Sewind (Shanghai Electric Group Co., Ltd.)

 Sewind (Shanghai Electric Group Co., Ltd.)

Sewind, a subsidiary of Shanghai Electric Group, is a leader in the field of wind turbine gearboxes, but also produces gear reducers for industrial applications. Known for its high-quality gear systems, Sewind has focused on producing gearboxes for both onshore and offshore wind turbines, as well as a variety of industrial gearboxes used in steel, energy, and other heavy industries. Their reducers are designed for high efficiency and reliability in harsh environments, with a strong commitment to environmental sustainability and energy-saving solutions.

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Hangzhou Advance Gearbox

 Hangzhou Advance Gearbox Group Co., Ltd.

Hangzhou Advance Gearbox Group Co., Ltd. (ADVANCE) is one of China’s leading manufacturers of gearboxes, marine gear, and hydraulic components. Established in 1960, the company has grown into a comprehensive enterprise with a focus on the marine and industrial sectors. ADVANCE’s gearbox products include marine gearboxes, industrial reducers, and automotive transmissions. Their gearboxes are widely used in ships, cranes, and various heavy machinery. With a strong focus on innovation, ADVANCE integrates modern technology and strict quality control systems, ensuring high reliability and durability of their products.

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Nanjing High Accurate Drive Equipment Manufacturing Group Co., Ltd. (NGC)

 Nanjing High Accurate Drive Equipment Manufacturing Group Co., Ltd. (NGC)

Nanjing High Accurate Drive Equipment Manufacturing Group Co., Ltd. (NGC), founded in 1969, is a globally renowned manufacturer of gearboxes and transmission equipment. NGC specializes in producing high-performance gearboxes for wind power, industrial, and marine applications. The company's industrial reducers are used in a variety of sectors including metallurgy, mining, cement, and material handling. NGC is known for its precision engineering and robust design, ensuring reliable performance even under extreme conditions. NGC's dedication to research and development has led to numerous innovations in gearbox technology, making them a key player in the global market.

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Advanced Coatings for Extending Gear Life

 Advanced Coatings for Extending Gear Life

Abstract

In modern industrial applications, gears play a critical role in power transmission systems. The longevity and performance of these gears directly influence the operational efficiency of machines and equipment. One effective method to enhance gear life and performance is the use of advanced surface coatings. This paper explores various coating technologies, such as Physical Vapor Deposition (PVD), Chemical Vapor Deposition (CVD), and Diamond-Like Carbon (DLC) coatings, and how they contribute to reducing friction, improving wear resistance, and minimizing corrosion. The application of these coatings significantly extends gear life, reducing maintenance costs and downtime.

1. Introduction

Gears are integral components in a wide range of mechanical systems, from automotive transmissions to industrial machinery. Over time, gears are subjected to extreme stress, leading to wear, friction, and even failure. This wear and tear not only affects the performance of the machine but also results in costly maintenance and downtime. One of the most promising solutions to mitigate these issues is the application of advanced surface coatings, which can significantly enhance gear durability by improving wear resistance and reducing friction.

This paper will explore the different types of advanced coatings available for gears, the processes involved in applying these coatings, and the specific benefits they offer in extending gear life.

2. The Need for Advanced Coatings in Gear Applications

The primary causes of gear failure include wear, pitting, scuffing, and corrosion. Traditional methods of improving gear life, such as using high-strength materials or increasing the size of gears, have limitations in terms of cost and practicality. In contrast, advanced surface coatings offer a more efficient and economical approach to improving gear performance.

Coatings can address several key factors that contribute to gear degradation:

Friction: Gears experience significant friction during operation, which leads to heat generation and material wear.

Corrosion: Exposure to moisture, chemicals, and other environmental factors can cause gears to corrode, reducing their strength and reliability.

Wear and Fatigue: Continuous mechanical stress can lead to surface fatigue, causing cracks and wear that eventually lead to gear failure.

3. Types of Advanced Coatings

Various advanced coating technologies have been developed to address these issues. Some of the most effective coatings for gear applications include:

3.1 Physical Vapor Deposition (PVD)

PVD is a process in which a thin layer of material is deposited onto the surface of a gear in a vacuum environment. This coating is typically composed of hard materials such as titanium nitride (TiN), chromium nitride (CrN), or titanium carbonitride (TiCN). These coatings are known for their hardness, wear resistance, and low friction properties.

