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Drop In Replacement Gear Reducers

Drop In Replacement Gear Reducers
Steel Mill Galvanizing Line

These various sized units were ordered to replace the existing boxs which were no longer available. The original manufacturer had introduced a new line with a new bolt pattern rendering the old model obselete. The prime objective was for a ratio change to speed up the galvanizing line. Delta came on site and measured up all the boxs so that the new ones could be made to suit the existing mounting configuration.


Drop In Replacement Gear Reducers
Cooling Tower Drive

Ordered to fit where a replacement couldn't be found.


Drop In Replacement Gear Reducers
Inline Reducer

This reducer was available from the supplied with a cast iron housing only. The steel mill where it was used found that even a small bump with a several ton roll of steel would break the box. The machinery was built around the reducer which prevented any other reducers from being used as is. Delta's solution was to build a new fabricated steel housing while utilising the old gearing. Further units were supplied completely new as the mill replaced all the cast iron units. Reducers that were averaging 4.5 months over 2 years have now been running in excess of 2 years.


Drop In Replacement Gear Reducers
Plumbed for Lubrication

External electric lubrication installed for lubrication to all bearing as well in into mesh.


Drop In Replacement Gear Reducers
SR-18

An older model reducer that was very common in Pulp & Paper Mills is replaced By a new Delta box with gearing made to current AGMA standards. The service factor is increased by more than double of what was. Maintenance, noise and cost were all reduced.


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Delta Catalog Gear Reducer

Delta Catalog Gear Reducer
Delta Catalog Reducer

Gear Cutting Gallery

HELICAL GEARS
HELICAL GEARS
DOUBLE HELICAL GEARS
DOUBLE HELICAL GEARS
INTERNAL GEARS
INTERNAL GEARS
SUN GEARS
SUN GEARS
PLANET GEARS
PLANET GEARS
SPROCKETS
SPROCKETS
SPUR GEARS
SPUR GEARS
INTERNAL AND EXTERNAL SPLINES
INTERNAL AND EXTERNAL SPLINES
PINION SHAFTS
PINION SHAFTS
36 inch Gear Shapers
36 inch Gear Shapers
Spline Hobbing
Spline Hobbing
Case Hardened and Profile Ground Helical Gears
Case Hardened and Profile Ground Helical Gears

Open Gears1

Open Gears1
Helical Gears

Open Gears1
Helical Pinions

Open Gears1
Fabricated Bull Gear

Open Gears1
Critical Mounting Patterns

Open Gears1
Internal Ring Gears

Open Gears1
Case Hardened & Ground Double Helical Gear

Open Gears1
Custom Sprockets

Custom Gearbox Housing

Delta Dynamics is ISO certified Custom Gear Design Manufacturer, well known and respected in the industry for its professionalism and dedication to ensuring its products exceed the customer’s requirements. We use our years of gearing and machining experience to provide “fill-in-the-blank” design service, acting as an extension of our customers’ design and machine shop teams at every stage of the production process.

The continued success of Delta Dynamics is founded on our ability to:

•    Assist each client from design to delivery of every part
•    Provide in-depth design assistance
•    Apply decades of machining and designing experience to every job
•    Identify and solve problems before they arise


Custom Gearbox Housing

Delta Dynamics has designed and manufactured a large number of custom gearbox housings, industrial gearboxes, and speed reducer housings for a variety of industrial applications. Our housings are manufactured from welded-steel, offering greater flexibility in design of custom parts. This greatly decreased cost for low volume production compared to casting, and a stronger, less porous and more impact- and shock-resistant solution that is durable and unlikely to crack. We produce housings for new and drop-in gear boxes, as well as replacement housings for existing reducers. 

 

Custom gearbox housing is useful because if you have specific mechanical components to enhance your machinery an all-encompassing gearbox won’t satisfy your specific needs. Any company would want their machinery to run as smoothly as possible and custom gearbox housing allows a machine to do so with sufficient mechanical support for moving components.  

An industrial gearbox would also be extremely useful, as Delta Dynamics has gearboxes suited for particular fields. The gearboxes available for machinery in different industries vary. When compared to a custom gearbox, an industrial gearbox demonstrates more of a set format with only slight variations related to the machine and the customization needed. As a company happy to fulfill your machinery needs, Delta Dynamics will evaluate and consult with you as to whether a custom gearbox housing unit or a traditional industrial gearbox is better for you. 

