Join Gleason's special online event to learn about the design, manufacturing, and inspection of e-drive gears. This four-day event, March 11–14, features one topic per day, addressing the specific requirements and challenges of e-drive transmission design, manufacture, and inspection, with particular attention to minimizing gear noise. The E-Drive Days are an excellent opportunity for newcomers and experts alike.

Day 1—March 11, 2024:E-Drive Gearbox Design and Optimization, 60 min

High rpm’s, reversal of load direction, low vibration excitation, high contact ratios, deformed housings ... the design, optimization, and service life calculation of gears for e-drives is a world of its own. Experience how individual requirements can be covered by the choice and variation of gear geometry, modifications, and manufacturing deviations, and learn about the specifics of strength calculation in case of frequent changes in torque direction with torque-time series measured from test rigs. In addition, the calculation of noise excitation within the drive train is important for NVH analysis and optimization of the gearbox. KISSsoft results will be shared with the multibody simulation program RecurDyn to facilitate a system response of the housing in the form of an airborne sound as a base for further optimization.

Day 2—March 12, 2024:Manufacturing of E-Drive Gears, 60 min

E-drive transmissions are different from conventional transmissions, creating new challenges for manufacturing technologies and processes. The 2nd day of the E-Drive Days showcases processes for soft machining and hard finishing of typical e-drive transmission gears. Featured processes include hobbing, chamfer cutting, shaping, power skiving, threaded wheel grinding, and gear honing. Specific technology updates will be presented for Hard Power Skiving of internal gears, Polish Grinding, and Combi Honing.

Day 3—March 13, 2024:Gear Noise Analysis and Advanced Inspection Systems, 60 min

On day 3, gear metrology experts explain the latest hard- and software solutions for accurate measurement and analysis of gear noise. Gear noise can arise from various sources such as manufacturing inconsistencies, tooth surface irregularities, meshing conditions, and load distribution. Understanding these sources is crucial for effectively tackling and mitigating gear noise in different applications. Attendees will gain insights into latest software tools that aid in gear noise analysis. In addition, the webinar will showcase advanced hardware for 100% gear inspection in the production flow, enabling precise and real-time measurements for accurate analysis and diagnosis of gear noise, as well as continuous quality monitoring and process surveillance.

Day 4—March 14, 2024:Design and Manufacturing of Differential Gears, 60 min

Differential gears in e-drive transmissions face significantly higher stress compared to conventional, combustion engine applications. The new Coniflex® Pro design and manufacturing system is ideally suited to accommodate such needs for stronger, quieter, and more reliable e-drive differentials in high volumes for automotive, truck, bus, and off-highway transmissions. Coniflex Pro is part of Gleason’s GEMS design software suite featuring state-of-the-art FEA analysis tools for sophisticated strength analysis of gears. In combination with the Coniflex Plus carbide cutters, Coniflex Pro provides great productivity in a closed-loop production environment.