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Special Edition

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Small-sized gear skiving center GS200H

Reforming Gear Production with a World-First Product. Widely Contributing to the Evolution of Monozukuri

Gears are used as component parts of machines in all fields. Various machining processes are required for gear production, therefore production lines must consist of special-purpose equipment for each process arranged in a row. JTEKT developed a gear skiving center that integrates all gear machining processes into one machine for higher-efficiency production of higher-accuracy gears. Gear skiving is helping to reduce size and weight as well as improve productivity for machines of all fields.

A world-first product created through collaboration beyond business boundaries

There are various gear machining techniques. Skiving is the most recent of these and involves tilting the tool on an angle against the workpiece, then simultaneously rotating the tool and workpiece at high speed in order to generate gears. Compared to conventional techniques, skiving offers the advantages of reduced machining time, smaller and lighter gears, etc. The doctrine behind skiving was presented in Europe in the 1960s however there were many issues due to the level of technology at that time, and it never reached the practical realization phase. JTEKT began development of production equipment with the skiving technique in 2005. Aiming to improve the commercial viability and production efficiency of TORSEN, a product for automotive use made from various gears, the JTEKT group company that manufactures TORSEN in Belgium and Japan’s Machine Tools & Mechatronics Operations Headquarters went beyond the traditional business boundaries to bring their respective wisdom together. From 2006, JTEKT accumulated tool and control technologies while mass producing gears using the skiving technique. As a result of these efforts, the GS300H gear skiving center was commercialized in 2013 and was the first case of the skiving technique being used on a machining center in the world.

Integrating processes that required 5 special-purpose machines into 1

GS300H integrates the gear machining processes that conventionally required five special-purpose machines into a single machine, thereby contributing to space-saving and power-saving on manufacturing shop floors. Workpieces only need to be loaded once to proceed with multiple processes, meaning error that tends to arise during loading and unloading is significantly reduced, which in turn helps to increase machining accuracy. Based on this solid track record, in 2015, JTEKT released GS700H as the second machine of the GS series.
GS700H is optimal for machining large gears used in industrial robots, construction machinery, trucks, etc. JTEKT is answering the needs of faster, high accuracy gear machining in a wider range of industrial fields.

*GEAR SKIVING CENTER is a registered trademark of JTEKT Corporation.

Achieving groundbreaking size reduction and a significant Increase in accuracy

Then, in May 2017, GS200H was released as the third machine of the GS series. This machine is optimal for machining small gears used in cars, etc. GS200H inherits all of the technologies and know-how JTEKT has accumulated to date, such as process integration, our proprietary tool and control technologies, etc. at the same time as achieving a groundbreaking size reduction whereby installation space (footprint) is less than half of that required by GS300H. Furthermore, machine rigidity has been increased by more than double that of GS300H, and the design minimizes distortion of the equipment due to heat, thereby increasing machining accuracy. In addition, as a part of our IoE (*) initiatives, a TOYOPUC-AAA is a standard feature of GS200H as a module for the accumulation and analysis of data. By gathering and analyzing data on vibration during machining, it is possible to identify signs of malfunction and tool replacement, which helps achieve the goals of quality improvement and greater maintenance efficiency.

* IoE In recent years, much attention has been given to “IoT” (Internet of Things), however JEKT proposes “IoE” (Internet of Everything), which includes connection between not only “things” (objects) but also people and services.

In conventional equipment, two individual parts had to be machined separately, then welded (left), however the GS series enables machining of a single integrated part (right).
This means strength is improved as welding is no longer required.

The strength of having machine tool users within JTEKT

GS200H enables car parts to be made smaller, lighter and integrated, therefore it can be anticipated as a model that will help improve fuel efficiency. Moreover, GS200H reduces abnormal noises by improving the accuracy of gears, of which a high number are used in cars, thus contributing to a higher degree of quietness. The strength of JTEKT’s Machine Tools & Mechatronics business is that we have a steering business, driveline business and bearing business within our own company. Due to having manufacturing car parts directly within our own company, we have the advantage of an environment in which we can easily incorporate the users’ opinions in our development of new machine models. Moreover, JTEKT is also capable of developing and mass producing bearings, which are necessary to increase the performance of machine tools. The GS series was born by taking full advantage of this ideal environment. “JTEKT designs optimal tools and sets optimal machining conditions to enable customers to create the parts they want. Drawing out the capability of machine tools to the maximum extent possible as we have through these developments is, I believe, also important in fulfilling our customers’ wishes.” (Natsuda) “I am convinced that one of JTEKT’s major strengths is our culture of engaging in machine model development by listening closely to our customers’ viewpoints. I want to continue evolving machine tools as one with our customers.” (Ootsuka)

“I think that it is important to not only evolve existing technologies, but also create technologies that don’t yet exist in this world. My future goal is to be able to contribute to the advancement of monozukuri.” (Zhang)

*TOYOPUC is a registered trademark of JTEKT Corporation. *TORSEN is a registered trademark of JTEKT Corporation.