30 years of experience in manufacturing of gears is our argument for highest quality.

Starting as a family enterprise, Modul Kft has been manufacturing machine parts and gears since 1986. Our corporate activities are highly diverse as customized parts and gears are manufactured by way of piece or batch production for gear pumps, pumps, farm machinery, railway vehicles, various drive gears, and machinery applied by food, chemical, mining, and power industries.
The EU market, as well as German and Austrian companies in particular, are taking up an increasing share of our products. Besides, meeting our regional business and individual customers’ demands, even the low-volume ones, is also a special priority as we intend to help them each solve their technical problems right from the design phase to the manufacturing phase.

By never abandoning their continuous vocational training, our specialists perform their work with 30 years’ professional and manufacturing experience. Speed and competitive prices are their trademarks

Unsere wichtigsten Ziele:

highest qualtity
customer satisfaction
excellent time management
competitive prices

Our competent professionals carry out their work with years of work and production experience and constant further education.

To Top

Benefits

Our services and disciplines in gear manufacturing.

The construction of gears and gear drives for our company is more than just a profession, we see this as a vocation! Gears are essential components for the conversion and transmission of mechanical energy. This technique has proved to be a milestone in human development from ancient times to the present day – to manufacturing technology of gear profile – constantly evolving. Every little gear in combination with other components are relevant members for the functionality of complex mechanical movement processes and is believed by us in the future, will never lose its importance. These findings are basic foundations of our corporate actions!

Our know-how and many years of experience in combination with the latest design software guarantees high quality of our products, the satisfaction of our customers and therefore also for the economic success and competitiveness of our company. Design and production is our primary objective through the fulfillment of customer requirements addition, reliable transmission to construct with highly efficient and clear structure that can be produced economically. Complete contracts, including manufacturing, quality and reliability of the produced components are guaranteed by our decades of experience and the constantly optimized plant park.

We are ISO 9001: 2008 and 14001: 2004 certified.

Consultation

What do you need?

You have any questions regarding. The manufacture of machinery parts or gear production? Feel free to contact us. We like to advise you.

Construction

Individual planning of various machine parts

Need individual Machinery productions? We plan and design for you gear drives, industrial drives, complete drive trains, transmissions, sequential gearbox of special design, etc.

Manufacturing

Production of various machine parts

We manufacture cylindrical gears with straight, oblique, curved, open gearing, cylindrical gears with internal and external teeth, bevel gears, gear hypioden couples, worm gears, planetary gears, cycloidal drive, and much more.

Determination

Error detection of defective transmissions

We determine the cause of damage in case of damaged, defective gear pairs and gears.

Refurbished

Repair transmissions

Our service also includes the repair of gear drives. If necessary, the re-design of gear systems.

Opinion

Development of Expertise

Preparation and assessment of expert opinions and reports.

Bei Aufträgen wird garantiert

operational reliability with appropriately designed and precisely produced transmission designs

the wide choice of materials for the gear produced from refined, for the nitride and case hardening steels suitable (hardened and ground gears with excellent accuracy IT) to polymer gears/li>

if necessary by crack detection tested gears for maximum durability and safety

the axes of all gears with carefully constructed storage with sliding or rolling bearings for the uniform and favorable load distribution

Construction of gears with single, kompensierter- and general teeth

Checking the viability of tooth surfaces including the calculation of life (even against pitting and hard drive

Careful profile optimization to reduce a reduced noise level

possible simply constructed and designed drive housing for easy mounting, precise manufacturing and integrated bearing formwork

relaxed welds

efficiency-optimized gear profile, leading to several thousand euros in electricity cost savings, reduced wear and reduced operating temperatures

Elaboration of the construction documentation and depending on the agreement and the complete manufacturing documentation

daily updated knowledge, flexibility and openness to new possibilities in the design and production

To Top

Gear manufacture

Many years of experience in the manufacturing of gears is one of our core competencies.

