Improving Equipment Speed and Simplifying Maintenance
The existing equipment (pipe bender) uses a ball screw mechanism. A new long-stroke model is under consideration for development; however, a long ball screw causes deflection and results in significant vibration. In addition, the takt time is too long to meet the specifications required by the customer, making it difficult to meet customer requirements. A spur gear rack-and-pinion system was also considered, but issues related to stopping accuracy, noise, and maintainability could not be resolved.
Solution/Countermeasure
To achieve higher accuracy, faster operation, and lower noise levels, the adoption of the TCG Runner was explored. Furthermore, to enhance maintainability, a prototype was built and evaluated in combination with the TCG Lubrication Supply System "TLS".
The TCG Runner differs fundamentally from conventional rack-and-pinion mechanisms in its contact and meshing principle. It achieves rolling contact through the meshing of a rack with a tooth profile based on a trochoidal curve and a pinion using roller pins.
This design delivers non-backlash, high-precision positioning and excellent maintainability (low wear and low particle generation), which led to its adoption.
Effects/Benefits
By adopting the TCG Runner, it was possible to achieve higher operating speed and improved quietness while maintaining high precision.
In addition, the combined use of the TLS (TCG Lubrication Supply System) — a solid lubricant mounted on the pinion — significantly improved maintainability, contributing to a reduction in maintenance frequency and running costs.
* TLS (TCG Lubrication Supply System) is a system that supplies lubricant to the TCG Series. A special porous resin is impregnated with high-viscosity lubricating oil. By keeping it in contact with the roller pinion, an appropriate amount of lubricant is automatically supplied to the contact surface, ensuring that an oil film is constantly formed on the meshing surfaces. No replacement is required until the end of the pinion's rotational service life. When used in combination, initial lubrication is not required, and no additional lubrication is needed, enabling virtually maintenance-free operation.
In addition, the combined use of the TLS (TCG Lubrication Supply System) — a solid lubricant mounted on the pinion — significantly improved maintainability, contributing to a reduction in maintenance frequency and running costs.
* TLS (TCG Lubrication Supply System) is a system that supplies lubricant to the TCG Series. A special porous resin is impregnated with high-viscosity lubricating oil. By keeping it in contact with the roller pinion, an appropriate amount of lubricant is automatically supplied to the contact surface, ensuring that an oil film is constantly formed on the meshing surfaces. No replacement is required until the end of the pinion's rotational service life. When used in combination, initial lubrication is not required, and no additional lubrication is needed, enabling virtually maintenance-free operation.
Products Used：
TCG Runner,
CRA&CPA / CRC&CPC series
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