Posted by alexander bartosch on Thu, Feb 02, 2012 @ 12:09 PM
Below is the first look at our newest product: A non-lubricated linear Slide.
Posted by Simon Barrell on Fri, May 13, 2011 @ 12:52 PM
Lubricating a rack and pinion gear drive is often done manually. In industries, such as in food processing or packaging, where frequent washdowns are required, or where the gears are difficult to access, lubrication may be done only infrequently. Automated lubrication systems represent additional cost and require regular monitoring as they can clog up.
Intech Power-CoreTM gears do not require lubrication, reduce noise, and transmit motion with higher efficiency. The gears are precision machined from Intech’s Power-Core material with integral metal core for a secure shaft attachment. For wash down applications the core is available in stainless steel.
An important factor in designing today’s high speed machines is low inertia especially in systems where reversing motion is required. Intech Power-Core gears are up to 7x lighter compared to steel, absorb shock and vibration when movement in one direction is reversed, allowing higher machine speeds without sacrificing performance or wear life.
Intech engineers review each application and using a proprietary gear calculation, will advise the customer about the expected life of the gear. In many instances engineers are able to suggest design modification significantly improving the gear’s wear life. Intech rack and pinion gears can be found in bakery conveyors, position devices on packaging machines, cutting mechanisms on plastic bottle blow machines or on long gantry motion systems, to name a few.
Power-CoreTM gear for bakery conveyor system
Posted by Georg Bartosch on Wed, Mar 30, 2011 @ 10:52 AM
I recently attended a round table discussion with Mrs. Beryl Blecher, Minister Counselor for Commercial Affairs U.S. Mission to the European Union based in Brussels. One topic stuck in my mind – energy efficiency. Mrs. Blecher emphasized that energy savings are very important to European governments, industrial buyers and consumers alike. She also said that US manufacturers often lose in competition with European manufacturers as their equipment does not exhibit the same energy efficiency, perhaps even if the price is lower. Here are links to details about the energy ruling by the EU commission you might find useful.
Current action plan
New action plan coming
CSEU Market Research Report (Please note that EU law on energy performance of buildings has since been adopted).
While it is a somewhat lengthy reading, it speaks of ambitions goals of 20% in saving energy by 2020 and I believe, points out a big opportunity for US manufacturers. The lower value of the Dollar is already giving us a head start and energy efficiency built into your equipment could help to close the sale.
Relying on our 30 year history, we at Intech Corporation would like to be a part of your efforts to design and produce energy efficient equipment by providing low inertia, high efficiency gears and linear motion products.
Do you have an application we can help you analyze to see where we can identify energy efficiencies? The analysis is free. Please give me a call at 201-767-8066 or
Toll-Free on 1-877-218-2650 and ask for Georg.
Posted by Simon Barrell on Mon, Mar 28, 2011 @ 10:53 AM
To increase the capacity of their metal deposition furnaces with typically one cathode and one anode, we were approached by a metal refining company to design an electrically insulated gearbox that would rotate a multitude of electrodes suspended in a electrolyte solution. The design called for three stationary and one rotating cathodes and three rotating anodes. In the electrolytic process, exotic metal is transferred from the cathodes to the anodes and the rotating movement ensured an even deposition of the metallic particles.
The task was twofold, to rotate and electrically insulate in the gear box cathodes and anodes suspended in the electrolyte solution. Picture 1 shows the final solution. Intech engineers designed a planetary gear arrangement using Intech Power-Core™ gears with 316 stainless steel core, mating with a stainless steel sun gear. The drive gear was connected to one of the planetary gears. The electrodes are inserted through the extended, hollow gear hubs and clamped in place.
Picture 1) Intech Power-Core™ lower and upper plate (not shown) were used to anchor shafts with bearings and to electrically insulate them.
The electrical current is applied to the protruding electrical ends. To provide precise gear mashing and good gear life, precision SS bearings were pressed onto the hubs. While Power-Core gears have insulating properties, the electrical current could still escape through the hub/bearing/housing connection. To insulate the current, two Power-Core cover plates were precision machined to construct a housing for the gear box. The Power-Core gear box was then mounted on the metal cover of the furnace, see Picture 2.
Picture 2) Power-CoreTM electrically insulated gear box is mounted on the metal cover of the furnace.
In an earlier design, Picture 3 below, with a central drive and anodes and cathodes rotating, ceramic bearings were used to insulate the gear carrying plate. Using Power-Core plates and sealed SS bearings to anchor the gears in the gear box housing proved less costly and more reliable in the harsh conditions present in the electrolytic metal deposition environment.
