I. Functionality and Application Fields of Universal Joint Products
1. Product Introduction: Universal joint is a mechanical part that realizes variable angle power transmission. It is used in the position where the direction of the transmission axis needs to be changed.
2. Product Functionality: In design cases where space issues or design angle problems lead to misalignment or angularity between driving and driven shafts, universal joints can be used to solve these issues (couplings cannot achieve this).
3. Application Fields: Universal joints have a wide range of applications, especially suitable for shaft transmission under working conditions with large inclination angles and limited radial dimensions, such as in lithium battery coating machines, AGV vehicles, multi-axis screw machines, roller plate straightening machines, packaging post-processing and transportation equipment, etc. It can be said that basically, any situation with the following conditions can use universal joints:
① Shafts with different alignment (theoretical 0-30 degrees misalignment between two shaft centerlines);
② Shafts that are parallel in space but do not intersect or intersect in space;
③ Shafts with variable angularity during operation.
II. Product Classification and Application Conditions
1. Product Classification
① Single Joint: Suitable for use when there is an angularity of 0~15 degrees between axis and axis during torque transmission
② Double Joint: Used when there is eccentricity between the two connected shafts, with an angularity of 0~30 degrees
③ Telescoping Joint: Used when there are changes in position/angularity/eccentricity in space during the movement of axis and axis, with an angularity of up to 0~30 degrees
④ Quick Lock: One end can be quickly detached from the shaft, with a maximum angularity of 45 degrees
⑤ Needle Bearing Joint: High-speed (0~4000r/min), low noise, and tight joint fitting.
2. SWC Lightweight Universal Joint Example
① Product disassembly diagram is shown below
Cross shaft universal coupling parts structure diagram
② Outstanding advantages: a. Has a large angle compensation capability, with a shaft angle of up to 15°~25°; b. Compact and rational structure, using an integrated fork head, making the operation more reliable; c. High load-bearing capacity, compared with other types of universal joints with the same rotating diameter, it can transmit a larger torque, up to more than 3000KN·M, which is more advantageous for mechanical equipment with limited rotating diameter; d. High transmission efficiency, with a transmission efficiency of 98-99.8%, which is significant for energy-saving in high-power transmission.
③ SWC Type Universal Joint Application Scenarios: Widely used in metallurgy, lifting, engineering transportation, mining, petroleum, ships, coal, and paper-making machinery industries. Main equipment includes paper-making equipment, general machinery, water pump equipment, and test benches, mainly suitable for large inclination and long-distance transmission conditions.
III. Universal Joint Selection Factors
1. Material: Stainless steel SUS304, alloy combined steel SCR440
2. Surface Treatment: Stainless steel surface polishing, SCR440 blackening, SCR440 natural color, compared to universal joints on the market, SCR440 material parts can meet the salt spray requirements for 24H
3. Nominal Torque: Choose the suitable shaft and matching universal joint based on the nominal torque.
4. Example:
- Model: DDC01-d6
- Type: Single Joint, Round Hole Type
- Material/Internal Diameter: SCR440 Blackening /d=6
Note: When selecting, the internal diameter parameter should be the main reference item; for other parameters, please refer to the website or catalog.
IV. Universal Joint Manufacturing Process and Advantages
Currently, domestic manufacturers generally use a turning and milling compound processing technology, which is relatively costly and time-consuming. For our regular products, we use a hot forging process, which allows for mass production and sufficient semi-finished inventory, with a standard product lead time of 1 day and a semi-finished inventory lead time of 1-3 days. The production workshop is self-assembled, reducing production costs.
Our universal joint product models are complete, compact design, high transmission capacity, excellent rotation precision, and durability (all parts made of SCR440 undergo carburizing and quenching), and have advantages in precision, strength, durability, and price.
V. Universal Joint Product Personalization
1. Product Recommendations:
Medical Industry SUS304
Low Noise, High Speed - Recommended DDC51/52/61/62/71/72/81/82 Needle Bearing Types
2. Customer Customization Requirements
① Installation size, rated torque, structure: When selecting a universal joint, customers first consider whether the installation size is sufficient, such as shaft diameter, total length, structure. The next is the rated torque, which can be increased by increasing the outer diameter while keeping the inner hole constant, with a direct proportional relationship;
② Assembly method: In the official product models, the fixing methods include pin + circlip fixing, keyway + top screw locking, and the newly launched SWC flange connection, some customers will choose bolt clamping + keyway, two-protection measures to prevent slipping and equipment damage when the instantaneous torque overloads;
③ Custom surface treatment: The lithium battery industry prohibits zinc, copper, nickel; we generally recommend galvanizing, chrome plating, nickel plating, phosphating treatment or select 304 stainless steel, etc.
VI. Precautions
1. Universal Joint Powder Falling: For non-needle bearing type universal joints, it is recommended to use lubricating oil at the fork joint part during use, otherwise, it is easy to fall powder due to dry grinding. It is recommended to regularly lubricate the joint parts for maintenance.
2. Salt Spray Requirements: Currently, the products on the market use SCR440 material, and the standard products are natural color or blackened, which cannot provide good rust prevention for the product, generally salt spray is within 24 hours. If there are special salt spray requirements, surface treatment customization should be carried out.
VII. Industry Analysis
|
Industry |
Demand Characteristics |
|
Drilling and Tapping Machines |
Few models, high demand, high price sensitivity, strong vendor connection capability. |
|
Woodworking Machinery, Furniture Industry |
Few models, strong vendor connection capability, high price sensitivity. |
|
Medical Equipment |
High quality requirements, mainly stainless steel materials, price insensitivity. |
|
Printing, Packaging |
Many customizations, price sensitivity. |
|
Lithium Battery Industry |
Medium to high quality requirements, low price sensitivity, tight delivery requirements. |
|
FA Equipment, Robotics, Photovoltaics |
Many customizations, wide range of quality and price requirements, weak delivery planning. |
|
Smelting, Military, Heavy Industry, Automotive |
High quality requirements, technical needs connection, many customizations, weak delivery planning. |
VIII. Market Status
The universal joint product has a broad application scenario, used in lithium battery, photovoltaic, new energy, 3C industry, traditional processing industry, military, etc. The current market is mainly dominated by small and medium-sized processors, with ununified product quality standards, poor capability for multi-batch small batch, and custom service, without forming scaled production, high production costs, and no brand effect.
Our company's products are self-assembled and produced, with guaranteed quality through semi-finished and finished product inspection and delivery, with a price of 70% of the industry.