What I am about to share with you will blow your mind! I built my small and profitable (up until last year) business from scratch, working diligently to become an authorized distributor for some of the top manufacturers of Roller Chain & Power Transmission parts in the world. Names such as Hitachi, U.S.Tsubaki & power Rite. What you may not know, is in order for me to get the great pricing that I pass on to you, I must sell a certain amount of product from the manufacturers each year.
Unfortunately, I did not meet that quota in 2009 with some of the manufacturers. By providing competitive pricing and great customer service I was able to maintain my small customer base in my local area. The problem was that when my small group of customers felt the crunch of the recession, so did I.
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What does this mean for you? It means BIG savings at a time you could really use it. You know how important it is to replace parts and service your Industrial Machinery on a regular basis. Not having a ten foot box of chain or even a master link on hand could cost you hours of downtime.
I am going to sell to you at unheard of prices! Industrial Roller Chain, Sprockets & other Power Transmission Components at wholesale prices. I can supply you with quality, name brands shipped to you directly from the manufacturers.
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I do not know how long I will be able to maintain my business selling to you at wholesale pricing on your roller chain parts & sprockets. Don't wait, give us a call at 407-276-1170. Send us a fax at 407-287-4824, or email us at firstname.lastname@example.org . Give us the opportunity to earn your business today.
A worm gear reducer, also known as a worm drive, is the smallest mechanical speed reducer. It enables an incredibly high application of torque in a small space. A linear gear together with grooves cut into it like a screw drives a circular gear. The term 'worm drive' relates to the arrangement - the linear gear is referred to as the worm, while the gear is known as the worm gear.
Once the worm spins at a high speed, the worm gear moves little by little, but with a significant amount of force, allowing it to move high-inertia objects. These right angle gear reducers often heat the surrounding air up to 100 degrees hotter than the ambient temperature, which may seem high for a gear reducer, but is considered low when it comes to industrial applications.
It is essential to note that worm gear drives are not frequently used for high-horsepower applications. Worm gear drives usually are low priced solutions to produce high levels of force, but in regards to high-speed, high-horsepower applications, the more expensive helical gear reducers are utilized.
Additional Advantages of Worm Gear Reducers
As said, the chief purpose of worm gear reducers is to utilize high levels of torque in a small space. Essentially, they used in industrial load lifting applications, to enhance the strength of small electric motors for toys, as differential gears for automobiles, and as exact tuning mechanisms for musical instruments. These applications are chosen due to the following additional benefits:
- Non-Reversibility - Worm gears may be turned by the worm shaft, however high levels of friction prevent the circular gear from turning the shaft back the other way. In industrial lifting applications, this often serves as a secondary braking mechanism, helping to keep heavy loads from free fall and regulate lowering speeds. However, because of the unstable nature of frictional forces, it is a good idea to use load brakes rather than relying upon the self-locking, non-reversible characteristics of these right angle gear reducers.
- Low Cost - Small electric plastic toys are usually produced cheaply in bulk, but the motors will have to be powerful enough for a 21st century youth market. The cheap, high-torque qualities of worm gear drives make them suited to toy electric cars and other such items.
- Highly Precise - Find the pegs on guitars that could be turned to adjust the sound of several strings; these generally use worm gear drives. For precision applications for instance tuning, worm gear reducers allow for musicians to make minute adjustments to their musical instruments with rather broad movements.
The cam belt is an important part of car's engine as it provides a connection between the crankshaft and camshaft, that is why it is very important to look out for any symptoms that suggest that a replacement is needed. The timing belt monitors and regulates the opening and closing of valves in the vehicles engine. It also guarantees the hassle-free operation of the motor. Subsequently, having the timing belt changed when required is important for the well being of the engine of your vehilce.
All four stroke vehicle engines have been designed in a way that the valves in the engine open and close with the revolving of the crankshaft. This nicely illustrates that it is not a good idea to put off the replacement of the crank shaft.
Usually, timing belts are fairly tough and are assembled to last for a very long time. Even so, you still may need to replace it if it gets run-down. Lots of folks need to recognise the timing belt's warning signs that identify that it is due to be replaced. There are lots of indicators that will tell you that you should now let a mechanic take a look. They are not difficult to understand once you know what you are looking for.
