Pitch Control Gear Shaft

Pitch Control Gear Shaft must maintain minimal backlash to ensure precise blade pitch control. Gear flanks are profile-ground to achieve backlash under 0.01 mm and pitch deviation below 4 µm. This ensures accurate angular response during rapid load changes without delay. 

Material Grade & Specification

AISI 4140 Alloy Steel, ASTM A182 F22 (or equivalent), for high strength and fatigue resistance

Dimensional Tolerances

±0.005 inches (±0.13 mm) for critical dimensions, ±0.002 inches (±0.05 mm) for keyways, bores, and splines

Surface Finish Requirement

Ra ≤ 1.6 µm (63 µin) for bearing and gear contact surfaces, Ra ≤ 3.2 µm (125 µin) for non-critical areas

Heat Treatment Specification

Quenching and Tempering (QT) to 28-32 HRC for increased strength and wear resistance, or as per custom requirements

Shaft Alignment Tolerances

≤ 0.002 inches (0.05 mm) for shaft concentricity and alignment tolerance in relation to gears or hubs

Product Description

Pitch Control Gear Shaft endures high-cycle bidirectional torque. Manufactured from case-hardened steels like 18CrNiMo7-6, it maintains core strength above 1000 MPa and surface hardness above 58 HRC. Geometry is optimized to withstand over 10 million torsional reversals. 

Load Bearing Capacity

10,000 N (or per custom specification) to support operational forces in wind turbine gear systems

Hardness Requirement

28-32 HRC (after heat treatment) for optimal wear resistance and high load-bearing capacity

Non-Destructive Testing (NDT) Requirement

Ultrasonic Testing (UT), Magnetic Particle Testing (MT), Dye Penetrant Testing (DPT) as per ISO 9712 or equivalent

Coating/Plating Requirement

Zinc Plating or Epoxy Coating for corrosion resistance, or customer-specific coatings (e.g., ceramic coating for extreme conditions)

Certification Standard

ISO 9001:2015, IEC 61400 (for wind turbines), CE Marking, ATEX (if applicable for hazardous environments)

Technical Advantages

Pitch Control Gear Shaft operates in salt-laden, moisture-rich environments. To prevent degradation, it is treated with nitriding or zinc-nickel coatings. These coatings protect internal surfaces without affecting gear tolerances or fatigue life. 

Pitch Control Gear Shaft must fit custom pitch actuator systems. Shafts are produced with DIN 5480 or custom splines, with tolerances to IT6 and AGMA 12. This ensures accurate mating with no additional alignment or correction. 

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Industry Applications

Onshore Wind Turbines

Transmits controlled torque from pitch actuators to blade root interface, maintaining optimal aerodynamic angle during variable wind conditions. 

Offshore Wind Turbines

Operates in corrosive marine environments, enabling continuous blade angle adjustments under extreme weather and fluctuating wave-induced load cycles. 

Yaw and Pitch Drive Test Benches

Used in durability testing rigs to simulate cyclic pitch control forces, validating gearbox, actuator, and shaft fatigue performance. 

Multi-Megawatt Turbine Platforms (>5MW)

Handles high-torque blade rotation demands with minimal backlash, ensuring pitch accuracy under high-inertia and emergency feathering conditions. 

Hydraulic Pitch Control Systems

Integrates with hydraulic actuators requiring mechanical linkages for pitch transfer, with tolerance for pressure-induced transient torque surges. 

Electric Pitch Drive Assemblies

Links servo motors to blade hubs, requiring high torsional stiffness and accurate spline engagement under rapid directional reversals. 

Defect Detection and Reliability

Pitch Control Gear Shaft undergoes Level 2 ultrasonic testing and magnetic particle inspection to detect internal or surface defects. Balancing to G1.0 grade minimizes dynamic stress, reducing unplanned downtime from shaft fatigue. 

Pitch Control Gear Shaft is produced with heat lot traceability and distortion control. Predictive simulations reduce post-heat machining by 40%, enabling consistent geometry across volumes and supporting standardized fleet replacement.

Pitch Control Gear Shaft

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure consistent spline engagement in Pitch Control Gear Shafts across different actuator designs?

Frigate uses modular spline tooling to match DIN, ANSI, and custom pitch profiles during final machining. Spline geometry is CNC-milled and verified with optical profile projectors. Runout and keyface concentricity are measured using CMM to ensure alignment with actuator coupling. This ensures zero-fit issues during assembly and long-term wear control. 

What corrosion protection methods does Frigate apply for offshore Pitch Control Gear Shafts?

Frigate applies gas nitriding or zinc-nickel coatings depending on environmental exposure and shaft duty cycle. These treatments are selected to preserve core strength and avoid hydrogen embrittlement. All coatings are tested for layer thickness and adhesion as per ISO 9227. This improves shaft longevity without compromising tolerance fits. 

How does Frigate handle material traceability for Pitch Control Gear Shafts in fleet applications?

Each Pitch Control Gear Shaft is linked to a unique heat number and forging batch. Material certificates, UT/MPI reports, and dimensional logs are stored digitally. Frigate provides full traceability from raw material to final dispatch. This helps operators manage fleet maintenance and part replacement history efficiently. 

 

Can Frigate manufacture Pitch Control Gear Shafts with asymmetric loading conditions in non-standard turbine platforms?

Yes, Frigate designs custom gear shafts using FEA to model asymmetric torque paths. Shaft cross-sections and fillet transitions are adjusted to minimize localized stress. Special hardening zones are applied to critical wear points. This approach allows performance tuning for unique turbine architectures. 

How does Frigate reduce lead time for high-volume Pitch Control Gear Shaft production?

Frigate uses in-house forging, CNC machining, and hardening to control the full production cycle. Pre-qualified blanks and modular tooling allow quick setup for repeat batches. Gear inspection and balancing are done parallel to machining stages. This reduces production downtime and ensures consistent delivery schedules. 

 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Pitch Control Gear Shaft

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