Transfer Case in Testing Lab

Cotta’s Transmission systematically and comprehensively monitors the quality of all internal processes.  In addition to first-piece inspection, which is conducted on every machining sequence, once assembly is complete, Cotta tests every transmission product that is shipped.   As well as having an exceptional staff, Cotta’s testing capabilities has played a key role in Cotta becoming a preferred and trusted gearbox solution provider in numerous markets worldwide.

Cotta’s assembly team has been busy getting an order of transfer cases ready for shipment.  The final gearboxes are going through testing and paint.  Cotta has been supplying these transfer cases to a customer for over a decade.  The units are used in workover rigs, and as with all of Cotta’s industrial gearboxes, they are designed to withstand extreme temperatures, pressure, and difficult conditions.

Learn More:  Cotta’s Testing Capabilities

 

 

 

 

Pump Drive for Offshore Application

Cotta recently completed assembly on this pump drive, which will be used in an offshore application.  Cotta’s customer manufactures hydraulic and electric powered movable structures, designing the entire systems for civil, industrial, military, marine and offshore applications and jacking systems.

Pump Drive Specifications: 

  • Ratio: 1 to 1.67 Overspeed
  • Anti-Engine Rotation
  • Max Output Speed: 5800 RPM
  • Max Input Torque:  1450 Ft-Lb
  • Approximate Weight:  1000 Lbs

Cotta Pump Drives provide years of dependable and efficient performance in the harshest, most demanding conditions. Some of our most popular pump drives are listed on the link below, but please contact Cotta for your specific application needs.

Cotta Pump Drives

Transfer Case Used in Mobile Rail Welding Truck

Plasser & Theurer is headquartered in Austria, and is the only manufacturer in the world that offers a complete range of machines for the laying and maintenance of railway tracks. The company also has a location in Chesapeake, VA, operating under Plasser American, which manufactures and services railroad equipment.  Back in 2016 a company that was assisting Plasser with building a truck during product development, reached out to Cotta for a custom transfer case that would be used in a new mobile rail welding truck.  Cotta’s engineering team worked closely with the customer, and offered a solution that met the weight limitations and all other requirements.

David White, contracting/service rep for Plasser American, stated “The Cotta gearbox has been working solid.  The past 2-3 months we have been running the unit even harder 6-7 days a week, sometimes double shifts with 16-20 hours/day.”  David expressed how happy they have been with the Cotta transfer case, and that they have had no issues with the unit.  He further stated, “Whenever we’ve had regular maintenance on the unit and needed parts, Cotta’s service was always great and we never had any issues getting parts in a timely manner.”

Plasser succeeded in integrating their top technology for rail welding into a truck vehicle that doesn’t exceed Federal Bridge Law weight limits. Plasser is breaking through an old market with this product line.

Technical Data on Truck:

  • Length:  39′ 3″
  • Width:  10′ 3″
  • Height:  11- 4″
  • Weight-Weld Head:  12,000 Lbs
  • Weight-Truck Complete:  79,000 Lbs
  • Truck Engine Power:  599 HP
  • Auxiliary Engine:  130 HP
  • Generator Nominal Current:  520 AMP
  • Generator Output:  500/100 V/Hz

LEARN MORE: APT1500RL

Transfer Case Specifications:

  • Ratio: 1 to 1 PTO Drive
  • Max RPM:  3000 Direct Drive; 2300 PTO Drive
  • Max Thru Torque:  12500 Ft-Lb
  • Max Torque thru Gears:  2300 Ft-Lb
  • Approximate Oil Capacity:  4.5 Gal
  • Approximate Weight:  1200 Lb

Creep Drive Design

Cotta’s Model TR2273 is an auxiliary gearbox designed to provide precision vehicle speed control by using a hydraulic motor to rotate the vehicle’s drive shaft.  The Creep Drive control gearbox is installed in the drive-line between the main transmission and rear axle. In road mode power is transmitted normally via a through shaft in the gearbox.  In creep mode the main transmission is shifted to neutral and the hydraulic motor and reduction gear-set in the gearbox are engaged to rotate the drive-line.  Applications include paint stripers, feeders, spreaders, lifts, road/rail, and similar uses requiring inching or remote operations.

SPECIFICATIONS:

Max Input Speed:  3000 RPM drive shaft

Max Torque:

  • Drive Shaft-12,500 lb -ft.
  • Motor pad – C spline   475 lb -ft
  • Motor pad -CC spline  900 lb -ft
  • Motor pad – D spline   1250 lb -ft

Reduction Ratio:

  • 3:1 gearbox
  • 13.5:1 using optional 4.5:1 input planetary

Through Shaft Spline Size:  2.75 x 10 straight side

Motor/Pump Pad:  SAE “C”

Mounting:  (4) 1/2″-13 tapped holes on 11″ x  13″ rectangular pattern

Lubrication:  Internal reservoir. Splash delivery

Shifting:  Dual acting air cylinder

Approximate Weight:  400 lbs.

Contact Cotta for more information at sales@cotta.com, or call 608-368-5600.

 

Reversing Gearboxes for Rail Maintenance Vehicles

With 2000+ standard and custom designs to our credit, Cotta combines our prior experience with forward thinking to provide the exact product you require.  We continue to solidify our reputation as a preferred high-performance gearbox supplier by consistently improving our current product line, while also developing new innovative products.  An example of specialized solutions that Cotta offers is with our rail maintenance vehicle reversing gearbox.

Our engineering team is always working to improve the quality of our high-performance gearboxes. Some of the numerous enhancements that were made to the design of our rail maintenance reversing gearboxes include:

  • Enhanced housing casting
  • Upgrade bearing design
  • Improved serviceability
  • Increased speed capability
  • Improved durability

Rail Maintenance Vehicle

Contact a Cotta Sales Engineer to review your personal requirements and specifications with us.  You can click on the link below, or call

608-368-5600.

