300 Lateral deformation + Torsion + Flank line modification
Line load [N/mm]

250 280 N/mm

285 N/mm 20 19.50
Amount [μm]

200
15
FE wheel body

10 12.50
150
5
100
0

50
K​Hß​ 1.07
Left flanks in contact
Amount [μm]

2
0
0 5 10 15 20 25
Contact width in u-direction [mm] 1

Line load [N/mm]

?
Line load (tolerance range) [N/mm] 0
0 5 10 15 20 25

Contact width in u-direction [mm]

350

300 Figure 9—Deformation in tooth contact; with Weber-Banaschek (top) and FE

wheel body (bottom).
FE wheel body
Line load [N/mm]

250
297 N/mm
263 N/mm
200
The cylindrical wheel body is compared with an FE
150 solution to validate the pressure distribution on the tooth
100 flank over the gear mesh, using the FVA STIRAK program
(Ref. 11) as a reference. For consistency, the meshing
50
K​Hß​ 1.07
Left flanks in contact parameters defined in Ref. 16 are used for the FEM solu-
0
0 5 10 15 20 25 tion, as described in Table 4. To accelerate the calcula-
Contact width in u-direction [mm]
tion, only the teeth that come into contact are meshed.
Figure 8—Comparison of the load distribution with (top) and without FE The total contact ratio determines the minimum number
wheel body (bottom). of teeth to be meshed.

46 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 Number of elements Over the tooth height 16 ered with the available resources, it must be assumed to be
At tooth root 8 sufficient. The wheel bodies are positioned such that the
holes are always located directly under the gear for the cal-
Over the tooth thickness 8
culation to maximize their effect.
Common face width 32
Meshed teeth 4 Web width Relative Load Wheel body Relative
# [mm] web width distribution weight [kg] weight
Table 4—FE meshing parameters for the gear and wheel body. factor KHb[-] change
1 25 100% 1.07 1.911 0%
The calculated pressure distribution for the analytical 2 25 100% 1.07 1.469 -23%
solution with reduced FE wheel body and the FE calculation 3 20 80% 1.12 1.239 -35%
with STIRAK are shown in Figure 10. Direct comparison
4 15 60% 1.13 1.095 -43%
shows that the pressure distributions are very similar. The
maximum pressure for the STIRAK solution is 1440 N/mm2, 5 10 40% 1.15 0.952 -50%
with 1381 N/mm2 for the analytical solution. This difference 6 5 20% 1.23 0.808 -58%
is considered negligible.
Table 4—FE meshing parameters for the gear and wheel body.
x-Axis: Contact width in u-direction [mm]
y-Axis: Path of contact [mm]
z-Axis: Pressure distribution [N/mm²] Variants 1 and 2 from Table 5 are cylindrical wheel bodies.
Variant 1 corresponds to the calculation from the previous
1500
analysis; holes have been added to Variant 2 for additional
weight savings. The holes are evenly distributed around the
Hertzian contact stress

1000
circumference and centered between the outer diameters of
the wheel and hub.
Consideration of the relative weight differences between
500
the variants clearly shows the potential of this type of wheel
body. For example, a weight savings of over 60% can be
0 achieved in Variant 6 with a web width of 5 mm.
Figure 11 shows the transverse load factor and the
Max. hertzian stress: 1439.52 N/mm² weight over the web width. As is to be expected, the graph
shows that the weight decreases linearly with the web
x-Axis: Contact width in u-direction[mm]
width. For the first two variants, it clearly shows that the
y-Axis: Path of contact [mm]
z-Axis: Pressure distribution [N/mm²]
holes do not have any effect on the transverse load factor.
The transverse load factor increases as the web width is
1500
reduced. Surprisingly, moderate web widths only have a
slight effect on the transverse load factor. In this case, the
Hertzian contact stress

1000 holes have no effect on the load distribution across the

face width, as the wheel body was designed with a suffi-
500 ciently thick gear rim. However, it can be assumed that the
holes will have an influence on the transverse load factor
0
with thinner gear rims.

