What are bellows couplings?

A bellows coupling is a type of coupling design which consists of a thin walled, flexible corrugation (bellows) that is connected between two clamping hubs.  They are traditionally used for servo motion control applications that have high positioning accuracy, speed, and torque requirements.

Cross Section View of Bellows Coupling

What makes bellows couplings unique?
Bellows couplings are unique because of the construction of the bellows which can flex and compensate for minor shaft misalignments (axial, lateral, radial), while still providing a zero backlash and torsionally rigid connection.  They are a unique blend of rigidity and flexibility.

How to specify bellows couplings
To specify a bellows coupling, the first parameters we typically look at are the torque and connecting shaft sizes which will help to give a general sense of the coupling size.  The nominal torque rating (continuous torque transmission)  of the coupling should be greater than the peak torque of the application to ensure a secure connection.  We then check the connecting shaft sizes which  must also be within the acceptable range of the coupling.  If the shaft diameter is smaller than the specified range on the coupling, the torque transmission value of the coupling can decrease.  From there, we check other application specific parameters which include the speed, shaft alignment, temperature, and drive resonance.  We need to make sure they are within the coupling specifications, if not, we look to apply a safety factor when applicable; otherwise we select a different coupling size, or design. 


Bellows couplings applications examples
When introduced, bellows couplings were first widely accepted in the Machine Tool industry for spindle drives.  Since then usage has expanded to a vast number of industries including Automotive, General Automation & Assembly, Material Handling, Medical, Packaging, Robotics, to name a few.


For more information about couplings, visit www.gamweb.com

GAM Introduces the SPH Flange Gearbox

GAM, a manufacturer of high precision gear reducers, servo couplings, and linear mounting kits, introduces the SPH Flange planetary gearbox.

The SPH Flange (SPH-F) is the first high performance inline flange gearbox from GAM.  Based around high precision helical gear technology, the SPH Flange is produced to the elevated standard of quality and reliability customers have come to expect from GAM’s SPH product line.  The helical gears are precision cut and ground for extremely quiet and smooth torque transmission with a standard backlash rating of <3 arcmin for single stage ratios.  For applications that require more precision, the gearbox can assembled for further reduced backlash at <1 arcmin.

“We are excited to launch the SPH-F as it is the first high precision inline flange gearbox in our product offering,” said Mike Parzych, Product Marketing Manager at GAM. “We’ve already had some great customer successes with the product and are looking forward to further market acceptance.”

The compact SPH-F gearbox can be used when space is limited and the ISO 9409 compatible output flange allows for easy mounting of machine elements such as pinions, pulleys, or other adapters.  To accommodate direct connection to machines, the SPH-F has strong taper roller bearings set at a wide distance and a fully supported planet carrier for high load carrying capacity.  The ring gear is machined directly into a single piece steel housing for improved torsional rigidity.  Currently offered in three frame sizes, the SPH-F is rated for up to 450Nm nominal and 675Nm acceleration torque in the largest size.

Please visit www.gamweb.com for more information on the SPH-F including fully configurable CAD models.

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A PDF of the Press Release - GAM Introduces the SPH Flange Gearbox

About GAM
GAM is your complete source for Gear Reducers, Servo Couplings, Linear Mounting Kits, and other innovative products used in automation technology. With one of the largest product offerings in the motion control industry as well as the engineering expertise and capabilities to develop customized solutions, GAM can help with your application.  Being flexible to meet the needs of customer requests and great service are what set them apart from the rest.  For more information visit: http://www.gamweb.com.  GAM is also on Twitter http://twitter.com/#!/GAM_Gear and Facebook https://www.facebook.com/GAMGear.

Introducing the EDC Elastomer Drive Shaft Coupling

The EDC is designed, machined, and assembled to order in Mt. Prospect, IL.  CAD models are online and easily configurable for download in minutes.  The EDC is available in four sizes based on the torque rating: 25Nm, 35Nm, 80Nm, and 110Nm. Derived from the design of GAM's EKC elastomer coupling, the EDC is a quality drive shaft solution at an economical price for this torque segment.

