Intech Power-Core Thermoplastics Engineering Blog

Intech Gears Could Eliminate Noise From Your Segway Gearbox

Posted by Alexander Bartosch on Jan 30, 2014 8:56:00 AM

Does your segway make too much noise? Have you ever wondered where it is coming from? Segway drive gears in the segway gear box are all metal (figure 1)

Segway Helical gear Gearbox

The metal on metal movement, in this beautifully constructed helical drive gearbox, creates noise. This noise can become worse with time as the gears wear.  See the video below for an example of the noise we are talking about.

Intech has conceptualized a segway replacement gear box to dampen vibration and reduce the noise of the segway metal on metal wear. Our simple bolt on attachment benefits from our  PA12GC Power-Core Cast Nylon (polyamide) which doesn't absorb moisture and won't crack in subzero conditions. The self-lubricating material allows our gears to run quietly and oil free. Removing another annoyance from the maintenance of your segway and its gearbox.

Using plastics to design high load, high shock, and highly critical applications is our specialty here at intech and being engineers the segway was always a toy we've wanted to tinker with. Making plastic gears for an application of this type was not without challenges. The first of which is the tooth root stress, you see metal gears can be much thinner and carry far more load than any plastic. The second is power transmission, very few - if any plastics can evenly and continuously transmit the power needed to drive a segway in the way its meant to operate. Imagine a right gear box transmitting less efficiently than the left and the circles or compensation a rider would need to make. Luckily, Intech's Power-core PA12GC material and its unique gravity casting process allows it to chemically bond to a metal core allowing it to transmit power evenly and continuously while perserving the benefit of a self lubricating gearing.

The retrofit is not inexpensive but if noise or vibration are causing you problems a new intech gearbox might be the solution to give you the quite and smooth riding personal movement device you've always wanted.

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Tags: Power-Core gears, cast nylon 12, gear box, gear backlash, gear design, plastic gears, Power Train Design, Plastic gear box, plastic helical gears

Plastic Gear Train Design For Zipper Pouch Packaging Machine

Posted by Simon Barrell on Oct 5, 2009 1:59:00 PM

During the developmental stage of a new zipper pouch packaging machine, Hayssen, a division of Barry-Wehmiller, the largest packaging automation group in the Western Hemisphere asked us to devise a Power-Core™ non-lubricated gear solution to replace a structure of timing belts and pulleys that required frequent, lengthy machine shut-downs for maintenance and replacement service.

Hayssen’s Lead Developer for the integrated transverse zipper applicator noticed that the original timing belt and pulley design had significant problems with precision feed length, cut, placement and seal of thicker, higher profile zipper tapes. In addition, the difficult-to-reach timing belt and pulley assemblies stretched around tight radii and became prone to breakage and frequent maintenance.

Intech’s engineering team were able to determine a non-lubricated solution to the power train design using our gear system that capitalized on a truly unique power train design and resultant production uptime.

A pouch/pillow bag with integrated zipper is formed on the Hayssen vertical form/fill/seal machine using an exact amount of zipper material by applying it to the film before it is formed into the finished bag. Intech engineers responded to mechanical design issues that included overall clearance and tight-quarters required by the zipper tape pathway and a minimal backlash by designing small pitch diameter Power-Core gears for the gear train. In addition, concerns for USDA-3A compatibility mandated the use of stainless steel and non-corrosive gear materials.

Using proprietary gear life calculations and a special gear tooth modification to accommodate the set center distances and speed ratios of the rubber rollers, Intech was able to overcome the tight center distances and frequent stop and go requirements with a design solution that Intech calculated to last a minimum of 4 years in continuous operation without lubrication.

Hayssen geared roller assembly 

Geared Roller Assembly

Tags: Power-Core, non-lubricated, Power Train Design, Gear Tooth, Pulleys, Rubber Rollers, Tim Belts, Zipper Pouch Packaging