CASE STUDIES

Customer:

Pioneers in Development of Earth Moving Equipment's

Challenge: 

Intro of 60T Rear Dumper with stringent Timeline

Requirement: 

Full Floating, Double Reduction, Std Differential with Calliper Disc Brake & Oil Cooled Wet Multiple Disc Service Brake with Planetary Axle.

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Problem Statement

Pre-mature rear axle  break down (target test life-cycles 100,000. loading cycle of 70% & transportation of 30%) Wheel wobble, noise, axle brake friction causing wear & overheating, oil leakages & deterioration Unable to achieve top speed of 38 kmph in 6 to 8 sec in cold condition

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Customer

Leading OEM of heavy-duty transmissions for construction & mining equipment, material handling equipment, oil-field, railways & defence applications

Business Challenge

 Cross drive transmission introduction for defence tracked vehicles within the confined layout.

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Customer

Leading OEM of heavy-duty transmissions for construction & mining equipment, material handling equipment, oil-field, railways & defence applications

Business Challenge

 Cross drive transmission introduction for defence tracked vehicles within the confined layout.

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Overview

Customer is the global leader in design and development of the axles and brakes for heavy vehicles in commercial, military and off-highway application. Customer is targeting on the light commercial vehicle segment to expand its market reach in India. Intended to start with design and development of 2-ton Light Commercial Vehicle drive axle.

Customer Requirement

• Phase-1: Preliminary design and costing (Feasibility of design and cost)
• Phase-2: Value additions and design optimization
• Phase-3: Prototype manufacturing and testing

Complexity/Challenges

• Preliminary designing of the axle meeting target bench mark axle for costing
• Achieving efficient hypoid gear set
• Lack of duty cycles data considered for the bench mark axle
• Getting benchmark axle

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Re-Engineering of DTH drilling Rotary Head Gearbox to improve the reliability and reduce the manufacturing cost of the Gearbox

Customer Pain Points

Frequent Bearing failures Structural failures Higher warranty claims Higher cost of product.

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Engineering of 3 PTOs on an existing transfer case for driving Hydraulic Pump, Compressor & Alternator.

Requirement

• 3 PTOs Design
• Design Calculations for Gears and Bearings
• Engineering Analysis of Case
• Detailed Drawings

Challenges

• Managing the space for mounting 3 PTOs for already designed transfer case
• Incorporating pneumatic actuator to operate all 3 PTOs independently within the case

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