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Gearbox Design for Assembly
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LRT is a Gearbox Specialist, Mechanical Engineer, Product Design Engineer, Gears and Power Transmissions Design and Development Consultant, Gearbox Technology Consultant with world-class expertise in gearbox technology, design and development of gears and power transmissions.
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The challenge in this case was to design a gearbox with improved assembly characteristics and therefore with reduced assembly costs.
The worm and the two spherical bearings were pre-assembled. The design of the worm and the gear was straight instead of single or double enveloped, which makes the assembly easier.
Both housing and cover were made out of Zamac 5 Zinc using the Die Casting process, which made it possible to use thin walls and therefore make the assembly as small as possible. Zinc die casting alloys have much to offer. They are strong and tough, and most importantly they can frequently be cast "net shape". No secondary operations are necessary.
The housing and the mating cover were designed in such a way that no additional fasteners were necessary.
Screws or rivets are commonly used to secure the cover to the housing. However, these are additional components that are not easily installed in an automated process.
The cover has a die-cast base including four die-cast posts. The housing includes a base with four holes. The four die-cast posts of the cover are aligned with the housing holes during assembly.
The die-cast posts are staked to secure the cover to the housing.
The grease was pumped through a filler hole in the upper housing and then the hole was closed with a plug.
Every gearbox was then tested for noise and amperage draw before it was ready to go into the main assembly.
Working closely with the die-casting engineers from early on in the development phase gave the die-caster a first place award in the annual North American Die Casting Association competition for this set of zinc housing castings.
Read other articles by this KKAI Associate:
Design of New Cost Reduced Gearbox
Development of Plastic Servo Cover
| Gearbox Specialist, Mechanical Engineer, Product Design Engineer, Gears and Power Transmissions Design and Development Consultant, Gearbox Technology Consultant, gearbox technology, design and development of gears and power transmissions. | |
| Resume of RBE | gearbox design, structural dynamics, expert consultant |
| Resume of JAM | gear, materials, mechanical expert consultant |
| Resume of HBU | industrial lubricant, tribology expert consultant |
| Resume of JOP | bearings expert consultant |
| Resume of GLN | acoustics, vibration, vehicle dynamics, expert consultant |
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