Custom-Made Gearbox
Process
The process of non-standard customized reducer
(1) Demand Analysis
First of all, fully communicate with customers to understand their performance requirements for the reducer, such as torque, speed, accuracy, noise level, etc., as well as working environmental conditions, such as temperature, humidity, corrosion, etc. At the same time, also consider the installation method and space limitations.
(2) Scheme Design
Based on the results of the requirements analysis, the design team began to develop a preliminary design scheme. This includes determining the structural form of the reducer, gear parameters, shaft size, etc.
(3) Technical Assessment
Carry out technical evaluation of the design scheme, including strength calculation, life prediction, efficiency analysis, etc., to ensure the feasibility and reliability of the scheme.
(4) Sample Production
After the proposal has been evaluated, the production of samples begins. This usually requires high-precision processing equipment and processes.
(5) Test and Verification
Perform comprehensive performance tests on the sample, including no-load test, load test, temperature rise test, etc., to verify that it meets the design requirements and customer requirements.
(6) Optimization and Improvement
If the test results are not satisfactory, the design needs to be optimized and improved, and the sample is re-made and tested until the requirements are met.
(7) Mass Production
After the sample has passed the test and confirmed the design is mature, mass production is carried out.
CAUTIONS FOR NON-STANDARD CUSTOMIZED REDUCER
(1) Precision Requirements
For high-precision applications, it is important to ensure that machining accuracy and assembly accuracy are strictly controlled during the design and manufacturing process.
(2) Material Selection
According to the working environment and load requirements, choose the right material to ensure the strength and durability of the reducer.
(3) Lubrication and Cooling
Consider appropriate lubrication and cooling measures to reduce wear and improve the efficiency and life of the reducer.
(4) Cost Control
Under the premise of meeting the performance requirements, the cost is reasonably controlled to avoid unnecessary waste.
ACTUAL CASES STUDY
Take a food processing company as an example, they need a planetary reducer to drive the conveyor belt, which is waterproof and rust-proof, can operate stably in a humid environment for a long time, and the size should be small to accommodate limited installation space.
In the demand analysis phase, key information such as the load of the conveyor belt, the operating speed, and the humidity and temperature of the working environment are learned.
In the design of the scheme, special sealing structure and anti-rust treatment materials are used, and the internal structure of the reducer is optimized to reduce the volume.
In the technical evaluation, the strength calculation and life prediction confirm that the scheme can meet the requirements of long-term operation.
After the sample was made, strict waterproof tests and load tests were carried out. During the test, it was found that due to the imperfect sealing structure, a small amount of water penetrated.
After optimization and improvement, the sealing structure was redesigned, and the problem was successfully solved after re-testing.
Finally, the mass production of non-standard customized planetary reducer to meet the needs of customers, stable operation in food processing enterprises, improve production efficiency.
