In keeping with its corporate policy of specializing in precision molding, TAKAHATA is now refining the accuracy of its precision gears. Among our customers, those in the office equipment, audio-visual, and automobile industries face particularly stringent demands for higher-accuracy gears. TAKAHATA is honing its technologies to meet those challenging demands. •Flow of Precision Gear Development •Product Design Contour design is the most important point in the production of precision gears. The quality of the design significantly influences the accuracy of the products. Over its long years of operation, TAKAHATA has accrued an abundance of design know-how to meet the diverse needs of its customers. •Molding Important Points of Molding 1. Hold Pressure: Improved replication and circle accuacy Accuracy of the die is stably replicated and reproduced on products. Optimization of molding conditions and molding die temperature. 2. Motor-driven molding • Uniform produce weight through stable weighing. • Closed loop control (dwell pressure and time, cooling time, etc.). 3. No flow marks and weld lines. 4. Reproducibility of molding conditions. 5. Effective utilization of multi-step control based on the product profile. 1. Molding in a clean room Strict temperature and humidity control ensure that molding and control are performed under the same conditions at all times. A very low level of dispersion results. Temperature 25 +/-2 degC; humidity 45 +/-5%. 2. Molding by electric molding machiness • Uniform product weight through stable weighing. • Closed loop control. *Interfering factors eliminated to ensure high molding reproducibility. • Periodic overhaul: Scheduled and implemented based on the production quantity and molding frequency. • JIS measurement: Implemented at ‘change points’ within processes (changes in molding machines, molding conditions, and dies). *The above is the basic control. The optimum maintenance procedure is determined based on the products, materials, and molds. •Measurement and Analysis The accuracy of precision gears is improved in several steps: the true gear accuracy is measured to identify error; the causes of error are analyzed; and the result is reflected in the final manufactured product. After molding, the gears are kept at a constant temperature and humidity for at least 24 hours and then measured to precisely determine the bore size, gear dimensions, gear engagement, and JIS measurements. All of these measurements are indispensable for any precision gear. The results of the analysis are reflected in the final products. •Production Stable molding and reproducibility are two important control items in the production of precision gears. Stringent daily control and molding die maintenance are required. The following basic control is used at TAKAHATA. The optimum maintenance procedure is determined based on the products, materials and molds. 1.Daily maintenance • OD, bore diameter, deflection of OD, total length, weight, appearance (flow marks, flashes, etc.) • Molds for helical gears: CAV rotation. • Molding die temperature (control of actual temperature), cleaning of gas vents. • Removal of mold deposits. • Maintenance of molding die upon the completion of molding. 2.DPeriodic control • Periodic overhaul: Scheduled and implemented based on the production quantity and molding frequency. • JIS measurements: Implemented at ‘change points’ within processes (changes in molding machines, molding conditions, and molds). *The above is the basic control. The optimum maintenance procedure is determined based on the products, materials, and molds.