 

At Delta Dynamics we work with our customers from design to delivery, with our experienced and certified production team using their expertise and extensive knowledge to assist in the revision and perfection of each part’s design and production path. This “fill-in-the-blank” style of design and engineering assistance allows our customers to put our years of gear design and machining experience to work in ensuring they receive a precise, top-quality product that exceeds their expectations and requirements. Each drawing or part we receive is reviewed by our operations, engineering and production teams, with each specified dimension, tolerance, material and material treatment, as well as the part’s overall functionality and application, being thoroughly analyzed to guarantee superior form and function of the final, manufactured part. A streamlined and detailed production process then is created for each part, and is designed to guarantee that the manufactured part conforms closely to the precision and tolerances of the design, while remaining cost-effective to produce. Our production staff continually monitors the manufacturing process of each part as part of our ISO 9001 certified Quality Management System, to ensure an efficient, reliable and top-quality product. At numerous key stages of the production process dimensions of the part are inspected by our full-time inspection team to check that they fall within the tolerances specified in the design. Delta Dynamics can produce, upon request, a detailed Dimensions Inspection Report as our assurance of the precision and quality of our work. This attention to detail and dedication to precision ensures that all parts of an assembly fit into the housing with appropriate clearance and can be mounted with extreme accuracy to create efficient and effective gear meshing. This helps prevent collision, shock and wear on gears and other assembly parts, and increases the life-expectancy and durability of all parts, while reducing noise and wasted space within the housing.

 

A unique production path is created for each part or product we manufacture, with each person, from machinists to production supervisors and operations managers, working collaboratively from concept to completion. Our machine shop staff has extensive experience and knowledge in the operation of both manual and automated systems, and programs and runs all machines quickly and efficiently, producing consistently excellent results that meet or exceed design specifications without sacrificing cost-effectiveness and run-time efficiency.

 

Delta Dynamics has manufactured housings and other parts and assemblies for numerous industries. Our expertise and knowledge of gearing and machining have been used in the creation of innovative and effective solutions for a wide range of challenges, including multi-roll timed gearboxes and conveyor reducers for the forestry industry, top drives and draw works for companies in the oil & gas field of work, and cooling tower reducers and planetary drives for the steel industry. We have extensive experience in the use of a wide variety of materials, including countless steel and aluminum alloys, and material treatment processes, such as carburizing, nitriding, plating and peening, enabling Delta Dynamics to produce versatile, customized and long-lasting housings and parts. 

 

 

Our number one goal at Delta Dynamics is Customer Satisfaction. We strive to provide each customer with top quality, cost-effective and on-time solutions that meet or exceed both the customer’s and Delta Dynamics’ requirements. We work with the customer and provide design assistance at every stage of the production process, from design to delivery, implementing an outstanding Quality Management Process to guarantee that all parts and products made by Delta Dynamics meet our exacting quality demands. Delta Dynamics is large enough to accommodate large volume and dimension orders, while remaining small enough to maintain close connections with our clients and provide the extensive service we are known for. This makes Delta Dynamics your logical choice in Custom Gear Design Manufacturers.

CNC Machining

CNC machining for gears is an extremely powerful resource. Using CNC machines, precision and meticulousness is exhibited with every project throughout its entire developmental process due to CNC gear cutting and grinding. Examples of our previous, rigorous work is shown below. We are happy to help you achieve the same precise results so that your custom-made gears fit your device accurately. 


CNC Machining
Prototype Mandrel

This star shaped mandrel was formed using CNC gear cutting and grinding to fit very tight tolerances on a 4-axis Vertical Machining Center from a solid 8" diameter 4340 Heat Treated steel bar. The efficiency created with CNC machining for gears is incomparable.  


CNC Machining
Gearbox Machining

Accurate gears require exactitude with housing development in order for there to be maximum load capacity and durability of gears. This custom designed top drive drill housing requires a collaborative procedure between the customer and Delta Dynamics to eliminate stress relief distortion caused by green castings. We pride ourselves on our ability to communicate comprehensively as we provide you with exactly what you are looking for when it comes to CNC machining for gears. 


CNC Machining
Oil Field Drilling Spindle

We have assisted many clients in the oil industry. The oil field drilling spindle is essential when it comes to oil rigs. CNC lathe turning and boring on high tensile forging is common in the development of products in this field. Contact Delta Dynamics if you need help producing precisely constructed machinery. 


CNC Machining
CNC Turned Shafting

Eccentric bearing fits on Splined Shafts must be created meticulously, which is why Delta Dynamics uses CNC machines to produce exactly what you need. We collaborate with every client to find out what they are looking for and then use CNC dynamics to develop the structure that is needed for their product to run smoothly. 