Split Hub Design

The EDC has a split hub construction for easy installation.  This design feature allows the coupling to be installed by placing it directly over the shafts that need to be connected.  The shafts can remain fixed and do not need to be retracted during installation to get proper shaft engagement.

GAM's Drive Shaft Lineup

The EDC is the latest addition to GAM's family of drive shaft coupling solutions. GAM now has three options to cover various motion applications and torque requirements.

Option 1 - EDC
The EDC is rated up to 110Nm of torque and was designed to be an economical drive shaft option, suitable for general motion / lower torque applications.

Option 2 - EKZ
The EKZ is rated up to 700Nm of torque and is the next progression in GAM's drive shaft coupling range.  While still an elastomer style drive shaft coupling, the EKZ is suitable for higher torque applications.

Option 3 - WDS
The WDS is rated up to 1600Nm of torque and is GAM's highest performing drive shaft coupling, intended for dynamic applications that require high positioning accuracies.  It features a torsionally rigid bellows design which yields a 1208% increase in torsional rigidity over an elastomer style drive shaft coupling of a comparable torque rating.

Spiral Bevel Gearboxes - When Size Matters

With torques up to 4,440Nm, frame sizes up to 350mm, and power ratings up to 267kW, the V-Series is tough enough to handle demanding power transmission applications.   

For miniature mechatronic applications when space is a premium, our L-Series is the best option available on the market. The housings are manufactured from high-strength aluminum which means they are light weight, dissipate heat efficiently, and resist corrosion.       

Learn More About L-Series Miniature Gearboxes

Considerations for Continuous Running Spiral Bevel Gearbox Applications

Spiral bevel gearboxes are often selected for continuous running applications due to their high efficiency ratings up to 96%.  However, in low ratio configurations, the input and output shafts will be running at higher speeds resulting in greater heat generation.  A properly sized gearbox will be able to dissipate the heat effectively and the temperature will stabilize to an acceptable level. 

While there are several factors that impact the gearbox temperature, two important considerations are the input running speed and mounting orientation.  These two criteria will help to determine if minor adjustments can be made to the gearbox during assembly to aid heat dissipation.  Adjustments can be made to the backlash, bearing pre-loads, lubrication (volume/viscosity), and a vent filter or oil cooling system may ultimately be required.  Spiral bevel gearboxes that cannot be adjusted may not be suitable for continuous running applications. 

The chart above graphs the housing temperature of a V-Series gearbox (blue-dash) and a competitive spiral bevel gearbox (red-dotted) of comparable size.  Both gearboxes were 1:1 ratios and tested at a continuous input speed of 1,800 RPM for 2 hours.  Because the V-Series gearbox (blue-dash) was sized and assembled for the continuous application, it was able to dissipate the heat properly allowing the temperature to stabilize to an acceptable value of approximately 80°C.  The competitive spiral bevel gearbox (red-dotted) could not dissipate the heat and the gearbox temperature continued to rise to 140°C before the test was terminated to avoid eventual failure.

To help prevent a spiral bevel gearbox from failing due to overheating, it is important to specify the duty cycle, input running speed, and mounting orientation.  Those criteria are specified in GAM's V-Series type code to help ensure the gearbox is ordered and assembled to best suit each application. 

Size a V-Series Spiral Bevel Gearbox

GAM Spiral Bevel Gearboxes: Dependable by Design

1. Housing: Sturdy cast iron housing (Aluminum in size 35mm and 45mm) - all 6 sides can be used for mounting 

2. Bearings:  Deep groove ball bearings handle axial and radial loading. (Reinforced and taper roller options available)

3. Spiral Bevel Gearing:  Precision cut, hardened, and lapped in pairs for ideal tooth contact. Mathematically precise ratios from 1:1 to 6:1

4. Input:  Available with shaft input or integrated motor adapter and coupling to easily mount to any IEC, NEMA, or servo motor

5. Output:  Solid shaft with key or keyed hollow shaft are standard. (Smooth shaft or shrink disc clamping available)

6. Seals:  Lubricated for life and protected with high quality NBR seals. (Viton® and FPM seals available) 

Carefully engineered and crafted with high quality materials, GAM spiral bevel gearboxes are robust and can handle high shock loads. Since they are maintenance free and lubricated for life, have confidence knowing that they are built to last. Put one onto your machine and forget about it!

