Project

Overhaul and Refurbishment of Gripper Gear Reducer in Hot Forging Press System 

✅ Localization Project for Imported High-Load Gear Reducer

 

1. Project Overview

EasternGear successfully completed an overhaul and performance improvement project for the high-load gripper drive gear reducer applied to a hot forging press system at a domestic metal parts manufacturer.

Previously, a specialized gear reducer imported from Germany was used, but recurring issues such as delays in parts procurement and the impossibility of repairs posed significant operational risks.

To address these challenges fundamentally, EasternGear designed and manufactured a custom gear reducer optimized for high-load environments. By localizing the key components, the company significantly improved procurement stability and maintenance convenience.

As a result, the client was able to mitigate downtime risks and secure long-term operational efficiency of the production equipment.

 

---

 

 

2. Problem Diagnosis and Technical Analysis

• Severe wear observed on critical components such as bearings, seals, and gear teeth due to repeated operation in high-temperature environments

• Equipment downtime caused substantial cost losses, with imported parts being unavailable or having excessive lead times

• No domestic alternatives existed; low gear ratio gear reducers could not be implemented

• The original reducer lacked design drawings, requiring precise reverse engineering and reconstruction
  
  

---

 

 

3. Process

• Reverse Engineering & Analysis: Disassembly and precise measurements were conducted to redefine specifications such as gear ratio, center distance, shaft layout, and output torque 

• Design Modification Using Domestic Components: The conventional cylindrical worm gear was replaced with a globoid worm gear set, and standard domestic bearings and seals were adopted to ensure easier future maintenance

• Redesign for High-Temperature and High-Load Environments: Material selection and heat treatment conditions were reinforced for repeated operations under elevated temperatures
  
  

---

 

4. Improvement Results

• Enhanced Precision and Durability: Post-overhaul, the reducer exhibited improved torque transmission stability and reduced vibration

• Maximized Equipment Uptime: No failures reported over three months of continuous operation; the load rate improved significantly from approximately 50% to 20%

• Maintenance Efficiency: Replacement time was reduced; after-sales response time improved by 70% with localized parts, enabling preventive maintenance planning
  
  

---

 

 

5. Localization Success Case

This project stands as a successful example of localizing imported equipment beyond mere repair.

• Achieved technological independence for the core drive system

• Reduced total cost over the equipment life cycle

• Strengthened supply chain risk management capabilities
  
  

---

 

6. Future Plans

Based on this case, EasternGear aims to expand its localization and customized refurbishment services for imported gear reducers used in high-load industries such as press machines, forging, injection molding, and robotics.

 

• Tailored overhaul solution packages for specific equipment

• Establishment of cooperative models for standardized domestic parts and inventory operations

• Expansion of the precision reducer product line for servo motors