GWJ is Celebrating 15 Years of Providing Web-based Calculation Software

GWJ Technology GmbH from Braunschweig, Germany, is marking the 15th anniversary of its web-based calculation software eAssistant – the engineering assistant. The eAssistant software allows calculation, design and optimization of machine elements, including shafts, bearings, gears, different shaft-hub connections and bolted joints etc.

After several years of development, eAssistant was released in 2003 during Hannover Fair. Dial-up internet was literally the only kind of internet modem back then. The actual release was in May 2003 and included three calculation modules for shafts, rolling bearings and interference fits. The development process of the eAssistant continued thanks to the positive market response. Further modules for parallel keys, serrated and splined shaft connections as well as involute splines were added in 2003 and 2004. At the Hannover Fair 2005, the first version of the “Cylindrical gear pair“ was introduced. Even back then, this module already included the real gear tooth form based on a mathematical simulation of the manufacturing process. Based on this, the first 3D CAD plugins for SOLIDWORKS, Solid Edge and Autodesk Inventor were implemented shortly afterwards.

This was followed by the release of an English version and other gear modules. Single cylindrical gears, cylindrical gear pairs, planetary gear trains, three- and four-gear train systems, gear racks, bevel gears as well as worm gears can now be determined. eAssistant provides different standards in order to calculate the load capacity. DIN 3990 / ISO 6336 Method B or ANSI / AGMA 2101 are available. Calculation modules for bolted joints, timing belts, clamp connections and bolts and pins are also part of the eAssistant.

By the end of 2012, GWJ reached another major milestone – SystemManager, a true software application for complete systems of machine elements, was released. It runs as a classic desktop application, including FE libraries. The individual system elements are directly linked to the eAssistant calculation modules.

The software engineering process of eAssistant and SystemManager is heavily influenced by user feedback to improve the software quality. The applications are constantly being developed.

Visit www.gwj.de for more information or contact GWJ at +49 (0) 531 1293990 or send an email to info@gwj.de.

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GWJ Expands Automotive Engagement

GWJ Technology GmbH from Braunschweig, Germany, is a leading manufacturer of calculation software for machine elements and gearboxes. By participating the international VDI Dritev Congress – Drivetrain for Vehicles – GWJ plans to further expand its involvement in the automotive business.

The international VDI Dritev Congress will be held from from 27. to 28. June 2018 in Bonn, Germany. The exhibition at the Dritev congress features a unique mix of over 100 national and international companies and has become a central marketplace of the industry. Dritev gives an efficient overview of the most important providers across all sectors of development, simulation and production of gearboxes and drive components.

GWJ will be part of this congress as exhibitor and is glad to welcome visitors at Booth #109. GWJ will present the latest version of TBK. For more than 30 years, the TBK software is a widely accepted calculation software and is used by many companies around the globe in different industries.

The GWJ product range of innovative calculation software is wide – from standard software for classical machine elements to the determination of whole systems up to a complex special software. There are common features that all GWJ solutions share – intuitive design, sleek interface, easy to use and suitable applications for all users from beginner to very advanced.

GWJ´s extensive product portfolio covers many different applications – the web-based calculation software eAssistant and the classical software TBK for gearboxes including 3D CAD integration modules, system calculation for multi-stage gearboxes and GearEngineer to determine and generate the real 3D geometry of complex gearings. This geometry provides the basis to manufacture cylindrical and bevel gears in conjunction with multi-axis machining centers.

Based on our wide-ranging and scalable technology platforms, GWJ considers itself an ideal partner for the automotive branch from prototype manufacturer to supplier of components and systems in the drive technology business to the develeopment of complex transmission systems for vehicle manufacturers.

Visit www.gwj.de for more information or contact GWJ at +49 (0)

531 1293990 or send an email to info@gwj.de.

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Enhanced Functionalities and New SKF Bearing Data for Web Calculation

The eAssistant – in use worldwide and successful for more than 15 years – is a web-based software for the mechanical engineering. The software allows for a fast, easy and professional calculation, design and optimization of an extensive range of machine elements.

In order to keep the customers up-to-date of the latest bearing data, it was agreed with the well-known bearing manufacturer SKF that a regular update of the bearing data would be added to the eAssistant software. Updated SKF bearing data from 2018 are now available.