Learn More About V-Series Gearboxes

High School Students in Career Exploration Course Visit GAM

Students enrolled in a Summer Career Exploration Course sponsored by Oakton Community College and NSERVE, visited GAM to see what a future in engineering and advanced manufacturing could be like.  Through the Career Exploration Course, students get first hand experience of the careers and work environments in the areas of their choice.  The program is open to sophomores, juniors, and seniors from nearby high schools.

What are Engineers?  

What things do Engineers build? 

What skills must one have to become an Engineer?

What is the job outlook like for Engineers?  

These were some of the questions answered in an interactive presentation with the students.  Students also learned how important internships are to discover their interests in addition to getting an upper hand at landing a job after college.  After the presentation, the students were split into three groups for a factory tour to see different functions at GAM including design engineering, machining, and assembly.

This is the third STEM program that GAM has been involved in this year alone.  In addition to participating in educational programs such as this, GAM often has internships available for high school students interested in engineering, manufacturing, and business.  For factory tours or information on internships, please contact info@gamweb.com.  For more information about the Career Exploration Course, please visit www.nserve.info

Why are Hypoid Gearboxes Ideal for Right Angle Applications?

This example will compare a traditional planetary bevel gearbox (left) with a hypoid gearbox (right), in a 5:1 gear reduction ratio.

Planetary Bevel Gearbox
By construction, a planetary bevel gearbox is the combination of an input bevel gear stage and an output planetary gear stage.  In order to achieve any gear reduction ratio, this type of gearbox always requires two or three gear stages.  In this example, the first stage is a 1:1 bevel gear ratio and the second stage is a 5:1 planetary gear ratio.  For a 3,000 RPM application, the motor speed is continued throughout the entire first gear stage, which means the input bearings and seals, gears, and output bearings and seals are all rotating at 3,000 RPM.  The actual reduction doesn't occur until the planetary gear stage.  Higher speeds throughout the gearbox means higher heat and can also result in a 50% service life de-rating for continuous applications.

Hypoid Gearbox
A hypoid gearbox on the other hand can achieve up to a 15:1 ratio with only a single gear stage.  In this 3,000 RPM application, the motor speed is immediately reduced to the final reduction speed of 600 RPM which is ideal for the gears, seals, bearings, and shaft.  A lower speed means less heat, which is important to maximizing the life and load carrying capabilities of the output bearings in a gearbox.  GAM’s Dyna Series hypoid gearbox has a 30,000 hour service life rating which is 50% more than a comparable planetary bevel gearbox.  In addition to the performance advantages of using a hypoid gearbox, as mentioned in a previous post there is also a substantial space saving benefit.  In the example above, GAM’s hypoid gearbox is 46% more compact than the planetary bevel gearbox.

Thomas Middle School Students Visit GAM - 5-1-2014

GAM has partnered with nearby Thomas Middle School to help educate students interested in STEM (Science, Technology, Engineering, and Math) fields.  For several years now, students visit GAM as a part of the Careers Connection class which includes a job shadow.

The day started with a presentation on the different types of engineering fields, followed by another on the various manufacturing processes.

After the presentations, things got hands on as the students got to design a phone docking station.  They rough sketched the initial concept on a whiteboard and made sure to include all features and dimensions.

With some help from one of GAM’s engineers, the students created a 3D model of their part using Solidworks.  They tweaked the model until it was perfect and then created a dimensional drawing which would then be sent for manufacturing.

