Below is the first look at our newest product: A non-lubricated linear Slide.
Intech Power-Core Thermoplastics Engineering Blog
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
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.
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.
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
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.
The original gear box design resembled a tightly fitting cassette made with standard off-the-shelf gears. Unfortunately, as the latex material was being processed, the gears reacted with the latex material and expanded in size until the ceased turning. Cleaning required a complete disassembly of the cassette, followed by awkward and time-consuming hand scrubbing of individual components to yield less-than-satisfactory results.
In addition to requiring an easier cleaning process, the medical device manufacturer wanted longer wear-life and improved performance from the gears. Frequent cleaning and premature gear failure caused by gear swelling resulted in wear stress that resulted in system downtime and replacement on average every few months.
As part of a failure analysis, Intech provided an engineering design review that included a custom gear life calculation. Our engineering team recommended a system design modification to address performance uptime, improve wear life, and to create a user-friendly non-hazardous cleaning process.
The gear box modification design features custom Intech Power-Core™ gears with a larger pitch diameter, wider face width, and an integral stainless steel shaft that extends on each side of the gear and rotates directly within the load bearing cover plates. The open sandwich design, which can be seen in this image, allows for easy cleaning.
Compared to the previously used injection molded gears which vary in size due to internal stresses and moisture absorption, the precision machined Intech Power-Core™ gears provide consistent, smooth-running operation at reduced torque. Uniform Power-Core material will not distort or change size, so individual gears can be interchanged easily without matching pre-existing gears for a uniform fit, whereas injection molded gears had to be matched to other gears in order to function.
Intech Power-Core™ gears are machined from an inert, stress-free non-hygroscopic material with integral stainless steel shaft that offers outstanding performance where corrosion, abrasion, noise, lubrication, vibration, shock, and moisture create hostile operating environments.
Intech was selected by Bombardier to provide replacement rollers for the platform safety door on the Orlando People Mover System.
Bombardier Transportation, with a reputation for excellence in designing high capacity urban transit systems and automated people movers, required longer wear-life rollers, with increased reliability to reduced maintenance. Our design engineers at Intech Corporation, explored how the engineered Intech powercore rollers might address Bombardier Transportation’s requirements.
Concave Rollers for Guide Door Openings Once application details, including angle, load, door weight, linear speed, temperature variations, humidity levels, rail material and cycling information were presented, Intech was able to custom design a concave roller. The assembly features a precision machined Intech Power-Core™ tire thermally installed over a sealed ball bearing. At a radial load of 100 lbs. per roller running at 53.82 ft/min, Intech determined roller performance life of between 500 to 700 million door-opening cycles, which could potentially provide the Orlando International Airport with 5 to 7 years of quiet, trouble-free and maintenance-free operation.
Intech Power-Core™ rollers do not absorb moisture and maintain outstanding performance characteristics throughout a temperature range that extends from -40°F to 140°F. The precision thermal-fit tire is credited with providing a reliable and secure fit under varying load and temperature situations.
After one year of continuous operation, there are no visible signs of wear on the roller surface. Additionally, Intech Power-Core™ rollers are being installed on the heavy 200 lb. glass station doors in order to reduce noise and increase resistance to grinding and wear. Station door rollers for Leg A2 are in the process of being replaced at the Orlando site with Intech Power-Core™ replacement rollers. Bombardier field technicians are installing the replacement rollers and, where applicable, will ensure that they are timed to open and close at precision-controlled intervals so that the doors orchestrate perfectly with the opening of train doors to provide a safe, smooth passage.
Please download a white paper showing many of the applications and advantages of intech rollers:
As manufacturers, transport operators, processors and service providers seek to achieve more environmentally benign operations, Intech Corporation steps up to the challenge with the environmentally friendly Power-Core material and Engineering calculations to predict performance wear-life and cost-savings.
Specially formulated, self-lubricating Intech Power-Core™ composite material exhibits a characteristically tension-free crystalline-structure that provides exceptional stability, quiet performance and outstanding tensile and flexural strength.
Power-Core material reduces wear, noise, vibration, maintenance, lubrication and contamination. A key characteristic of the Power-Core material is its exceptional self-lubricating, long-wearing performance in demanding high temperature, sub-zero, high moisture, high voltage, high friction and weight bearing applications that often cause metal components to fail.
Lubrication-free Power-Core components eliminate the need for hand or centralized lubrication and the attendant problems they cause when lubricating pipes or lines dry out or the content becomes too viscous or runny and clogs or overflows into the machinery—resulting in unscheduled production line shut-down, emergency cleanup, product waste and damage to machinery, equipment, personnel, plant facilities and the environment.
Similarly, the environmentally friendly Intech Power-Core products avoid safety concerns related to worker exposure to noise and direct contact with the lubrication, lubricated parts, hazardous odors, spills, falls resulting from spills and seepage from stored lubricant or wastes.
In addition, Power-Core materials are perfect for long-wear, accuracy and quiet performance like those required in ski lift operations, high speed paper processing and converting, airplane cargo door hardware, packaging equipment, elevator guides, neo-natal incubators, x-y linear positioners, electrically insulated car painting robots and in-plant equipment subjected to demanding high speeds or frequent wash-down cycles.
Power-Core rod with cast-in metal core for machining into gears
Our Engineering team at Intech offer custom sizing and design assistance for replacing cast iron, steel, nylon and Delrin® parts with Power-Core materials.