Troublesome Ignition - Many automobiles with increased mileage may suffer ignition troubles when their timing belt is weakened. In most of these cases, the vehicle may not start up and you might have to hold the key for a while just to get it going.
Dripping and Overheating in the Engine Bay - Heat and high temperatures can ruin your timing belt because they are made from rubber. When they are broken, the motor will not have the ability to work in sync and constant overheating can happen, and that is typically succeeded by leakage.
Shaky Engine - You might sense that your vehicle is shaking if its timing belt may have become faulty. This is among the most effective symptoms that suggest that is has worn out. The timing with valves and pistons is set effectively by a working timing belt. Therefore, if it is damaged, this timing can fail resulting in the shuddering of car when it is running.
Too much Firing - Due to a defective timing belt, your vehicle may experience excessive firing, and that might cause major problems later on. This can be easily repaired by a timing belt replacement.
Whenever you see any of these timing belt warning signs in your vehicle, be sure that the day has arrived to change it. You can get this done by taking your car to any respectable auto repair shop.
It might be advantageous if you can analyze the replacement charges for the timing belt as it can spare you some money. Generally your timing belt replacement cost will likely be fairly low, but if your car is in need of repair or replacement of additional parts, then your overall repair cost may grow to a great extent.
All vehicles including cars, trucks, buses, and various other machines have manual or automatic gear boxes to transmit the power generated by the engine to the wheels. These gearboxes or transmissions require lubrication in the form of transmission oil or gear oil to lubricate the gears as well as to cool them so as to seamlessly transmit power to the required wheels.
Take SUVs for example; these 4-wheel drive options need a little help to negotiate those rough and steep terrains. This is done with a transfer case, which in turn needs transmission oil so the vehicle runs smoothly. Automatic transmission vehicles use ATF (automatic transmission fluid), and manual transmissions use gear oil for the gearboxes.
Remember; newer vehicles that utilize automatic options will have more gears involved. This means you have to be plentiful when it comes to the transmission oil. This is very important if you want any sort of longevity from your machines. If you're looking for the best oils then it has to be one that offers a special formula of chemical detergents, anti-foaming additives, rust preventatives, dispersants, and even anti-wear or anti-oxidation properties. Your ATF will be matched with specific criteria, but if you can't figure it out on your own then check the manual. Some of the manufacturers will even mention preferred oil brands. These are by far the best options for your transmission.
When talking about manual transmissions they will still require certain gear oils so the gears continually shift with ease. If you didn't know this already, manual gear boxes are usually given an oil bath. In fact, the lower portion of the gears is immersed in gear oil permanently. This also helps spread the oil to other gears thanks to the rotation. Take the time to view the oils available with American Petroleum Institute (API), starting with GL.
Thus API GL 1 usually specifies gear oil for light use in simple gearboxes while GL 2 and GL 3 usually specify oil for moderate uses. GL 4 is one of the most commonly used oils in most light, medium, and heavy vehicles, especially in Europe. Finally, API GL5 and GL 6 are used in extreme conditions and these oils have varying levels of anti scuffing agents to handle heavy use. Again, many manufacturers do list their preferred brands in their owner manuals although owners can still choose a matching oil of their choice. However, owners should replace these oils within the mentioned time-frame to avoid jamming or slipping of gears.
It's also possible that some synthetic transmission oils are required if you need to improve performance levels. The difference between these and others is that they offer better lubrication abilities, as opposed to mineral oils. Now, they will cost more than your regular transmission oil, but its well worth it. You can do your own research on this, but the biggest oil available that is approved by several manufacturers is Shell.
Just about everyone has heard of them before, so it's helpful to know their oil selection is for both manual and automatic transmissions. It can work for a variety of parts like; axles, transfer boxes, power steering units, as well as other components under Spirax and Donax. When it's time to figure out what transmission oil to use it can find the exact specifications. This also works for gear oil, and thanks to big name promotions you will find that General Motors approves Donax TX oil. Their version is the GM Dexron III.
If you can find the ideal transmission oil or gear oil for your needs, it will ensure the transfer of power from engine to wheel and owners. Your goal is to find the best possible oil for your vehicle's transmission, or even your company's machines. Once you're able to utilize oils with longer draining times, they will be extremely beneficial in all areas; including those harsh conditions. In the end it helps keep drivers safer on the roads, and operators being able to handle their machines better, and for longer periods of time.