1.3 2
ISO � Max. hertzian stress: 1380.91 N/mm²
Full disc wheel body 1.8
1.25
1.6
Figure 10—Pressure distribution comparison; pressure distribution with STIRAK
Weight of the wheel body

Full disc wheel body

1.4
Transverse load factor

with holes
(top), analytical pressure distribution with reduced FE wheel body (bottom). 1.2
1.2

1.15 1
Influence of the Wheel Body on the Gear 0.8
Modification 1.1
0.6
The previous example clearly shows the influence that the
0.4
axial force of a helical gear can have on the tilting of the 1.05
wheel body. It can therefore be assumed that the web width Transverse load factor Weight 0.2

will also have an effect on the gear modification. Thus, a 1 0

5 10 15 Web width 20 25 30
wheel body will be calculated with a varying web width in
this analysis. The geometry is documented in Table 5. As the
load-carrying capacity of the wheel body cannot be consid- Figure 11—Transverse load factor and weight over the web thickness.

MARCH 2023 Power Transmission Engineering 47

 TECHNICAL

The additional deformation can be compensated for Orders output shaft � ?

Gear mesh orders

with a suitable helix angle modification. However, the Shaft rotation orders

0.3
modification to the drive and coast side flanks can dif-
fer significantly. It is essential that all relevant operating 0.25

points are considered.

Amplitude [µm]
0.2

Influence of the Gear Body on the Noise Excitation 0.15

The previous results suggest that holes in the wheel body
also have an influence on the tooth contact. Thus, the fol- 0.1

lowing will calculate four wheel bodies with different hole

0.05
diameters. To more easily identify the influence of the holes
in the evaluation, only four holes will be added. The analysis 0
50 100 150 200 250 300 350 400
is performed using a wheel body with a web width of 15 mm Order

to minimize its influence.

Figure 13—Transmission error spectrum of a wheel body without holes.
With this simulation technique, a rotating gear can be
represented as rotation of the wheel body. The static reduc- The following overview shows the excitation behavior for dif-
tion must be reperformed after each rotation. The rotational ferent hole diameters. The left column shows the transmission
increment is one tooth. error, and the right column shows the spectra from an FFT.
To identify the influence of holes in the wheel body on the Figure 14, which shows the transmission error over a single
transmission error, a wheel body without holes is calculated rollover and the associated FFT spectra, provides a summary
in the first step. Figure 12 shows the transmission error over of the calculation results. With regard to the transmission error,
the angle of rotation of the wheel body. Qualitatively, it can it can be seen that the magnitude of the oscillations increases
be observed that the results fluctuate slightly. This is due to with the hole diameter. The oscillation width increases more
imperfections in the meshing. The transmission error curve than nine-fold, from an initial 0.79 µm to 7.5 µm.
shows a regular pattern with periodically recurring charac- Looking at the spectrum of the transmission error, it shows
teristics, as is to be expected from common excitation calcu- that the tooth meshing orders are predominant with small
lations. As long as no holes are included, the influence of the hole diameters. As the hole diameter increases, additional
wheel body on the excitation is negligible. Harmonics can orders can be seen in the spectrum. From a 5 mm hole diame-
also be identified in the Fast Fourier Transformation (FFT) ter, the 4th order is clearly visible as an additional order with an
in Figure 13. amplitude of 0.1 µm. This order increases with the hole diam-
The meshing orders, marked as light blue lines, are eter. With a 20 mm hole diameter, the 4th order greatly exceeds
particularly noticeable in the transmission error spec- the defined axis with 2.9 µm. Furthermore, it can be observed
trum. The meshing orders are oriented to multiples of that sidebands appear at the tooth meshing frequencies as the
the number of teeth at the 43rd, 86th, 129th, and 172ⁿd hole diameter increases, with a spacing of ±4 orders. These
orders. Small amplitudes can also be seen between the orders can all be attributed to the number of holes and the hole
first and 42nd orders due to harmonics in the transmis- diameter. It can therefore be stated that the hole diameter and
sion error and the meshing. These amplitudes occur the number of holes have a clear influence on the excitation
when the reduction points are not located directly at a behavior. If the holes become too large, the excitation of the
mesh node. hole dominates over the excitations from the gearing.

