Helical Gear Rack – Module 1.0

Smooth, Quiet, and Built to Last:

Introducing the Helical Gear Rack – Module 1.0

Experience the difference in power transmission with our state-of-the-art Helical Gear Rack – Module 1.0. Designed to outperform traditional Spur Gear Racks, this precision-engineered component boasts a unique helical tooth profile that sets it apart from the competition.

In the world of CNC machining, the decision between helical and spur gear racks profoundly influences performance and efficiency. Helical gear racks, distinguished by their angled teeth spiraling along the rack’s length, offer a multitude of advantages over traditional spur gear racks.

Helical gear racks ensure quieter operation and minimal vibrations, essential for CNC machines demanding superior precision and accuracy. This characteristic facilitates smoother motion control, reducing disturbances during operation and enhancing overall machining quality.

The helical design of gear racks provides a larger contact area compared to spur gear racks of the same module, enabling more efficient load distribution. This broader contact area minimizes wear and tear on components, ensuring consistent performance over extended periods—a critical feature for CNC machines executing repetitive, high-precision tasks.

Helical gear racks offer a larger face width compared to spur gear racks. This allows for larger loads to be evenly distributed across the tooth surface, reducing stress concentrations and increasing durability. In CNC machines that handle heavy workloads and frequent gear engagement, this gradual engagement leads to smoother operation and extends the life of the rack.

In essence, integrating helical gear racks into CNC machines provides numerous benefits, including reduced noise and vibrations, enhanced load distribution, smoother engagement, and increased torque-carrying capacity. These advantages not only elevate machine performance but also contribute to prolonged rack life and overall operational efficiency, establishing helical gear racks as the preferred choice for precision engineering applications in CNC machining.

How to install and align the Helical Gear Rack

When installing the Helical rack onto the Maker Store 40 Series extrusion, use the Maker Store Helical Rack installation tool shown.

Additionally, you will need the following hardware:

40-Series Installation (Per 500mm of Rack)

• 4 x Cap Head M6 x 20mm Bolts
• 4 x 40-Series M6 Sliding T-Nuts

20-Series Installation (Per 500mm of Rack)

• 4 x Cap Head M6 x 16mm Bolts
• 4 x 20-Series M6 Sliding T-Nuts

Why Choose The Helical Gear Rack – Module 1.0?

• Reduced Noise and Vibrations:
  The helix angle ensures smoother engagement and reduced vibrations, enhancing motion control and accuracy.
• Top Quality Material & Finish:
  This helical pinion is manufactured from hardened C45 steel, which provides excellent wear resistance and durability. The surface is finished with a black oxide coating to protect against corrosion.
• High Torque Carrying Capacity:
  With a High Contact Ratio and lower stress during engagement, our helical rack system delivers superior torque-carrying capacity compared to traditional racks.
• Higher Tooth Engagement:
  Gradual engagement distributes the load evenly across the tooth surface, optimizing performance and durability.

Need to join two helical gear racks?

Opposite Helical Tooth Gauge Tool

Don’t forget your accompanying Opposite Helical Tooth Guage Tool to easily install and align two racks!

Read More

How to use the Opposite Helical Gauge Tool

1. Clean the Helical Gear Racks and ensure the mounting surface is free of debris.
2. Mount the two Helical Gear Racks onto the mounting surface placing them side by side. Make sure to keep the bolts loose.
3. Align the first rack to the mounting surface and tighten the bolts.
4. To butt join the racks, an opposite tooth gauge tool is used. This tool has Left Oriented Teeth (opposite to the rack). Place the tool over the junction of the racks. See the image below:
   
5. Using 2x C-Clamps to firmly attach the tool and the racks as shown in the image below
   
6. The distance between the teeth of the racks at the junction will adjust due to clamping, allowing for smooth movement of the pinion.
7. Align the right rack onto the mounting surface and tighten the bolts.
8. If the racks need to be removed or replaced in future, insert dowel pins in the far end holes, through the racks into the mounting surface or use the Maker Store Alignment tool to realign the racks.
9. Remove the clamps and the opposite tooth gauge tool.

Helical Gear Rack – Module 1.0 Specifications:

Get the longest lifespan – Don’t forget the maintenance!

Maintaining a helical gear rack is crucial to ensure its optimal performance and extend its lifespan. One of the key aspects of maintaining a rack is to keep it clean and free of particulates and debris. Regular cleaning of the rack will prevent the accumulation of dirt and grime, which can cause wear and tear, and eventually lead to the rack’s failure.

For best performance, it is recommended to lubricate the pinion/rack with a Lithium-base NLGI No 2 Grease such as the Mobilux EP 2 Moly. This type of grease provides excellent protection against wear, corrosion, and oxidation, and helps to reduce friction and noise.

It is also important to inspect the rack for any signs of damage or wear, such as cracks, chips, or missing teeth. Regular inspection and maintenance of the helical gear rack will ensure that it operates smoothly, efficiently, and safely.