This is how you optimize your manufacturing with minimal noise levels and maximum accuracy.
Why is noise reduction in bevel gearboxes so important in precision assembly?
A lower noise exposure in precision assembly is crucial, as it increases the concentration of employees and can reduce error rates – in some cases by up to 2%. In addition, minimal vibrations lead to a higher product quality und accuracy of the manufactured parts, which can reduce the reworking rate by up to 5%, for example.
What design features make a bevel gearbox “low-noise”?
Low-noise bevel gearboxes are characterized by several features: an optimized tooth geometry (e.g. helical gearing, precise tooth profile corrections), the use of high-quality, low-friction bearings, a careful material selection for gears and housings (e.g. damping materials like aluminum casting) as well as a precise manufacturing and assembly. These factors can significantly reduce noise emissions, sometimes by 5 dB(A) or more.
Can existing machines be retrofitted with low-noise bevel gearboxes from ATEK?
Yes, retrofitting is often possible. ATEK Drive Solutions GmbH offers comprehensive consulting and can configure or develop suitable low-noise bevel gearboxes for existing facilities through its modular system as well as the ability to develop customized special solutions. This enables an improvement in acoustics and precision without complete redesign of the machine.
How does material selection influence the noise level of a bevel gearbox?
Material selection has a direct impact on noise generation. While steel signifies high load-bearing capacity, special plastics (e.g. PEEK, POM) can significantly reduce the noise level – by up to 10 dB in certain applications. Housing materials such as – in bestimmten Anwendungen um bis zu 10 dB. Auch Gehäusematerialien wie aluminum casting or gray cast iron also contribute to noise minimization through their damping properties.
What role does lubrication play in minimizing gearbox noise?
Proper lubrication is essential for the quiet operation of a bevel gearbox. High-quality lubricants, especially synthetic oils, form a stable lubricant film that reduces friction and wear. Additionally, they can dampen vibrations and positively influence noise generation. On the other hand, incorrect lubricant choices can increase noise by 2-3 dB.
Are low-noise bevel gearboxes also suitable for high torque applications?
Ja, Low-noise design principles can also be applied to bevel gearboxes for high torques. ATEK Drive Solutions GmbH combines decades of experience in gearbox construction with modern manufacturing techniques to provide robust and simultaneously noise-optimized solutions even for demanding applications. The design always considers the required torque and specific load cycles. anzubieten. Die Auslegung berücksichtigt dabei stets das erforderliche Drehmoment und die spezifischen Lastzyklen.
How does ATEK ensure the quality and noise reduction of its bevel gearboxes?
ATEK relies on a combination of decades of experience, a modular system for high variability, precise manufacturing and development modular system. Through comprehensive technical consulting and a large inventory, it is ensured that customers receive the optimal, including low-noise, drive solution. If necessary, specific tests for noise measurement can be conducted.
For which typical precision assembly applications are ATEK’s low-noise bevel gearboxes suitable?
Die Low-noise bevel gearboxes from ATEK are excellent for a variety of precision assembly applications, including in the machine and plant engineering, in the packaging industry, in the machine tool manufacturing, in the robotics and automation as well as in the medical technology. Wherever high accuracy, low vibrations, and reduced noise emissions are required.
The use of low-noise bevel gearboxes in precision assembly leads to significant improvements: it can reduce the rework rate by up to 5%, decrease the error rate by 2%, and improve the surface quality by up to 10%.
Optimized design features such as helical gearing, precise manufacturing (e.g. grinding can reduce noise by up to 5 dB(A)), high-quality bearings, and damping materials (e.g. plastics can reduce noise by up to 10 dB) are crucial for minimizing noise generation.
A Careful selection and system integration, supported by experienced providers like ATEK Drive Solutions GmbH, is essential for the maximum performance and longevity of low-noise bevel gearboxes. Correct alignment can significantly extend the bearing life..Discover how low-noise bevel gearboxes can revolutionize precision in your assembly. Learn more about technology, applications, and selection criteria.
In the world of precision assembly, every detail matters – including the noise level. Low-noise bevel gearboxes are the key to quiet and efficient manufacturing. Are you looking for the perfect solution for your application? Contact us now Contact with our experts!
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Introduction to low-noise bevel gearboxes for precision assembly.
A high noise level in precision assembly affects concentration and accuracy. Specific low-noise gearboxes reduce noise and improve precision and efficiency. In precision assembly, minimal vibrations and noise generation are crucial for product quality.A low-noise bevel gearbox can reduce the reworking rate by up to 5%. Modern gearboxes with servo motors also benefit from this. In semiconductor manufacturing or medical technology, loud gearboxes are disruptive..