42.47 µm - 43.26 µm
Fluctuation range: 0.79 µm

43.2
Transmission error [µm]

43

42.8

42.6

0 5 10 15 20 25 30 35 40

Pitches [-] �

Figure 12—Transmission error of the gearbox input stage for a wheel body without holes.

48 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 42.47 µm - 43.26 µm Gear mesh orders
Orders output shaft � ?
Fluctuation range: 0.79 µm
1 Shaft rotation orders

54
Wheel body with 20 mm holes

Transmission error [µm] 52 0.8

50

Amplitude [µm]
0.6

48

46 0.4

44
0.2

42
0 5 10 15 20 25 30 35 40

0
50 100 150 200 250 300 350 400
Pitches [-] �
Order

42.67 µm - 43.74 µm
Fluctuation range: 1.07 µm

54
Wheel body with 15 mm holes

52
Transmission error [µm]

50

48

46

44

42
0 5 10 15 20 25 30 35 40

Pitches [-] �

43.41 µm - 45.64 µm Gear mesh orders

Orders output shaft � ?
Fluctuation range: 2.23 µm
1 Shaft rotation orders

54
Wheel body with 10 mm holes

52 0.8
Transmission error [µm]

50
Amplitude [µm]

0.6

48

46 0.4

44
0.2

42
0 5 10 15 20 25 30 35 40

0
50 100 150 200 250 300 350 400
Pitches [-] �
Order

44.76 µm - 49.16 µm Gear mesh orders

Orders output shaft � ?
Fluctuation range: 4.4 µm
1 Shaft rotation orders

54
Wheel body with 5 mm holes

52 0.8
Transmission error [µm]

50
Amplitude [µm]

0.6

48

46 0.4

44
0.2

42
0 5 10 15 20 25 30 35 40

0
50 100 150 200 250 300 350 400
Pitches [-] �
Order

46.71 µm - 54.18 µm Gear mesh orders

Orders output shaft � ?
Fluctuation range: 7.47 µm
1 Shaft rotation orders

54
Wheel body without holes

52 0.8
Transmission error [µm]

50
Amplitude [µm]

0.6

48

46 0.4

44
0.2

42
0 5 10 15 20 25 30 35 40

0
50 100 150 200 250 300 350 400
Pitches [-] �
Order

Figure 14—Overview of calculation results for hole diameters of 5 mm, 10 mm, 15 mm, and 20 mm.

MARCH 2023 Power Transmission Engineering 49

 TECHNICAL

8
Peak-to-peak transmission error

7
6
5
[µm]

4
3
2
1
0
0 5 10 15 20
Hole diameter [mm]
Figure 15—Influence of wheel body holes on the peak-to-peak transmission error.

In Figure 15, the ranges of variation of the transmission It can be seen that the wheel body has a strong influence
errors are evaluated. The fluctuation ranges are determined on the excitation behavior. This influence should be taken
as maximum value—minimum value. The fluctuation range into account when designing the gear teeth and should be
increases non-linearly with increasing hole diameter. simulated using suitable tools.

Conclusion and Future Work

This study presents a simulation method for considering complex wheel bodies in an analytical tooth contact model. The wheel
body is considered using reduced FE stiffness. Reduction points are defined over the width and linked with the analytical gear.
For cylindrical wheel bodies, comparative calculations show fewer deviations from the expected results with the new
method. This is due to the additional degrees of freedom in the FEM model. In the calculation with cylindrical wheel bod-
ies, bending due to axial force in tooth contact could also be verified in addition to the deformation in tooth contact and the
influence of the shaft-bearing system.
The influence of the web width on the tooth contact could also be demonstrated in the analysis of the face modification.
The axial stiffness decreases with the web width, and the wheel body deforms under the load. As long as they are known,
these deformations can be taken into account via additional helix angle modifications. In doing so, it is important to consider
partial load conditions, as the lower loads result in smaller deformations. This is also principally the case without the wheel
body; however, the wheel body introduces additional elasticities into the system which must be considered.
It could be demonstrated that the noise excitation is particularly affected by holes in the wheel body. Holes can be detected
in the noise excitation and in the spectrum, almost irrespective of their size. The larger the holes, the greater their influ-
ence on the noise excitation. In particular, the low-frequency vibration components, such as the amplitudes from the hole,
become significantly more important with increasing speeds in electrified powertrains. While lower speeds were common
in the transmissions of internal combustion engines, higher speeds are frequently used in electric drives. For example, the
speed4e concept drive (Ref. 17) uses 30,000 rpm on the drive side.
The heavy dependence on the finite element (FE) meshing quality poses a challenge, as the user must deal with different
meshes and perform a convergence analysis to find the appropriate meshing quality. It would be preferable to specify a struc-
tured mesh on the surface at the transition between the FE wheel body and the analytical gear. This would ensure that the
reduction points are always located on the nodes of the FE mesh.
Fast simulation is essential for being able to calculate the influence of the wheel body on the gear as early as possible in
product development. With this simulation method the greatest effort is the static reduction, which must only be performed
once. The calculation times were documented in the project and are summarized in Table 6. These speeds suggest that this
method is suitable for product development.
Calculation step Duration
Static reduction 30 seconds to 15 minutes, depending on the FEM meshing size
System calculation Between 1 and 3 seconds, depending on the gearbox size
Table 6—Summary of calculation times.

