Mechanical Assembly Service
Mechanical assembly service is the core of the manufacturing industry, mainly including the following professional services:
1.1 Precision parts assembly services, new energy batteries;
1.2 Precision assembly of bearings, shafts, gears, couplings and other key transmission assembly, such as reducer, gearbox, sun wheel set;
1.3 Integrated assembly of hydraulic and pneumatic systems, such as cylinders and valve bodies;
1.4 Hydraulic cylinder assembly: such as hydraulic cylinder and its assembly system;
1.5 Reducer and transmission system assembly, such as transmission, torque converter;
1.6 Gear box assembly, such as large gear box;
1.7 Planetary reducer assembly, such as small drives;
1.8 Industrial robot system integration, such as robot manipulator;
1.9 Intelligent conveying system assembly, such as intelligent logistics car;
1.10 photovoltaic tracking system assembly, solar tracking photovoltaic panels;
1.11 Wind power gearbox assembly, such as wind power turbocharger;
Steering power cylinder application in wind power field variable pitch system cylinder
Yaw brake cylinder hydraulic station performs cylinder solar tracking system cylinder
Clean robot hydraulic actuator mine support regulating cylinder hydrogen energy application
Hydrogen storage tank test cylinder Hydrogenation gun actuator fuel cell stack pressure loading cylinder
For more details, please link to Blog
2. Component composition and key process of cylinder assembly
1.1 Precision parts assembly services, new energy batteries;
1.2 Precision assembly of bearings, shafts, gears, couplings and other key transmission assembly, such as reducer, gearbox, sun wheel set;
1.3 Integrated assembly of hydraulic and pneumatic systems, such as cylinders and valve bodies;
1.4 Hydraulic cylinder assembly: such as hydraulic cylinder and its assembly system;
1.5 Reducer and transmission system assembly, such as transmission, torque converter;
1.6 Gear box assembly, such as large gear box;
1.7 Planetary reducer assembly, such as small drives;
1.8 Industrial robot system integration, such as robot manipulator;
1.9 Intelligent conveying system assembly, such as intelligent logistics car;
1.10 photovoltaic tracking system assembly, solar tracking photovoltaic panels;
1.11 Wind power gearbox assembly, such as wind power turbocharger2.1 Core components of the cylinder
Cylinder assembly: high strength alloy cylinder or fine drawn tube
Piston rod assembly: piston body, wear-resistant piston ring
Piston rod assembly: forging + precision machining + chrome plating + precision grinding machining of the whole piston rod
Connector: end cover (forgings), flange (forgings) to avoid sand holes, guide sleeve
2.2 Sealing system assembly:
Sterseal combination seal
Glace circle installation
Dust ring pressing
2.3 Performance Test Verification
Verification, testing and yield testing of materials
Withstand voltage test
Oil pressure or air pressure leak test
Durability test
2.4 Typical applications of oil cylinders
Electric vehicles use the battery pack lift cylinder change mechanism to execute the cylinder;
3.the components and key processes of the reducer
As the core part of the industrial transmission system, the performance of the reducer and the precision of the assembly directly affect the operating efficiency, reliability and life of the equipment.
3.1. Core components of reducer
3.1.1 Gear system (core transmission components)
Cylindrical gear (spur gear, helical gear)
Planetary gear (sun wheel, planetary wheel, inner gear ring)
Worm gear
Technical requirements:
Materials: SAE8620H (carburizing and quenching), 42CrMo4/4140 (tempering), 16MnCr5, 35MnCr5
Accuracy level: ISO 1-12 (the smaller the number, the higher the accuracy level)
Heat treatment: carburizing quenching (HRC58-62), nitriding (improve wear resistance)
Tooth surface treatment: grinding/honing (Ra≤0.8μm), reduce noise
3.2 Shafting components (support and drive)
Input shaft gear: connect the motor, connect the input power;
Intermediate shaft gear: After power input, through the multi-stage reduction shaft gear in the reduction structure, reduce speed and increase torque, increase horsepower output;
Output shaft gear: Power and torque input through the intermediate gear shaft to the output shaft gear, at which time the output shaft is connected to the load, so that the motor power is converted into other energy functions, such as (propeller yacht)
Gear ring: fixed input shaft, intermediate shaft, output shaft, static transmission principle, but its role in the deceleration system is no less than other gears and shafts.
Technical requirements:
Material: 4140, 42CrMo4, 40Cr (high strength alloy steel)
Heat treatment: tempering (HB229-320), carburizing and nitriding treatment (improve wear resistance)
Accuracy: radial runout ≤0.01mm, axial channeling ≤0.03mm
Surface treatment: Grinding (Ra 0.4-0.8μm), rust-proof lubricating oil
3.3 Box (structural support and seal)
Cast iron case (HT250, high rigidity)
Large gear ring (42CrMo4), if at sea, you need to do dacromet anti-corrosion external surface treatment
Technical requirements:
Rigidity: Resistance to deformation (optimization by finite element analysis)
Sealing: Joint surface sealant (oil resistant type), shaft end with oil seal/labyrinth seal
Heat dissipation: reinforcement design/forced lubrication (high power reducer)
3.1.4 Bearing (support and friction reduction)
Deep groove ball bearing (light load high speed)
Tapered roller bearing (heavy load, high axial force)
Technical requirements:
Precision: P5/P6 (high precision)
Lubrication: grease lubrication (long-acting grease) or oil lubrication (forced circulation)
Life: L10 life ≥20,000 hours (heavy duty)
3.4 Application of reducer
Differential reduction all-in-one wheel drive reducer wind power applications
Main gearbox variable speed reducer photovoltaic power generation application
Tracking system reducer cleaning robot reducer energy storage system application