While the students ate some pizza for lunch, their part was programmed on a CNC machine.  After lunch, students got to watch as the machine took a block of aluminum and turned it into the phone docking station they designed.  The students were thrilled to leave with the part they actually designed!

GAM Employees Participated in the Shelter Inc. 5K

This past weekend, GAM employees participated in the Shelter Inc. 5K race in Arlington Heights.  Several employees actually took home awards for finishing.  Dan came in 2nd overall, Matt and Jesus both placed in their age group.  Shelter, Inc. provides community based, emergency and longer-term housing for children and adolescents who are abused, neglected, dependent or in need of supervision.  For more information on Shelter Inc. or to donate to their cause, please visit http://shelter-inc.org/

Right Angle Gearbox Comparison: Hypoid Gear Technology vs. Planetary Bevel

Right angle gearboxes using hypoid gear technology offer several mechanical advantages compared to gearboxes using a planetary bevel gear combination.  Hypoid gearboxes achieve gear ratios up to 15:1 in a single stage and still yield mechanical efficiencies up to 96% depending upon the ratio throughout the speed range.  Planetary bevel gearboxes can be just as efficient, however they require two to three gear stages regardless of ratio which results in a much larger footprint.

The hypoid gearset is spatially efficient because its component parts are compact individually, and

their “overlapping” mesh geometry helps to minimize the mass of both moving components and the support housing. The hypoid gear design is also thermally efficient, so the housing can be kept smaller and free of heat-dispersing elements (cooling fans/aluminum fins). A single-piece cast aluminum construction for the housing keeps the weight low with maximum rigidity.  The result is a gearbox that by itself is compact and lightweight.  Compared to standard right angle gearboxes, the Dyna Series hypoid gear reducer as shown above has a more compact profile that fits into smaller spaces. And the low mass of the moving components minimizes running inertia.   

For more information on the GAM Dyna Series Hypoid Right Angle Gear Reducer 

Students From Local John Hersey High School Visit GAM

Students from local John Hersey High School (District 214) visited GAM as a part of their Career Trek curriculum.  Career Trek is a program that gives students the opportunity to visit actual companies in professions they are interested in and expose them to what a potential career may be like.  These particular students enjoy building things with their hands and have shown an interest in manufacturing.
As noted in a recent Forbes article, right now, "there are over 600,000 unfilled manufacturing jobs in America.  And in order to fill those jobs, we need to invest more in STEM education programs that engage and prepare American students for these careers".  The Career Trek is a great example of what a STEM program can do.  The day started off with a presentation that reviewed manufacturing processes, job outlook, compensation, skills required for a career in manufacturing, and Q&A with GAM machinists.

After the presentation, the students toured GAM's facility where they saw how gear reducers and servo couplings are manufactured.  They got to watch modern CNC machines in action transforming raw material into finished products.



Safety glasses (and goggles) are a must at GAM

By the end of the day, students had an understanding of what a career in manufacturing can be like, along with the critical skills and training that can give them an edge when they enter the job market.  A few days after the tour, we received great news that several students went directly to their guidance counselors to sign up for manufacturing classes for their schedules next year.  Who knows, maybe they will return to GAM in a few years as an intern or an actual employee.  For more information about internship opportunities available at GAM, please contact careers@gamweb.com.

Meet the Newest Members of the GAM Team

We are focused on growth at GAM.  But in order to grow properly, you need the right people, processes, and technology.  And while processes and technology are extremely critical, people are the most essential part of that equation.  Meet the newest members of the team that are helping to take GAM to the next level:

Jeanne - Materials Manager - Jeanne comes to GAM with 28 years of manufacturing experience.  Her leadership and strong background in planning, purchasing, and materials management have already made a great impact at GAM.  She is thoroughly knowledgeable in Project Management, ERP Implementations, Supply Chain Optimization, MRP, Kanban, and Strategic Planning.  Outside of work, Jeanne enjoys fishing.