In conclusion, it can be stated that the use of weight-optimized wheel bodies is possible and useful. However, this should
be considered in gear calculations as early as possible, as the wheel body has an influence on both the load-bearing capac-
ity and the noise behavior.

50 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 References
1. Wimmer, J. A., 2006, “Cylindrical Gear Load Losses: Design Influences, 10. FVA Research Project 592 I–II: Validation and Investigation of
Efficiency Maximization, Tribology,” Ph.D. thesis, TU Munich Gear Application Limits of the FVA RIKOR Gear Program Based on
Research Center (FZG). Deformation Measurements, Forschungsvereinigung Antriebstechnik
2. FVA Research Project 484 V, Elastic Wheel Bodies, e.V. (FVA).
Forschungsvereinigung Antriebstechnik e.V. (FVA). 11. FVA Research Project 127 I–IX, STIRAK FEM Tooth Contact Analysis,
3. Weber, C. and Banaschek, K., Form Modification and Profile Relief of Forschungsvereinigung Antriebstechnik e.V. (FVA).
Cylindrical and Helical Gears. Antriebstechnik series of publications 12. FVA Research Project 571 I, Planetary Stage Load Distribution in the
11, Vieweg Verlag, Braunschweig. FVA-Workbench, Forschungsvereinigung Antriebstechnik e.V. (FVA).
4. FVA-Workbench Version 7.0 – Description of Modules (2022), FVA 13. Breuer, M., Theoretical and Experimental Determination of Rolling
GmbH. Bearing Stiffness, VD Progress Reports, Series 1, No. 241 (1994).
5. DIN 3990-1:1987-12: Calculation of load capacity of cylindrical gears; 14. FVA Research Project 711, Integration of Elastic Casing Structures
introduction and general influence factors, Beuth Verlag (1987). in Gearbox Design with RIKOR and Visualization of the Entire
6. ISO 6336-1:2019-11: Calculation of load capacity of spur and helical Transmission System in the FVA-Workbench, Forschungsvereinigung
gears—Part 1: Basic principles, introduction and general influence Antriebstechnik e.V. (FVA).
factors, Beuth Verlag (2019). 15. Wikidal, F., 1998, “Calculation of the Flank Pressure of Cylindrical and
7. Schmidt, G., 1972, “Calculation of the Rolling Contact Pressure of Helical Gears Under Consideration of Load and Production-Related
Helical Gears and Consideration of the Pressure Distribution,” Ph.D. Deviations,” Ph.D. thesis, TU Munich Gear Research Center (FZG).
thesis, TU Munich Gear Research Center (FZG). 16. FVA Research Project 892, FE Calculation of Plastic Gears in the FVA-
8. FVA Research Project 30 I–VII: Pinion Modification Program—RIKOR, Workbench, Forschungsvereinigung Antriebstechnik e.V. (FVA).
Forschungsvereinigung Antriebstechnik e.V. 17. Speed4E project website: speed4e.de/Joomla/index.php/e
9. FVA Research Project 338 I–VII, Dynamic Tooth Force Program—DZP,
Forschungsvereinigung Antriebstechnik e.V. (FVA).