The new release also adds SKF Explorer bearings. The Explorer bearings are marked with “*“ which makes it much easier for customers to select the right bearing.

A new filtering functionality called “Popular item“ has also been introduced. This function is supported only by the bearing manufacturer SKF. Popular items have a high level of availability and generally provide a cost-effective solution.

If a bearing is selected from the table, the user gets some additional bearing details, such as dynamic and static load rating or the fatigue limiting load, displayed below the bearing table. There is also a new direct link to open the SKF catalogue. By clicking the button „SKF online catalogue“ or double-clicking the bearing, the user gets instant online access to SKF´s product data sheets with all technical details. The user can also export the data sheet as PDF. The new information “SKF Explorer“ and “Popular item“ is added to the calculation report under the section “Bearing comment“.

Visit www.gwj.de for more information or contact GWJ at +49 (0) 531 1293990 or send an email to info@gwj.de.

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System Calculation Enhanced With New Features

SystemManager is an extension to the web-based calculation software eAssistant (web solution) and TBK. eAssistant and TBK have been around for many years now and are among the most popular software solutions in the business today. SystemManager is a true software application for complete systems of machine elements, i.e., the software is a coupled FE calculation of multi-shaft systems with gears as non-linear coupling elements.
The new version provides an alternative method of importing and automatically meshing housings and planet carriers. This offers an even better mesh quality and allows a meshing of very complex geometries, for example the geometries of gearbox housings in automotive applications are known to be very complex.
The system calculation considers now rotating 3D elastic parts for the calculation of eigenfrequencies (e.g., of planet carriers) using modal reduction.
Coupling connections were added in addition to the previous connection types cylindrical gears, planetary gear trains, bevel gears, worm gears and belts. It easily allows to consider hydraulic or electric connections between subsystems.
Many small extensions had been added like splitting or merging shafts in addition to copy, shift or mirror options. All bearings types are now drawn with separated inner and outer rings in 2D and 3D views. The animations for 3D mode shapes therefore allow a better understanding of the movement in the bearings.
Graphics can be frozen inside the program to allow comparisons and a copy option using the system clipboard was added for graphics for quicker transfer into other documents. The default format for reports is now PDF/A instead of standard PDF. The software documentation is now available as context sensitive help allowing faster access of information to certain inputs.
There are other new additions to the integrated bearing calculation.
Visit www.gwj.de for more information or contact GWJ at +49 (0)
531 1293990 or send an email to info@gwj.de.

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Motor Spindle Safety System MS³

The most common accidents involving the use of machine tools include spindle crashes. Common causes include programming errors, incorrectly defined tools, disregarded interference contours, or unintentional high-speed operation. The forces involved are so enormous that components of the motor spindle, ceramic spindle bearings, shafts, encoders, clamping system and the entire machine geometry can be affected or even completely destroyed. A case study from RWTH Aachen shows that repair costs after a crash in the amount of five-digit euro amounts are not uncommon. Collision avoidance systems for machine tools minimize damage and reduce downtime and repair costs in the event of a collision. Nevertheless, only very few machine tools have a spindle collision protection at all. This is usually based on compression elements that act like a car bumper and are completely destroyed in the event of a crash.

Although the spindle components remain intact, downtime still occurs. The motor spindle protection system MS³ from JAKOB Antriebstechnik GmbH detects collisions by means of several sensors and reports them electronically to the machine control. This can bring the feed axes of the machine tool to a halt with measures such as braking and reversing the drives. But beyond that, the motor spindle protection system can immediately interrupt the power flow at the interface between the spindle box and the motor spindle by means of 3D deflection in the event of a collision-induced overload, even before the electronic emergency stop, mechanically and energy-autonomously.

This effective combination of mechanical protection system and active electronic sensor monitoring makes the system superior to purely electronic collision avoidance systems and effectively protects the shock-sensitive components of the motor spindle from the high force peaks of the collision. The resulting kinetic energy of the crash intercepts a built-in shock absorber. The difference is made by a double flange system with built-in permanent magnets. They can guarantee the required high holding forces and rigidity. During the disengaging process, compression springs guide the motor spindle and then return it to its original position. The downtime is limited to the exchange of tools, additional external service is no longer needed. The system is energy self-sufficient, maintenance-free and adaptable to all common motor spindle geometries.