Austin- Assembly and Shipping - After starting in the coupling cell, he was quickly promoted to gearbox assembly after demonstrating a strong mechanical aptitude.  He takes pride in fully understanding each job and doing it right the first time.  Outside of work, Austin enjoys basketball, volleyball, hunting and fishing.

Ron - Manufacturing - Ron comes to GAM with over 15 years of manufacturing experience.  He is mechanically inclined and skilled in CNC manufacturing setups.  As he gets more familiar with GAM's machines, he hopes to learn CNC programming.  Outside of work, Ron enjoys relaxing.

Jesus - Manufacturing -  Jesus is new to the workforce and is eager to learn and operate all of the machines at GAM.  His attitude and adaptability make him a great fit for our culture.  Outside of work, Jesus enjoys spending time with his family and playing soccer.

The greater the face width of a gear, the greater the permissible torque

The face width of the helical gears in GAM's SPH Series are up to 70% longer than some competitor's gears, which means more tooth contact and greater overall torque density.
In order to achieve high torques, especially during shock loading or dynamic applications, the gears must be strong.  SPH gears are case hardened which imparts strength deeper into the gear compared to nitriding which hardens just the surface.  Lastly, they are ground for smooth and quiet operation as well as higher precision

Visit GAM at ATX 2014

GAM will be at booth #4589 with the Quatro Automation Group for the ATX Automation Technology Expo West, February 11-13 at the Anaheim Convention Center.  Register for the show here.

MCA 2014 Business Conference

GAM will be attending the 2014 MCA Business conference this week in Orlando, Florida.  For more information on the MCA (Motion Control Association) or the MCA Business Conference visit here.

GAMMY Winner - December 2013

Steve received the GAMMY award for the month of December.  He is in charge of GAM's final assembly and inspection cell, making sure that everything is made exactly to the customer specification and is ready for packaging.  Over the last few months, GAM has been shipping more product than ever before (this includes the record shipping month in September).  Steve won the GAMMY for his display of Professionalism as he made sure that quality and consistency remained the highest priority.  Click for more information about GAM or our core values.

GAMMY Winner - November 2013

Austin was awarded the GAMMY award for the month of November.  He is in charge of GAM's coupling cell and played a big role in helping GAM to hit a record shipping month in September and another great shipping month in October.  All along the way, he displayed great teamwork and professionalism.  For more information about GAM or our core values.

The GAMMY Award

The GAMMY is an award given out every month to the employee who best displays GAM’s core values.  While it may not be gold plated (yet), the GAMMY is crafted from high quality precision gearbox components.  The award is a way to recognize employees for their hard work and acts as a visual reminder of GAM’s core values.  What are GAM’s core values?

Teamwork, Action Oriented, Long-term Relationships, Professionalism and Fun

Teamwork:  We will be respectful and helpful to one another and be held accountable for our actions and our work. Great teams perform well when everyone is working together for the common good and genuine desire to help!

Action Oriented:  We are doers not talkers, meaning, “We walk the talk.” We take responsibility of a problem or opportunity to the end and not hand it off to another person until it is resolved. There is strong sense of urgency because solving problems quickly and accurately will prevail in the customer’s mind.

Long-term Relationships:  We are not interested in relationships that are short-lived. Relationships are the core to our business and trust is the foundation of our relationships. We will be true to our customers, our vendors and our employees. We strive for great friendship in these relationships because in the end we are here to enjoy one another and serve.

Professionalism: We are not just talking about our appearance when we are defining professionalism.  It‘s about being knowledgeable, learning to better oneself, truly listening to  others when they are talking, doing it right the first time (quality not quantity)and taking pride in the work you do.

Fun: We strive for a fun atmosphere at GAM. We know that with every business, there is pressure but we need to balance that pressure, with fun. We encourage activities that build friendships to know the “whole person” not just the “work person”.

GAM can match your motor dimensions

Need a gearbox but can't change your mounting interface?  GAM can take a standard gearbox design and modify it so the output dimensions match those of your motor, making installation easy.  See what else GAM can do.