Benjamin Abert is head of After studying mechanical

consulting and service at FVA engineering at Technical University
GmbH. He studied at the Clausthal of Munich, Dr. Georg Hammerl
University of Technology. Abert did his PhD in the field of
began working for FVA in 2013 computational mechanics. He joined
as a calculation expert for plain FVA GmbH in 2017 to further
and rolling bearings. These develop the FVA-Workbench. He is
responsibilities increased to expert an expert in finding smart solutions
support and sales in 2018. for complex problems, so the user
can safely reach the goal with
simple workflows.

For Related Articles Search

tooth load
at www.powertransmission.com

MARCH 2023 Power Transmission Engineering 51

 INDUSTRY NEWS

AMT and connectivity for data management

and process optimization, as well as
Solutions trade show held annually in
Nuremberg, Germany. It is Europe’s
Mesago digital twin technology and new solu-
tions for CAD/CAM and ERP/shop
leading trade fair for digital industrial
solutions. SPS 2022 attracted 44,000
Frankfurt management software.
“The Automation Sector at IMTS
visitors and featured about 1.2 mil-
lion square feet of gross exhibition
COLLABORATE TO EXPAND expands IMTS’ appeal as a must- space and 1,000 exhibitors involved
AUTOMATION ACROSS THE
attend event for businesses that want in advanced automation solutions. As
UNITED STATES
to increase their manufacturing effi- an international meeting place for the
Two of the global manufacturing ciency through automation,” says industry and representing the com-
industry’s premier organizations, Douglas K. Woods, president of AMT, plete spectrum of smart and digital
AMT—The Association For Manufac- which owns and produces IMTS. “By automation, SPS—Smart Production
turing Technology and Mesago, a sub- working with SPS—Smart Production Solutions in Atlanta will benefit from
sidiary of Messe Frankfurt Group, have Solutions, IMTS 2024 will have even the international network already
announced a collaboration to create more exhibits featuring advanced established in Germany.
the Automation Sector at IMTS—The motion systems, vision and imaging, Together, both events will facilitate
International Manufacturing Tech- data analytics, systems integration, a faster exchange of knowledge, which
nology Show in 2024, and SPS—Smart artificial intelligence, and cloud and is particularly relevant to global issues
Production Solutions in Atlanta, Geor- edge computing." involving supply chains, logistics, staff
gia, in 2025. shortages, and cost pressures. All these
The Automation Sector at IMTS and Solutions Tomorrow issues increase the need for automa-
SPS—Smart Production Solutions in SPS—Smart Production Solutions tion technologies that leverage worker
Atlanta will be held in alternate years, will be held Sept. 23–25, 2025, at the productivity and boost business profit-
and both events will be supported by Georgia World Congress Center in ability. “The SPS in Atlanta in the alter-
Gardner Business Media (GBM). Atlanta. The inaugural event will host native years allows for the continu-
exhibits from simple sensors to intel- ity of this ever-important exchange,”
Automation Essential ligent solutions, from what is feasible underlines Martin Roschkowski, pres-
The Automation Sector at IMTS 2024, today to the vision of a fully digitalized ident of Mesago Messe Frankfurt. “The
powered by SPS—Smart Production industrial world. strength of SPS in the global automa-
Solutions, will feature an expansive “Manufacturing in the Southeast tion industry, coupled with IMTS, will
offering of automated, robotic, con- region is flourishing, and as one of the provide important business platforms
nected, and digital manufacturing tech- national leaders in advanced manufac- for companies involved in this rapidly
nologies. IMTS 2024 runs Sept. 9–14 at turing, Georgia is the perfect backstory changing environment.”
McCormick Place in Chicago... for an automation industry event in Mesago Messe Frankfurt also pro-
IMTS 2022, the largest manufac- the United States,” says Constantin von duces SPS fairs in China, Italy, and the
turing technology event in North Vieregge, president and CEO, Messe Middle East, as well as events focusing
America, witnessed an unprece- Frankfurt Inc. “Working in concert with on electronic assemblies, intelligent
dented number of demonstrations AMT, GBM, and our sister company, motion, and additive manufacturing.
featuring robots, cobots, vision sys- Mesago, the development of SPS— “Creating the Automation Sector
tems, and other automated solutions Smart Production Solutions in Atlanta at IMTS and SPS—Smart Production
around manufacturing processes will cater to a multiplicity of sectors Solutions in Atlanta reflects our com-
such as additive manufacturing, CNC providing a platform to elevate the mitment to helping manufacturers
machining, metrology, and part han- advancing technological innovations.” enhance and accelerate their produc-
dling. Exhibitors featured complete The Atlanta event is an expan- tivity and support the expanding US
system-solutions that also included sion of the SPS—Smart Production manufacturing market,” says Woods.
“By working with Mesago Messe
Frankfurt, we can showcase an even
broader spectrum of digital technolo-
gies that are essential for fueling man-
ufacturing growth.”
Additionally, Mesago Messe
Frankfurt, AMT, and Gardner Business
Media recently announced a collab-
oration to bring several Formnext
additive manufacturing events to the
United States, including launching
Formnext Chicago in 2025.
imts.com

