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2005
Conference Paper
Titel
Schmiermittelarme Leichtbauzahnradgetriebe durch Beschichtungen
Abstract
One of the central problems in manufacturing gears is to lengthen the life and increase the load capacity of transmissions and drive elements made from lightweight materials. Using lighter materials significantly reduces the moment of inertia, meaning higher dynamics can be achieved. In the framework of the joint project LEZABS ("Lightweight lubricant-free or low lubricant gear transmission through DLC coatings") a gear transmission with backlash for a circular saw of the firm Metabowerke GmbH & Co. and a Harmonic Drive gear transmission free of play that is suitable for positioning changes in robots or machine tools were investigated. Int both applications traditional steels are being replaced with lighter, easier to work materials. Aluminium and titanium alloys are being investigated for the play-free transmission gears, with sintered steels and ETG 100 for the gear transmissions with backlash. Variations of coatings were checked in extensive wear and application-orientated model tests. The laboratory results were transferred to realistic gear transmission elements. In order to maintain optimal total power output, calculations and simulations to improve gear geometry and the meshing of the gears were carried out. As the result of all this development work METABO experienced a tool life incrase from 50 to 300 hours for their circular saw with the same size and load. Production costs could be held steady by substituting the use of an a-C:H coating for a hardening process, while at the same time improving toothing quality. Aluminium and titanium alloys with an a-C:H coating were successfully used as the material for the play-free Harmonic Drive gear transmission. The total weight of the gear transmission could be reduced, while maintaining the same performance characteristics. The results of the LEZ-ABS project are already being transferred into industrial projects. Thus for example the company Bosch Rexroth AG is using Harmonic Drive gear transmissions with aluminium components in assembly robots.
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