Challenges in bearing support for planetary gear sets

The bearing support for gears in planetary gearboxes is structurally demanding: high circumferential speeds and varying loads must be accommodated within a confined space. At the same time, friction losses must be minimized and uniform load distribution within the planetary carrier must be ensured. Here, the bearing design and material selection play a decisive role in determining the efficiency, noise behavior and service life of the entire drivetrain. 

EMPT crimped shaft as a compact bearing solution for planetary gearboxes

Crimped shafts can be used for the hydrodynamic bearing support of planetary gear sets. In this process, a hydrodynamic bearing bushing is connected to the shaft via a form-fit using EMP technology. The function of the hydrodynamic bearing is thus directly integrated into the component. 

The electromagnetic pulse precisely shapes the bushing to match a contour or groove on the shaft, creating a high-load-capacity, backlash-free bearing that integrates perfectly into the limited installation space of a planetary gearbox. Combined with optimized bearing materials, this concept enables high load-carrying capacity, excellent sliding properties and significantly improved power density.

Taking the next step in system optimization together

For anyone who wants to switch from roller bearings to hydrodynamic bearings

If you have been using roller bearings for the support of your planetary gear sets and are considering switching to hydrodynamic bearings, we will guide you from the initial concept through to a production-ready solution. Through rapid technological and tribological validation, we will demonstrate whether your system will operate reliably with hydrodynamic bearings and what performance and service life benefits are possible. Upon request, we can also directly assess whether EMPT-crimped shafts are already the next logical step for your gearbox.

For anyone who already uses hydrodynamic bearings and wants to take the next step with EMPT

If hydrodynamic bearings are already established in your gearbox, we can help you exploit their full potential with EMPT-crimped pins. Together, we will analyze your current design for the support of bearings in gear trains, identify reserves in terms of installation space, weight, and power density and examine how EMPT technology can further optimize your existing hydrodynamic bearing solution - from concept study to series application.

Comprehensively tested: Ensuring EMPT works reliably in your application

In collaboration with renowned university partners, we have developed a robustly validated simulation model that allows us to make statements about adhesive strength, material interlocking in the carrier and long-term tribological behavior even before sample production.

In addition, EMPT crimp connections are intensively tested on test benches – including axial and torsional load tests and endurance tests under realistic conditions. On this basis, we accompany customers through the entire development cycle: from the concept phase to prototypes and series approval.

Practical example: EMPT-crimped pin in wind turbine gearbox

A good example of a successfully implemented EMPT application in a crimped shaft for the bearing support in a wind turbine planetary gear set. Here, EMPT-crimped pins with different bearing materials were first tested on an internal bearing test bench under realistic load conditions of a planetary gear set and subsequently evaluated in a large-scale demonstrator gearbox during field testing. Tribological investigations show that the crimped bearing support reliably meets the required performance limits and that high-performance Miba alloys - such as an AlSn bearing material or the new lead-free bronze “InnoAlloy” - significantly outperform the standard reference material CuSn12Ni2. This demonstrates, both on the test bench and under real operating conditions, that EMPT-crimped bearing assemblies represent a robust and durable alternative to conventionally joined solutions for demanding wind turbine gearboxes.