Thinking of putting off the oil change for yet another time? If you've got a lot on your plate at the moment, having to drop by a car repair shop is something that you'd prefer to do when it's absolutely necessary.
Oil change after every 3,000 miles?
If you're still driving a car that's more than ten years old, then you should have an oil change after every 3,000 miles as advised by most service stations. Oil serves to lubricate the moving parts of car engines, preventing the metal surfaces from grinding against each other and wearing out because of friction. It also prevents corrosion, and it helps cool the engine and keeps it clean by soaking up the harmful by-products of combustion. Oil, once dirty from use, won't get the job done in the way that it should.
Determining when you should have an oil change depends on the type of car you drive. Different makes of cars now have various kinds of engines that will differ in the way they use oil. For instance, a 2010 BMW 3Series can go up to 15,000 miles before you need to change oil under ideal conditions. A 2008 Porsche Boxster can go for 12,000 miles, a 2007 Chevrolet Malibu for 7,500 miles, and a 2005 Toyota Tacoma for 5,000 miles before you may need to change the oil. Read the manufacturer's recommendations in your car owner's manual to see how often you should get an oil change for your particular make of car.
Should you continue to schedule an annual car tune-up?
A tune up is a preventative maintenance procedure for your engine to detect potential problems before they become real issues that require expensive repairs. In ten-year or older cars, a tune-up is needed every year or after every 30,000-45,000 miles, whichever comes first. During a tune up, a mechanic typically tests and examines details under the hood such as spark plugs, the fuel filter, the fuel pump injector system, the PCV (Positive Crankcase Ventilation) valve, the vehicle's points and condenser, the carburetor, the ignition coils, the air filter, the battery, and so forth. The tune up will also involve checking the tire pressure, assessing the functionality of wiper blades and lights, and other maintenance tasks.
In newer makes of cars, particularly those that comes with computer-controls, tune ups are usually scheduled based on the vehicle's mileage. In the car owner's manual, the manufacturer indicates the mileage-based intervals for the replacement of car parts and other recommended maintenance services. Of course, even if it's not yet the scheduled date, you may need to have a tune up if you find your car performing unusually poorly. For instance, if it doesn't start as easily as before, or if it jumps or runs roughly when started, or even if you are getting lower mileage than you have been used to, you may consider scheduling a tune up.
Do you need to have your timing belt replaced?
The timing belt is the ribbed belt that keeps the cylinder head and valves in sync with the crankcase and pistons in the engine of your car. If you drive a '90s or older car, chances are good that you have a timing belt under the hood. Manufacturers have different schedules and measures for you, should you wonder whether you need a timing belt replacement. The general rule, though, is that you should replace the belt every five years or after every 60,000 miles, whichever comes first.
Newer cars tend not to feature timing belts. Instead, they use metal timing chains that are theoretically maintenance-free and claimed to last as long as the engine. Of course, whether you have a timing belt or a timing chain, you really have no choice but to have it replaced if it snaps.
In industrial machinery, the use of belts is the simplest and most cost-effective method of achieving power transmission. The demands on a belt-driven transmission system are large, which has lead to several variations of the concept and idea of transmitting power through belts. There was a time when certain systems could not use belts--only gears and chains--improvements in belt-engineering have now allowed the use of bets in those systems as well.
Another advantage of using belt-driven transmissions is the fact that belt drives do not require axially aligned shafts to operate. Belt driven systems have always been highly efficient (90-98%), have a high tolerance for misalignment and are of relatively lower cost if the shafts are far apart.
Over the decades, various types of belt transmissions have been devised to suit various applications and to meet certain challenges.
Flatbelts saw widespread use in the 19th and early 20th centuries in line shafting to transmit power in factories. Countless other applications such as farming, mining, electrical generators, etc have made use of them. Flat belts are still in application today but not as much. This is primarily due to some slippage issues experienced in the course of their use. For most of the part, they have been replaced by Vbelts for industrial use.
Vbelts (also known as vee belts or style V-belts) were devised to address the issue of flat belts slipping on the pulley face. It is now the basic belt design used for power transmission, with most other modern designs being derived from it. The name comes from the trapezoidal shape of the general cross-section of the vee belt. The "V" shape of the belt catches on to a mating groove on the pulley, thus ensuring that slipping isn't possible. Also, the vee belt has a tendency to wedge into the groove as the load increases, thus improving torque transmission. Thus, the V-belt requires lesser width and tension than flatbelts.
