Intech Power-Core Thermoplastics Engineering Blog

Powercore Offers Unique Balance Of Properties

Posted by Alexander Bartosch on Jan 7, 2013 2:40:00 PM

From cheap plastics to the world’s most expensive composites, many types of polymers have been machined, molded or cast into power transmission components.  We’ve focused our development efforts on the use of a proprietary, gravity cast Polymer called Power-Core®.

Thanks to the interplay of its intrinsic physical properties and low-stress casting process, Powercore represents the ideal material choice for power transmission applications. Here’s why:

Remains Stable and Dampens Vibrations.  Power-Core has an unparalleled ability to maintain its physical properties under a broad range of operating conditions. This stability allows us to make highly accurate predictions of the material’s behavior and lifecycle even when the application has variations in moisture, temperature and chemical exposure.

In particular, Power-Core’s stability in persistent high-humidity or total-immersion conditions makes it uniquely well-suited to power transmission applications and sets it apart from other polymers. Unlike Power-Core, most high-performance polymers absorb moisture. As they do, they lose their tensile strength and swell. Power transmission components made from moisture absorbing, or “hygroscopic,” polymers can end up too weak to carry the loads they were designed for and too swollen to work with mating components.

For an idea of how severe the moisture problem can be, consider the difference between Power-Core and the much more common nylon 6. While both are nominally “polyamides,” powercore outperforms other nylon 6 and nylon 12's dramatically as moisture content increases.

Power-Core also exhibits excellent vibration damping characteristics, which contributes to its ability to reduce noise and absorb the shock loads commonly seen by power transmission components.

 

Eliminates Internal Stresses. Power-Core isn’t just a material but also a manufacturing approach that encompasses gravity casting and precision machining. We gravity cast the Power-core over metal hubs or thermally install it over rollers bearings to produce the beginnings of a cam follower, roller or gear. We then precision machine these blanks to form a finished component.

With engineering polymer applications, the interplay between manufacturing methods and the inherent polymer properties matters as much as the choice of the polymer itself.

Power-Core is no exception. In this case, the gravity casting contributes to low internal stress state that gives the polymer an inherently uniform crystalline structure. As a result, Power-Core components have a consistent machining resistance that improves overall machining precision–and allows the material to retain that precision over time. And under external load, the dense crystalline structure helps thwart the stress-induced cracks or swelling that sometimes force molded plastic components to fail prematurely.

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Tags: Power-Core, plastic rollers, Self-lubricating, plastic gears, PA12G, Power-Core material, Nylon 6 vs Nylon12

Introducing Intech Non-lubricated Linear Slides

Posted by Alexander Bartosch on Feb 2, 2012 1:09:00 PM

Below is the first look at our newest product: A non-lubricated linear Slide.

Tags: cam follower, cam followers, maintenance, Power-Core, precision machined, minimum resistance, iCam Followers, lubrication-free, reduce noise, reduce shock, reduce vibration, plastic rollers, Self-lubricating, wear life, composite material, cast nylon 12, Linear Motion Devices, Precision Linear Slides, electrically insulated, energy efficiency, Clean rooms, Wash-downs

Roller Assembly Technology that Effortlessly Opens Doors & Partitions

Posted by Simon Barrell on Jan 27, 2011 12:31:00 PM

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.


Power-Core Track and Trolley System
INTECH Power-CoreTM Track and Trolley System



Manufacturers 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.

Tags: Power-Core, Linear Motion Devices, Precision Linear Slides, Intech rollers, Tensile strength, Trolley Assembly, Track and Trolley System

Why Do Intech Power-Core Gears Last?

Posted by Simon Barrell on Jan 19, 2011 3:50:00 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 gears

Intech Power-Core™ gears



Engineering 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.

Tags: Power-Core, wear life, shock load, anti-backlash

Power-Core Screen Support in Fish Crowder for Oregon River Project

Posted by Simon Barrell on Jan 17, 2011 1:26:00 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

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

Tags: Power-Core, fish crowder, screen supports, machined stainless steel

Drive sprocket for Escalator handrail extends maintenance intervals

Posted by Simon Barrell on Aug 10, 2010 5:06:00 PM

“Shut down for maintenance, use the stairs please.”shut escalator

We have grown accustomed to signs like these in public places like airports, hotels or department stores. The reason for the maintenance or repair shut down is often wear or broken teeth on the main driving sprocket.

The self-lubricating, precision machined Intech Power-Core™ escalator driving sprocket helps to extend the time intervals for scheduled maintenance, is wear resistant, absorbs shock and vibration, and reduces noise for a smooth and quiet ride. They are also suitable for outdoor use as the sprocket material does not absorb moisture and teeth do not break in sub-zero temperatures, when other plastic materials become brittle.

EscalatorDrive Sprocket for Handrail

Tags: maintenance, Power-Core, precision machined, Self-lubricating, moisture absorption, sub-zero temperatures, drive sprocket, escalator

Double-rowed Power-Core drive sprocket in packaging machine

Posted by Simon Barrell on Apr 19, 2010 5:20:00 PM

In food industry applications lubrication is always an issue, so for a packaging machine we designed a composite double-rowed drive sprocket machined from Intech Power-Core™ material with a SS core that prevents abrasion on the steel chain, even at high operating speeds.

This chemical resistant sprocket is corrosion proof and ensures that no lubricant is required which could contaminate the food.


Double rowed drive socket
Double rowed-drive sprocket used in a packaging machine


 

 

 

 

 

 

One drive sprocket is used for two different chain circuits, and this component provides an integrated solution with a cast-in stainless steel hub to securely attach both sprockets to the shaft.

