OTS-50 Gear Pump Line | High-Performance Gear Pumps for Industrial Coating Systems

Gear Pump

Overview

1. Introduction

The OTS-50 Gear Pump Line by OTSON Paint Shop Technologies delivers precision, reliability, and efficiency for industrial fluid transfer systems. Specifically engineered to handle a wide range of viscosities, from thin waterborne paints to thick industrial coatings, these gear pumps ensure consistent and smooth fluid delivery in even the most demanding environments. Designed for industries like automotive, aerospace, bicycle manufacturing, and general industrial coatings, the OTS-50 gear pumps are built to handle a variety of coating materials and applications.

With advanced features such as ATEX-certified models for hazardous environments, customizable gearbox ratios, and seamless integration with OTSON’s electrostatic spray systems, the OTS-50 line offers unparalleled durability, precision, and energy efficiency.

Target Customers

1. Competitor Gear Pump Replacement Market

If you’re using gear pumps from other manufacturers and noticing signs of wear, reduced suction, or inconsistent fluid delivery, the OTS-50 Gear Pump Line is the ideal replacement solution. Designed to outlast competitor pumps, OTSON gear pumps deliver longer service life, reduced downtime, and better overall efficiency.

2. Existing OTSON System Users

For customers already using OTSONs electrostatic spray systems, the OTS-50 gear pumps provide an easy upgrade to enhance transfer efficiency and system performance. Seamlessly integrate these pumps with your existing setup to minimize paint waste and maximize coating quality.

2. How the Gear Pump Works

The OTS-50 Gear Pump is a positive displacement pump that uses the meshing of gears to move fluid. It operates by trapping fluid in the spaces between rotating gears and the pump casing, then displacing it from the inlet to the outlet as the gears turn. The precise movement of the gears allows for controlled, consistent fluid flow, making gear pumps ideal for handling both low and high-viscosity fluids in a wide range of industrial applications.

Operating Principle:

Fluid Inlet:
- As the pumps gears rotate, they create a vacuum at the inlet, drawing fluid into the pump. The suction force is created by the separation of the gear teeth as they rotate away from each other.
Fluid Transfer:
- Once the fluid is drawn into the pump, it becomes trapped in the pockets between the gear teeth and the pump casing. As the gears continue to rotate, these pockets carry the fluid around the outer edge of the pump chamber.
Pressure Generation:
- As the gears rotate toward the discharge side, the teeth come back together, forcing the fluid out of the pump and into the connected piping or spray system. This pressure generation is essential for delivering the precise amount of fluid needed in high-pressure applications such as electrostatic spray systems.
Control Through Gearbox:
- Each OTS-50 Gear Pump is equipped with a 7:1 gearbox. This gearbox reduces the motor speed while increasing the torque, allowing the pump to handle high-viscosity fluids and deliver consistent flow even in challenging environments.
- By slowing the rotation of the gears, the gearbox ensures more efficient handling of fluids with varying viscosities while maintaining a steady output pressure, perfect for applications like automotive coatings or heavy-duty industrial paints.

Why Gear Pumps Are Ideal for Industrial Coatings:

High-Precision Delivery: The positive displacement mechanism ensures a steady, precise flow rate, which is crucial for uniform paint application.
Versatility: The OTS-50 series is designed to handle a variety of fluid viscosities, from thin liquids to thick coatings, without sacrificing performance.
Pressure Management: With the ability to handle pressures of up to 200 bar, the OTS-50 gear pump is ideal for high-pressure systems that demand reliability and consistency.
Durability: Thanks to the hardened materials and precise engineering, our gear pumps are resistant to wear, ensuring a long operational life even in abrasive or corrosive fluid environments.

Common Causes of Gear Pump Wear:

Over time, the gears in any pump experience wear due to the abrasive nature of industrial fluids, including paints and coatings. As the gears wear down:

Gaps between gear teeth widen.
The pumps suction ability decreases.
Fluid leakage may occur between the gear teeth, leading to reduced flow rates and lower efficiency.