Choosing a suitable low-noise gearbox is relevant for process stability Die Wahl eines passenden geräuscharmen Getriebes ist relevant für die Prozessstabilität, e.g. in microchip assembly. Our servo motors are often part of such solutions. Low-noise drives improve working conditions; an automotive supplier reduced its error rate by 2%. Lower vibrations also mean less wear and higher overall accuracy, which can lead to 10% better surface roughness in machine tools.Design features and optimization of bevel gearboxes for low noise generation.
Major noise sources in bevel gearboxes are tooth engagement, bearing, and housing vibrations. An optimized tooth geometry is crucial for noise reduction (e.g. Siemens SIMOGEAR insert pinion principle). Such designs are important for precise gearbox motors and a core aspect in the development of low-noise bevel gearboxes. Helical gears (e.g. ATEK Drive Solutions GmbH) offer acoustic advantages; a test stand manufacturer reduced emissions by 4 dB. High-quality manufacturing like grinding improves surface quality (up to 5 dB(A) quieter than milled). Tooth profile corrections minimize engagement impacts.
- Optimized tooth geometry significantly reduces noise.
- Use of helical gears for acoustic advantages.
- High-quality manufacturing methods like grinding improve surface quality and reduce noise.
- Tooth profile corrections minimize engagement impacts and associated noise.
- Low-friction precision bearings reduce friction noise.
- Correct lubrication with synthetic oils effectively dampens vibrations.
- FEM-optimized housings made of damping materials (e.g. aluminum/gray cast iron) minimize housing vibrations.
Low-friction precision bearings (e.g. Neugart PSBN) minimize friction noise.. Correct lubrication (synthetic oils) dampens vibrations; incorrect choices can raise noise by 2-3 dB. FEM-optimized housings made of damping materials (aluminum/gray cast iron) are beneficial, to enhance the overall performance of noise-optimized bevel gearboxes. A packaging machine manufacturer reduced housing vibrations by 15% through FEM analysis.Material selection and manufacturing techniques for low-noise bevel gearboxes.
For quiet gears used in low-noise bevel gearboxes , alloyed, hardened, ground steels are suitable. At lower loads, plastics (POM, PEEK) are a noise-damping alternative; a medical technology company reduced the level by 10 dB using PEEK gears. High-precision gearboxes. utilize such materials. An office equipment manufacturer achieved a 6 dB noise reduction with polymer gears. The choice of material for quiet gear boxes for precision tasks depends on load and environmental conditions.
Manufacturing precision is crucial. Techniques like grinding ensure surface quality, an important factor for noise-optimized bevel gear boxes. Precise manufacturing can increase lifespan by 30% and optimize noise. Tolerances in the micrometer range are standard in the production of components for quiet bevel gear boxes for precision assembly. A robotics supplier improved profile accuracy by 20% through more precise grinding, optimizing running noise and positioning accuracy. Heat treatments and special coatings (e.g. DLC) enhance wear resistance and friction.Applications and case studies for quiet bevel gear boxes in precision assembly
In robotics and automation, they are used for precise movements in customized special solutions. robot joints or positioning systems, which can increase repeatability by up to 15% High-precision bevel gear boxes. can complement such können solche quiet drive systems for precision tasks . The use of quiet bevel gear boxes for precision assembly leads to the following advantages in various application fields:
- Increase in repeatability in robot joints and positioning systems by up to 15%.
- Enabling higher cycle rates while reducing errors in automation.
- Ensuring minimal noise generation in medical technology, e.g., in surgical robots.
- Ensuring patient comfort and better concentration of medical staff.
- Improvement of surface quality in machine tools by up to 12%.
- Reduction of scrap rates, for example by 3% in assembly robots.
- Achieving better surface roughness in precision grinding machines (e.g. 0.05 µm).
In medical technology (e.g. surgical robots), minimal noise generation is important. Quiet gear boxes ensure patient comfort and concentration of staff (e.g. dialysis machines <40 dB). Machine tools benefit from improved surface quality (up to 12%) and lower scrap rates (e.g. 3% in assembly robots). Precision grinding machines achieve e.g. 0.05 µm better surface roughness, often supported by vibration-damped bevel gear boxes for precise assembly processes.Select and integrate appropriately: Ensure optimal gear performance
To select a quiet bevel gear box for precision assembly requirements (torque, speed, noise level) must be defined precisely. A detailed load analysis and definition of allowable noise emissions are essential (e.g. <45 dB(A) for inspection systems). Important is the calculation of the operating factor (f.s.). Common types are bevel gear boxes, play-free planetary gear boxes or noise-reduced gear motors; choosing the right low-noise gear box for fine assembly is crucial.
Manufacturer experience (e.g. ATEK Drive Solutions GmbH) and support are relevant. Careful system integration, correct alignment (0.1 mm misalignment can reduce bearing lifespan by 50%), and thermal verification (Pth critical) are central to the longevity and performance of quiet bevel gear boxes. A rigid assembly prevents additional vibrations and noise.
The careful selection and integration of a quiet bevel gear box for precision assembly greatly contributes to quality and efficiency in demanding assembly processes.
