CASE STUDY 1, MANUFACTURING FIRM 2013
Spur Gears can be noisy, due partly to their point of contact in meshing. They require having a good surface finish on their flanks and running true to their datum’s. Also if the correct procedures are not followed, process operations such as heat treatment can sometimes cause both growth and shrinkage.This can be a problem if the sections of the gear are thin.The client had informed us that he was not happy with the quality of the gears or the overdue deliveries he had been receiving from his current supplier. LMR produced prototype quantities within 14 days and they were immediately approved. The main batch followed on its due date and these comments were received the following day
The main batch followed on its due date and these comments were received the following day:
"We have installed 20 of the gear sets you provided and they have been a great success, so many thanks on solving a 5-year problem."
LMR looked at the distortion problems the previous supplier had experienced and identified the need to change the production and heat-treatment procedure.
Prior to gear cutting, the journals of the gears were pre-ground true to their centres. The gear-cutting operation was then carried out from these datum’s. The heat-treatment was modified to Low Pressure Carburising and Vacuum hardening which produces minimum distortion. When the gears came back from hardening they were finished ground using the same centres. Upon inspection the gears were found to be true to their datum’s thus producing quiet and efficient drives.
Our technicians have extensive knowledge of gear design and manufacturing procedures, which have been acquired over many years.
CASE STUDY 2, MANUFACTURING FIRM 2013
LMR has for years manufactured Spur Gears for one of the largest transportation corporations in America. They are supplied in pairs. One is manufactured from SG Iron the other from Phosphor Bronze.
They are in common use on the underground and on most main line stations. You will be familiar with the units once you have purchased your fare. As you swipe your ticket, the gears are used to open and close the paddles on the gates. The bronze gear is mounted directly on the motor shaft the other on the paddle.
Our customer was faced with a problem, if you were to “Drop Kick” the paddles you could sometimes move them thus gaining access without paying.
The gear was either keyed to the shaft, or in some applications, secured by the use of a roll pin. How could we add a further locking mechanism to prevent this from happening?
The gear had a boss, approximately 56 m/m in diameter and 18 m/m long. We machined a 12 m/m hole through the boss; we then manufactured two spacers 12 m/m in diameter by 10 m/m long.
One of the spacers had a 6 m/m thread the other a 6.1 clearance hole.
We then machined a radius on the edges of the spacers, which was the same diameter as the shaft the gear was mounted on. With the use of a 6 m/m cap screw the assembly was complete.
The two spacers were positioned through the boss, the 6 m/m cap screw drew the threaded spacer onto the mounting shaft drawing the clearance spacer with it, the radius on the spacers gripped the shaft securely locking it, this additional arrangement solved the problem.
CASE STUDY 3, CCTV Firm
We were contacted by a company supplying CCTV cameras for the 2014 World Cup, they had been seriously let down by their supplier, they required sets of gears within 3 days.
Works Manager visited the company in the Midlands the following morning to discuss requirements, then on to Nottingham to start sourcing materials. Back at LMR a 24 hour shift pattern was instigated to meet initial customer requirements.
Order was completed and delivered within turnaround time. The customer sent this comment to LMR,
"In all my years in manufacturing I have never experienced a service such as yours, none of the staff here can believe what you did, congratulations Mick to you and all your staff, you have just won a new customer"
LMR are now supplying over 1000 gears per month to this company
Case Study 4, Manufacturing Firm
Machine Failure - Lynx Deodorant - part of the production facility in the factory was shut down costing the company £2000 per hour.
Taxi couriered gearbox to LMR Friday late afternoon and photo of problem emailed to LMR.
Using photos and information received from customer, the material was sourced and collected from London.
LMR immediately arranged a night shift pattern, the 2 broken parts were reverse engineered and the gear box rebuilt. In the early hours of Saturday morning the goods were delivered by LMR and we had the machine up and running by 8.30am, thus saving the customer thousands of pounds in lost production. The customer sent this comment to LMR,
"Thank you for the excellent service that we received by LMR, we are all extremely impressed and would wish to thank your staff for all their efforts"
This company now has a 24 hour call-out arrangement with our company which has been used on many occasions since