Replacing worn gear pumps before severe performance degradation occurs can help prevent system downtime, reduce paint waste, and maintain optimal production rates.

Features

Key Features and Benefits

1. High-Precision Fluid Delivery

- Accurate flow rates ranging from 77 cc/min to 1543 cc/min ensure consistent coating application, even in high-demand production lines.
- Steady pressure control minimizes fluctuations and ensures uniform coatings, reducing rework and defects.

2. Superior Durability and Longevity

- Built from hardened alloys, carbon steel, and stainless steel, the OTS-50 gear pumps are designed to withstand corrosive environments, high pressures, and abrasive fluids.
- Advanced seals prevent leakage, extending the life of the pump and ensuring reliable operation.

3. Customizable Gearbox Ratios

- The standard 7:1 gearbox delivers high torque for handling thick, high-viscosity fluids, ensuring a steady flow under challenging conditions.
- Customizable ratios are available for specific applications that require tailored torque and flow adjustments.

4. Wide Viscosity Range Handling

- Capable of pumping fluids with viscosities ranging from 50 cP to 100,000 cP, making the OTS-50 series versatile enough to handle a broad range of materials, from light coatings to epoxies and polyurethanes.

5. Energy-Efficient Motor Integration

- 3-phase motor integration (220V, 60Hz) ensures consistent operation with low energy consumption. Compatible with Variable Frequency Drives (VFDs), the OTS-50 gear pump allows for precise speed control, saving energy and reducing operating costs.

6. ATEX-Certified Models

- ATEX certification ensures safe operation in hazardous environments where explosive vapors or flammable paints are present.

Industry Applications

The OTS-50 Gear Pump Line serves a wide array of industries, offering reliable and efficient fluid transfer for various applications:

Automotive Coatings
Used for applying basecoats and clearcoats on large body panels, the OTS-50 gear pumps offer even paint distribution and reduce material waste.
Aerospace Components
The OTS-50 pumps handle high-viscosity corrosion-resistant coatings, ensuring uniform coverage and high-quality finishes on critical aircraft parts.
Bicycle and Motorbike Frames
These pumps provide flexibility in handling both waterborne primers and powder coatings, delivering consistent finishes across complex geometries.
Woodworking and Furniture Coating
Ensure even application of lacquers and stains on large, flat surfaces or intricate designs, with reduced defects and high-quality finishes.
General Industrial Coatings
The OTS-50 series is perfect for applying abrasive and protective coatings to industrial machinery and tools, ensuring long-lasting durability.

Gear Pump with motor

Technical Specifications Table

The following table provides a comprehensive overview of the OTS-50 Gear Pump Line models, including key performance metrics, dimensions, and applications. This detailed information allows customers to compare different models and choose the one that best fits their fluid transfer and coating needs.

Flow Rate vs Viscosity (with 7:1 Gearbox):
This chart illustrates the effect of increasing viscosity on the flow rate for both pump models. As viscosity increases, flow rates decrease, with the 6cc/rev pump maintaining a higher flow rate compared to the 3cc/rev pump.

Pressure vs Flow Rate (with 7:1 Gearbox):
This chart demonstrates how increasing pressure reduces the flow rate for both pump models at 1000 RPM and 2000 RPM motor speeds. The 6cc/rev pump shows a higher flow rate at both motor speeds compared to the 3cc/rev pump.

Flow Rate vs Motor Speed (RPM) (with 7:1 Gearbox):
This chart shows how the flow rate increases with motor speed for both the 3cc/rev and 6cc/rev pumps, taking into account the 7:1 gearbox ratio. The 6cc/rev pump provides a higher flow rate compared to the 3cc/rev pump.