CNC Machining
Flanges and Unions

Exactness when it comes to flanges is very important. If you want your product to properly maintain its position then precise measurements should be taken. Thankfully, using CNC gear cutting and grinding the flanges are able to be produced with accuracy providing a secure rim. Unions must also be produced with certainty so that the flanges and unions may fit together correctly. You can rely on our CNC dynamics for skilled results. 


CNC Machining
Oil Field Casing Dies & Holders

Casing dies often have a multi-segment design and the tool joints must be adjusted accordingly. Due to the different segments, it is a colossal help to have CNC machinery formulate the oilfield casing dies and holders. Delta Dynamics’ custom design allows casing to fit into your product as they should to promote efficiency.


Gear Box Repair/Rebuild

Gear Box Repair/Rebuild
Custom Gear Box Rebuilds

Delta Dynamics can build a new set of gears in an old housing, painted to your specifications with all new hardware and plumbing, without a "new" price. This box was rebuilt in less time than it would take to cast a new housing, and met all customer requirements.


Gear Box Repair/Rebuild
A Tale of Two Rebuilds

This box was rebuilt and redesigned by another shop to handle the increased horse power that an Aluminum Smelter wanted to put through it. It lasted for 2 weeks.

The design looks good on paper, with large gear width being able to handle high horse power. However, large torque will wind up the pinion shaft so that the actual length of contact is nowhere near as wide as hoped.


Gear Box Repair/Rebuild
Rebuilt Right

This set of gears was used to replace the failed helical set above. The double helical design eliminated all thrust loads on the bearings as the bearings were one of of the constricting factors with the increase in horse power. The gears were case hardened with profile ground teeth. The double helical design with an axial float on the pinion allowed full face contact regardless of tortional windage.


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Drop In Replacement Gear Reducers

Drop In Replacement Gear Reducers
Steel Mill Galvanizing Line

These various-sized reducers were ordered to replace existing boxes which were no longer available. The bolt pattern on the OEM's new line of reducers rendered the old model obselete. Delta went on site, measured the existing boxes and manufactured new reducers to work with the existing mounting configuration.


Drop In Replacement Gear Reducers
Cooling Tower Drive

This reducer was ordered to replace a reducer discontinued by the OEM. The reducer was manufactured with case-hardened alloy steel gearing, 100,000 L10-life bearings, redundant acrylic seals and cast-iron housing with 4-point mounting to reduce noise and vibration.


Drop In Replacement Gear Reducers
Inline Reducer

The cast-iron housing of this Pulp & Paper Mill reducer was easily broken. Other mill machinery had been built around the reducer, preventing the use of a different reducer model. Delta built a new, welded steel housing with the old internal gearing. Brand new units were also supplied as the mill replaced all the old cast iron units. Reducer lifetime increased from 4.5 months to over 2 years.


Drop In Replacement Gear Reducers
Lubrication

A Continuous Splash lubrication system is used on most ratios and speeds for gear reducers. This reducer was built with a Forced Lubrication system, utilizing an oil pumps, filters, heat exchangers, sight gauges and an alarm system. Both systems greatly increase the longevity and power rating of the reducers.


Drop In Replacement Gear Reducers
SR-18

An older model reducer that was very common in Pulp & Paper Mills was replaced by a new Delta Dynamics reducer with gearing made to AGMA standards. The service factor was more than doubled. Maintenance, noise and cost were all substantially reduced.


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Gear Box Repair/Rebuild

Gear Box Repair/Rebuild
Gear Reducer Failure

Gear reducer failure is a serious problem which is why gearbox rebuild and repair is such an important part of what Delta Dynamics does. This reducer, pictured on the left, was designed and built by another machine shop to handle the increased horsepower that an Aluminum Smelter wanted to put through it. The gears lasted two weeks. 

The experts at Delta Dynamics were able to analyze the situation and perform industrial gearbox services. The large-width gears were theoretically capable of handling very high horsepower. However, the large torque in the system wound up the pinion shaft so that the actual gear contact length was much smaller than designed. With our help, gear reducer failure problems will be minimized and eliminated so that your machinery may work as it is intended to. 
  


Gear Box Repair/Rebuild
Reducer Rebuilt

As shown in the image on the left, Delta Dynamics built a set of gears to replace the failed helical set above. The double helical design eliminates all thrust loads on the bearings which really emphasizes the strength and power of gearbox rebuild and repair, as the bearings were one of the constricting factors with the increased horsepower. The double helical design with axial float on the pinion allowed full-face contact regardless of the torsional windage. The gear reducer has been running for well over 6 years without any concern. 


