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

Gearbox Test Facility

Cotta systematically and comprehensively monitors the quality of all internal processes. First-piece inspection is conducted on every machining sequence, starting at the source to support our zero-defect policy, and then we assemble and test every transmission product we ship from our plant.  Cotta’s three programmable test cell facility plays a key role in providing customer’s with the highest quality products.

High Speed Testing

  • 500 HP horizontal input (3,600 RPM)
  • 8 x 11 x 8.5′ test area
  • 25,000+ RPM input speeds
  • 2-150 GPM temperature-controlled oil lubrication system
  • Multi-channel FFT Spectrum Analysis

Low Speed Testing

  • 20 HP horizontal input
  • 7 x 16 x 7′ test area

Special Purpose Testing

  • 30 HP horizontal input
  • 7 x 19 x 7′ test area

Other test cell features:

  • Remote shifting
  • temperature, pressure, flow, vibration, load, sound, audio visual surveillance with DVR
  • Fully shielded and interlocked
  • Up to 5-ton crane capacity

To learn more about Cotta’s testing facility, contact sales at 608-368-5600 or email sales@cotta.com

Test Stand Gearbox – 25+ Years Still Running!

AAE Aerospace, located in Brampton, Ontario, has 65 years of experience in the design, manufacture, repair & overhaul, and distribution of components for aircraft, naval ships, and ground support equipment. AAE uses a Cotta gearbox on their in-house stands used for testing aircraft generators, typically 60kVA to 90kVA. The gearbox has been extremely efficient, running for over 25 years without a major breakdown.

Some of the required design specifications for AAE’s gearbox included:

  • Unit to be designed for bi-rotational rotation
  • High speed shaft torque to not exceed 31500 RPM
  • Continuous rating of 350 HP at 30,000 RPM
  • Maximum acceleration to not exceed 700 RPM per second
  • Oil temperature must be 90 deg F before reaching 6500 RPM
  • After reaching 6500 RPM, increase speed by 1000 RPM every 20 seconds until 12000 RPM is reached
  • After proper start-up procedure, maximum acceleration/deceleration rate to not exceed 4400 RPM per second

AAE’s Engineering Manager, Mark DeRoia, reflected on AAE’s relationship with Cotta Transmission.  He stated, “When we’ve ever needed a part or reported a service issue, Cotta is always responsive and meets our need within a week. They have a good, very consistent group of people there. We may need to install another test stand in the future. So, when we need a new high-speed gearbox, Cotta is who we’ll call.” Mark further stated, “AAE has specific requirements for stringent applications, like for running an F-18 aircraft generator at 26,000 RPM, and we can rely on high-quality results from their product.”

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 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.

VISIT:  AAE

QUICK LINKS:

High-Speed Gearboxes Catalog

View Complete Library of Product Specification Sheets

High-Speed Gearbox Application Data Form

Purchase Replacement Parts Direct from Cotta

If you have a need for any Cotta replacement parts or gearboxes, there is no need to go through a distributor.  You can contact Cotta directly!  Our genuine Cotta parts are designed to match our exact standards, tolerances and OEM specifications, so that they will fit perfectly and work optimally in your Cotta brand of equipment.

Cotta maintains an extensive inventory of standard service parts, and any non-stock parts are made to order in our Beloit, WI facility. Available is an online library of interactive part schematics linked to each unit’s bill of materials. You can select a unit, then the part number(s) for what you need to order, and then specify the number of items per part.  Cotta also offers expedited processing service as well, which reduces your lead time by “hand carrying” your order through the necessary steps.

Learn More: Replacement Parts

Contact Information:

Email: sales@cotta.com

Phone: 608-368-5600

Contact Form

Marian Domanski Joins Cotta Team

Cotta Transmission is excited to announce Marian Domanski as the new Customer Service Representative.  Marian will be taking over the responsibilities from Sara Brady, who is retiring the end of this week.

Marian is not a newcomer to Cotta, as he has held various positions at the company for over 30 years on and off. Marian’s first introduction to Cotta was through his father who was also a long time Cotta employee.  As a teenager, Marian remembers visiting the shop and seeing the huge machines his father worked on.  This sparked Marian’s interest in manufacturing and led him to work part time for the company after high school.  Prior to working full time at Cotta, Marian attended Northern Illinois University and earned a B.S. degree in Industrial Engineering.

Marian’s previous experiences also includes working as Plant Manager for Rockford Heat Treaters, Manufacturing Engineer for Coltec Industries, and Senior Manufacturing Engineer for Henry Pratt Company. Over his 30 years at Cotta, in addition to working with engine and turret lathes, grinders, vertical mills, radial drills, and shipping, Marian’s positions also included CNC Programmer, Process Engineer, Manufacturing Engineer, Continuous Improvement Manager and Inside Sale Manager.  The knowledge that Marian has gained over the years working with parts, processes, machining, engineering, etc. has already proven to be of tremendous value to the customers as well as Cotta.

Marian is excited to join the Cotta team again.  The company has been very important to his family over the years. At one point, he worked alongside two uncles, two cousins and his father.  Marian expressed how special the Cotta team is, and the working environment, and is happy to be back.

High-performance gearboxes. Collaborative team of experts.

Cotta Engineered Gearboxes are the most reliable and powerful products available in our industry. We take great pride in designing each unique gearbox with the latest technology. We deliver the best possible high-speed gearbox, speed increaser or reducer, pump drive, transfer case, or product type your situation requires.

High-Speed Gearbox Quote Industrial Gearbox Quote Other Quote Requests

Proudly Made in the USA

Proudly Made in the USA

Cotta, LLC

ISO 9001 Quality Management

Member Of The AGMA

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