We can manufacture our products to a tolerance of IT5. We outsource the processes after manufacturing, e.g. heat treatment, coating, welding etc.

straight toothed gears
helical tooth gears
arrow-toothed gears
gears with internal toothing
rack and cylindrical gear

Ranges:
module: from 0.3 to 14
diameter: 5 [mm] – 1500 [mm]

straight toothed bevel gears
helical toothed bevel gears
spiral toothed bevel gears

ranges:
module: from 1 to 9

hypoid gears
screw gears
cylindrical globoid worm drives

evolvent
cycloid

handled sprocket wheel
disc sprocket wheel
sprocket wheel with hub
sprocket wheel with spokes
sprocket wheel with welded hub

flat belt pulleys
V-belt pulleys
toothed belt pulleys

key interlocks
splined shaft – hub
polygon shaft joints
spline toothed shaft joints
Spline tooth profiles:
spline
flute
evolvent

Key-way cutting
Turning (conventional and CNC)
Milling (conventional and CNC)
Drilling
Electric spark machining
Jig boring

pins, bores
plane
tooth

info@modul-fogaskerek.hu

Any questions? Mail us.

Individual production of gears, sprockets and engine parts.
Reliable, precise fit, functional.

Engineering

Our expertise in production enigineering is what distinguishes us.

Classification of gear drives

General

Gear drives connect two shafts by means of shape, and they transmit rotating movement and torque. Geometrical constraint factors are constant shaft-to-shaft distance and shaft angle. The shaft-to-shaft distance is the minimum distance between the rotational axes of the pair of gears, that is, the length of the normal transversal of the rotational axes. Shaft angle is defined by the external angle of the angle between the angular velocity vectors of the gears in the pair. The shaft angle of a plane gear drive is the limit shaft angle (90º). If the shaft angle is lower than this, then we are talking about external teeth, if it is bigger, then we are talking about internal gears (because of the enveloping surface turning inwards). The speed space of gears is a cylindrical space only in special cases, in general cases it is a spiral space. The relative speed along the spiral axis intersecting the normal transversal perpendicularly is minimum. The moving axoids comprising the rolling surfaces of the gear bodies are essentially the image of the spiral lines on the gear bodies. In a general case, the enveloping surface or axoid of the drive pair is a rotational hyperboloid, in special cases a cylinder or cone. The constant gear ratio is a kinematic constraint factor, being the angular velocity ratio of the pair of gears (driver/driven).

When grouping gears, three considerations may be taken into account, one is the shape of the gear without the teeth, second is the geometry of the toothing and third is the relative position of their shaft angles. The gear blank in the majority of cases is a rotational body – except for gear racks, toothed arcs, gears with changing ratio and non-circular rolling curves – therefore it can be processed on lathes before toothing. The untoothed shape of the gear may be cylindrical, conical or globoid. From a cylinder, a gear with internal or external teeth may be manufactured. Based on the toothing shape, they can be classified as straight, helical or arrow-shaped. From a cone, conical gears or bevel gears are manufactured. In terms of the toothing geometry, the toothing direction may be straight, helical or curved. Regarding worm drives, single enveloping worm gears are frequently used in Europe, while in case of American gears, double enveloping worms are used, these are called globoid gear. If you increase the shaft distance of two cylindrical gears, you get a toothed rack because the circular cross-section of the enveloping surface is transformed into a straight line. If the half-cone angle of a bevel gear is 90 degrees, you call it a plane gear. The relative position of the axes of the pair of gears may be parallel, intersecting or out-of-line. The range of tooth profiles fulfilling the complex connection conditions is really wide, a few of the more popular tooth profiles: evolvent, cycliod, cogged, Wildhaber-Novikov, circular profile, but there are other special tooth profiles, too, including the Hlebanja-type hybrid profile, cosine profiles, asymmetric profiles or icona.

The range of tooth profiles fulfilling the complex connection conditions is really wide, a few of the more popular tooth profiles: evolvent, cycliod, cogged, Wildhaber-Novikov, circular profile, but there are other special tooth profiles, too, including the Hlebanja-type hybrid profile, cosine profiles, asymmetric profiles or icona.

The most popular tooth profile is the evolvent, since it is easy to manufacture, control, the pair of gears is not sensitive to the change of shaft distance, the relative slip of the tooth profiles is low, having a positive effect on wear and heat generation.

The cycloid tooth profile is made up of tooth profile segments formed by the two auxiliary circles rolling outside and inside the base circle of origin, from the convex epicycloid head and the concave hypocycloid foot, therefore it is convex and concave tooth sides that are connected. Due to this, the tooth surface strength is higher than that of the evolvent tooth, and lower numbers of tooth can be employed, but because of the difficulty of grinding and controlling the manufacturing tools, it is almost exclusively the manufacturers of hydrodinamic machines (Root blower, pumps) and the watch industry that use them, apart from cyclo-drives.

