THE ULTIMATE IN POWER TRANSMISSION PERFORMANCE Delivering world class …s21.q4cdn.com/204186877/files/doc_downloads/download... · 2017-06-08 · Delivering world class reliability

THE ULTIMATE IN POWER TRANSMISSION PERFORMANCE

Delivering world class reliability and speed forspecialized gear applications.

America was built upon the backs of heavy industry. Steel, oil and gas and mining are critical lynchpins of the American economy and powerful symbols of the industrial might of our country. What’s more, these industries represent the very best of American ingenuity and competitiveness. Today they stand stronger than ever on the global stage as examples of how to adapt, improve and innovate for the 21st century and beyond.

At Brad Foote Gearing, we’re proud to play a part in this ever-changing, fast-paced industry. Our world-class, precision gearing solutions are smarter, larger and more technologically advanced than ever before. We provide the total package for high-quality precision gearing with solutions that are fully integrated, from design and engineering to specialty weldments and testing. You can count on Brad Foote as your partner for all of your precision gearing needs. We are committed to delivering quick turn-around, on-time delivery and outstanding value on your custom industrial gearing projects.

A legacy of leadership. A powerful promise for the future.

Brad Foote Gearing deploys advanced engineering solutions, services and manufacturing processes to deliver world class reliability and speed for specialized gear applications.

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A heritage of gearing innovation.

Since 1924, Brad Foote Gearing has produced precision gears for industrial markets as diverse as oil and natural gas, mining, steel, transportation and power generation. We are a founding member of the American Gear Manufacturers Association and were honored to be the first U.S.- based gear manufacturer to be ISO 9001 certified.

Cicero, IL At Brad Foote’s headquarters, turn-key capabilities include hard and soft machining, grinding, testing, final inspection, customer packaging, warehousing, and shipping.

Pittsburgh, PA In addition to heat treating, this wholly-owned Brad Foote facility provides industrial gearbox remanufacturing, bar cutting, machining and fabricating services.

TOP: Our state-of-the-art 5-axis machine has the ability to cut both Gleason-style and Klingelnberg-style bevels.

BOTTOM: Brad Foote features in-house and third-party consultant gear design and engineering services along with specialized software.

Brad Foote is deploying its expertise in tight-tolerance gearing for wind turbines into broader energy and infrastructure markets.

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Unique experience and ingenuity.Through Brad Foote Gearing’s decades of experience, we’ve gained the ability to design, engineer, manufacture and service complex gearing systems.

G E A R C U T T I N G

Spiral Bevel gears over 100” in diameter With two of the four Gleason 675 bevel gear generating machines in the world in our shop, we specialize in Gleason designs and 5-Axis Klingelnberg designs and are well suited to supply large spiral bevel gears. We can produce curved tooth spiral bevels over 100” diameter and .6 DP and can skive them after heat treatment.

Our curved tooth spiral bevel induction hardener can significantly increase the power capacity over thru-hardened gearing without the distortion created by carburizing. This machine was developed by Brad Foote to pass an inductor through the entire tooth length to ensure the tooth is hardened in the critical root area to 50HRC min.

Our bevel cutting areas are supplemented by our world class manufacturing facility and grade 3 heat treat facilities.

Enclosed Drive Gearing With the latest design and manufacturing technology, our enclosed drive gearboxes offer the advantage of carburized, hardened and ground gearing in a wide range of sizes and features. Our engineers specialize in drop-in replacements, duplicating existing gear drives for a more precise match. We can design a new gear drive to fit customer specifications.

Custom Gearing With more than a century of experience in gear drive manufacturing and repair, we bring our history of expertise in the industry to custom gearing. We apply it with precision down to the micrometer or fraction of a millimeter to meet the tightest tolerances and the highest quality standards. Our hobbing capacity is up to and exceeds 130” diameter, and our internal DIN 1 and AGMA 15 tolerances.

H E A T T R E A T I N G

Brad Foote Gearing possesses one of the largest captive heat treatment facilities in North America, with a fleet of furnaces and a large quench tank. Our state-of-the-art facility covers 50,000 square feet, and features a computer control room to monitor heat levels, carbon potential and the cycle time of each heat treat load.

We manage non-destructive testing and precision measuring in-house with a full scale metallurgical lab, including micro-hardness testing equipment to verify micro-structure and case depth. Specialized heat treating provides metallurgical properties to AGMA Grade 3—the highest grade possible. In addition, we provide custom designed CNC controlled tooth-to-tooth induction hardening for gears up to 72-inch in diameter, and carburizing in house for gearing up to 85 inches in diameter and 150 inches in length.

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In-house heat treating features fully computer- controlled gas carburizing, Q&T, induction hardening and normalizing processes.

With a team of on-staff metallurgists and a full metallurgical lab, Brad Foote’s comprehensive testing capabilities include in-house non-destructive inspection to level 3, ultrasonic testing, magnetic-particle and nital etch inspection, hardness testing, Barkhausen Noise Analysis and destructive testing and evaluation services.

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With custom and serial production, gear repair, gearbox refurbishment and field service capabilities, Brad Foote provides a total gearing solution.

Case StudiesP A P E R & P U L P I N D U S T R Y

A gearbox with 150% increase in torque. “We partnered with a leading pulp and paper company to custom engineer a gearbox with 150% increase in torque to boost pulp manufacturing productivity by over 50%. This improvement helped maximize manufacturing efficiencies and reduce waste, which fit well with the company's commitment to sustainability.”