Application Data Design Form

Three Shaft Transfer Case

Cotta’s model TR2205 transfer case is designed for maximum application flexibility.  The transfer case has mirror symmetry, and provides four identical input/output stations.  Each station has a 2.75 X 10 splined shaft, and can be fitted with yokes or flanges.  A disconnect (de-clutch) can be fitted to the I/O stations to provide power interruption. An optional line of disconnects feature SAE pump pad outputs.

Cotta offers a special version of the TR2205 model that can be mounted horizontally. Depending upon option type, and placement, the TR2204 can be configured as a transfer case, drop box, PTO, or pump drive. Most options are available for field retrofit without having to return, remove, or disassemble the gearbox.

See Gearbox Specifications Below:

Nominal Application Power:  600 HP

Torque Capacity:

  • 2200 lb-ft. continuous through gears
  • 6800 lb-ft. continuous through shaft
  • 17000 lb-ft. momentary through shaft

Max Speed:  2800 RPM

Ratio:  1:1 input to output

Center Distance:  17 inches input to output

Rotation:  Outputs rotate same direction as input

Lubrication:  Internal reservoir. Lube pump furnished

Shifting:  Disconnects are air shift.  Mechanical shift option available

Output Shaft Size:  2.75 – 10 straight side spline

Common Options:  SAE to ISO yokes and flanges, disconnects, pump pads, clutches, stub shaft

Weight:  Approximately 600 lbs. w/o options

LEARN MORE:  TRANSFER CASES

 

 

Have a Need for Speed?

Cotta specializes in high-speed gearboxes for testing rotating components, with aerospace being one of the key markets. Built to provide many years of service, Cotta high-speed gearboxes are offered in a variety of standard and customized designs. Cotta has the ability to start with a “clean-sheet design”, which allows us to show you our versatility and experience to engineer a customized gearbox solution that fits your personal requirements and needs.

Cotta SN3396 High-Speed Gearbox

Cotta Model: SN2285

Output Speeds: Up to 90,000 RPM

Power Capacity:  300 HP

Weight; 270 lbs.

Market: Aerospace

Click the link below to view some of Cotta’s high-speed gearbox models:

High-Speed Gearbox Models

 

 

Cotta Custom Gearboxes

Cotta designs the best possible high-speed transmission gearbox, speed increaser or reducer, pump drive, or customized product for your application. Custom gearboxes are ideal when you have an application with unique requirements such as horsepower, torque,  material, size, etc.  Cotta’s engineers become an extension of your company by working with you from design to production, customizing a solution that will meet your application’s specific needs. Cotta’s product line supports a wide variety of industries and applications where demanding performance is required under the most extreme working conditions and challenges.

Cotta products include:

The knowledge gained from Cotta’s extensive history of designing and manufacturing custom gearboxes for 100+ years, allows us to customize each component of the gearbox to make sure the final product perfectly fits with the customer’s needs. To contact an Application Specialist about your application’s requirements, call 608-368-5600 or click on one of the links below:

Contact Us

High-Speed Gearbox Quote Request

Industrial Gearbox Quote Request

Other Quote Request

Diagnosing Gearbox Noise

Diagnosing any noise issues in your equipment can be time-consuming and difficult to diagnose, and determining whether noise is coming from the gearbox within your system can be even more difficult without sophisticated vibration measurement tools. However, some general guidelines are as follows:

High Pitch Whine Noise

Gear noise from deteriorating gear set is usually a high pitch “whine”. This whine is generated by the tooth meshing frequency. For example, an input gear with 30 teeth running at 1800 RPM would have a meshing frequency of 900 HZ. Compare this to the shaft rotation frequency of only 30 HZ (1800/60)

Growl Noise

Bearings rotate at input shaft speed or some increasing or decreasing multiple.  The rotation frequency of the shaft is several orders of magnitude below the gear mesh frequency. Therefore, then noise produced by bearings as they fail is closer to a “growl” or at least a frequency much lower than gear mesh frequency.  In the advanced stages of failure, the balls or rollers may slide producing a screech.

Pinpointing Noise

Pinpointing the noise is easier said than done, especially on systems without torsionally tuned couplings.  Noise transfers via shafts and other rigid members, and often sounds as though it is coming from a gearbox when it may actually be transmitted there from another source.  A “listening rod” may be used to help locate the noise. Troublesome bearings usually generate excessive heat. Look for hot spots on the gearbox.

When it comes to finding out why there is noise in your equipment, don’t be certain that the gearbox is the culprit.  Take the time to follow the general guidelines to get you started on the right path.

High Speed Gearbox Solutions for University R&D Facilities

Cotta has an extensive background in working with research facilities at universities worldwide, supplying high speed gearboxes for test stand applications.  Some of those facilities are involved with research and product development for OEM’s in the aerospace propulsion and power industries.

For over 50 years, Cotta has designed and manufactured a diverse line of high speed gearboxes that are used by some of the largest OEM companies in the world.  The gearboxes are developed for numerous R&D and production test stand applications for automotive, aerospace and industrial components. Cotta’s high speed gearboxes are also applicable for speed management in non-aviation, industrial applications – from turbine reduction gears to centrifugal driers, to numerous other instances where a highly specialized, powerful and reliable solution is needed.

On a recent project for a university, Cotta’s engineering team designed and manufactured a high-speed gearbox for a test stand.  See specifications below:

RATIO:  1 TO 13.02

MAX TORQUE:  700 FT-LB HIGH SPEED SHAFT

MAX SPEED:  23,000 RPM HIGH SPEED SHAFT

APPROX WEIGHT:  3000 LBS