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THE CHALLENGE
1 Analyzing the design of the housings for the horizontal gearbox and vertical gearbox, for a potential ten percent cost reduction.
2Designingmodificationsthatcouldnotcause changes in shape, materials, heat treatments and placements of shafts, gears, bearings and sealing systems.
COST REDUCTION – LONGWALL SHEARER
Case Study | Industrial Heavy Machinery
An important manufacturer of underground mining
equipment wanted to reduce the manufacturing costs for
its new longwall shearer and redesign the platform
rig frame so it could be mounted on either trucks
or tracks.
More. Faster. Better.
THE COMPANYThe world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. This global corporation, with a distribution network of nearly 200 dealers serving 182 countries, is based in the United States.
© 2016 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.
Phase 1 – Quick Start– Analyzed the stiffness of the housings and
determined areas where they were oversized, and where there was an opportunity to optimize shapeandconfiguration,maintainingtheminimumsafety factor.
Phase 2 – Fundamentals– Identifiedalternativematerialstobeusedfor
the housings.
– Changed the plate thickness for select components.
– Based on Finite Elements Analysis (FEA) results, changed the housings geometry in order to reduce
the number of components and consumption of materials.
– For the manufacturing surfaces, the machine allowanceswereoptimizedonallidentifiedareas.
Phase 3 – Advanced– Reduced the number of welded components,
thereby reducing the length of the welding seam.
– Provided cost reduction analysis using only materials and sheet metal plate thicknesses from the client’s lists.
Tata Technologies makes product development dreams a reality by designing, engineering and validating the products of tomorrow for the world’s leading manufacturers. Our clients are under increasing pressure to create more products, faster than before, and better than ever to stay competitive. For more than 20 years, we have empowered them with the tools, technology, and processes to meet – and exceed – market demands. To learn more, visit www.tatatechnologies.com today.
THE RESULT
Cost savings
11.5%Reduced vertical gearbox housing
total costs by 9.2 percentReduced horizontal gearbox housing costs by 15 percent
THE SOLUTION