Main electrical properties of Intech Power-Core™
- Volume resistivity at 10e10 to 10e14 (ohm.cm)
- Dielectric strength at 16-17kV/mm
- Dielectric constant of 4.0 (air dry), 50Hz)
Picture 3) In an earlier design ceramic bearings were used to insulate the gear carrying plate
Posted by Simon Barrell on Mon, Jan 31, 2011 @ 01:22 PM
One of our customers, who use an aggressive liquid bath in a plating process for coating metal parts, was experiencing a frequent breaking of the stainless steel chain drive which was corroding in the highly aggressive environment.
The parts are loaded into a large plating drum with a mesh exterior, which is then lowered into a tank containing a highly corrosive solution and heated to high temperatures between 120°F – 150°F. After coating, a series of cleaning and coating cycles are repeated across a battery of baths. A motor engages the drum drive, which needs to rotate slowly and steadily while carrying a high load into each step of the cleaning and coating process. The heavy metal parts in the drum can shift suddenly as the drum rotates, causing heavy shock load to be absorbed on the drive. The stainless steel chain, weakened by corrosion would give up under the shock load.
Intech engineers designed a large lubrication free Intech Power-Core™ gear and included a circular series of 2” diameter cast in ports made of Inconel™ in order to securely attach the gear to the drum. They also integrated a Power-Core bearing block in the shaft.
The Intech gear is resistant to the corrosive environment and was designed to absorb the sudden shock load, and proved to offer substantial savings to the customer.
Posted by Simon Barrell on Thu, Jan 27, 2011 @ 11:31 AM
Manufacturers and designers of precision sliding doors and indoor/outdoor architectural partitions are always searching for rollers that offer quiet performance and ease of operation to meet the customer’s demand for effortless, noise-free operation.
Intech Power-Core™ rollers were originally designed for demanding, high speed, linear motion devices, but have proven to be an ideal solution for use in opening doors and partitions. Intech Power-Core™ rollers and trolley systems have been designed to resist flat development, they will not absorb moisture, and do not wear out the rail. The durable, dimensionally stable tire material carries high load and retains strength over a wide temperature range (-40ºF to +140ºF).
The roller is assembled using a proprietary thermotechnology, rather than injection molding, to ensure precision and stable configuration. When combined with a precision roller bearing, this process creates properties that account for a very quiet and smooth ride.
INTECH Power-CoreTM Track and Trolley SystemManufacturers and designers of sliding weight-bearing products have found that Intech Power-Core™ rollers offer a unique excellence in ergonomic presentation, stability and performance under virtually any temperature, moisture or load condition. The Load capacity per trolley is 200 lb, while on our Aluminum Track and Trolley set the capacity is 400 lb.
Applications for Intech Power-Core™ roller and trolley systems include fine furniture, cabinets, sliding doors, office partitions, luxury boats, airplane cargo doors, oversize doors for commercial and industrial refrigeration units, and automatic doors for trains and commercial buildings.
Our team of in-house engineers review each application for suitability and provide expected wheel life calculations. Engineering support and assistance extends to the complete shaft and trolley system design.
Posted by Simon Barrell on Wed, Jan 19, 2011 @ 02:50 PM
Rugged, high performance Intech Power-Core™ gears, rollers, and cam followers are individually calculated and designed from high performance Power-Core™ material to meet each engineer’s specifications for durability, performance, stability, and wear life. Intech engineers analyze the application and provide gear tooth and anti backlash design modifications that have been developed specifically for plastic. Company president, Georg Bartosch asserts “We will not sell a product unless we can first assure ourselves, on paper, that the product will work.”
Intech Power-Core™ gearsEngineering calculations, developed in conjunction with a leading university, provide the wear-life and performance assurance the design engineer and OEM depend upon to gain a significant competitive advantage in product marketing and plant/equipment maintenance.
Intech Power-Core™ gears, rollers, and cam followers feature a very dense, stress-free, self-lubricating, homogeneous crystalline structure. The Power-Core™ material does not absorb moisture, offers exceptional impact strength (shock load) resists most chemicals, operates in temperatures from 40º to +160ºF, can be safely cast around metal cores, and can be machined, if desired, by using a fluid coolant.
The integral metal core allows a higher torque transmission via a secure gear attachment to the shaft. In addition, the metal core dissipates generated heat and reduces backlash requirements to make the gear quieter.