PIX Transmissions Ltd is one of India's leading manufacturers of mechanical belts, including Vbelts, along with related mechanical transmission products. The company has ultra-modern production units in India, with subsidiary offices in the UK, UAE and Germany. PIC Transmission manufacturers an extensive range of top quality Industrial Belts, along with belts meant for automotive belts, agricultural belts and special applications.
These are also known as synchronousbelts and/ or toothed belts. They are positive transfer belts and can keep track of relative movement. There toothy notches on the belt running across it's width, which groove into a matching toothed pulley. When used at recommended tension levels, timingbelts have no slippage, can run at a constant speed and are often used to transfer direct motion for indexing or timing purposes. This makes them an excellent choice for camshafts of automobiles, miniature timing systems in industrial devices and stepper motors.
When it comes to quality, PIX Transmission maintains the highest of standards, ensuring the company stands true to its vision of being a "dominant, global player in the Mechanical Power Transmission Industry".
Apart from industrial belts of various types, PIX Transmissions manufactures an extensive range of top quality Industrial Belts, Automotive Belts, Agricultural Belts, Special Construction Belts, Horticultural Belts, Special Application Belts and Taper Lock Pulleys and Bushes to suit a wide range of applications.
The company has always led the way when it comes to innovation and R&D. PIX is positioned as a highly prolific manufacturer owing to the amalgamation of investments, extensive experience, and state-of-the-art facilities.
For transferring power between the two parallel axels V pulley is solely used. The notable variation between other types of pulleys and this pulley is the geometry of the grooves, which are situated around the circumference of the pulley. These groves achieve traction on a v belt.
The V belt pulley provides a mechanical connection with a section that looks like an isolated trapezoid. The complementary pulley and v belt creates the most competent belt drive. These belts were built in the earlier days for torque transmission and belt reliability from the rotation to cracnkshaft assembly. These belts remain as a common type of winding belt today.
The transmission of the V pulley is a distinguished upgrade from the flat or round belt transmission. These belts provide a speed, load capacity and excellent traction, while enjoying a extended life with easy substitution. The transmission efficiency is increased by heavy loads since they wedge the belt further into the pulley groove, thus improving friction. However, v belt drives function among 1500 to 6000 ft/min, with 4500 ft /min, which is the ideal capability for standard belts. Some narrow belts can function at speeds of 10,000 ft/min. These pulleys need to be vigorously steady in nature. These pulleys may be located with side-by-side pattern or a singular pulley may possess multiple grooves around the circumference in order to accommodate a multi- belt drive. This type of drive distributes torque across numerous belts and thus providing a mechanical idleness.
There are some advantages of these pulleys, which are as follows -
ïƒ˜ These pulleys need minimal maintenance with no lubrication.
ïƒ˜ These pulleys are extremely reliable in nature.
ïƒ˜ There can be slow wear that can be identified easily.
ïƒ˜ These pulleys provide great speed range and wide horsepower.
ïƒ˜ These pulleys operate in a quite manner.
ïƒ˜ There is very little vibrating dampening for these pulley
ïƒ˜ These pulleys prevent overload
There are various kinds of pulleys that are used for v - belt transmission, but each has dissimilar implantation. The flat belt pulleys have the similar function of that of the ribbed v-belt pulley, as the pulley rotates in the opposite direction of the driven pulley when the backside of the v-belt is being used.
Standard Pulley - These pulleys have customary dimensions with one or multiple grooves, which mate with small engine and hexagonal style v belts.
Companion Pulley has integral spokes, which move radically on the pulley. These produce high strength to weight ratio that is advantageous to fractional horsepower pulley.
Step Pulley has two or more non-adjustable grooves, which has different pitches located around the same shaft. These pulleys change the speed ration of transmission.
There are some of parameters for selecting these pulleys.
* Belt Profile - The sizes of the style is integrated.
* Outside diameter- The distance across the pulley when measured between groove edges
* Grooves- The grooves that are located on the pulley include the angle, number and width of the flanges.
* Contact Arc- The degree of which the belt wraps around the pulley.
In order to allow the telescope movement of inner pipe, expansion joint is installed within a firmly mounted outer sleeve of pipe in order to accommodate the contraction ad expansion in the piping system. These are available in nominal piping sizes with maximum travel lengths. These joints are also used as repair coupling.
