Knowledge and proven understanding of gear form design is continually challenged as the engineers, using a combination of proprietary and powerful in house developed software, carry out in-depth analysis and validation of new designs and materials, to further optimise strength, weight and reliability.

The same unique process is also utilised in the design, analysis and validation of bespoke hybrid bearings where SKF Bearel software is used in conjunction with in house developed tools.
Gears are rated according to ISO6336:2006 - Calculation of load capacity of spur and helical gears, and utilises Xtrac's extensive materials libraries for bending and pitting resistance.  In-house standards are used where iterative modifications to the tooth profile have been proven in increasing the life reserves of the components.
Bevel gears are designed using the Klingelnberg KiMoS closed loop system which is fully integrated into the manufacture and inspection of the bevel gears themselves.
Finite Element Analysis (FEA) is carried out using high specification machines and Ansys software.  Specific FEA protocols have been developed and validated over many years to ensure timely yet accurate data.

The implementation of complex analysis software has complimented, not replaced, the traditional forms of research and development.

All aspects of the transmission and driveline are continually and rigorously examined on dynamic test rigs with the aim to reduce friction, raise efficiency and improve reliability.  Specific rigs used include:-

• Quasi-Transient Differential Test Rig (QT-DTR)
• Viscous & hydraulic differential test rig
• Heat rejection test rig
• Loaded steering rack and pinion test rig
• Multiple configurable spin test rigs
• Vehicle configurable gearchange test rig
• Loaded gearbox test facility up to 200kW
• ‘Quiet’ laboratory with NVH accelerometers
• Full load rig for CVT testing

Data acquisition is carried out using extensive HBM laboratory specification equipment, with an additional portable module for vehicle based acquisition to laboratory standard.
In addition a loaded gear coupon test rig provides a perfect validation tool for developments in gears, materials and lubrication to be assessed off the vehicle in a laboratory environment.

Seeking to optimise every transmission component, the material used becomes ever more critical to success. Xtrac continue to develop a range of steels and operate strictly controlled metallurgical processes to ensure that material physical properties meet precise performance criteria.

Ongoing testing of both new and existing materials, using the state of the art Bueler and Zeiss equipped research laboratory, often in conjunction with customers, allows the extra competitive edge in an ultra competitive and hostile environment.