Advantages: PVD coatings provide a hard, wear-resistant surface that reduces friction and improves overall gear efficiency. The coating is also resistant to corrosion, which extends the life of the gear in harsh environments.

Applications: PVD coatings are commonly used in automotive, aerospace, and industrial machinery applications where high durability and precision are required.

3.2 Chemical Vapor Deposition (CVD)

CVD is another vacuum-based coating process that involves the chemical reaction of gaseous materials to form a solid coating on the gear surface. CVD coatings are typically harder and thicker than PVD coatings, making them suitable for extreme wear conditions.

Advantages: CVD coatings offer excellent wear resistance and high-temperature stability, making them ideal for gears operating under high loads and in extreme environments. The thicker coating also provides better protection against impact and abrasion.

Applications: Gears used in heavy machinery, mining equipment, and high-performance engines often benefit from CVD coatings.

3.3 Diamond-Like Carbon (DLC) Coatings

DLC coatings are a type of amorphous carbon material that exhibits properties similar to diamond, including high hardness and low friction. DLC coatings can be applied using both PVD and CVD processes.

Advantages: DLC coatings are highly effective at reducing friction, which leads to lower operating temperatures and reduced wear. The coating also provides excellent corrosion resistance, making it ideal for gears operating in corrosive environments.

Applications: DLC coatings are used in high-precision gears, such as those in automotive transmissions and aerospace applications, where reducing friction and wear is critical to performance.

4. Benefits of Advanced Coatings

The application of advanced coatings to gears offers several significant benefits, including:

4.1 Improved Wear Resistance

The primary benefit of applying coatings is the substantial improvement in wear resistance. Hard coatings, such as those provided by PVD and CVD processes, create a protective layer that minimizes the surface wear caused by friction and contact stresses. This extended wear resistance results in a longer operational life for the gear.

4.2 Reduced Friction

Coatings like DLC significantly reduce friction between gear teeth during operation. Lower friction levels lead to reduced heat generation, which in turn minimizes thermal stresses on the gear. This reduction in friction also improves energy efficiency, making the machine or system more efficient overall.

4.3 Corrosion Protection

Gears that operate in corrosive environments, such as those exposed to moisture, chemicals, or extreme temperatures, are susceptible to rust and other forms of corrosion. Coatings, particularly those made of materials like chromium or diamond-like carbon, provide a robust barrier that protects the gear from environmental degradation.

4.4 Extended Service Intervals

By reducing wear, friction, and corrosion, advanced coatings enable gears to operate for longer periods without maintenance. This results in extended service intervals, which reduces downtime and maintenance costs for industrial equipment, leading to significant cost savings over the gear’s lifecycle.

5. Challenges and Considerations

While advanced coatings offer significant benefits, there are challenges associated with their application. These include:

Cost: The application of advanced coatings can be expensive, especially for large-scale industrial applications. However, the cost is often offset by the longer operational life and reduced maintenance requirements of the coated gears.

Process Complexity: Coating processes such as PVD and CVD require specialized equipment and expertise, which may not be readily available in all manufacturing environments.

Adhesion: Ensuring strong adhesion of the coating to the base material is critical for long-term performance. Improper adhesion can lead to premature coating failure and gear damage.

6. Conclusion

Advanced surface coatings offer a powerful solution to the challenges of gear wear, friction, and corrosion. Technologies such as PVD, CVD, and DLC coatings significantly enhance the durability and performance of gears, making them more resistant to the stresses of modern industrial applications. While the upfront costs of applying these coatings may be high, the long-term benefits in terms of extended gear life, reduced maintenance, and improved efficiency make them a worthwhile investment for industries that rely on high-performance mechanical systems.

By adopting advanced coating technologies, manufacturers can not only extend the operational life of their gears but also enhance the overall reliability and efficiency of their machines, leading to improved productivity and reduced downtime.

References

Holmberg, K., & Matthews, A. (2009). Coatings Tribology: Properties, Mechanisms, Techniques, and Applications in Surface Engineering. Elsevier.

Bouzakis, K. D., et al. (2012). "Wear Resistance of PVD-Coated Gears." Wear, 289, 73-80.

Donnet, C., & Erdemir, A. (2008). Tribology of Diamond-Like Carbon Films: Fundamentals and Applications. Springer.

Hasegawa, M., et al. (2019). "Application of DLC Coatings to Improve Gear Life in High-Speed Machines." Materials Science Forum, 969, 124-130.

This structure and content should meet the requirements for a full paper on the topic of advanced coatings for extending gear life.

