MEGASYNC™ Titanium

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.

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.

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.

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.