Engineering team
 info@moldedgear.com

 Mo-Fr: 8:00-17:00

+1 202 470 6030

 Gearbox Design

Custom or Upgrade Gearbox Design

Standard Gearboxes come in a wide range of load capacities. Specify the speed reduction and shaft configurations from our standard gearboxes and we customize them to meet your application needs. Our application engineer will work with you to understand the design specification and requirements and we will optimize the appropriate gearbox for your application.

We design, develop, and manufacture custom power transmission products by the following process:

  • Product Specification
  • Concept Design
  • Gear mesh & Structural Analysis
  • Detailed Design
 Contact with Us! 

Product Specification:

  • Engineering specification
  • Duty cycle and load spectra definition
  • Scope of Work

Review:

  • Technical specification and load spectra definition
  • Application power, torque, speed requirements, overhand loads
  • Mounting position and limiting geometry size
  • Motor or electric connection electronics integration
  • Ambient operating temperature and humidity
  • Thermal protection
  • Local or international standard application

Scope of work:

  • Project team
  • Engineering tasks
  • Statement of work
  • Risk assumptions
  • Customer deliverable items
  • Develop milestones
  • Acceptance criteria
  • MoldedGear deliverable items

Concept Design:

  • 3D/2D Concept design assessment
  • Functional evaluation and acceptance of engineering specification
  • Certified drawing and approval
  • System Risk Assessment
  • First cost estimate
 Contact with Us! 

Gear mesh & Structural Analysis:

Mechanical calculations: including Gears, Bearings, and Shafts

  • Spur and helical gear rating standard: ISO 6336, AGMA 2001-D04 and accuracy grade ISO 1328-1 or AGMA 2015-1-A01
  • Worm Gears standard: BS 721, ISO 14521
  • Shaft calculations standard: DIN 743
  • Bearing standard: ISO 281
  • Structural analysis and contact optimization
  • Structural analysis
  • Transmission gear mesh optimization
  • Finite Element analysis of housing
  • Reliability of the product

Thermal analysis:

  • Individual components power loss calculation
  • Gearbox thermal analysis
  • Efficiency calculation

Electrical calculations:

  • Motor selection
  • Standard reference: IEC 61800, IEC 60038, EN 60204, IEC 60034

Detailed Design:

  • Solidworks 3D CAD system and PDM
  • BOM and drafting process
  • GEO tolerance documentation
  • Individual components drawing
 Contact with Us! 
 Contact with Us!