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Web-based Calculation Software eAssistant Comes with New Features

GWJ Technology GmbH, the engineering specialist, headquartered in Braunschweig, Germany, is committed to constantly improving the quality of its software products for the calculation of machine elements like gears, shafts, bearings etc. The updated version of the web-based software eAssistant has been released now.
The latest software release introduces multiple enhancements making the life of engineers easier than ever before. One example is the new menu item "New". Clicking the menu item "New" closes the current calculation and opens the calculation module with the internal eAssistant default setting or the user´s own default file.
The calculation modules for single cylindrical gears (external/internal), three- and four-gear train systems and gear racks now include DIN 58405 for fine mechanics, ISO 1328 and ANSI/AGMA 2015 in addition to DIN 3961 for gear tolerances/gear qualities.
The definition of the basic rack profiles for the cylindrical gear pair and the single cylindrical gear (external) was supplemented by the semi topping flank and topping. Using the definition of the semi topping flank, the corresponding hobs can then be specified, and
they generate an addendum chamfer during the cutting process.
The option "Topping" allows to define the tip diameter directly with the dedendum coefficient of the tool, making it impossible to subsequently modifiying the tip diameter. The result, at the same time, will be tip diameter allowances analogous to the root diameter allowances directly from the tooth thickness allowances.
The eAssistant 3D CAD plugins for various CAD systems support the new function and the semi topping flank can be considered in the 3D CAD model.
Visit www.gwj.de for more information or contact GWJ at +49 (0)
531 1293990 or send an email to info@gwj.de.

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The New Benchmark in Crankshaft Finishing

A new line of tape finishing machines for the microfinishing of crankshafts with the narrowest bearing clearances has now been developed by Thielenhaus Microfinish. With the CrankStar HP (High Productivity) and the CrankStar HF (High Flexibility), the market leader in the field of high-precision machine tools for surface microfinishing meets the requirements of many engine manufacturers in terms of a flexible machine solution which is suitable for smaller crankshafts. Particularly narrow finishing units with an extremely large opening angle (80°) allow, for the first time, the economic and process-safe machining of crankshafts with a mere 33 mm depth gauge, which is required by the trend towards more compact engines with higher efficiency.

In addition, on the innovative microfinishing machine, all crankshafts made of cast iron or steel with a tip width of 500 mm (HP) to 800 mm (HF) and a maximum revolution diameter of 210 mm as well as a stroke of up to 100 mm can be finished in one step or more. Crankshafts for engines with three to six cylinders can even be processed without changing the set-up. In addition to the usual surfaces, such as main, lifting and fitting bearings, the front pins can also be finished and the flange bores can be deburred as part of the single-step or multi-step process.

A special highlight of the CrankStar HP is the optional decoupled loading system, which allows for a main time-neutral loading/unloading via an external portal. This allows reductions of the cycle time of up to 17 seconds. This saved time can be used as extended machining time, which can even enable you to dispense with an entire station.

Apart from its extra-slim and flexible tape finishing units, the CrankStar gained a lot of attention due to its innovative and ergonomically designed tape management system. A particularly ample belt capacity, various belt monitoring options and the best accessibility to the workspace guarantee the shortest downtimes. Tape end, tape feed and tape tear monitoring reports imminent and unforeseen interruptions in the tape feed and ensure consistently good results. All tape rolls can be replaced from the front of the machine, meaning complete operation can take place ergonomically from just one side. The innovative tape cutting system in the CrankStar HF also works reliably and without problems, even with different tape thicknesses. Depending on the requirements, the hard and/or soft tape pressing shoes can be easily exchanged without any tools by means of a quick-change system.

The CrankStar HP is designed for high output with the shortest cycle times and, with a width of 2,000 mm per station, has an extremely compact design. The modular design allows all the processing stages to be displayed. The CrankStar HF is designed for cycle processing and can therefore be integrated into flexible production lines.

The loading can take place via portal, robot or by hand into the machine. The standard new tape finishing machine is delivered with a particularly energy-efficient periphery.

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