* One should not weld the mating flanges with the expansion joints. There can be possibility of heat damage or spark.
* There should be proper support for the pipelines so that expansion joint should not carry pipe load.
* In the upstream and downstream, the anchors are placed at both ends of thermally contracting and expanding pipe length. These joints will not function and fall down unless the full thrust anchors are provided in place.
* One needs to check with the manufacturer that the pipe fitting can take the joints thrust, when the mechanical pipe fitting is installed in the joint line. If not, then anchoring for pipe is required on either side and two joints are installed rather than one. The arch area and thrust on the anchor in the pipeline area is multiplied by water pressure. The thrust of the pipe wall is only the area of the arch that is multiplied by water pressure.
* The control units should be used if it is not possible to anchor the pipeline in the above manner. There will no anchor on or both sides of the joint once the control unit is installed. Then the joint will open up the control rod lock out position and will remain in that position. The joint will not act to take up axial motion, rather it will provide make up for angular, misalignment and transverse motions.
* The cable assemblies should be substituted for rigid control rods, where the traverse forces are to be kept to a least. With the value of spherical seats on control seats, the force required to move the piping laterally very high, when control rods are used.
* Before installation of the joints, all the pipes are lined up in an accurate manner. The units will adjust them with the specified limits to misaligned flanges. Thus, it becomes difficult to force the joints to a position before they are rigidly bolted to the flanges.
These joints should not be piled one over another. After a period, the weight will be reduced to face-to-face length. Thus storing in shelves can prevent the reduction of weight. It is important to store the joints where they cannot sustain any sort of damage. These joints should be inspected for soundness and these joints require no maintenance. The detection of the leakage allows ample time for the replacement of flange tightening if it is required. If there is a deterioration of cover, from cleaning, then a coating of hypathelon paint is used to reduce the deterioration. It is good idea to check whether are joints are overly compressed, moving well, elongated or not after installation. Joints should be checked that whether they are operating outside of the rated movements.
The curved tooth gear coupling is the result of many years experience in the field of mechanical power transmission. The gear couplings are distinguished by the compensation of axial, angular and parallel misalignment of the connected shaft and their mechanical flexibility. These couplings are used extensively paper machinery, cranes, metal rolling mills , plastic and rubber industry compressors , fan blowers and many other industries. These gear couplings is manufactured with crowned external teeth, consists of two hubs and two outer sleeves with internal spur teeth.
The outer sleeves and gear hubs are manufactured from carbon steel and hardened to the required degree. They are machined to fine tolerances for proper meshing of the gears as well as for inter- changeability.
Gear Coupling Feature
The gear coupling has hubs with multi crowned teeth at chamfering on teeth and flank teeth.
For making the tooth thickness greatest at the center of the tooth, the flanks of the teeth are crowned. This puts more teeth at the given teeth in contact for a given angle and assures larger contact area per tooth for higher torque requirements. The tooth loading takes place at the center where the tooth thickness is greatest. The crowned flank also provides optimum load distribution, accommodates all types of misalignment with minimum backlash and eliminate end-to-end tooth loading.
The faces of the teeth adjacent to the tips are chamfered to eliminate the interface with the sleeve tooth fillets. This allows the sleeves teeth to be in contact with the true involutes flank of the gear teeth thus assuring the freedom of misalignment. The heart of the gear couplings are the hub and a great tooth profile and superior design enables these coupling to operate satisfactorily under all operating conditions with long life and reliability.
The tips of the teeth should be crowned. The crowned tip contacts the root of the internal gear teeth in the external sleeve, thus accurately piloting the sleeve with true concentric socket and ball action. This allows centering the sleeve physically to assure good physical dynamic balance and minimum diametric sleeve clearance under various misalignments and loading conditions.
The teeth of the gear hubs are generated by involute system and are crowned in nature. The amount of backlash values and crowning are chosen to ensure the best result greater flexibility, smooth operations and torque transmissions.
The internal teeth of the sleeves are produced in gear shaper ensuring a correct profile. These teeth are generated by involute system. The coupling sleeves are joined together with high tensile strength and are fitted with bolts by using the gasket in between them.
In order to stop the leakage of lubricant and entry of the dust particles O- rings are provided at the end of the coupling hubs. The O -rings can also withstand high degree of temperature of 120 Â° C.
