Product Description
ZLYJ Series Single Screw Gearbox for Plastic/rubber Extruder
Product Description
Brief Introduction .
1. CHINAMFG series reduction gearbox is a transmission part that possesses high precision
hard gear surface and thrust block designed for plastic screw extruder.
2.The design of product adapts all kinds of norm specified in ZBJ19009-88/it features
that gear and axis parts are made of high strength alloy steel.
3.The gear is processes by carburization, quenching and tooth grinding process.
4.The precision of gear is grade 6 specified in GB1009588.
5.The hardness of gear surface is HRC54~62. At front end of hollow input axis
there is large specification thrust bearing that will bear axial thrust force while
the screw is working.
6.The complete machine features compact, high in bearing capacity, stable in
transmission, low noise, high efficiency, etc.
| Standards, approvals, certificates | |
| OEM | YES |
| ODM | YES |
| Customized | YES |
| Certificate | Yes |
Applicable scope
Various plastic rubber industry
- The input rotation of prime mover shall be ≤1500rpm
- The peripheral speed of gear drive shall be≤20m/s
- The working ambient temperature shall be within -40°C~45°C. Per heat the lubricating oil to above 0°C when the ambient temperature is below 0°C.
- Rotation is available both forwards and backwards.
Company Profile
Factory
Office Block
Team
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| Application: | Machinery, Marine, Agricultural Machinery, Industry |
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| Function: | Change Drive Torque, Speed Reduction |
| Layout: | Coaxial |
| Customization: |
Available
| Customized Request |
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Shipping Cost:
Estimated freight per unit. |
about shipping cost and estimated delivery time. |
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| Payment Method: |
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Initial Payment Full Payment |
| Currency: | US$ |
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| Return&refunds: | You can apply for a refund up to 30 days after receipt of the products. |
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Technological Advancements in Agricultural Gearbox Design
Advancements in agricultural gearbox design have significantly improved the efficiency, durability, and performance of farming equipment. Here are some notable technological advancements:
- Materials and Manufacturing: The use of advanced materials, such as high-strength alloys and composite materials, has enhanced the durability and longevity of gearbox components. Precision manufacturing techniques, including computer-aided design (CAD) and computer numerical control (CNC) machining, ensure tight tolerances and reliable performance.
- Gear Tooth Design: Modern gear tooth profiles, such as optimized helical and spiral bevel gears, reduce noise, vibration, and wear. Advanced tooth design also improves power transmission efficiency and load distribution.
- Sealing and Lubrication: Improved sealing technologies, such as double-lip seals and labyrinth seals, help prevent contaminants from entering gearboxes while retaining lubricants. Advanced lubrication systems, including automatic lubrication and improved oil formulations, extend maintenance intervals and enhance efficiency.
- Electronic Controls: Agricultural gearboxes increasingly integrate with electronic control systems. Sensors and actuators provide real-time data on gearbox performance, allowing for condition monitoring, predictive maintenance, and adjustments to optimize machinery operation.
- Smart Gearboxes: Some agricultural gearboxes are equipped with smart features, such as load sensors, temperature monitors, and feedback systems. These features enhance precision, safety, and overall equipment performance.
- Hybrid Power Transmission: Integration of hybrid power transmission systems, combining internal combustion engines with electric motors, allows for more efficient power delivery and reduced fuel consumption. Gearboxes play a crucial role in managing power distribution in these systems.
- Reduced Environmental Impact: Advancements in gear design contribute to reducing environmental impact. Quieter and more efficient gearboxes minimize noise pollution and energy consumption while meeting emissions regulations.
- Customization and Modularity: Some modern agricultural gearboxes offer modular designs that allow farmers to customize gear ratios, output speeds, and other specifications to match specific tasks and conditions.
- Simulation and Testing: Computer simulations and advanced testing methods, such as finite element analysis (FEA) and computational fluid dynamics (CFD), help optimize gearbox design, reduce prototyping costs, and ensure reliability before production.
These advancements collectively contribute to the evolution of agricultural gearboxes, making farming machinery more efficient, environmentally friendly, and adaptable to the changing needs of modern agriculture.
Factors to Consider When Selecting the Right Gearbox for Farm Machinery
Choosing the appropriate gearbox for farm machinery is crucial to ensure optimal performance and efficiency. Here are the key factors to consider when selecting the right gearbox:
- Power and Torque Requirements: Assess the power and torque needed for the specific task the machinery will perform. Select a gearbox that can handle the required load without straining the components.
- Speed Variation: Determine if the machinery requires variable speed control for different tasks. Some gearboxes offer adjustable speed options to match varying conditions and applications.