Straight toothed external cylindrical gears

Force is transmitted between parallel shafts. When using these, an important factor is that they generate substantial noise when running fast, and there are high dynamic forces due to tooth deformations and the sudden load transfer at the limit points of the single tooth pair-double tooth pair connection. Multiple operations exist for its manufacture, and there is the highest range of machine park available. Their design is relatively simple, and they are less sensitive to the change in the shaft distance. For kinematic drives, changing gears of machine tools and when transferring high torques, they are highly preferred in all fields of motor sport, where the noise level is not an important aspect.

Helical and arrow-toothed cylindrical gears

It is also used for force transfer between parallel shafts. These are the type of gears to use for transmitting the highest speeds and loads. The noise level and the dynamic forces are lower. For helical tooth gears, auxiliary axial forces need to be taken into consideration when designing the bearings. In order to avoid axial forces, arrow or fishbone (v) toothing is to be used. When using such gears, axial forces even each other out. Two types of arrow toothings are differentiated, one is an open type with tool runout slot, the other is a closed toothing without a slot. Their use is widespread, typically in the automotive industry, and places where low noise levels and smooth running are required.

Internal tooth gear drive pairs

The drive pair consists of an internal and an external gear where an external small gear is connected to the large internal gear. These are characterised by more favourable kinematic and force transfer conditions than external gear pairs, due to the lower surface loads provided by the convex-concave contact surfaces. Typically, these are subjected to lower mechanical stresses, characterised by higher efficiency, lower wear and friction, and a further advantage is low space requirement. Indispensable parts of modern, high power density epicycloidal gear drives.

Bevel gear pairs

The bevel gear pairs are suitable for transferring movement and power with good efficiency between intersecting shafts. The angle between the shafts is usually 90º, but there might be different angles, too. We differentiate between straight, helical and helical toothed bevel gear pairs. For straight bevel gear pairs, there are substantial axial forces, since the radial load on one gear is transformed into axial load on the other. For ensuring a gapless engagement, precise adjustment and bearing is required. The power that can be transmitted by a single pair of gears is lower than the cylindrical pairs of gears with similar characteristics, because of the thinning of the teeth towards the centre and the unavoidable setup errors. For larger and high speed bevel gear drives, it is important to ensure the correct transfer image print in order to ensure uniform load distribution. Straight toothed bevel gear pairs are only designed and installed for kinematic drives, except for vehicle differential planetary gears. The helical toothing of certain helical pair bevel gear pairs enables grinding after hardening, therefore these can be exposed to higher loads than the straight toothed bevel gear pairs. The helical toothing provides a higher engagement factor, and due to grinding, toothing errors are reduced. All these ensure a more silent running. Due to the higher tooth slope of the helical gear pair, the engagement ratio is increased further, and therefore their strength and permitted speed is much higher than the types mentioned above. To transfer very high powers and speeds between intersecting axes, the exclusive solution is using helical bevel gear pairs.

Gear pairs with out-of-line axe

Hypoid gears
Similar to bevel gear pairs, but used for transmitting rotation between out-of-line shafts. An advantage over bevel gear pairs is that the dimensions of the small gear may be increased with a similar gear ratio, and the engagement factor is higher, therefore the tooth number of the small gear can be reduced further, increasing the gear ratio. For bevel gear drives, the smallest possible number of teeth of the small gear is 10, while for hypoid drives this is 5. Hypoid drives are mostly used in differentials of vehicles. The axis line of the small gear may be located under the axis line of the large gear, so the installation height of the propeller shaft may be reduced, bringing the center of weight down, improving the driving characteristics of the vehicle.

Screw gears
Screw gears are cylindrical gear pairs with external toothing, capable of transmitting power between non-parallel out-of-line shafts. In terms of tooth directions, we differentiate between helical toothing with identical or different inclination. The tooth surfaces engage point-like, therefore load is distributed over a very small area, even by taking flexible deformation into account. The slip between the tooth surfaces is relatively large, leading to heat-up and wear. The efficiency of such drives is low, therefore they can only be used for low-power drive systems. Applications areas are for example pump drives of internal combustion engines, speedometer drives, control purposes of machine tools.

