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Direct Gear Design
Service Mark Registration
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Direct Gear Design
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Gear geometry - primary,
tooling parameters - secondary
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Traditional gear design is based on the rack generation and preselected (mostly standard) tooling parameters and provides universally acceptable performance for standard gear applications. However, Direct Gear Design® is an application driven gear drive development process with primary emphasis on performance maximization and cost efficiency without concern for any predefined tooling parameters. It completely optimizes the gear tooth flank and fillet profiles and works perfectly with any gear application that’s demands high technical and market performance.
Modern Direct Gear Design is developed for involute gears and based on the Theory of Generalized Parameters created by Prof. E.B. Vulgakov. For more details about the Direct Gear Design method, please open the Publications page.
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Asymmetric Gears
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The two profiles (sides) of a gear tooth are functionally different for most gear drives. The workload on one profile is significantly higher and/or is applied for longer periods of time than for the opposite one. The asymmetric tooth shape reflects this functional difference to improve the performance of the drive tooth profiles on account of the performance of the opposite coast tooth profiles. The coast tooth profiles are typically unloaded or lightly loaded during relatively short work period. Direct Gear Design of the asymmetric gears independently defines the drive tooth profile for maximum load capacity, the cost tooth profile, and the fillet for sufficient flexibility. It provides high gear transmission performance with low noise and vibration.
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Tooth Flank and Fillet Profile Optimization
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The involute flank of the gear tooth is optimized for maximum mesh efficiency and tooth surface durability. The proprietary fillet profile optimization technique allows to evenly distribute the maximum bending stress along the fillet profile reducing stress concentration. It significantly (10-15%) reduces the bending stress level by comparison with the best currently used tooth proportion. This bending stress reduction is also exchangeable for additional increase of wear resistance, efficiency, and lifetime of gear transmission.
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High Gear Ratio Planetary Drives
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AKGears has developed and implemented the high gear ratio planetary arrangements. This enables gear ratios from 20:1 to over 200:1 in one stage and from 200:1 up to 100,000:1 (patent pending) in two stages. These planetary systems contain very few components, provide higher load capacity, and have less tolerance sensitivity than the harmonic or orbiting drives.
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Self-Locking Gears
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Most of gear drives are back drivable or inertia drivable. This means they can be put in motion by a torque applied to the output shaft. For many gear applications the back or inertia drivability is not desirable and different types of the brake systems are used. There are no back drivable gears (worm gears, for example) that do not require brakes. However, gears have very high gear ratio, low efficiency, and some of them (like worm gears) have angled or crossed axis.
Based on the previous studies, AKGears has developed and implemented the parallel axis self-locking gears. These gears can utilize any gear ratio from 1:1 and higher. They can be designed to prevent either the inertia driving, or backdriving, or both and be external, internal, or incorporated into the planetary gear stage. Their gear mesh efficiency is significantly higher than for the existing not back drivable gears.
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Plastic Gears
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Direct Gear Design® works ideally for plastic gears providing total design flexibility that is not achievable using the traditional gear design. It compensates for plastics' low strength and low thermal conductivity by balancing pinion and gear tooth bending stresses, reducing the bending stress concentration, minimizing and balancing specific sliding velocities resulting in maximum efficiency and minimum heat generation.
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When it comes to expertise in gear molding accuracy, inspection, and material selection, Gleason Plastic Gears is AKGears’ first choice. With two Materials Scientists on staff, expertise in KISSsoft gear and transmission design software, extensive gear metrology capabilities, and proprietary “No Weld-Line” technology, Gleason Plastic Gears is able to produce the most quiet, accurate, and lasting polymer gears on the market.
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