- Task Compatibility: Ensure that the chosen gearbox is compatible with the implements and attachments the machinery will use. Different tasks may require different gear ratios and torque capabilities.
- Efficiency: Opt for gearboxes known for their efficiency in power transmission. Efficient gearboxes minimize energy losses and maximize the output of the machinery.
- Durability: Farming environments can be demanding, so select a gearbox that is built to withstand the conditions, such as exposure to dirt, moisture, and impacts.
- Size and Weight: Consider the available space and weight limits on the machinery. Choose a gearbox that fits within these constraints without compromising performance.
- Maintenance: Evaluate the maintenance requirements of the gearbox. Gearboxes that are easy to maintain and service can minimize downtime and keep the machinery running smoothly.
- Cost: Balance the initial cost of the gearbox with its long-term benefits and performance. Investing in a quality gearbox can lead to better overall cost-effectiveness over time.
- Compatibility: Ensure that the gearbox is compatible with the power source (such as the tractor’s power take-off) and other components of the machinery.
- Manufacturer Reputation: Choose gearboxes from reputable manufacturers with a history of producing reliable and high-quality agricultural machinery components.
By carefully considering these factors, farmers can select the right gearbox that meets the specific needs of their farm machinery, leading to enhanced efficiency, productivity, and longevity of equipment.
Power Transmission in Farming Equipment with Agricultural Gearboxes
Agricultural gearboxes play a vital role in facilitating power transmission within various types of farming equipment. These gearboxes are integral components that enable the transfer of rotational power from a tractor’s engine to different agricultural implements and machinery. Here’s how agricultural gearboxes contribute to power transmission:
- Speed Reduction: In many farming operations, the engine of a tractor or other power source operates at a higher speed than is suitable for the optimal functioning of agricultural implements. Agricultural gearboxes provide speed reduction by using a combination of gears with different numbers of teeth. This reduction in speed allows the machinery to operate at the required speed for efficient tasks like tilling, planting, or harvesting.
- Power Multiplication: Some agricultural tasks require a significant amount of torque to operate effectively. Gearboxes can multiply the input torque from the engine to generate higher torque at the output shaft. This is crucial for tasks such as plowing, where substantial force is needed to break up the soil.
- Directional Change: Agricultural gearboxes also allow for changes in the direction of power transmission. For instance, a tractor’s power take-off (PTO) shaft may need to transmit power at a right angle to the tractor’s engine. Gearboxes with bevel gears or other arrangements enable this change in direction, ensuring that power is properly directed to the implement.
- Power Distribution: In certain cases, power needs to be distributed to multiple components or implements. Agricultural gearboxes with multiple output shafts can distribute power to different tasks simultaneously, optimizing efficiency and productivity.
- Attachment Operation: Many agricultural implements, such as plows, seed drills, and rotary mowers, require consistent and controlled power to function effectively. Gearboxes provide the necessary power and control to these attachments, ensuring uniform operation and accurate results.
By facilitating speed reduction, power multiplication, directional changes, power distribution, and attachment operation, agricultural gearboxes contribute significantly to the overall efficiency and productivity of farming equipment. They allow farmers to adapt their machinery to various tasks, optimize power usage, and achieve better results in different agricultural operations.
editor by CX 2024-05-06
China factory Precision Plastic Machinery Parts Orange ABS Injection Mold Parts with Great quality
Product Description
Product Parameters
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Material |
PA, POM, ABS, PP, PET, PC, PE, HDPE, PA66+GF, PVC, TPFE…. |
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Color |
Depends on customer’s requirements. |
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Support Software: |
Pro-E , UGS , SolidWorks ,AutoCAD |
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Soft ware |
CAD/IGS /STEP/STP /PDF |
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A surface request |
glossy ,texture |
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Mold life |
50,000-3000,000 times |
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Smaple : |
Free sample ! |
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Delivery time : |
15 days production, if opening mould, plus 15-20 days. |
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MIN Quantity: |
1000pcs |
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Package : |
Carton and Pallet , exact part with package every pc . |
Detailed Photos
About Injection Molding
Injection molding is the most common modern method of manufacturing plastic parts. It is used to create a variety of parts with different shapes and sizes, and it is ideal for producing high volumes of the same plastic part. Injection molding is widely used for manufacturing a variety of parts, from the smallest medical device component to entire body panels of cars. A manufacturing process for producing plastic parts from both thermoplastic and thermosetting materials, injection molding can create parts with complex geometries that many other processes cannot.
Other products
Production process
Company Profile
ZheJiang (HangZhou) Xihu (West Lake) Dis.xin Metal Products Co., Ltd is specialized in the production of aluminum die casting, zinc alloy die casting, and aluminum lightweight production. Since establish of 2006, we always provide the best die casting parts to customers, and now we also develop the lightweight process successfully and obtain many national patents. Our products are widely used in automobile, medical, power Industry, electrical appliance, construction, high-speed railway and so on. And we have exported to Japan, Germany, USA, Canada, Australia and many countries.