Each application is unique. With over 20 years of experience in designing plastic components, Intech engineers begin each project by asking “what if” questions and become involved with the design process.
Posted by Simon Barrell on Mon, Jan 17, 2011 @ 12:26 PM
As a result of writing these blog posts, we realize that increasingly we have become an integral part of projects that impact the environment in a positive way. Intech appreciates the trust of corporations and government organizations alike to use our Power-Core™ products for such projects.
Intech was approached by consultants working with the US Army Corps of Engineers to design special screen supports for an Adult Fish Collection Facility at the Cougar Dam and Reservoir. This facility is located on the South Fork of the McKenzie River directly downstream of the dam in Oregon.
The Fish Crowder barrier uses Intech screen supports made of machined stainless steel, these ensure safe operation and a long life in the collection facility. The crowder is used in the concrete raceway for cleaning, grading and herding fish together for loading tank trucks or pumping into other collection ponds through pipes. This fish collection facility is due for completion in May 2010.
Fish Crowder barrier with Intech Screen Supports
You can read about other related Fisheries and Wildlife Resources projects at the US Bureau of the interior web site: http://www.usbr.gov/pmts/fish/Capabilities.html
Posted by Simon Barrell on Thu, Jan 13, 2011 @ 09:54 AM
When Dexter Magnetic Technologies introduced a dual axis robotic manipulator to control sputtering in the manufacturing of computer hard drives, it was an instant success that relied upon a sophisticated drive and pulley system that all too quickly developed a troublesome, excessive wear problem that was resolved with a solution presented by Intech Corporation.
Chris Ras, Product Development Manager at Dexter Magnetic Technologies, describes the drive system as “consisting of two single sided timing pulleys configured into two independent drive sections, each of which utilizes two single-sided timing belts.“ During tests at a customer’s plant, the faster of the two compact belt drives required frequent and precise tensioning to eliminate belt stretching and excessive wear.
Ras, in exploring a gear design as an alternative to the belt drive, contacted Tody Mihov, our Engineering Manager at Intech Corporation, to discuss how self-lubricating plastic Intech gears might work into his design. The application offered limited space, featured both high torque and reversing torque, and the gears needed to be retrofitted into existing equipment on location at the customer’s facility.
Upon reviewing load data using a proprietary gear calculation developed by Intech in conjunction with a leading university, Mihov determined that the Intech gear would work. He then decided to maximize the load carrying capacity of the Power-Core™ gears by applying an innovative Intech developed plus/plus gear mesh modification to the gear train. With the addition of two stainless steel drive gears, an Intech Power-Core™ idler gear that has an integral stainless steel core and a proprietary backlash-free plastic gear design, the desired smooth manipulator motion was assured. In addition, a special idler gear shaft was designed to provide an easy, field-ready retrofit.
An in-house test was constructed to determine how the Intech solution performed relative to visible wear patterns and drive efficiency. As per his expectation, Ras determined that drive efficiency increased by a full 15%! He reasoned that this was achieved in part by eliminating the radial stresses that belt tensioning transferred to the bearing. With the Intech Power-Core™ gears running stress-free, the only force transmitting onto the mating gear teeth was the torque, which traveled on a precision-machined pitch line.
With the retrofit Intech gear replacement system in place to manage reliability of the rotary axis, Dexter Magnetic Technologies has gained even greater industry attention.
Self-lubricating, Anti-backlash Gear Solution
Posted by Simon Barrell on Fri, Aug 27, 2010 @ 10:26 AM
In a high speed can making production line, light inspection is required to find pin holes and split flanges after the necking process. Once cans have been coated and sealed, these finished cans are tested for leaks using a light tester, which can detect holes 0.002” wide, smaller than a human hair, and also spot cracked flanges as small as 0.015”.
When Intech iCamFollowers® are installed on the light tester ram they ensure that 3,000+ inspections can be performed per minute, more than sufficient to keep up with the high speed can production line and offer several important benefits.
After installation, the lubrication lines originally used to grease the metal cam followers can be disconnected, cutting down on periodic maintenance and possible contamination of the can. Another important benefit is the fact that the cam propelling the ram back and forth is now protected from wear by the IPC tire.
Fitted with precision ball bearings the Intech iCamFollowers® are easy rolling and the plastic tire does absorb shock and vibration for overall smoother performance.
The Intech iCamFollowers® have also been running successfully for many years in the necking operation on Belvac neckers, both on rams made by Intech, the light weight, self-lubricating square ram, as well as on the original Belvac rams.
