In matters of industry, even the most minor component can make a difference in machinery manufacturing. As introduced by the Industry 4.0 concept, industrial automation has enhanced the development of more precise rack and pinion products in Asia, allowing the area to slowly catch up to the more developed industrial nationals of Germany and Italy.
The pinion and rack have better rigidity than the ball screw and can achieve the fastest ideal linear motion. Alongside gears, pinions and racks are the most common components in advanced machinery, such as laser cutters and robotic transfer units.
The region’s advances in the production of racks have opened up more applied uses for the racks in screen manufacturing and car equipment production lines, offering components to make the most precise manufacturing processes possible.
With over 15 years of experience in rack manufacturing under their belt and rank among the top five rack manufacturers in Asia, Kai He Machinery Co., Ltd. is also the first Taiwanese company to use all German-made machinery while insisting on only using Taiwan-produced steel.
Kai He stresses the importance of its ten manufacturing processes and is adamant that these processes are the reason that it could provide products of high precision, high rigidity, and great precision, just like those produced by German brands.
Observing that many rack providers only manufacture 1m long products - which cannot fill the length of machinery with long travel-time - Kai He produces racks that reach up to 2m. This length ensures unwavering precision from the machine as racks have sufficient length to line the machine without needing to be chained together.
The manufacturing processes that Kai He has developed over its 15 years in the industry significantly decrease the chances of racks becoming warped after heat treatment and give the company maximum control over the material’s physical reaction and the precision of its rack products.
Observing that many of its clients experience rack warping during installation, a result of the racks not having undergone a bending balance routine, Kai He uses a servo-hydraulic system hooked up to computers to adjust the pressure value applied to racks.
The computer-generated data, in addition to the company’s experiences in the industry, allows the company to conduct multiple bedding balance procedures resulting in more efficient and better rack bending and reducing the chances of warping effects caused by grinding or heating from setting in.
It believes that balancing the rack on all four sides - a process that many rack manufacturers of renown will not undertake - is necessary, as such procedures create racks with tooth pitches meeting the company’s ideal standards. In addition, straighter and smoother racks would be easier to install.
Kai He uses the German Institute for Standardization (DIN), and using the DIN 5-grade - equivalent to the Japanese Industrial Standards (JIS) 1 - rack as an example, the company said that the deviation rate for the final products’ tooth pitch must not exceed 0.024mm.
Using the latest and most cutting-edge Computer Numerical Control (CNC) milling and grinding machines from Germany, Kai He ensures that the rack tooth surfaces are uniform and of the same quality even when mass produced.
All final products must pass a last quality check using the Wenzel-brand coordinate measure machine (CMM), which utilizes an English-manufactured tactile sensing probe, before the company forwards the results to its clients.
Kai He’s CMM is custom-made to detect 2m long racks and can detect the teeth profile and the teeth bars on the rack, Kai He Sales Engineer Wang Da-ren said.
Kai He’s custom-made CMM is why it is confident it can provide clients with only the most precise and accurate data, such as the helix angle, pressure angle, pitch error and total pitch error of the gears are in line with the original design, instead of approximate values with margins of error. Data accuracy also enhances clients’ efficiency when installing racks manufactured by Kai He, Wang added.
In the face of the 2022 global inflation, Kai He’s racks maintain the same quality while their prices are more competitive than European rack manufacturers. Its experiences in the industry also allow for greater production rates, increased delivery speeds, and superior products.
“Kai He is confident of its international competitive edge. I know this because all of our foreign clients leave with expressions of satisfaction after touring our production line and products,” Wang said.
KAI HE is mainly specialized in the production of transmission rack gears. the first ground rack manufacturer in Taiwan , while today it is a certified company (ISO 9001 : 2015), technologically advanced and structured with updated production plants.
Internally HAI HE has highly qualified personnel in order to offer customized answers to the most complex demands of every customer. Today, thanks to the production flexibility and to the industrial automation, KAI HE is able to realize products with high competitive prices in all over the world, both with standard features and with the most elaborate customizations.