Seal carriers are provided in order facilitate replacement and inspection of O- rings without the disturbing the alignment.
When we talk about the most integral parts that go into a power tool, bearings are one of them. Rotational and linear movement of your power tool depends on the condition and quality of the bearings. Bearings help all the moving parts to function properly and without bearings your power tool is as good as a dead duck.
WHY DO BEARINGS GO BAD?
The most common reason is the usual wear and tear that happens with time and use. There is always a chance of human error and accidental adversities but generally usual wear is the culprit.
HOW DO YOU KNOW WHEN BEARINGS HAVE GONE BAD?
There is an easy way to detect the signs of a damaged bearing. For starters, your power tool may generate a lot of heat and it may become completely unresponsive producing a mere whimper every time you try to start it. Another symptom is that characteristic sound of a damaged bearing that can be classified as a "screech". If you are able to hear that "screech" you should know right away that there is something wrong with the bearing.
That screeching sound is produced because of the lack of lubrication in the bearings. Bearings need some grease to reduce friction and work smoothly, so when that grease isn't there, dried up bearings produce that uncomfortable sound. Now most bearing sets are self contained so you can't grease them up. The only thing that works is replacing them with the new ones. If you try to re-lubricate the bearings, you will be putting your expensive power tool at risk.
ADDITIONAL SIGNS OF DAMAGED BEARINGS
Besides the aforementioned signs, when the bearings are damaged, your power tool has to work extremely hard to give its usual performance and that puts a lot of pressure on electric motor resulting in excessive amounts of heat. In some extreme but rare circumstances, it may even cause the electric motor to melt down completely. That's why when bearings go bad they usually take a few surrounding internal parts with them and that's why it's necessary to replace the bearings at your earliest to avoid further damage.
Sometimes bad bearings also cause your power tool to freeze and become unresponsive. That happens when the bearings fail completely to move. That means the electrical energy cannot be converted into mechanical energy which is the whole purpose of a power tool.
WHERE TO GET HIGH QUALITY REPLACEMENT BEARINGS?
It depends on the power tool and the brand and model you're using. If it belongs to well known brands like Panasonic or Milwaukee then you can get bearings easily as Milwaukee replacement parts and Panasonic replacement parts can be found easily on online shopping stores and portals. However, if your power tool is from the manufacturer that doesn't offer replacement parts then you might have to look for aftermarket parts.
Thin dense chromium and XADC coatings can provide absolute adhesion and corrosion protection equal to 440 series stainless steel. This allows the use of metals that are less expensive, easier to machine, more resistant to fatigue, and longer-lived. These coatings can successfully be applied to ball, roller and linear bearings, brining them to Abex 9 classification. Dimensional stability is maintained with engineered deposits from .000050/.0002".
The nodular surface of the special coatings allows them to work against themselves, increasing wear and lubricity characteristics in roller and needle bearing applications and allowing them to be completely coated. The test indicates no negative effects on expected fatigue life. Bearing operating temperature may be reduced when the coatings are applied; the coatings work well on 52100, M-50 NIL, 440C, pH Stainless, 8620 and many other base materials. Surface hardness is increased to 78 Rc with the coatings and to 98 Rc with a special diamond coating.
Introduced in 1996, the coatings offer the industrial design and engineering community the opportunity to expand their options to enhance the performance of their equipment and tooling. With the addition of nano-diamond spheres to the coating, thin dense chromium technology is unique, but still allows for cost effectiveness. The special coatings enhance the durability of components used in a wide range of applications from plastic injection mold tooling to coating aerospace applications that require long life expectancy, extreme wear protection, low frictional characteristics and corrosion protection.
The XADC uses thin dense chromium coating solution as its base, but is infused with a synthetic diamond particulate, which is responsible for the extreme hardness quotient. Both coatings, at a microscopic level, provide a nodular (as opposed to flat) finish. Unlike traditional hard chrome, a thinner deposit of the coating does not inhibit the coatings' efficiency, and may prevent excessive edge build up.
The coatings are applied using the general principles of electroplating, but employing proprietary chemistry and proprietary fixturing methods/materials. This process is known as "cool": parts will see temperatures no higher than 160F. Lower temperatures means no risk of heat-induced damage (annealing, distortion, warping). Due to the prep procedures, the coatings bond mechanically and absolutely to the surface of the substrate.
