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Success Stories

Planetary Gearbox for Aluminium Settler/Thickner Gearbox

CHALLENGE:

Earlier client was using European planetary gear boxes which showed Recurring failure.

SOLUTION:

Top gear analyzed the problem and identified root cause behind failure of planetary gear boxes. Top Gear redesigned gearboxes with splined forged output shaft along with heat treatment and nitriding, and capable to withstand high torque. The planetary drive was designed in such a way that it exactly matched to existing mountings with increased factor of safety.

Results:

Top gear replaced all the 24 Nos. of imported gearboxes. These gearboxes are running successfully for last 8 to 10 years without any failure. Client also achieved Substantial cost saving

Review from client

It was very much difficult for us to get service & spares support from those earlier installed imported drives which showed frequent problems. Top Gear has provided us with high quality of products which served as better solution to match our requirements. Now we are getting proper support & service from top gear & our all drives are performing well.
Client Name :-

Client Name :-

National Aluminium Company Ltd.

Product Name

Planetary Gearbox

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Hoist Planetary Gearbox For EOT Cranes

CHALLENGE:

The conventional hoist used by client was having helical open gearing which was bulky in design and required more space.

SOLUTION:

Top gear designed a special kind of gearbox for hoist drive. This gearbox is designed in such a way that it completely fits inside the drum and has output shaft splined. The shaft is being locked & drive to the drum is given by annulus. B5 mounted brake motor is mounted outside the drum on the flange. These gearboxes are supplied with long life synthetic lubricants.

Results:

Earlier Hoist design was replaced by very slim concentric drum design. This resulted in Compact Gearbox solution which was economical and had high efficiency and improved life.

Review from client

The structural cost drastically reduced with compact planetary gearboxes. These Planetary gearboxes are more efficient & maintenance free. These gearboxes are best suitable for hoist application.

Client Name :-

Client Name :-

Hercules Hoist Ltd

Product Name

Hoist Drive

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Planetary Gearbox For Construction Bar Bending Machines

CHALLENGE:

Earlier Client used the conventional gear box with spur gearing for bar bending machine. These kind of gearboxes were bulky in size & gave various maintenance issues such as belt failure. This kind of gearbox required separate hub to mount on gear box output shaft.

SOLUTION:

Top Gear designed special planetary gear box with hollow out put shaft to which the bending wheel of machine is attached. This arrangement eliminated the need of other connecting parts resulting into simple construction. This kind of gearbox was offered with flange mounting for direct attachment of the motor to eliminate the belt pulley arrangement. This drive was supplied with long life synthetic lubricants.

Results:

Client got a simple solution for bar bending machine which was very easy to install and simple in construction. This drive increased the efficiency of bar bending machine and reduced the number of parts thereby reducing the cost. High torque was available due to utilization of multiple planet planetary drive. This drive resulted in increased production capacity of Equipment Manufacturer.

Review from client

The efficiency of bar bending machines increased after utilization of planetary drive. Operational cost reduced due to less maintenance.
Client Name :-

Client Name :-

Spartan India Pvt Ltd.

Product Name

Planetary Gearbox

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Planetary Gearbox For Travelling Grate

CHALLENGE:

Earlier client was using hydraulic drives which were inefficient in operation. The movement of travelling grate was not uniform which resulted into jamming and showed lot of wear and tear in rachet and pawl. This drives had more operating & maintenance cost for hydraulic oil pumps & accessories. There were lot of leakage problems observed due to use of this drives. Cost was also very high. High maintenance due to oil replacement.

SOLUTION:

Top gear designed highly efficient planetary drive with high reduction ratio designed in foot & shaft mounting to suit properly for the given application.

Results:

Uniform movement of travelling grate was achieved which eliminated Jamming and wear & tear of Rachet Pawl. Earlier energy conversion was from electric to hydraulic and from hydraulic to mechanical, in this arrangement energy conversion was directly from electric to mechanical which resulted in less energy losses and helped to achieve huge power savings(about 40%). Installation of direct shaft mounted drives eliminated the leakage problems. Compactness of drive resulted into more space saving. This drive also reduced initial cost of installation with negligible operating & maintenance cost.