Worm drive pairs
Worm drives are used for transmitting power and movement between out-of-line shafts. In terms of their functions, we differentiate between “power transmission” and “kinematic” worm drives. For “power transmission” drives, the purpose is transmitting big power, while for “kinematic” drives this is the precise transmission of movement. With worm drives, it is possible to implement relatively large gear ratios, for reductors this is i=5-70, while for multipliers (where the worm gear drives) it is i=5-15. Worm drives are mostly used in the elevator industry, where the advantage is the large gear ratio implemented in small sizes, and that worm drives are usually self-locking, so they can be used as auxiliary brakes.

Gear manufacturing technologies

Manufacturing straight and helical tooth evolvent cylindrical gears

Profiling
In profiling, a tool appropriate for the tooth groove processes the groove, this can be a disc cutter, cherry cutter or grinder disc. Wjen processing, the tool moves in parallel to the rotational axis of the gear under process on a route length identical to the tooth width, while the gear is stationary. After completing the tooth groove, the gear is indexed one tooth pitch by an index head, and another tooth groove is processed. When manufacturing helical toothing, the tool moves along a spiral relative to the gear.

Hobbing
During hobbing, the cutting edges of the tooth cutter tool envelope the surface of the rack. Three types of hobbing can be differentiated: hobbing, tooth planing with a chasing bar and tooth planing with a cutting roll. The most popular and at the same time most productive gear manufacturing process is hobbing. The sides of the rack forming the tooth grooves are mapped by the cutting edges on the helical surface of the hobbing tool during the relative movement of the cutter and the blank. These movements together may be regarded as if an infinitely long rack would be rolling over the workpiece, forming the gear. The accuracy of the process is increased by multiple cutting edges working at the same time during processing and due to the rolling action, the pitch is continuous. When tooth planing using a chasing bar, the tool performs alternating movements, and in terms of the gear under process it performs tangential and radial movements. In the meanwhile, the blank rolls along the rack of the chasing bar with a rotating movement. The radial movement persists until the required tooth depth is achieved. Tooth planing may be performed using a cutting roll as well. The gear blank performs a rotating movement, while the gear-shaped tool performs alternating and rotating movement and establishes the required tooth depth by moving towards the gear centre at the same time.These hobbing processes are suitable for making helical tooth gears as well, in these cases the tool must be inclined in the required tooth angle.

Manufacturing bevel gears

Bevel gears may be manufactured, too, using a hobbing process with straight cutting edge tools, similar to the hobbing of cylindrical gears. During such process, the teeth of straight and inclined tooth bevel gears are made by tooth slotting and hob-planing. During the process, the gear under process is rolled together with the matching imaginary plane wheel according to the hobbing process. The engagement is like if the gear under process would be rolling along a rack. The straight cutting edge knife or knife pair, reproducing the tooth of the plane wheel, performs a planing movement to create the tooth’s evolvent profile, that is, the spherical evolvent is approximated by a plane evolvent. Straight tooth and helical tooth bevel gears may be ground with a process based on hobbing. Thanks to grindability, the surface distortion of the gears after heat treatment may be processed, and more accurate gears may be produced, having a positive effect on tooth engagement.

Manufacturing helical tooth bevel gears

The tooth shape of helical gears is defined by the manufacturing process. In terms of the toothing system and the shape of the tooth creator, we differentiate between arc toothing (Gleason), evolvent toothing (Klingelnberg-palloid) and looped epicycloid toothing. The toothing tool used for creating a Gleason arc toothing is a disc-shaped knife-head, with trapezoid shaped knife inserts according to the plane profile. For the large gear, the arc’s tooth direction line is created by broaching or hobbing, and for the small gear this is hobbing. The processing is performed by teeth, that is, after creating a tooth groove, the tool retracts from the bevel gear, the machine indexes the gear by one pitch and the processing of the next tooth groove starts. The evolvent tooth direction toothing is created by hobbing. The trapezoid profile cutting edges are located along the conical helical surface of the manufacturing tool, with a tooth height identical along the cone generatrix. The tool can roll together with the manufacturing rolling cone of the gear under process thanks to its conical shape. The tool used for creating the cycloid-arc toothing is also disc-shaped, with trapezoid knife inserts shaped identical to a plane wheel profile located along multiple spirals. Out of the knives located in each spiral, the first performs roughing, the subsequent two hob the right and left sides of the teeth. The continuous rotating movement and the hobbing process together result in the imaginary tooth direction line on the imaginary plane wheel being a looped epicycloid.

