Project ‚The lightest buffalo in drive engineering‘

Customer Information

Sector               Plant construction energy industry
Location             Vienna, Austria & Miami, USA
Employees       > 6.500 employees worldwide
Revenue          > 1 billion

Project start 09/2009 – ongoing

Project Description

Initial Situation

In 2009, the technical developer and design engineer of a large corporation approached MAS with a risky request: to develop and build a gear with high drive power and minimal weight to be used under aggravating conditions in electric dead space adjustment of gas compressors in energy-generating technology.
Initially, these requirements seemed inconceivable and impossible to realize:

  • Performance: 3000 Nm
  • Maximum weight: 85 kg, motor included
  • Worldwide exterior use in all kinds of weather and temperatures ranging from -30° C to +60° C
  • Durability: > 30 years
  • Warranty: 10 years
  • low maintenance
  • intensive serial testing of all parts according to ISO 9001
  • Compliance with all standards required for use around the globe

Solution

Kompressortechnikhersteller MAS Sondergetriebe

Thanks to the persistent and continuous efforts of Helmut Haas and his team at MAS this drive element with all its specific requirements has become a reality. In close collaboration with the client’s R&D-department his visionary ideas and joyful perseverance have led to the development of a perfect drive system. This goal was reached via the following steps:

  • the analysis and calculation of countless drive variants.
  • the design of a new, horizontal bearing technology.
  • directly implemented into the transmission for the required weight reduction.
  • the search for a progressive special motor for the economization of the energy supply.
  • in collaboration with an industrial designer, the optimization of usability and of the outer design.
  • the preparation and continuous updating of work and qc-documents (documentation).

The result is an extra-light, free-hanging spur gear unit with a maximum of 85kg including a motor with high drive load (2.800 Nm drive power at 4 rpm). Used outside (IP67) it withstands temperatures ranging from -40 to +70° C.

Highlights

What is special about this project is that it shows how intensive and exciting tinkering can make the impossible possible. The breakthrough came when we developed horizontal transmission bearings. That we could come up with a workable solution was also thanks to the smooth cooperation with our customer’s leading developer, allowing for direct access and communication and collaborative development. In the course of an unintended total crash test the transmission showed the whole extent of its capacity by emerging unscathed. The transmission is also an economic success for us, as we are able to remain under the target price thanks to cost-efficient production.