Review from client

The drives are efficient & its initial cost is very much less compared to Hydraulic drives. These drives are maintenance free.
Client Name :-

Client Name :-

Sitson India Pvt Ltd

Product Name

Planetary Gearbox

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Planetary Mixer Gearbox For Concrete Mixing

CHALLENGE:

Earlier client was using Agitator type concrete mixer. Wherin the drive was given through bottom and required various mechanical arrangements such as couplings and seperate bearing housings. There was only pushing of concrete so mixing was inadequate. The mixing of concrete with the help of this mixer was very slow & non uniform.

SOLUTION:

Top Gear designed Planetary mixer drive with mixing arms and scrapping arm.The arrangement of gears were done in such a way that the mixer arm rotated at high speed as compared to that of scrapper arm. The mixing arm was designed to be rotated along their own axis as well as while rotating along their own axis they rotated along common axis of gear box.

Results:

This kind of arrangement provided high homogeneous mixture in shorter mixing time. High quality gearbox with perfectly selected RPM resulted in to less energy consumption and increased the service life of the mixers. For mixer manufacturers it was very easy to mount this drive at top of vessel without any critical alignment and accuracy. Use of double speed planetary drive served as an economical solution for better & uniform mixing of concrete. The new method used for mixing was easy to install compared to earlier method. Now customer can fit direct drive to get double speed mixing process.

Review from client

Top Gear Provided us highly effective and Cost benefit solution. Compressive strength of concrete mixture increased due to proper collision effect. Mixing cycle time is reduced. The planetary mixer drive is very Easy to install.
Client Name :-

Client Name :-

Balaji Construction Machines and Spares Pvt.Ltd

Product Name

Planetary Mixer

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Towing Winch for Bulldozer

CHALLENGE:

Earlier client used tjap towing winches in bulk volumes which resulted in huge inventory carrying cost and high lead time. The spare parts were also not easily available to client. Morever there was no Flexibility or adaptability for any internal change in design.

SOLUTION:

Top gear studied existing design and redesigned the product taking into consideration the equivalent Indian material. The Prototype was developed taking into account various constraints and requirements specified by client. The prototype was tested rigorously at factory as well as site. Further Design modifications were done as per customer requirements. Design was validated as per the customer requirements followed by free trials

Results:

Now Client can purchase the product as per his requirements which reduced the inventory carrying cost. The product is easily available to client with minimum lead time. The Spare parts are also easily available to Client with quick service support. Top Gear also provided the flexibility to client to adapt for any internal changes in design.

Review from client

The Towing Winch gave results equivalent to those imported earlier. It met all the functional requirements and passed the tests specified by BEML. As a result of which few towing winches were sent to UNESCO by Indian army. Inventory carrying cost and lead time was also reduced due to successful supply of towing winch from Top Gear Transmissions.
Client Name :-

Client Name :-

BEML India

Product Name

Towing Winch

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Auxiliary Gearbox for mobile cranes

CHALLENGE:

Earlier client was buying entire driveline assembly. This resulted in huge inventory carrying cost and time. To reduce the cost and time client demanded auxiliary gearbox separately to suit various Make of drive axles. The effective working of crane demanded variation in speed as per the different driving conditions. For example cranes require high speed while running on plane roads whereas very low speed in off road conditions. The earlier gearbox used in cranes failed to meet this low speed requirement in off road conditions and increased the chances of accidents.

SOLUTION:

Top Gear studied the speed requirements of cranes for different driving conditions. Accordingly Auxiliary gearbox was designed to match the both high speed and low speed requirements of crane for effective working of cranes. The auxiliary gearbox was developed in such a way that it was suitable for various make of drive axles.

