|
|
|
Custom Design Solutions
At Mach III a free flow of communication and cooperation between engineering, sales and production staff provides us with the ability to design and manufacture custom tailored products quickly and economically. Mach III has no minimum order quantities for custom designs and delivery times average only one week longer than for catalog standard products. Below are just a few examples of the requirements and conditions we can accommodate:
- Length and diameter restrictions
- Special pulley, sprocket or sheave specifications
- Corrosive and food handling environments
- Foot bracket mounting
- English to metric component coupling
- Keyless Shaft/Hub Locking Devices
- Special flanges and adapters
We’ve manufactured more than ONE THOUSAND custom products, below are a few examples.
|
 Taming the Gorilla
Mach III was contacted by a facility which uses large manually operated control valves. The quarter-turn valves are driven through right angle worm reducers by hand operated chain wheels. Due to the unfortunate fact that human beings are not equipped with torque sensors in their muscles, costly downtime failures were occurring when excess force was applied to the worm reducer via the chain wheel. Working with the facility's engineer, Mach III designed a special, keyless, friction torque limiter to connect the chain wheel to the reducer shaft.
In addition to designing and manufacturing the torque limiter, Mach III also provided the customer with a mounting diagram (Click here to view) including suggested dimensions for machining their existing chain wheel to accept the new device. Although Mach III offers the service of machining existing mating components, in this case the customer's shop felt comfortable with the task. The torque limiter was successfully installed and adjusted to a setting where it would slip to protect the worm reducer when the shop gorilla swings on the chain.
Those accustomed to working with other clutch suppliers might assume that only an application promising considerable quantities would merit this level of attention. But this customer needed only three torque limiters, and spent just about one thousand dollars. So what is the motivation? A report from the customer that the new system "worked perfectly".
If you've got a nagging issue needing a clutch, brake or torque limiter solution and are concerned that no one will think it's worth their while, give Mach III a call. We know you will be pleasantly surprised.
Gorilla Image from: www.kidsplanet.org |
|
Wash-Down Compatible Replacement for Electric Clutch
The clutch pictured at the left was designed for a wash-down conveyor system at a commercial bakery facility. The electric c-face clutches that were originally installed on the system were failing on an hourly basis and they quickly needed a clutch suitable for wash-down that would fit in the existing restricted space while providing more torque and additional support for the failing input bearings. Mach III met all of the design requirements and delivered eleven clutches within four weeks of the initial inquiry. After a successful trial period, the bakery commenced replacement of thirty additional clutches on the system. |
|
Food-Safe Combination Air Set Clutch / Air Set Brake
A manufacturer of food packaging equipment contacted Mach III looking for a combination clutch/brake which would stop and start a pinch roll shaft with constant input from an attached pulley. The clutch/brake had to meet the following special requirements:
- covered & made of food-safe materials
- end of shaft, flange mounting
- capable of handling the pulley belt load on the unsupported end
The resulting design shown above is built from anodized aluminum, stainless steel and electroless nickel plated steel parts and food grade grease. To support the overhung belt load special bearings are used between the housing and drive hub. The clutch/brake is attached to the machine frame using the tapped holes in the end plate. This combination air set clutch/air set brake is rated at 286 lb-in clutch and 143 lb-in brake at 80 PSI and is only 4-1/4" in diameter.
With an average lead time of only three weeks for production of custom designed units Mach III is the best choice for your special project. Contact our engineering department toll free: 866-291-0849 (859-291-0849) for immediate assistance. |
|
| Mach III Custom Design Reduces Lead Time and Price
Mach III Clutch, Inc. was contacted by a pneumatics distributor seeking an expedited solution for one of their customers. The customer was faced with an extremely long lead time to replace a failing foot mounted electric combination clutch/brake on a European made machine. Axial space was constrained by the input and output pulley and gear placement. When it was determined that the customer was willing to change to pneumatic operation a package was designed which duplicated all the mounting dimensions and metric shaft sizes with the exception of the centerline height. The concept was accepted and the new clutch/brake was built and shipped within four weeks instead of the months that had been quoted by the European OEM. The new design has considerably more surface area so the service life should be extended as well. As an added bonus, the cost was a fraction of that of the original unit!
Mach III has the design capabilities to produce replacements for the discontinued or difficult to obtain clutches, brakes, combination clutch/brakes and torque limiters you are seeking. Contact our engineering department today with your requirements. US Toll Free 866-291-0849 (859-291-0849). |
|
Servo Motor Brake Solution
A manufacturer of plastics forming machinery needed a replacement for a troublesome caliper disc brake but no manufacturer offered a servo brake that would match their Japanese servo drive (metric) and U.S. made gear reducer (English). Mach III’s design team saved the OEM the expense of modifying the machine design by offering a c-face, spring applied brake to fit between these two components. Since this successful application, the OEM has requested similar designs for other models in their line of equipment.
|
|
Zero Backlash Torque Limiter RetrofitAfter a series of large automated assembly fixtures performing a critical positioning function experienced overload failures, Mach III designed a zero backlash torque limiter that fit within the limited space available by including an existing pulley in the design. The entire project from design to delivery of five units was accomplished in just over two weeks. |
|
Spark Resistant Clutch for Paint Booth Environment
This unit engages a back-up drive for a paint robot used inside an automotive paint booth. The sealed, all-aluminum clutch design minimizes the possibility of sparking making it suitable for the paint booth environment. It has been approved for use by several large auto manufacturers. |
|
Custom Clutch for Laminator
A manufacturer of wide-format laminating equipment required a clutch to drive a roller. Instead of the usual female bore configuration, an integral male output shaft was included as part of the clutch to minimize components and simplify machine assembly. |
|
Spring Set Brake with Special Housing
Brake was designed for use on a square drive with very limited axial space and no keyway in the shaft. The brake housing was manufactured to match the mating face. A keyless shaft locking device was incorporated into the bore for attachment to the existing shaft. |
|
C-Face Conveyor Clutch – NEMA 56C Frame
This C-face clutch was designed to replace magnetic particle clutches which were failing prematurely in a high cycling production environment. Optimized for heat dissipation and extended wear life, this clutch continues to be standard equipment for this manufacturer of specialized material handling equipment. The design shown is also available as a brake, or a combination clutch/brake. |
|
Click here
