In the automotive industry, gears are the core parts of key components such as transmissions and differentials. Taking new energy vehicles as an example, BYD has focused on gear technology in the research and development of its hybrid and pure electric models. The gears of traditional fuel vehicles usually have a working speed of about 3000 rpm, while the reducer gears of BYD new energy vehicles need to be adapted to high-speed motors, with a working speed of up to 16000 - 20000 rpm, and at the same time, it is necessary to ensure that the noise in the car is less than 40 decibels to improve the driving experience. To this end, BYD uses high-strength alloy steel and uses precision forging and advanced teeth grinding technology to increase the gear accuracy from the traditional 6-7 to 5-6 levels, effectively reducing gear meshing noise, improving transmission efficiency, extending gear service life, and meeting the strict demands of new energy vehicles for high efficiency, silentness and long battery life.
The industrial robot industry has extremely high requirements for gear accuracy and performance. Fanuc uses self-developed high-precision RV reducer gears in its industrial robot joint drive system. This type of gear is manufactured at microns with high rigidity and long life. Taking an industrial robot with a load of 10 kg as an example, the RV reducer gear at its joints can be used to improve material strength and wear resistance through special material formulations (such as adding rare metals to enhance material strength and wear resistance), as well as advanced manufacturing processes (such as special heat treatment to enhance hardness on the tooth surface), which can ensure that the robot can achieve accurate positioning and stable operation under high-speed, frequent start and stop working conditions, and the repeat positioning accuracy can reach ±0.05mm, meeting the industrial production needs for high-precision and high-reliability operations, and promoting automation and intelligent upgrades in manufacturing.
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In the field of wind power generation, gear boxes are important components of wind turbines. Goldwind Technology has achieved remarkable results in the research and development of gearboxes for megawatt-class wind turbines. The working environment of the wind turbine is harsh, and the gearbox needs to withstand huge torque and complex alternating loads. Goldwind Technology uses digital design technology to optimize the design of the internal gears of the gear box, such as reasonably adjusting the tooth shape parameters and optimizing the gear overlap. In terms of material selection, high-quality carburized quenched alloy steel is used to improve the load-bearing capacity of the gears; during the manufacturing process, intelligent production equipment and testing systems are introduced to ensure gear processing accuracy and quality stability. Through these technological improvements, the failure rate of its wind turbine gearbox has been significantly reduced, and the maintenance cycle has been extended from the original 1-2 years to 3-5 years, effectively improving the power generation efficiency and economic benefits of the wind farm and providing strong support for the large-scale development and utilization of clean energy.
It can be seen from these cases that the gear industry is currently developing towards high precision, high performance and lightweight. The advances in materials science, such as the application of new materials such as high-strength alloy steel and carbon fiber composite materials in gear manufacturing, have significantly improved gear performance; manufacturing processes are constantly innovating, and technologies such as precision forging, powder metallurgy, and 3D printing are gradually popularizing, improving production efficiency and product consistency; digital technology is integrated into the entire process of gear design, manufacturing and operation and maintenance, realizing intelligent and traceable management of gears. In the future, with the continuous development of emerging industries such as new energy vehicles, industrial robots, aerospace, etc., the gear industry is expected to usher in a broader development space driven by technological innovation.
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