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Gear Box quality

 1. Materials Selection for Enhancing Gearbox Durability

This paper will explore how the choice of materials impacts the overall quality and longevity of gearboxes. It will focus on the advantages of high-strength alloys, surface treatments like nitriding, and composite materials in reducing wear and tear over time.

2. Lubrication Techniques for Improving Gearbox Efficiency

Lubrication is crucial for reducing friction in gears, which directly affects the lifespan of a gearbox. This paper will discuss different lubrication methods (grease, oil mist, solid lubrication) and how they contribute to prolonging gearbox life by minimizing wear and enhancing performance.

3. The Role of Precision Manufacturing in Gearbox Performance

Precision manufacturing techniques like CNC machining and advanced quality control systems improve the dimensional accuracy of gearbox components. This paper will discuss how tighter tolerances, minimized surface roughness, and proper alignment help in reducing operational noise and improving durability.

4. Impact of Heat Treatment on Gearbox Longevity

Heat treatment processes, such as quenching and tempering, significantly influence the mechanical properties of gearbox components. This paper will examine the effects of various heat treatment methods on the fatigue resistance and hardness of gears, and how these processes can increase the operational lifespan.

5. Vibration Analysis for Predictive Maintenance in Gearboxes

This paper will delve into how vibration monitoring systems can detect early signs of gearbox failure. By using predictive maintenance techniques, it is possible to avoid catastrophic failures and prolong the service life of the gearbox through timely interventions.

6. Design Optimization for Reducing Gearbox Wear

Gearbox design plays a critical role in determining its wear resistance and efficiency. This paper will explore design factors such as gear geometry, load distribution, and gear ratio optimization, emphasizing how these factors reduce operational stresses and extend component lifespan.

7. Advanced Coatings for Extending Gear Life

Surface coatings like PVD, CVD, and DLC can greatly enhance the wear resistance of gearbox components. This paper will examine different coating materials and methods, comparing their effectiveness in reducing friction, preventing corrosion, and improving the gearbox’s operational lifespan.

8. Improving Gearbox Life Through Thermal Management

Thermal stress is a major cause of gearbox degradation. This paper will investigate the importance of thermal management strategies, such as improved cooling systems and thermal insulation, in preventing overheating and maintaining gearbox integrity over time.

9. Quality Control Practices in Gearbox Manufacturing

This paper will discuss the importance of quality control systems, such as ISO certifications and automated inspection processes, in improving the reliability and lifespan of gearboxes. It will focus on how rigorous testing and inspections ensure that each component meets strict quality standards before assembly.

10. The Role of Proper Installation and Alignment in Gearbox Longevity

Incorrect installation and misalignment are common causes of premature gearbox failure. This paper will focus on the importance of precision installation and alignment methods, such as laser alignment and condition monitoring, in reducing unnecessary stresses on the gearbox components and prolonging their service life.

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Anhui Dongyun Rotary mill

 Anhui Dongyun Intelligent Equipment Manufacturing Co., Ltd.

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ANHUI ANCHI Chain

 ANHUI ANCHI FORING CO.,LTD

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AOFU Check valve

 Aofu Hydraulic (Ningbo) Co., Ltd. is the exclusive operation center of German Auer in China. It highly adheres to the successful manufacturing experience, management experience, and innovative manufacturing technology of the German headquarters Aofu has established a modern production workshop and sales chain in Ningbo, thereby achieving international quality in Chinese manufacturing. Aofu has a hydraulic customized type test bench, factory test bench, spring performance and life testing machine

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AFRISO gauge

 As a full-range manufacturer, AFRISO offers a broad product portfolio from a single source. A wealth of experience from numerous applications make us a reliable partner in your industry. We know what is necessary as a result of our many years as a supplier in the OEM business and our intensive contact with standardisation committees, associations and guilds. We tap our employees' know-how and expertise in the industry to make our customers' processes simpler, safer and more competitive.

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Airsak(Jiangsu)

 Airsak(Jiangsu) is located in Suzhou. Airsak provides customers with industrial Ethernet solutions. Including (main communication protocols: Profinet, Ethernet/IP, EtherCAT, Modbus) digital IO module, cylinder sensor, electronic components, software development and other products, can be widely used in automation equipment, new energy, photovoltaic, construction machinery, automobile manufacturing, 3C equipment and other related industries.

