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Glass Manufacturer
Glass sheets transferred from production to stacking were still warm. As a result, glass stuck to the belts , leaving the belts’ herringbone cover as an impression on the product. This required the manufacturer to remove the marking from the glass before shipping. In some cases, glass went into the market, which led to customer complaints. To address the situation, the manufacturer had to slow production and introduce a cleaning method . This led to increased production costs and lower glass production output.
Read moreAluminum Handling
In the extrusion process, the extremely high product temperature reached is the key factor for the selection of the correct transfer belts used. Megadyne, working closely with an aluminium extrusion facility, provides specially fabricated belts to meet the demanding environment. Are you involved in a similar project? Read more about this case study.
Read moreConveyor Belt System Motor Drive
SITUATION/APPLICATION A leading industrial facility was facing persistent challenges with its conveyor belt system, primarily due to inefficient power transmission from the motor to the belt. The frequent wear and tear of components led to regular maintenance, unplanned downtimes, and increased operational costs. Moreover, the existing system was bulky, consuming valuable floor space and limiting flexibility in the facility’s layout. The company needed a solution to improve the system’s reliability and efficiency while reducing space requirements. THE PROBLEM The current belt system was underperforming, struggling to transmit the required power effectively, and wearing out prematurely under heavy loads. As a result, the conveyor required frequent belt replacements, causing regular disruptions to production. Additionally, the large size of the power transmission system limited the facility’s ability to optimize space for other critical operations
Read moreRoller Conveyors Transmission
SITUATION/APPLICATION In ceramics manufacturing, tiles need to be moved, sorted, or processed on smooth and efficient transportation system. Overall, belts are integral in ensuring the synchronized movement of rollers, thereby providing an efficient and controlled method for transporting tiles across different stages of processing lines. THE PROBLEM Standard belting solutions can encounter significant issues: – Rapid wear of the toothed side due to constant start-stop operations in the roller conveyors. – Reduced performance, caused by high ambient temperatures and abrasive ceramic dust. In addition, the increasing weight of ceramic tiles, from as little as 0.01 kg to 200 kg, demanded greater force for movement, stressing the belts and further decreasing their lifespan. This results in frequent downtime and high maintenance costs.
Read moreBlower Intake On Drag Race Car
SITUATION/APPLICATION A blower intake on a dragster is part of the forced induction system designed to significantly increase the engine’s power output. The blower, or supercharger, forces more air into the engine’s combustion chambers than would normally enter through natural aspiration. This increased air allows for more fuel to be burned, which in turn generates more power. The intake specifically directs this compressed air into the engine. In drag racing, where performance and speed are critical, the blower intake helps maximize the engine’s efficiency, resulting in higher horsepower and faster acceleration down the track. THE PROBLEM The drag racing community faced challenges with the longevity and performance of belts installed in blowers for their monstrous engines. These engines push an astounding 1800 ft-lbs at 2,000 horsepower, with a staggering 7,700 RPM at the motor. When we discuss performance at this level, the stakes are extremely high. Through one of our valued distributors, our sales team reported a recent installation of the MEGASYNC™ Titanium belt in the blower of a drag race car. This isn’t just any drag race car. These vehicles can speed through a quarter mile in less than 5 seconds, with the belt enduring up to 7,200 RPM on the blower for the engine. The belts in this application were being replaced every 5-6 times down the 1/4 mile track.
Read moreGlass Breaker
SITUATION/APPLICATION Recycling converts waste materials into new materials while reducing the consumption of fresh raw materials. It also benefits the environment by reducing energy usage, air pollution (from incineration), and water pollution (from landfilling). A key process in recycling is the reclamation of food and beverage glass containers. They are 100% recyclable and can be recycled endlessly without loss in quality or purity. They can substitute up to 95% of fresh raw materials and over a ton of natural resources are saved for every ton of glass recycled. Glass Breakers are an essential piece of equipment used in the glass recycling process. They crush the glass and reduce it to a uniform size acceptable to the recycling process. These units require a very strong, compact and reliable drive system that guarantees long life. They must withstand years of punishing use with minimal maintenance. THE PROBLEM A manufacturer contacted Megadyne with the challenge of designing a cost effective, compact drive system to actuate the rotating, glass-crushing drums of a glass breaker. They required a durable light weight system with low maintenance requirements. Due to the great amount of torque required to rotate the drums, a very strong drive system was required
Read moreFlat-bed Die Cutting Machine
SITUATION/APPLICATION A flat-bed die-cutting machine is a crucial tool in the paper industry, for its ability to produce high-quality, precise cuts and designs, which are critical for various paperbased products. The machine typically consists of a flat cutting bed (that holds the die) and a moving platen pressing the material against the die to create precise cuts and shapes. Many modern flat-bed die-cutting machines are automated, featuring computerized controls for greater efficiency, accuracy, and speed. THE PROBLEM The belts in the die-cutting machine are subjected to high and irregular torque. This strain can cause wear, tear, and frequent belt breaks. Belt failures cause unplanned downtime, disrupting the production schedule and reducing overall efficiency. Frequent belt replacements increase operational costs. On top of that, irregular torque can lead to inconsistent cutting quality, affecting the final product’s appearance and functionality.
Read morePelletizers
SITUATION/APPLICATION Pelletizers are machines that form material into the shape of a pellet for various uses. The material is compressed through a die to form the pellets. A wide range of different materials are pelletized including chemicals, iron ore, animal feed and wood pellets used for burning in heating stoves. Pelletizers commonly utilize a two-stage belt drive transmission to achieve the proper gear reduction for desired die speeds. The first stage is normally a shockabsorbing v-belt while the second stage is driven by a synchronous belt. These belts offer a reliable, cost effective, and efficient system with a compact design. THE PROBLEM A Pelletizer manufacturer contacted Megadyne regarding issues with their two stage drive. While some slippage was desirable to absorb frequent peak shock loads on the first stage of the drive, the standard raw edge rubber v-belts used did not last very long on this demanding drive. The slippage caused by the frequent peak loads generated excessive heat, reducing the belt life to unacceptable levels. The second stage of the drive also had problems. The polyurethane synchronous belt suffered shrinkage caused by elevated temperatures. The heat was generated by the high flex rate of the belt due to the excessive speed of the drive. The resulting shrinkage increased belt tension, negatively affecting belt and bearing life and requiring frequent and expensive replacement of both. Additionally, the customer considered the stiffer, less flexible, polyurethane belt to be more difficult to install. These problems all combined to reduce the efficiency and productivity of the machine.
Read moreFood filling machine
Designed to minimize the area required for parking cars, the use of automated parking systems (APS) is becoming more popular in urban areas. In multi-story parking garages they provide parking for cars on multiple levels, stacked vertically to maximize the number of parking spaces while minimizing land usage.
Read moreVertical lift modules
As space becomes increasingly limited, the focus has shifted towards maximizing storage capacity and efficiency. The OEM, already in the design phase of a new solution, sought to address these challenges by reducing the space occupied by vertical storage modules while enhancing their overall performance. The goal was clear: develop a next-generation vertical lift modules that would occupy 90% less space than a traditional ones (with the same amount of stored goods), operate more quietly, consume less energy, and ensure fast and secure retrieval of goods. Read more!
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