Intech Power-Core™ sprockets are available with or without metal core. The material’s properties lend themselves to superior wear characteristics of the sprocket teeth. Intech Power-Core™ sprockets do not wear out the chain, reduce noise and absorb shock and vibration.

Tags: Power-Core, reduce noise, reduce shock, reduce vibration, stainless steel, drive sprocket, packaging machine, corrosion proof, wear characteristics

High speed rotating face cams machined from Power-Core™ outlast steel

Posted by Simon Barrell on Feb 2, 2010 1:23:00 PM

Exact steerage requires dimensionally stable cam tracks with narrow tolerances. Our cams are precision machined from solid blocks of cast Intech Power-Core™ material, offering a longer lasting solution than stainless steel.

In high speed machines Intech Power-Core™ cams exhibit damping behavior which leads to reduced stress peaks. Additionally the high performance plastic cam offers exceptional resistance to wear with limited or no lubrication, which is critical to avoid contamination.

The face cam converts circular motion to linear motion or vice versa, typically it is a disc with a groove cut in its face, in which a cam follower travels. The attached image shows such a cam used in a tableting machine.

In this case the customer required self-lubricating material performance and had experienced constant stress problems using cams machined from plastic materials with low levels of crystallinity, such as Delrin®. However they found that Power-Core™ material, with higher crystallinity levels, can be used to produce a more stable cam that does not suffer stress peaks.

Industries in which our cams have been used include packaging, food processing, printing, as well as stitching machines and other general engineering applications.

In high speed machines Intech Power-Core™ cams exhibit damping behavior which leads to reduced stress peaks. Additionally the high performance plastic cam offers exceptional resistance to wear with limited or no lubrication, which is critical to avoid contamination.


The face cam converts circular motion to linear motion or vice versa, typically it is a disc with a groove cut in its face, in which a cam follower travels. The attached image shows such a cam used in a tableting machine.

In this case the customer required self-lubricating material performance and had experienced constant stress problems using cams machined from plastic materials with low levels of crystallinity, such as Delrin®. However they found that Power-Core™ material, with higher crystallinity levels, can be used to produce a more stable cam that does not suffer stress peaks.

Industries in which our cams have been used include packaging, food processing, printing, as well as stitching machines and other general engineering applications.

Face Cam for Tableting Mach resized 600

Face Cam precision machined from cast Intech Power-Core™ material reduces inertia, absorb shock and vibration.

Tags: Power-Core, Self-lubricating, shock load, vibration, non-lubricated, stainless steel, cams, crystallinity, Delrin, face cam, stress peaks, tableting machine

Crystalline structure absorbs energy in high speed Power-Core roller.

Posted by Simon Barrell on Jan 19, 2010 1:35:00 PM

A special design by Intech’s engineering staff, using a composite tire material, a tested method of manufacturing and assembly, all contribute to the exceptionally quiet performance of Intech Power-Core™ rollers.

Image100 Rollers

Intech Power-Core™ rollers


The design marries a precision roller or ball bearing with an Intech Power-Core composite tire. The quiet roller ride can be attributed to the tire material with its tension-free, homogeneously crystalline structure, achieved through a unique casting process. This fine crystalline structure exhibits excellent energy absorbing properties while resisting flat development under load, while the Power-Core tire also protects the metal rail against wear.

Tires are precision-machined, and then heated in an oven to 250° to 300° F before the bearing is pressed in through a specially designed snap-in lip. After cooling, the tire is effectively shrunk onto the bearing. The precision-machined tire, with OD tolerance within 0.0001”, has excellent roundness contributing to the smooth and quiet ride.

The expected life of the roller in number of roll-overs, and flat-free time under load, are determined with a calculation and data developed by a leading university.

Tags: Power-Core, reduce noise, wear life, Intech rollers, roller life

Composite Worm Gears Extend Wear Life in Tough Applications

Posted by Simon Barrell on Jan 7, 2010 2:23:00 PM

Intech engineers are frequently asked for help to determine worm gear size, design parameters and to make wear-life projections using our proprietary gear calculations. As a result of these calculations, Intech Power-Core™ composite worm gears are chosen to replace industry-standard bronze gears in demanding operations to increase transmission efficiency with quieter, longer-wearing performance.

Intech Power-Core Worm Gears


Intech Power-Core Worm Gears


Power-Core material does not require special grade oil or frequent oil changes and the composite material does not generate abrasive particles which become suspended in the oil as a contaminant that contributes to wear. The tough, self-lubricating properties of the composite gear material enable Intech Power-Core worm drives to consistently outlast conventional bronze worm gears.

We completed a 1,000 hour test that compared gear performance between the Intech Power-Core gear and a case-hardened ground steel worm gear, and the results confirmed the capacity of Power-Core material to absorb shock load and vibrations. Test data showed an average noise reduction of 6 dB, with up to an 8% increase in gear transmission efficiency and no wear was detected on the 6.5 PD Power-Core worm gear.

In applications such as conveyors for glass washing or light load semi-conductor manufacturing machinery, the Intech Power-Core worm gears run with only light grease lubrication, or completely dry. Even in high torque applications that result in friction, the self-lubricating Power-Core worm gear can run for extended periods without lubrication.

The mating worm shaft can be made of conventional materials utilizing standard manufacturing methods. The low-maintenance Power-Core composite worm gears use readily available machine oil to lubricate the gear box, instead of more expensive specialized synthetic oil that is usually recommended for bronze worm gears.

Tags: Power-Core, wear life, composite material, gear box, shock load, vibration, self-lubricating gears, bronze gear, Gear Calculation, gear life calculation