Results:

The supply of individual Auxiliary Gearbox suitable for different makes of drive axles eliminated the need of buying entire drive line assembly and reduced the overall product and inventory carrying cost. Client got the design solution which was more suitable for their equipment. This Auxiliary gearbox served as an cost effective solution that enhanced the performance of cranes. This overall resulted as a safe and reliable product for end users.

Review from client

ACE LTD is in crane manufacturing since last 25 years and developed new generation cranes 20 years back.
2. As per our requirement M/S TOP GEAR developed AGB and winches for our new generation cranes and supplying since last 20 years.
3. At initial stage there were few problems and immediate corrective actions were taken by M/S Topgear with excellent service support.
4. As on date we are getting stable product with respect to quality and supply.
Client Name :-

Client Name :-

Action Construction Equipments

Product Name

Auxiliary Gearbox

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Centrifuge cycloidal gb for Decanter

CHALLENGE:

Before this client was importing such kind of centrifuge drives from other country as there was no manufacturer of cycloidal Centrifuge drive in India . Client was in search of Indian manufacturer so as to reduce the overall cost and inventory carrying cost of product. Immediate availability of spare parts and local service support was something that client was craving for.

SOLUTION:

Top Gear studied and analyzed the working of decanter and its application. Taking into consideration the dimensional constraints and other requirements top gear designed & developed cycloidal centrifuge drive. Due to high speed application top gear specifically selected the tolerances and accuracy of internal components to meet functional requirements. Top gear also ensured proper dynamic balancing of this gearbox due to its high speed application. The Design was validated at factory level for actual simulated conditions. Top Gear transmissions earlier experience in planetary centrifuge drive was the driving force behind successful development of Cycloidal centrifuge drive

Results:

As a result of this clients like MBE coal got Indian manufacturer who can manufacture cycloidal centrifuge drive fulfilling all accuracy and quality requirements of this drive. This reduced the inventory carrying cost with immediate spare parts availability and service support.
Client Name :-

Client Name :-

MBE Coal

Product Name

Centrifuge Drive

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Shaft mounted drive for Mill Drive

CHALLENGE:

In ancient time the drive to mill was given through Steam turbine. Which was further replaced by electric motor. Electric motor was connected to mill roller with two bulky helical gearboxes and open gearing. This kind of arrangement accommodated large space and resulted in huge transmission and energy losses.

SOLUTION:

Top Gear Transmissions designed and developed highly efficient shaft mounted mill drive that can be directly attached to individual rollers.

Results:

Mounting of shaft mounted mill drive to individual rollers eliminated the need of various mechanical components such as huge bulky high cost foundation, high cost wire rope coupling and in between pinions. This reduced the power consumption and energy losses. This arrangement was also very compact and huge space was saved as compared to conventional drive. As a result huge power and cost savings were achieved which were highly appreciable. This kind of arrangement had an additional benefit of Precise speed setting of individual rollers which helped to get desired output results.
Client Name :-

Client Name :-

Meru Industries

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Drive for platform truck

CHALLENGE:

Client had designed a platform truck wherein dc electric motor was used to drive the axle. Two stage helical gearbox was used for speed reduction. This kind of arrangement had an impact on ground clearance of the vehicle due to offcentre helical gearbox and its size.

SOLUTION:

Top Gear suggested the use of inline planetary drive to client. The planetary drive was designed in such a way that its output shaft had an flange coupling to directly connect to propeller shaft. To take into account the high radial load due to propeller, the planetary gearbox was designed with taper roller bearings. The speed reduction was achieved in single stage of planetary drive which in turn resulted into high efficiency of the drive.

Results:

This solution served as an cost effective solution to the client as lot of cost was saved due to implementation of inline planetary drive. Inline planetary drive also eliminated the problem of ground clearance of the vehicle due to its compactness. The client received the product as per their planned schedule. This overall resulted into supply of highly efficient and reliable product to the client.
Client Name :-

Client Name :-

Godrej

Product Name

Planetary Gearbox

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