Gear Box Repair/Rebuild
Gear Reducer Rebuild

Delta Dynamics can build a new set of gears in an old housing, painted to your specifications with all new hardware and plumbing, without a "new" price. This box, pictured on the left, was rebuilt in less time than it would take to cast a new housing and met all customer requirements. 


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Shafts Gallery

Downhole drilling tools c/w API certified threads
Downhole drilling tools c/w API certified threads
Top Drive Quill
Top Drive Quill
275 Ton Spindle
275 Ton Spindle
Sub-Crossover Shafts - NC50 Box to NC46 Box
Sub-Crossover Shafts - NC50 Box to NC46 Box
Nitride Hardened and Chromed Splined Shaft
Nitride Hardened and Chromed Splined Shaft
Forklift Transmission Shaft
Forklift Transmission Shaft
API NC50 Thread
API NC50 Thread
Top Drive Spindle Machining
Top Drive Spindle Machining
ACME Thread Shaft
ACME Thread Shaft
Gear Reducer Input Pinion
Gear Reducer Input Pinion
Splined Motor Shaft
Splined Motor Shaft

List

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Prototype Mandrel

This star shaped mandrel was CNC milled to very tight tolerances on a 4 axis Vertical Machining Center from a solid 8" diameter piece of 4340 heattreated steel.


List
Gearbox Machining

Accurate gears require an accurate housing for maximum load capacity and durability of the gears. This custom designed Top Drive Drilling housing required a collaborative procedure between the customer and Delta Dynamics to eliminate stress relief distortion caused by green castings.


List
Oil Field Drilling Spindle

CNC Lathe Turning and Boring on High Tensile Forging


List
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Gear Reducer

Gear Reducer
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Special Purpose Gear Reducers

Special Purpose Gear Reducers
Custom / Special Purpose Gearbox's

These Gear Boxes were designed and build by Delta Dynamics for a new prototype wood manufacturing process. Through detailed review with the end user they were able meet the exacting demands that were not available on the market. Delta was chosen as the supplier as their ability to understand the customers needs and recommend unforeseen requirements proved from the start to be what was needed for the best end result. The result is expressed well through the chief design engineers comment,” This is a truly stunning performance mainly by you and your staff. I would like to thank everybody for the excellent work which yielded this absolute stunning result." Stay tuned for further progress as the patents are all coming through on this revolutionary machine.


Special Purpose Gear Reducers
Assemblies

Special Purpose Gear Reducers
Pulp & Paper

This special purpose reducer was no longer available from the O.E.M.

With Delta's onsite inspection, a new unit was manufactured to suit the existing, unusual mounting required.


Special Purpose Gear Reducers
Oil Field Hydraulic Power Divider

Special Purpose Gear Reducers
Planetary Reducer

This custom designed gearbox used a 2 stage compound planetary to drive 250,000 lbf/ft torque. Delta worked in consultation with the design engineering group to develop and manufacture this very unique planetary housing. Confidentiality agreements restrict us from raving about the success of this unique application.



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Delta Drive

Delta Drive

The Delta Drive Arbor was designed through consultation between sawfilers, sawmill maintenance personnel, saw manufacturers and arbor manufacturers.

While this drive form may be new to the North American sawmill industry, it is based on a long established European engineering polygonal profile drive standard.

 

 



· Manufactured from premium vacuum degassed alloy steel to aid in uniform hardness and high tensile strength.

· Machined on computer numerical controlled C.N.C. machinery to ensure repeatable accuracy.

· Induction hardened to minimize distortion.

· Hard chrome plated for increased wear resistance,

corrosion resistance and reduced coefficient or friction.

· Different profiles available for fixed and for shifting applications.

· High torque transmission for increased feed speed

· Large surface contact area reduces contact stresses and increases arbor life.

· Self centering properties aid in consistent bite per tooth.

· Balanced, symmetrical distribution of forces reduces vibration.

· Easy, safe handling of saws with no sharp teeth.

· No grooves or gullets to collect chips that can cause imbalance on arbor.



The Polygon Drive System is being used as a standard saw drive by a leading sawmill manufacturer in Sweden.

One of the largest machine-tooling manufacturers in the world uses the Polygon Drive for its premium modular tooling for C.N.C. machining where locational stability is essential.

A leading American gear-cutting machine manufacturer uses the Polygon Drive as their primary drive for change gears where concentricity and ease of assembly are critical. Delta Drive arbors and sleeves are now being used in more than 40 various edgers across North America and are showing excellent results. The majority of users state that they are very pleased with the performance. They prefer it to other systems they have tried, and will not switch back to their older drive. Reference names and test results are available upon request.