Manufacturing worm drives

The tooth profile of the ZA type Archimedean worm is an Archimedean spiral in the frontal section, and trapezoid in the axial section. It is generally manufactured using a trapezoid profile turning cutter, with cutting edges located in the axis plane, but at the same time it can be manufactured with an inclined tooth evolvent profile cutter disc, too. The tooth profile of the ZI type evolvent worm corresponds to a large inclination angle evolvent toothing. The straight generatrix of the worm surface touches the base cylinder of the worm and the helix on that, and the tooth profile of the worm in the frontal cross-section is evolvent. The worm gear may be manufactured by hob-milling and hob-grinding. The ZN type colvolute worm has a straight profile in the normal cross-section. It may be manufactured by a trapezoid shaped turning cutter inclined by a medium pitch angle located in the normal cross-section of the tooth groove or the tooth. We differentiate between ZN1 and ZN2 type worms, depending on whether the cherry cutter is located in a plane perpendicular to the medium chordal normal helix of the tooth (ZN1) or the tooth groove (ZN2). The ZK type worm may be manufactured by a cherry cutter or a disc cutter. The ZK1 type worm is processed using a cherry cutter on a vertical mill. The ZK2 type worm is manufactured on a horizontal thread mill, with the tool being a trapezoid shape disc cutter.

Drive Systems

The task of a gear drive is to establish the connection between the powerplant and the working machine, to transmit energy and to tune the parameters of the powerplant’s mechanical power (T – torque, ω – angular velocity) to the demands of the working machine. In the special case when the nominal working points of the powerplant and the working machine are identical, they can be connected directly by a clutch, but in most cases there is a need to modify the torque and the angular velocity, performed by a gear drive. Classified according to the type of energy used, drives may be mechanic, electric, hydraulic and pneumatic drives. (The main profile of our company is manufacturing components used in mechanical drives, therefore in the following we are only discussing these). Mechanical drives may be classified into two types based on power transmission, shape or force-based drives, also in both types we can differentiate between drives with or without mediator elements.

Shape-based drives without a mediator element are gear drives (cylindrical gears, bevel gears, hypoid gears, spiroid gears, worm-gear drives). Shape-based drives with a mediator element are chain drives and toothed belt drives. A force-based drive without a mediator element is the friction drive. Force-based drives with mediator elements are belt drives, and steel belt drives. In terms of gear ratio, we differentiate between constant ratio drives, changing ratio drives and variable ratio drives. Constant ratio drives are gear, worm, belt, chain and friction drives. Changing ratio drives are implemented by using non-circular gears and crank drives. Changing the ratio may be implemented by using selectable gears or drives with continuous ratios.

Quality, customer satisfaction, timely delivery and competitive prices are our guiding principles.

Quality

Durable products Quality and efficient cooperation with our partners guarantee maximum customer satisfaction.

In line with the constant dynamization of economic, technical and environmentally relevant conditions of competition, we strive to be a step ahead of the requirements of the European Union as far as possible by means of targeted and ongoing measures.

Our primary goal is to continuously optimize products, production culture, competitiveness, product quality and personnel integration in our company, to meet the growing customer requirements at the highest level and thus to ensure complete satisfaction of all parties involved. We see this ambitious goal as a very important barrier to our sustainable economic success!

We are ISO 9001: 2008 und 14001: 2004 certified.

Environment

Environmental awareness and sustainability. The standard of our entrepreneurial activity.

Each of our colleagues is committed to performing their best to get our environmental policy implemented and the related environmental objectives achieved. Environmental awareness and reliability are our key selection criteria for our major suppliers. The separate collection and shipment or recycling, as appropriate, of our technology-generated waste involve our top priorities. To make sure that no pollution is caused, we expect our staff to be aware of the environment as well as rationally utilise our resources. To make sure that no unnecessary pollution is caused, we expect our staff to be aware of the environment as well as rationally utilise our resources.

We are committed to the prevention of environmental pollution and we continuously work on reducing our environmental emissions.