52 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

 CALENDAR

April 18–19—Nextlub 2023 tions in manufacturing automation technology from more

Lubricants and tribological systems are undergoing rapid than 600 leading exhibitors. Each day also offers inspirational
change. The challenges and uncertainties are enormous. keynote sessions and theater presentations to help attendees
Ecological challenges such as the de-carbonization of find the best solutions for their unique business needs. In
industry, mobility and society on the one hand, economic addition to seeing demos of the latest automation solutions,
challenges such as the resilience of global supply chains on Automate show attendees can watch keynote sessions
the other, are changing the way lubricants and tribological highlighting how these technologies solve real-world chal-
systems will be developed, validated, produced and applied lenges or participate in small group discussions in the theater
in the future. Within the Nextlub program (Dusseldorf, sessions covering important topics.
Germany) innovative solutions will be addressed to cope
with the major challenges of future tribology engineering.
The topics span from base materials and chemical composi-
tions over new design, development and validation require-
ments to new applications and operation boundaries.
powertransmission.com/events/940-nextlub-2023

May 4–10—Interpack 2023

Around 2,700 key players and newcomers from all over the
world are using Interpack as a stage to present their
premières and celebrate the long-awaited reunion of the
global packaging industry (Dusseldorf, Germany). Numer-
ous specials, like the lecture program as well as trending
topics of the industry add to what is offered for visitors. To
help visitors not get lost in 18 trade fair halls, the halls
feature a custom concept based on the core target groups
food, beverages, confectionery and baked goods, pharma- powertransmission.com/events/941-
ceutical products, cosmetics, non-food and industrial automate-2023
goods. "Every part counts” is the motto of the Components
trade fair, which takes place parallel to Interpack as its own May 24–25—CTI
event. This is where you find companies offering technol- Symposium USA 2023
ogy for drives, control units and sensors, products for The CTI Symposium USA (Novi, Mich.) will update attend-
industrial imaging, handling technology, industrial soft- ees on the latest technical developments and applications
ware and communication as well as comprehensive auto- on automotive transmissions for conventional and alterna-
mation systems for the packaging industry. There are also tive drives. Exchange experiences, discuss technologies and
machine parts, components and equipment, peripheral strategies with automotive experts from the United States,
devices as well as components and aids for packaging. Asia and Europe. The conference and exhibition provide
expert-led plenary and technology sessions as well as
expert discussions and product showcases representing the
full range from complete drivetrain systems to components
and engineering services. CTI drives progress in passenger
cars and commercial automotive transportation. Manufac-
turers and suppliers are actively demonstrating how to keep
pace and staying ahead of customer needs, environmental,
institutional and economic demands.

powertransmission.com/events/943-
interpack-2023

May 22–25—Automate 2023

Between intimate workshops, news making keynotes, net-
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tions, Automate offers comprehensive automation education
and cutting edge robotics, vision, AI, motion control and other powertransmission.com/events/942-cti-
technologies. Automate (Detroit) delivers the latest innova- symposium-usa-2023