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ABLE motor

 Able Electric Motor Group., Ltd. was established in 1993. It is a leading enterprise of the small and medium size motor, and one of the top three aluminum housing motor manufacturers in China. It integrated R&D, production and sales. There are three manufacturing bases located in Fujian Nindge, Fuan, and Shanghai Pudong area.

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San-ei Air hoist, Air crane, Air motor, air winch, air balancer

 

SAN-EI

Home > Manufacturer > San-ei >

SAN-EI SEIKI SEISAKUSHO CO LTD

Since 1925, san-ei have been a manufacture of hydraulic and pneumatic machinery. san-ei's products are air motor, air hoist, air winch, air balancer, hydraulic motor and others.

These machinery are designed and manufactured by respective qualities, and delivered to various fields as Iron manufacture, ship building, machine manufacturing, chemical plant, oil refinery, mining, consturction, automobile manufacturing etc.

In these days, san-ei's products and services are always satisfied by both domestic and overseas user. San-ei develop the new products for new age and the new field. Withourt the old habitation, all of our stuff make up the originality and the unique idea and to produce the newest machinery's and euqipment.

San-ei have a superior technology and top level facilities, we hope to solve your hard problems in mechanical, pneumatical, hydraurical. So please contact us in anytime or in anywhere.

San-ei Air Hoist


SAN-EI’s V series air hoist can help users improve work efficiency with the folloing features

1. High speed to Low speed Lift speed can be controlled from high to low speed to meet your
work’s demand.
2. Simple speed controls With the push button type, speed can be controlled by the touch
applied to the button. With the string type, by how the string is pulled.
3. Smoother operability The newly introduced unique structure provides smoother operability,
easier handling and quick response.
4. Compact and light-weight The weight is very light compared with electrical chainblocks of
the same capacity.
5. High durability for use in high temperature and humidity This hoist enables the use of
this product even in inflammable gas.
6.Effective braking Durable pneumatic brake enebles safety stop.
 

Capacity	air pressure	lifting speed	Air consumption	lift	Model	type	weight
Kg	Mpa	m/min	N-m3/min	m	-	-	kg
250	0.6	17	1.6	3	VLX25LP	Pendant	23
	0.5	15	1.3		VLX25LP-PR	Plain Trolley	40
	0.4	13	1		VLX25LP-GR	Geared Trolley	47
					VLX25LP-MR	Airmotor Trolley	47
500	0.6	12	1.6	3	VLX50LP	Pendant	23
	0.5	10	1.3		VLX50LP-PR	Plain Trolley	40
	0.4	7	1		VLX50LP-GR	Geared Trolley	47
					VLX50LP-MR	Airmotor Trolley	47
1000	0.6	6	1.6	3	VLX100LP	Pendant	33
	0.5	5	1.3		VLX100LP-PR	Plain Trolley	49
	0.4	3.5	1		VLX100LP-GR	Geared Trolley	56
					VLX100LP-MR	Airmotor Trolley	57
2000	0.6	2.5	1.6	3	VMX200LP	Pendant	45
	0.5	2	1.3		VMX200LP-PR	Plain Trolley	65
	0.4	1.5	1		VMX200LP-GR	Geared Trolley	72
					VMX200LP-MR	Airmotor Trolley	74
2800	0.6	3.5	3.1	3	VHX300LP	Pendant	115
	0.5	2.8	2.5		VHX300LP-PR	Plain Trolley	178
	0.4	2	2		VHX300LP-GR	Geared Trolley	185
					VHX300LP-MR	Airmotor Trolley	187
5000	0.6	1.9	3.1	3	VHX500LP	Pendant	115
	0.5	1.5	2.5		VHX500LP-PR	Plain Trolley	178
	0.4	1.1	2		VHX500LP-GR	Geared Trolley	185
					VHX500LP-MR	Airmotor Trolley	187

 San-ei Air Motor

San-ei VANE MOTOR（TYPE VA）（One way rotation）,VANE MOTOR（VF）（Two way rotation）,RADIAL PISTON MOTOR（TYPE DM）,GEAR TURBINE MOTOR （TYPE AGM）



Vane Motor VA

VANE MOTOR（TYPE VA）（One way rotation）

Model	Out put（0.6Mpa）
VA30	0.27kW
VA50	0.45kW
VA100	0.90kW

VANE MOTOR（TYPE VA） With Reducer（One way rotation）

Model	Out put（0.6Mpa）
VA30※-※005	0.23kW
VA30※-※010	0.23kW
VA30※-※020	0.23kW
VA30※-※030	0.23kW
VA50※-※005	0.39kW
VA50※-※010	0.39kW
VA50※-※020	0.39kW
VA50※-※030	0.39kW
VA100※-※005	0.78kW
VA100※-※010	0.78kW
VA100※-※020	0.78kW
VA100※-※030	0.78kW