Environmental Impact Assessment & ISO 9001 Certied
Selecting a reliable and qualified partner is more different & difficult than just choosing a supplier. We have obtained the license of EIA from government and get certied of ISO 9001, and we will always process our production per as EIA & ISO requirement strictly, to guarantee the stable production, to supply the qualified parts to you and enlarge your business finally. We sincerely hope we can become your faithful partner and develop a flouring future with you.
Certifications
Packaging & Shipping
FAQ
1.Are you a manufacturer or a trading company?
We are a 3000-square-meter factory located in ZheJiang , China.
2.How can I get a quote?
Detailed drawings(PDF/STEP/IGS/DWG…) with material, quantity and surface treatment information.
3. Can I get a quote without drawings?
Sure, we appreciate to receive your samples, pictures or drafts with detailed dimensions for accurate quotation.
4.Will my drawings be divulged if you benefit?
No, we pay much attention to protect our customers’ privacy of drawings, signing NDA is also accepted if need.
5. Can you provide samples before mass production?
Sure, sample fee is needed, will be returned when mass production if possible.
6. How about the lead time?
Generally, 1-2 weeks for samples, 3-4 weeks for mass production.
7. How do you control the quality?
(1)Material inspection–Check the material surface and roughly dimension
(2) Production first inspection–To ensure the critical dimension in mass production
(3)Sampling inspection–Check the quality before sending to the warehouse
(4)Pre-shipment inspection–100% inspected by QC assistants before shipment
8. What will you do if we receive poor quality parts?
Please kindly send us the pictures, our engineers will find the solutions and remake them for you asap.
Specifying a Ball Screw
When you need a high-quality ball screw, it is important to select 1 with the proper dimensions and specifications. When you are looking for the best product, you should consider features such as preloading, surface finish, and internal return system. You can learn more about these features in this article. If you’re unsure which type of ball screw to select, contact a reputable supplier for further guidance. To find the best product for your needs, click here!
Brinelling
When specifying a Brinelling ball screw, it is crucial to know how much axial load it can safely bear. The static load capacity, which is given in the catalogue, applies only to pure axial loading, and any radial load that is smaller than 5% of the axial load won’t pose a problem. For more information, contact a CZPT engineer. Brinelling ball screw service life calculation should be performed using the following data:
Preload: The amount of load a ball screw can handle during a single revolution. Preload is the load applied before the ball screw starts moving, and the load is usually between 5 and 10 percent of the dynamic capacity. However, a ball screw that is subject to vibration will experience higher preload, requiring more frequent lubrication. The resulting mechanical stress may cause the ball screw to buckle, or cause the nut to re-circulate the balls.
Critical ball speed: The maximum speed at which the ball can move through the ball nut is called the critical ball speed. In contrast, running the ball screw at its critical shaft speed can lead to excessive vibrations, leading to premature failure of the end support bearings and brinelling of the ball track. Thus, it is recommended to operate a ball screw at a lower speed than the critical ball speed to prevent brinelling and plastic deformation of the balls.
False brinelling: False brinelling is a form of Fretting. False brinelling occurs when the bearings are not rotating. The movement will result in depressions or wear marks in the bearing raceway. This will cause noise, wear, and eventual fatigue. If these conditions persist, a newer ball screw should be used to test the system. The machine should be run for several hours and tested before replacing the bearing.
Preloading
The process of preloading ball screws minimizes backlash by applying pressure to the threads in the opposite direction of the screw’s direction of rotation. It prevents any movement of the screw relative to the nut. Various methods are used for preloading. A common 1 is to use oversized balls inside the ball nut. A double nut system may also be used. Both methods are equally effective. Regardless of the method used, the end result is the same – minimal backlash and increased efficiency.
In the conventional method of preloading ball screws, the motors operate simultaneously in opposite directions, causing them to have a relative motion of approximately equal magnitudes. This reduces the frictional resistance of the system, resulting in rapid traverse. The system is able to operate with minimal backlash during 110 inches of travel, reducing the heat developed by the drive nuts and the problems associated with ball screw heating. Moreover, this method can be used in a wide range of applications.
Another method of preloading ball screws is known as the ball-select method. This method includes the use of over-sized balls that force the balls into more contacts with the screw and nut than a normal ball screw. The advantage of this method is that it reduces backlash because the balls are not machined to high tolerances. The disadvantage of this method is that the ball screw will cost more to manufacture than a standard ball screw and nut.
