Custom Stainless Steel Reel Position Sensor Gear

Custom Stainless Steel Reel Position Sensor Gear

JG manufactures the Custom Stainless Steel Reel Position Sensor Gear as a precision stainless steel weldment for industrial reel-position sensing and motion-control equipment. Drawing 577272 Revision C combines a profiled sensor gear, two protective gear plates, a machined tube, a sensor weld core, a flexible rod and a precision rod head. Accurate fixture location and controlled welding are essential because the completed assembly must preserve gear alignment, shaft angle and plate spacing after GTAW welding.

Product Overview

The Custom Stainless Steel Reel Position Sensor Gear uses AISI 316L stainless steel for the main gear plate, sensor weld core, rod, flex rod head and gear guards. The machined tube is AISI 304 stainless steel. The mixed-component assembly provides corrosion resistance, structural strength and stable performance in industrial environments. The drawing specifies a raw stainless steel finish with no additional coating.

Component and Drawing Relationship

Manufacturing Process

1. Material verification for AISI 316L and AISI 304 stainless steel
2. Precision profile cutting of the main gear and two guard plates
3. CNC machining of the tube, weld core and flex rod head
4. Drilling and machining of fixture alignment and assembly holes
5. Deburring and cleaning of all individual components
6. Fixture-controlled assembly of the gear plate, guards and shaft components
7. GTAW welding with a controlled sequence to limit heat distortion
8. Inspection of gear diameter, plate spacing, tube projection and shaft angle
9. Visual weld inspection, final cleaning and protective packaging

Gear Profile and Guard Plate Alignment

The circular profile of the Custom Stainless Steel Reel Position Sensor Gear contains closely spaced external sensing teeth protected by guard plates on both sides. Consistent tooth geometry and controlled concentricity support repeatable sensor output. The guard plates are positioned through dedicated fixture-alignment holes so the protective faces remain correctly located relative to the toothed gear.

GTAW Welding and Distortion Control

The drawing calls for gas tungsten arc welding at the central shaft connection, rod head and six specified plate locations. Welding heat can pull thin stainless steel plates out of alignment or change the shaft angle. JG uses rigid fixtures, balanced weld sequencing, controlled heat input and intermediate checks to maintain the required geometry of the Custom Stainless Steel Reel Position Sensor Gear.

Shaft Angle and Axial Dimension Control

The machined tube must remain nearly perpendicular to the gear face, with an angular range of 89.5 to 90.5 degrees. The drawing also controls the gear assembly width, tube projection and total rod-head reach. These relationships are inspected after welding because the completed stainless steel sensor gear must install correctly and transmit reel position without binding or misalignment.

Technical Specifications

Machined Stainless Steel Components

The AISI 304 tube is machined from 3/4-inch outside-diameter tubing and includes a controlled through-wall hole. The AISI 316L weld core and flex rod head require accurate bored holes, flats and end geometry. The slender 316L rod is cut to controlled length before final assembly. Each component is deburred and cleaned before entering the welding fixture.

Quality Control

Quality control for the Custom Stainless Steel Reel Position Sensor Gear focuses on the finished weldment rather than isolated component dimensions alone. Inspections cover gear profile, guard-plate alignment, fixture-hole location, axial spacing, tube projection, shaft angle, rod-head position and weld appearance. Material certificates and dimensional inspection reports are available according to OEM customer requirements.

Product Features

• AISI 316L and AISI 304 stainless steel construction
• Precision external sensor-tooth profile
• Two protective stainless steel gear guards
• Fixture-controlled GTAW welded assembly
• Controlled shaft perpendicularity and axial dimensions
• Deburred and cleaned raw stainless steel finish
• Custom OEM manufacturing according to customer drawings

Applications

• Industrial reel position sensing systems
• Web handling and winding equipment
• Packaging and converting machinery
• Motion-control and indexing assemblies
• Custom industrial sensor mechanisms

OEM Stainless Steel Weldments from JG

JG supplies the Custom Stainless Steel Reel Position Sensor Gear from component production through completed assembly. Our manufacturing scope combines profile cutting, CNC machining, precision drilling, dedicated fixturing, GTAW welding, dimensional verification and final cleaning. This integrated process helps OEM customers control alignment, reduce assembly risk and receive a repeatable stainless steel sensor gear ready for installation.