Delta Drive

Delta Drive

The Delta Drive Arbor was designed through consultation between sawfilers, sawmill maintenance personnel, saw manufacturers and arbor manufacturers.

While this drive form may be new to the North American sawmill industry, it is based on a long established European engineering polygonal profile drive standard.

 

 



· Manufactured from premium vacuum degassed alloy steel to aid in uniform hardness and high tensile strength.

· Machined on computer numerical controlled C.N.C. machinery to ensure repeatable accuracy.

· Induction hardened to minimize distortion.

· Hard chrome plated for increased wear resistance, corrosion resistance and reduced coefficient or friction.

· Different profiles available for fixed and for shifting applications.

· High torque transmission for increased feed speed.

· Large surface contact area reduces contact stresses and increases arbor life.

· Self centering properties aid in consistent bite per tooth.

· Balanced, symmetrical distribution of forces reduces vibration.

· Easy, safe handling of saws with no sharp teeth.

· No grooves or gullets to collect chips that can cause imbalance on arbor.

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The Polygon Drive System is being used as a standard saw drive by a leading sawmill manufacturer in Sweden.

One of the largest machine-tooling manufacturers in the world uses the Polygon Drive for its premium modular tooling for C.N.C. machining where locational stability is essential.

A leading American gear-cutting machine manufacturer uses the Polygon Drive as their primary drive for change gears where concentricity and ease of assembly are critical. Delta Drive arbors and sleeves are now being used in more than 40 various edgers across North America and are showing excellent results. The majority of users state that they are very pleased with the performance. They prefer it to other systems they have tried, and will not switch back to their older drive. Reference names and test results are available upon request.

Gear Reducer Gallery

Parallel Shaft Single-Stage Reducers
Parallel Shaft Single-Stage Reducers
Parallel Shaft Single-Stage Reducer - Side View
Parallel Shaft Single-Stage Reducer - Side View
Parallel Shaft Double-Stage Reducer
Parallel Shaft Double-Stage Reducer
Parallel Shaft Double-Stage Reducer - Gearing
Parallel Shaft Double-Stage Reducer - Gearing
Parallel Shaft Triple-Stage Reducer
Parallel Shaft Triple-Stage Reducer
Planetary Gear Reducer
Planetary Gear Reducer
Single stage reducer with fan cooling
Single stage reducer with fan cooling
Vertical Shaft Cooling Tower drive
Vertical Shaft Cooling Tower drive

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PRODUCT SECTION

Drop In Replacement Gear Reducers
Drop In Replacement Gear Reducers
Custom/Special Purpose Gear Reducers
Custom/Special Purpose Gear Reducers
Delta Catalog Gear Reducers
Delta Catalog Gear Reducers
Sawmill Edger Arbors
Sawmill Edger Arbors
Open Gears
Open Gears

Delta Drive

Delta Drive
Delta Drive

The Delta Drive Arbor was designed through consultation between sawfilers, sawmill maintenance personnel, saw manufacturers and arbor manufacturers.

While this drive form may be new to the North American sawmill industry, it is based on a long established European engineering polygonal profile drive standard.

 

 

· Manufactured from premium vacuum degassed alloy steel to aid in uniform hardness and high tensile strength.

· Machined on computer numerical controlled C.N.C. machinery to ensure repeatable accuracy.

· Induction hardened to minimize distortion.

· Hard chrome plated for increased wear resistance, corrosion resistance and reduced coefficient or friction.

· Different profiles available for fixed and for shifting applications.

· High torque transmission for increased feed speed

· Large surface contact area reduces contact stresses and increases arbor life.

· Self centering properties aid in consistent bite per tooth.

· Balanced, symmetrical distribution of forces reduces vibration.

· Easy, safe handling of saws with no sharp teeth.

· No grooves or gullets to collect chips that can cause imbalance on arbor.

 

The Polygon Drive System is being used as a standard saw drive by a leading sawmill manufacturer in Sweden.

One of the largest machine-tooling manufacturers in the world uses the Polygon Drive for its premium modular tooling for C.N.C. machining where locational stability is essential.

A leading American gear-cutting machine manufacturer uses the Polygon Drive as their primary drive for change gears where concentricity and ease of assembly are critical. Delta Drive arbors and sleeves are now being used in more than 40 various edgers across North America and are showing excellent results. The majority of users state that they are very pleased with the performance. They prefer it to other systems they have tried, and will not switch back to their older drive. Reference names and test results are available upon request.