Improvement of processing and production efficiency, cost reduction (Proposal to replace Ball screws)
In the existing equipment, a ball screw is used in the feeding and cutting process of the workpiece.
Because the workpiece is several meters long, a rack-and-pinion system was initially considered for the feeding mechanism. However, due to the effects of backlash, stopping accuracy was insufficient. Achieving precise positioning would have required additional mechanical components and control systems, and the idea was abandoned due to cost and space constraints.
The current system therefore uses a ball screw. However, the large reduction ratio results in slower feed and return movements, leading to lower production efficiency.
Furthermore, since a long ball screw is required, a larger shaft diameter is used to prevent deflection, which increases overall costs.
Because the workpiece is several meters long, a rack-and-pinion system was initially considered for the feeding mechanism. However, due to the effects of backlash, stopping accuracy was insufficient. Achieving precise positioning would have required additional mechanical components and control systems, and the idea was abandoned due to cost and space constraints.
The current system therefore uses a ball screw. However, the large reduction ratio results in slower feed and return movements, leading to lower production efficiency.
Furthermore, since a long ball screw is required, a larger shaft diameter is used to prevent deflection, which increases overall costs.
Solution/Countermeasure
To address both transport speed and cost issues, we are considering replacing with TCG runners. Five additional 1-meter racks will be connected and installed for prototyping and evaluation. TCG runners can be extended by connecting additional racks. Unlike ball screws, there is no concern about bending, enabling stable long-stroke transport. Additionally, unlike conventional spur gears, which rely on contact and meshing principles, the TCG system achieves rolling contact through rack tooth profiles using a trochoid curve and pinions with roller pins, providing backlash-free high-precision positioning and excellent maintainability (low wear and low dust generation).
Effects/Benefits
By adopting TCG runner, high-speed operation was achieved while maintaining the required stopping accuracy. It became possible to accelerate and decelerate smoothly without the backlash seen in spur gears. Additionally, replacing the larger diameter ball screws contributed to cost reduction.
1. Improved production efficiency through high-precision positioning and increased speed.
2. Achieved smooth acceleration and deceleration with non-backlash.
3. Contributed to cost reduction by replacing larger diameter ball screws.
1. Improved production efficiency through high-precision positioning and increased speed.
2. Achieved smooth acceleration and deceleration with non-backlash.
3. Contributed to cost reduction by replacing larger diameter ball screws.
Products Used：
TCG Runner,
CRA&CPA / CRC&CPC series
Related Applications