Ball Bearings and cylindrical roller bearings are used in the shafts of gearboxes with power ratings of up to 27,000 kw. Tandem bearings are used for supporting the extremely high axial loads on the worm shafts. Bearings are very important, picking the coating that is going to extend their life and save you money is very important.
Power transmission systems form the backbone of nearly every industrial process. Assembly lines are driven by mechanical propulsion systems and they are the most common method for mass production of products, from automobiles to consumer goods. Liquids are moved in chemical processes by pumps that make gasoline, diesel, heating oil, and plastics and specialty chemicals. In the home, compressors can be found in the back of every refrigerator to run the refrigeration cycle that keeps our food fresh and in the air conditioners that cool our homes. Commercial appliances, farm equipment, and business equipment all use power transmission systems to run businesses and make our lives easier.
Power transmission systems break down into sub-systems, motors, drive systems, and bearings. In this article, we will examine each sub-system and analyze the choices and applications available for industry.
Motors That Drive Industry
Motors are ubiquitous in industry. Converting energy, be it electrical, steam, or compressed air, into work is the paradigm that runs manufacturing. They are the essential part of power transmission systems and are thus seen in every facet of life even outside of manufacturing.
Motors can be used to move air by driving fans. Fan blades can either be attached directly to the motor's shaft, or a drive system, typically a belt, can link the power generated to the fan blades. In order to compress gases, motors run compressors. Pressurized gases are the working fluid for refrigeration systems. Every piece of food that is kept cold and every air conditioner utilize a motor driven compressor. Pressurizing air is another widely used application for powering tools.
Motor driven pumps are the essential component when moving liquids. Centrifugal pumps use a motor to spin an impeller, which accelerates the movement of liquid. It then flows through a volute or diffuser to increase the liquid pressure. Positive displacement pumps pressurize liquids by trapping them in a chamber and then using a motor to apply a force. Imagine a piston in a cylinder, similar to a car engine.
Motors are found practically everywhere, from cars and refrigerators to industry and business.
Powering Mechanical Drive Systems
In a power transmission system, where the motors generate power, drive systems transfer that power to perform work. In a technical sense, drive systems convert a motor's cyclical power into linear motion. This is how a motor can spin in a circle, but provides the power to run a conveyor belt in a straight line.
The most simple drive system is a direct coupling. Take a spinning motor shaft and weld fan blades onto the end to create a fan to move air. Centrifugal pumps' impeller fans are also directly coupled, as well as sealed to contain liquid, to the drive shaft of the motor. While simple in design, direct coupling is limited to one device operated per motor, and the need to have many motors.
To transfer linear motion to a device that is not directly coupled to a motor, belt and pulley systems are often used. Belts have been in use since the 18th century in water-powered textile mills. The concept is that the motor turns a pulley with a belt attached that runs to a series of pulleys and bushings all attached to other equipment. In this way, one motor can drive multiple machines, as its power is transferred via the belt. Belt and pulley systems can also be synchronized, like the system in a car engine that uses power from the engine to run the alternator, air conditioner, and power steering.
Chain systems are another form of power transmission of linear motion. Often seen in conveyor belts, chain systems transfer a motor's power directly into work, such as moving an assembly line. Mass production facilities utilize this direct application of power as their means of production.
The Right Bearings To Maintain Operation
With all of these heavy metal components in motion, lubrication is needed to ensure smooth movement and power transmission as well as to reduce the load that friction will apply to materials. Bearings are used as the essential method for ensuring that metal does not grind against metal, destroying the machinery. They consist of a set of concentric rings with ball bearings and lubricating fluid set between them. Bearings will support a load in any direction depending on their configuration so they can be used in rotary and linear motion applications.
Linear motion bearings are commonly seen as rollers that will guide material along a specific path. Radial bearings support loads that run perpendicular to the axis of rotation and thrust bearings support loads that run parallel. A full set will support a motor shaft and prevent excessive vibration, friction, and material wear. Advanced bearings will include ports that allow a steady flow of fresh lubricant to enter the bearings and provide a cooling effect for high temperature applications. Ultimately, bearings can be custom made to even support non-uniform shapes.
When all of the components of a power transmission system are designed with integration in mind, work is accomplished more effectively with less down time. Motors that are properly supported by bearings and a drive system that transfers energy into work are the cornerstones of manufacturing processes.