Zeal Gears Pvt. Ltd. is one of the largest manufacturing company for high Quality Helical Gear Box for Plastic & Rubber Extrusion Machinery Under Brand Name Of “ZEAL”. With More Then 25 Years of Experience of Mr. Nilesh. M.Patel, (founder of the company) and concentrating in only Plastic & Rubber Extrusion Field. The “ZEAL” now has became a reference point in this field.

RESEARCH, DEVELOPMENT and QUALITY are the company’s first priorities. This vision is what has Allowed “ZEAL” to manufacture high tech products with high performance and excellent reliability

To achieve total customer satisfication, “ZEAL” has adopted advanced manufacturing techniques with The latest machinery and technology. “ZEAL” Helical Gear unit is now known for it’s “Smooth, Smart And Silent” function as widely acknowledged by leading plastic machine manufacturers as well as users.

QUALITY

First, “ZEAL” Helical Gear units are manufactured with a careful selection of raw material and components. They are then precisely machined on advanced CNC Machine tools. Our quality assurance process ensure that all parts are checked throughout the entire machining process. Finally, assembly is performed by our highly experienced Engineering group. “ZEAL” Helical Gear assures total quality through continous improvement of product, process & services.

DESIGN

Our DESIGN engineers work with the latest computer systems and software to prepare complete designs as per your requirement, with onlt few basic dimension required from your end. If you need additional design, modifaction or development our 15 years of precision gear box experience & technology is at your diposal. Our ample R & D Design capabilities are what help to satisfy our customer’s specific requests.

GEAR BOX BODY

The GEAR box bodies are initially cast in Gery Cast Iron, designed for the latest acoustic and heat transfer technology. Then the gear box bodies are machined on our advanced CNC Machining Center under careful observation by our highly skilled engineers. The inside walls of the gear box body is coated with special high performance oil and heat resistant coating.

GEAR & PINION

The GEAR & PINION assembly is made from high quality case carburized Alloy Steel. After the assembly is carburized and hardened, the tooth profiles are ground with high accuracy with profile correction for high load transmission, low noise level and efficent use. Lastly, our Quality Control Department performs a tooth profile and lead accuracy check on our highly precise lead & profile tester machine.

BEARINGS

We Use only top qualtiy heavy duty trust & roller bearing in “ZEAL” Helical Gear Units. All bearings are selected by precisely calculting the radial and axial trust loads of the gear box.

LUBRICATION

The pinoin, gears and bearing are automatically thoroughly lubricated by the splash of oil from the sump. Thus, Only periodical checking of the oil level is necessary. In larger size gear boxes, we implement an attached oil pump to force lubrication of the entire internal system.

COOLING SYSTEM

The simplest and most economical cooling system is the internal cooling coil which is made from copper pipe and is precisely mounted inside the gear box.

What makes it more complex?

Well, the fact that we would be using different subsets and obviously there would be some kind of interaction between those subsets. That makes the whole designing procedure a Whole lot more tedious if you ask me.

Now, the choice of gear width and the centre distance that you keep between the different subsets is going to influence the gear reduction capacity of helical gearboxes greatly.

So, our engineers optimize the dimensions of the subsets of the gearboxes in such as way that it provides you with maximum gear reduction and high power transmission capacity. Thus, making your procedure a whole lot more efficient.

They have a compressive range of constraints groups utilized in the designing process. Till date at least 24 constraints groups have been studied and implicated in the designing of two stage helical gearboxes.

Now, the basic function of these constraints groups is to minimize the overall volume and second to minimize as much power loss as they can.

Basic design

The basic design of the helical gearbox two stage remains the same as the one stage helical gearboxes.

In essence, they are cast in the same grained iron or steel alloys with anticorrosive metals added to it. And their interior is coated with the coat of anticorrosive paint, high-performance oil and heat-resistant materials.

They have proper lubrication are sealed at the junctions to prevent any oil spillage. They are as efficient as helical gearboxes can be with high power transmission capacity, torque and heat transmission capacity.