A conventional design includes a mechanical mechanism that uses a series of balls to rotate a shaft. The problem of backlash is exacerbated by the mass of the shaft. The mechanical system is more complex than necessary and often requires a lot of effort. The present invention eliminates these problems by providing an improved method and apparatus for driving ball screws. This method provides a more efficient preload force that is dynamically adjustable while the mechanism is operating. The method can also improve friction and wear.
Internal return system
There are 2 different types of ball screws. The first type is external and the second is internal. The external type uses return tubes that protrude from the ball nut and extend above and around the outside of the screw. The internal type uses a single tube that spans the ball track, while the more common design uses multiple tubes spanning 1.5 to 3.5 ball tracks. The internal system involves a single return tube and several pickup fingers that guide the balls into the tubes.
The external return tube design is an easier, less expensive choice. The external ball return system has limited space but can handle a wide range of shaft diameters and leads. However, its physical size makes it incompatible with many high-speed applications. Therefore, careful consideration should be given to the mounting options. Internal ball return systems are best suited for small leads and ball sizes. Those that need a high speed will likely benefit from the external ball return system.
Internal ball screw technology has also kept pace with the demands of linear drive systems. Ball screw technology is now more durable than ever. Robust internal ball return systems circulate ball bearings through a solid pickup pin. These deflectors help the balls return to the screw in the correct location. They are crucial components in computer-controlled motion control systems and wire bonding. If you’re interested in the latest advances in linear screw technology, contact us today.
Ball screws are superior to lead screws in many ways. Ball screws are more efficient than lead screws, converting 90% of rotational motion into linear motion. As a result, they are more expensive than lead screws and acme screws. They also provide a smoother movement over the entire travel range. Furthermore, they require less power for the same performance. It’s no wonder that the ball screw is so popular in many different applications.
Surface finish
The surface finish of a ball screw is 1 of the key factors in determining the performance of the system. A ball screw with a good surface finish has superior performance in rolling resistance, backlash, and wear characteristics. However, it is critical to improve the surface finish of a ball screw to achieve precision movement, low wear, and low noise. To achieve this, special wire brushes will be used to polish precision-ground shafts.
For a ball screw to perform well, it must be hard, have a smooth surface, and retain lubricant. The surface finish of a ball screw should be smooth, free of cracks, and retain the lubricant well. Cracks and annealing are both undesirable during the manufacturing process, so a quality machine should be used for its surface finish. During the production process, a CBN cutting insert with full round or gothic arch profile can be used to achieve a high-quality surface finish.
Another finishing operation used in the manufacture of ball screws is lapping. Lapping improves surface quality and travel variation. It involves complex relative movements of abrasive particulates with the workpiece. This removes a thin layer of material from the workpiece, improving its surface quality and dimensional accuracy. The lapping process can be carried out under low-pressure conditions. It also enhances the friction torque and lubrication.
In lapping experiments, friction torque has the largest influence on travel variation and surface roughness. A friction torque of about 1 N x m is optimum. In addition, rotational speed has only a minimal effect. The best combination of these parameters is 1-1.5 N x m and 30 rpm. The minimum surface finish of a ball screw is around 800 mesh. The smallest variation in travel is observed at around half-way through the travel.
Lubrication
Proper lubrication of ball screw assemblies is critical to maintain optimum performance and life. Ball screw assemblies should be lubricated with grease, which is introduced directly into the ball nut. The lubrication port can be located at various locations on the product, including on the flange or in the external threads of the ball nut. Some ball nuts also feature a zerk fitting for easier lubrication.
The lubrication of ball screws is required in the case of operating conditions over 100oC. The minimum load for a ball screw is usually realized with a preload force. The lubricant is conveyed through the narrow lubrication gap due to the relative movement of the 2 surfaces. The increased viscosity of the lubricant enables separation of the contact surfaces. To avoid over-lubrication, it is important to check the lubricant level regularly.
The oil used in lubrication of ball screw assemblies can be either mineral or synthetic. The oil is composed of mineral or synthetic oil, additives, and a thickening agent, such as lithium or bentonite. Other thickening agents include lithium, barium complexes, or aluminum. The lubricant grade NLGI is a widely used classification for lubricating greases. It is not sufficient to choose a specific type of lubricant for a particular application, but it provides a qualitative measure.
Despite being essential to the performance of a ball screw, lubrication is also essential to its lifespan. Different types of lubricant offer corrosion protection. Before using a lubricant, make sure to thoroughly clean and dry the ball screw. If there is any buildup of dirt, it may damage the screw. To prevent this from occurring, you can use a solvent or lint-free cloth. Lubrication of ball screw assemblies can greatly extend the life of the assembly.