Vane Air motor VF

VANE MOTOR（TYPE VF）（Two way rotation）

VANE MOTOR（TYPE VF）With slowdown machine（Two way rotation）

RADIAL PISTON MOTOR（TYPE DM）

GEAR TURBINE MOTOR　（TYPE AGM）

San-ei Air Winch



San-ei long term experiences and excellent techniques gave a birth to epoch-making Air Winches.
Versatile San-Ei's Models have been widely used in metal mining, construction, shipbuilding,
heavy machinery manufacturing, chemicals and other industries.
Easy operation [ Control Lever only ] and Safe mechanism [ Brake ] are designed.
Compact light weight can be moved quickly from one location to another.
Dusty environment is acceptable for use.
No sparks are generated.
No damage with overheat occurs even for overload.
Contiuous operation at full capacity is available.
Drum diamter is large enough to prolong life of rope.

This is the multi-purpose air winch and it is attached standard radial piston type air motor, and control valve.The handling of this winch can be easily and safety.We delivered to various fields as Civil and building construction, Shipyard, Off-shore usage and others.

POPPET/SPOOL VALVE is used for the control valve to eliminate air leakage.
Reverse revolution is available. VALVE HANDLE operation allows free handling of the load,
as air flows into the control valve.
Strong RADIAL PISTON AIR MOTR is built in.
OIL DISC in the SEALED CRANK CASE contains oil bath lubricates all sliding parts.
BALL/ROLLER BEARINGS minimize friction loss.
Set-up reduction ratio works on rope pull and rope speed.
CLAW CLUTCH mechanism allows safe,accurate handling in locked ON/OFF positions.
BAND BRAKE manual or automatic.
SEALED BALL BEARINGS completely prevent oil leakage from the casings.

AH- 1C 2 kN
W- 05 -03  5 kN
W- 10 -220 10 kN
W- 20 -220 20 kN
W- 30 -36 30 kN
W- 50 -36 50 kN

NAME	SAN-EI SEIKI SEISAKUSHO Co., Ltd
REPRESENTATIVE	Etsuko Yamamoto
ESTABLISHMENT	May, 1925
CAPITAL	JP Yen 50,000,000

History

1925-5-1	Establish to SAN-EI SHOTEN in Otaru-city Hokkaido as the dealer of the mining machinery
1935-4-1	Named SAN-EI　SHOTEN Co,.Ltd and establish as annex to SAN-EI SEIKI SEISAKUSHO for the manufacturer of the Air Motor, Air Winch, Rock drill.
1938-10-1	Move head office to Tokyo city, and start branch factory and branch office in Korea and North China.
1942-4-1	Designated by government as a munitions factory to produce Semi diesel Engine, Aircraft Parts etc.
1946-4-1	Designated by the Ministry of Commerce and Industry as a mining machinery manufacturer.
1954-10-1	Move head office to Otaru-city and start Tokyo office and Fukuoka branch.
1961-6-1	Established Fukushima factory in Kohri-cho Date-gun Fukushima to increase the production of the Air Motor.
1963-10-1	Start Osaka branch and renamed Fukushima factory as KOHRI SEIKI SEISAKUSHO Co.,Ltd.
1967-4-1	Start manufacturing of Hydraulic Motor.
1975-4-1	Rename SAN-EI SEIKI SEISAKUSHO Co.,Ltd. to OTARU SEISAKUSHO Co.,Ltd. and to produce the other field's goods.
1975-5-1	Rename KOHRI SEIKI SEISAKUSHO Co.,Ltd. to SAN-EI SEIKI SEISAKUHO Co.,Ltd. and succeed to manufacturing.
1976-1-1	Obtain the Permission of Crane and Hoist Manufacturing.
1978-12-1	Increase the capital to \20,000,000.
1984-1-1	Increase the equipment investment to \200,000,000. by purchasing the machining centers.
1989-2-1	Inaugurate Mrs. Etsuko Yamamoto as the president.
1992-3-1	Start manufacturing of Air Balancer.
1995-4-1	Restrict the organization to unite business section and production section.
1998-5-1	Increase the capital to \50,000,000.
1998-9-1	Move Tokyo office from Nihonbashi to Asakusabashi.

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