MARCH 2023 Power Transmission Engineering 53

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 Y WERPLAO

Metaphor: An Object in Motion

Aaron Fagan, Senior Editor

A still from Noah Baumbach’s adaptation of Don DeLillo’s novel White Noise. (Netflix)

Streaming now on Netflix is director Noah Baum- ADAS are already in operation in railways in many coun-
bach’s adaptation of author Don DeLillo’s 1985 classic tries around the world, such as automatic train protection,
White Noise, a postmodern campus novel about the collision avoidance, and automatic train operation systems.
dangerous influence of the careless use of scientific ADAS is used for condition monitoring track and rolling
inventions and technology which won the National stock providing real-time information to train drivers and
Book Award the year it was published. control centers. With the increasing dependence on ADAS
White Noise opens with a college lecture from Professor technology, the importance of cybersecurity will become
Murray Siskind (Don Cheadle), addressing both his students more critical. Future ADAS systems will need to be designed
and the viewer: “Roll film,” he begins as the movie roars to with robust security measures to prevent hacking and other
life with a montage of car crashes drawn from the history malicious attacks.
of American filmmaking—the whole of cinematography is ADAS is expected to play a crucial role in the develop-
reduced to its essential conceit: an object in motion. ment of autonomous vehicles, with the goal of eventually
The etymology of cinema is from the ancient Greek κίνημα reaching full automation. The continued development of
(kínēma) meaning “movement,” and a movie is a fiction using sensors and data processing algorithms will enable ADAS
metaphor, which, incidentally, is also from the Greek for technologies to provide more accurate and reliable infor-
μεταφορά (metaforá) meaning “to transport.” Prof. Siskind mation about the vehicle’s environment with the poten-
isn’t simply interested in motion; he’s obsessed with colli- tial of advancing the safety, performance, and efficiency
sion yet careful not to frame the scenes in morbid or macabre of transportation.
terms. “Don’t think of a car crash in a movie as a violent act,” White Noise presents a satirical view of the overreliance
he urges his students. “No, these collisions are part of a long on technology and the illusion of safety that it can cre-
tradition of American optimism,” the professor argues. “Each ate. It highlights the ways in which people can become so
crash is meant to be better than the last,” he explains. “There’s dependent on technology that they lose touch with reality
a constant upgrading of tools, skills, a meeting of challenges.” and become vulnerable to unexpected events. ADAS in rail-
At the heart of the film, a massive train accident leads to ways can be seen as an example of how technology can be
what is termed an “airborne toxic event” resulting in the used to enhance safety and efficiency, but also as a poten-
evacuation of a neighboring town. Truth is still stranger tial source of complacency and a loss of agency for human
than fiction and at times fiction collides with reality: On operators. In this way, the use of ADAS in transportation
February 3rd, the actual neighboring town, East Palestine, could be interpreted as a contemporary manifestation of
Ohio—where White Noise was filmed and many of the locals the same underlying themes that DeLillo critiqued in White
were hired as extras—was evacuated after 20 train cars car- Noise when he wrote:
rying hazardous materials derailed. “The car seemed to have no sense of being alive, no sense
What the incident calls attention to in the real world is of its own reality. It was pure function. The tires contacted
a society where the “constant upgrading of tools, skills, a the road, the motor pressed us forward, the brakes stopped
meeting of challenges” Prof. Siskind celebrated are being us, the steering mechanism directed us. All of it was robotic,
exercised to create transportation that is designed to avoid inhuman. There was no sense of being part of a living thing,
or minimize the impact of a collision. This can be achieved of participating in the flow of the universe. It was as if we had
through various technologies such as advanced driver assis- removed ourselves from the natural order of things, from
tance systems (ADAS), autonomous driving capabilities, the cycles of birth and death and regeneration, and entered
and smarter vehicle design. into a world of pure technology, a world of perfect efficiency
Some manufacturers are already incorporating these and control…. The road ahead of us seemed infinite, like a
technologies into their vehicles, and different types of tunnel with no end. Anything could happen.”

56 Power Transmission Engineering MARCH 2023 WWW.POWERTRANSMISSION.COM

Automation
made easy.
Fully integrated drive components, control electronics
and automation software – all from a single source – and
all designed to work together perfectly.

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