Noise Reduction in Novel Transmission with 3D Point Contact Gear System

Increasing challenges on reducing fuel consumption has opened the new directions in Powertrain technologies. The example of such technology implemented in geared transmission is the usage of novel type of gears with 3D point system of mesh engaging which was invented, patented and developed by Alexei P. Popov. The paper identifies the milestones of R&D that were undertaken to create the new type of geared transmission. Using the Winkler hypothesis Alexei P. Popov has developed and designed new type of point contact which made possible to lower a contact stresses in comparison to the values of a contact stresses for teeth having linear contacting interaction. The new shapes of tooth were invented and the methodological tools were developed for engineers providing the formulas for design and forming geometry of tooth with high stress capacity. The patented profiles would be applied for a design of all kinds of transmissions successfully replacing the conventional vehicle gear transmissions. The results of theoretical analysis combined with experiments on prototypes illustrate the proof of developed mathematical modeling. The synthesis of new type of gearing is presented. The test results for transmission of extra heavy vehicle and for transmission of light truck are discussed. The 25% - 40% reduction of sizes and weights, and reduced noise levels up to 22 dBA are the advantages of transmissions based on invented gears having 3D point system of engaging.