Custom-engineered gearing components
Are you looking to integrate new gearing components into your drive system? Would you like to upgrade your existing design? Or have you reached a point where individual gears are stalling the development and production of your drive system?
We specialize in the design, construction, and manufacture of gearing components. We’re well aware that a single gear can determine the success or failure of an entire drive system. That’s why we’re the right development partner for you if your goal is to harness the potential of customized components.
We implement your individual gearing solution with technical excellence and cost efficiency. Working with metal and plastic, we ensure tight coordination between development and production—all of this backed by our more than 110 years of expertise in drive technology.
Which drive would you like us to develop your gearing components for?
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Our development offering
You choose how you would like to collaborate with our development team depending on your application and the gearing you require. That’s why we offer you not only customized gearing components, but also a customized development process.
This is how your components could be developed:
Case 1: You require a precisely defined gearing solution
Do you know exactly what you want? Have you defined the size of the installation space, decided on a type of gearing, and determined the gear ratio you need? In this case, we’ll design the gear or gear set you require to your exact specifications as well as the connection to your drive system. Our mission is to exceed your requirements in terms of efficiency, operating noise, and weight.
For example: Precision specialist maxon developed a high-precision drive with offset input and output shafts. For this drive, we designed the appropriate speeroX gearing, constructed the interfaces, and optimized the load capacity and manufacturability within the defined limits.
Case 2: You need a gearing solution that fits into the existing environment
Do you know exactly where you need which gearing solution and would you like to integrate it into the overall concept of your drive with perfect technical precision? In this case, we’ll take care of the design of the required gears or gear sets while also considering the resulting changes for your drive system as a whole. The result is new gearing within a coherent overall concept.
For example: A customer approached us with a request to reduce the weight of their drive. To do this, we were asked to replace the existing steel gear wheel with a plastic spur gear at one stage. Since a plastic gear wheel is wider than a comparable steel gear wheel with the same load capacity, we also redesigned the next stage to create sufficient space.
Case 3: You would like to improve your entire drive with gearing
Would you like to improve your drive as a whole, for example by means of higher efficiency, lower weight or smaller installation space? In this case, we’ll carefully examine your application and suggest several concepts with different geometries and gear types. Once you’ve decided on a concept, we’ll design the required gearing and work with you to define the interfaces to the overall system. In the process, you have full control over the development of the housing and the overall system.
For example: A customer from the agricultural machinery industry wanted to work with us to take a push rod drive into the next product generation. We developed several concepts using different sizes. The customer ultimately opted for speeroX gearing. This allowed them to significantly reduce the size of the housing while also simplifying the design of the gearbox.
Find out more about our product portfolio:
Development steps at Framo Morat
Even though our development process varies from project to project, there are three steps that are essential for our development team:
- Specification
- Design and material selection
- Design
Step 1: Specification
Your application is at the outset of every component design. Where is your drive used? Which mechanical properties do our gearing components need to deliver? Which environmental conditions do they have to be able to cope with? Which regulatory requirements must they comply with? And what special challenges are there? The first step in our collaboration is to understand the context in which our gears will later be used. In the specifications, we jointly define the test requirements and approval criteria on which we base the design of your gearing components.
Step 2: Design and material selection
During the design phase, our team develops the geometry of the gearing. Key features include the module and the shape and size of the teeth. In the process, we take into account the requirements for material, gear type, transmission ratio, efficiency, installation space, load capacity, weight, and service life, optimizing the gearing to meet your design priorities.
We design your gearing components based on current calculation standards (DIN 3990 and ISO 6336) and safety factors using state-of-the-art CAD and calculation tools. We use the digital models for static and dynamic load-bearing capacity calculations, for stress analyses applying the finite element method, and for failure mode and effect analyses. This allows us to effectively minimize the risk of subsequent issues right from the development phase.
However, it’s our employees’ decades of experience that are the key to successful development. They are thoroughly familiar with the specific challenges and sources of error involved in gear development, which enables them to respond appropriately to mechanical issues.
When it comes to selecting materials, we can draw on the entire range of materials available. These include steel and non-ferrous metals with numerous hardening processes, engineering plastics, high-temperature-resistant polymers such as PEEK, and hybrid components made of plastics and metals or two plastics with different properties.
Step 3: Component design
During the design phase, we create the entire component—in other words, everything extending beyond the gearing. In this step, we produce the final 3D model and derive the technical drawings.
An important task in this phase is the production-oriented configuration of the design data. Thanks to our high level of vertical integration, we have all the quality-determining processes in metalworking and precision plastic injection molding at our disposal in-house. This means we are fully aware of the challenges involved in manufacturing and can incorporate tool radii, undercuts, as well as filling and shrinkage behavior, directly into the design.