Project Engineering Manager, Brad Foote Gearing

M I N I N G I N D U S T R Y

High horsepower, high torque gearbox. Brad Foote custom engineered a double input, single output gearbox with super-high horsepower and torque to be used interchangeably for both industrial applications in the gold mine. Dual-purposing the gearbox helped to increase mine productivity and profit-ability, and offered a competitive edge against the competition, which is vital to the success of this company and their customers’ businesses.

M A R I N E I N D U S T R Y

Specialty gearbox. In business for nearly a decade, this leading global marine construction and infrastructure company specializes in dredging and tunneling technology for channels, levees and shorelines, as well as building hurricane and natural disaster protection structures around the world.

“We designed the custom industrial gearbox for use in multiple configura-tions and various dredging applications to meet the needs of a wide range of marine projects,” states Richard Tallerico, Engineering Director at Brad Foote Gearing. “They needed a highly flexible service application for dredging, and we delivered exactly what they needed.”

S T E E L I N D U S T R Y

Custom-engineered double-horsepower gearbox. The project specifications of this gearbox project required Brad Foote to custom engineer a single speed gearbox that more than doubled the horsepower within the same footprint. This project enabled our steel manufacturing customer to produce 70% thicker walled steel tubing to meet market demands of the heavy construction industry, enabling them to grow their market penetration and increase sales growth.

Brad Foote engineers and produces enclosed drive gearboxes, including drop-in replacements and custom units to meet your precise specifications.

Robust gearbox assembly, testing and remanufacturing capabilities. Our in-house design and engineering team has built more than 600 custom gearboxes over the past decade, some weighing more than 100,000 pounds. Brad Foote offers Drive Test Reporting including thermal imaging, decibel readings, SKF vibration analysis, unloaded spin testing, verification of contact patterns, backlash settings, and Mag particle of all weld seams to ensure they are not leaking.

G E A R B O X D E S I G N & S E R V I C E S

Brad Foote’s design team has more than 65 years of experience in gearbox development.

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When it comes to the finishing stage, Brad Foote’s experienced machinists, technicians and state-of-the-art equipment provide a high level of quality and precision to every product. As part of our extensive tooth grinding capabilities, we employ on-board coordinate measuring machine (CMM) gear inspection technology, which verifies precise accuracy to meet your most stringent specifications. Our extensive precision form tooth grinding capabilities extend to 157 inches in diameter, AGMA Q15 and DIN 1.

F I N I S H I N G

As one of the largest gear grinding and carburizing companies in the world, Brad Foote meets the highest AGMA and DIN specifications to deliver gears with the tightest tolerances and utmost industry standards.

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Our state-of-the-art 5-axis machine has the ability to cut both Gleason-style and Klingelnberg-style bevels.

With extensive finishing capabilities, Brad Foote can exceed the ever-increasing `quality requirements of the most demanding applications.

Gear Cutting to AGMA 10 DP OD FACE

Spur .75-12 to 140” to 42”

Helical .75-12 to 140” to 42”

Double Helical .75-12 to 140” to 42”

Spline Int/Ext 1.25-12 to 59” to 12”

Gleason Bevel Straight .6-12 to 100” to 12”

Gleason Bevel Skew .6-12 to 100” to 12”

Gleason Bevel Spiral .6-12 to 100” to 12”

Gear Grinding to AGMA 15 DP OD FACE

Spur .75-12 to 157” to 42”

Helical .75-12 to 157” to 42”

Double Helical .75-12 to 157” to 42”

Spline Int/Ext 1.25-12 to 145” to 42”

Shafts• Shafts furnished complete to 150" OAL

Turning• Live axis - CNC to 84" OD - gears• Live axis - CNC and manual to 30" OD - shafts

CNC Milling• Vertical - 72" OD to 150" OAL and Z = 42”• Horizontal - X = 120", Y = 90" and Z = 28"

Heat Treating• Grade 3 (ISO 6636) carburize and harden to 84" OD and 150" OAL• CNC tooth-to-tooth induction hardening to 120" OD and .6 DP to match all gear cutting performed, including all bevels• Normalizing and thru-hardening• In-house metallurgical lab

Recreate Existing Gear Drives• Up to 102” diameter and 15,000 lbs. on CMM

Notable• Isotropic super-finishing • Non-destructive inspection to level 3 - Magnetic Particle, Nital Etch, Ultrasonic• Fabrication to 385,000 lbs. and 10" thick plate• Shot peening to 80" OD and 110" LOA• Waterjet cutting • CNC OD and ID grinding to match gearing and shafting• Full inspection services including 2 CMM's to 2.6/102”• Access to local gearbox field service team to meet your service needs• First member of AGMA certified to ISO 9001

Extensive Gearing Expertise and Services Capabilities

© 2017 Brad Foote Gear Works, Inc. All rights reserved. Rev. 3/173250 South Central Ave., Cicero, IL 60804 708.298.1100 www.bradfoote.com

MEMBER

Backed by Broadwind Energy.Broadwind Energy (NASDAQ: BWEN) is a precision manufacturer of structures, equipment and components for clean tech and commercial applications. Helping to foster energy independence in America, Broadwind Energy applies decades of deep industrial expertise to provide components and gearing solutions for customers in the energy, infrastructure and industrial markets.

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