Explanation of Key Metrics :

Displacement (cc/rev): The volume of fluid moved by the pump for each revolution of the gears. Higher displacement values indicate a larger volume of fluid is being pumped per revolution, suitable for applications requiring higher flow rates.
Max Pressure (bar): The maximum operating pressure the pump can handle. This is particularly important for high-pressure applications like electrostatic spray systems, where maintaining consistent pressure is critical for proper fluid atomization and application.
Motor Power (HP): The power output of the pump’s motor, measured in horsepower (HP). This metric reflects the energy the motor can deliver to ensure the pump operates effectively, especially when handling higher viscosity fluids or operating at higher pressures.
Torque (Nm): The rotational force generated by the motor and gearbox combination, expressed in Newton-meters (Nm). Higher torque values are essential for pumping thicker fluids or handling high-resistance applications, ensuring the pump delivers the necessary force for fluid movement.
Gearbox Ratio: This indicates the gear reduction used to slow the motor’s speed while increasing torque. The 7:1 ratio means that for every seven turns of the motor, the gears rotate once, ensuring higher torque output, which is ideal for pumping high-viscosity or abrasive fluids.
ATEX Certification: Indicates whether the pump is certified for use in explosive or hazardous environments. ATEX certification ensures that the pump can safely operate in zones where flammable substances are present, such as chemical plants or paint manufacturing facilities.
Max Temperature (°C): The highest temperature at which the pump can safely operate. This is particularly relevant for applications dealing with high-temperature coatings or fluids that need to be maintained at elevated temperatures during application.
Viscosity Range (cP): The range of fluid viscosities the pump can handle, measured in centipoise (cP). A broader viscosity range allows the pump to handle a variety of fluids, from thin waterborne paints to thick, high-viscosity coatings.
Material: The construction material of the pump’s components. OTSON offers pumps made from carbon steel, stainless steel, and hardened alloys to ensure durability and longevity, particularly when handling corrosive or abrasive fluids.
Weight (kg): The total weight of the pump, which may impact installation and handling requirements in specific applications.
Dimensions (L x W x H) (mm): The physical size of the pump, providing an indication of the space required for installation. Smaller pumps are typically easier to integrate into compact systems, while larger pumps may offer higher capacity and pressure ratings.
Flow Rate (cc/min) (with Gearbox): The volume of fluid the pump can move per minute, depending on its displacement and the motor’s speed. This flow rate helps determine the pump’s suitability for specific coating applications, ensuring it can meet production requirements.
Transfer Distance (m): The maximum distance the pump can transfer fluid before a significant drop in pressure or flow rate occurs. This is especially important in large production facilities where fluids need to be transported over long distances.

Choosing the Right Pump for Your Application:

The technical specifications of each model in the OTS-50 Gear Pump Line are designed to meet the varied needs of different industries. Whether you require high pressure for electrostatic spray systems, the ability to pump highly viscous or abrasive fluids, or ATEX-certified models for explosive environments, the OTS-50 series offers the flexibility and reliability needed to optimize your fluid transfer processes.

Industry

Customer Testimonials/Case Studies

To demonstrate the real-world effectiveness of the OTS-50 Gear Pump Line, this section provides testimonials and case studies from customers who have successfully integrated our gear pumps into their operations. These examples highlight the performance improvements, cost savings, and system efficiency our customers have achieved by switching to OTSON gear pumps.

Case Study 1: Automotive Manufacturer

Challenge:
A leading automotive manufacturer was experiencing issues with inconsistent paint thickness on large body panels, leading to high levels of material waste and defects in their production process. Their existing gear pump was nearing the end of its lifecycle, causing flow rate fluctuations and overspray.

Solution:
After switching to the OTS-50-V6-CL gear pump, the manufacturer saw immediate improvements in flow control and coating consistency. The OTS-50’s precise flow rate and steady pressure control allowed for a more even application of basecoats and clearcoats on large vehicle panels. The manufacturer integrated the pump into their existing OTSON electrostatic spray system, ensuring seamless compatibility.

Outcome:

30% reduction in paint consumption due to improved transfer efficiency.
20% decrease in rework and defects, resulting in higher-quality finishes.
Increased production speed as the pump maintained consistent output even during long production runs.

Testimonial:
“Switching to the OTS-50 gear pump has been a game-changer for our automotive coating line. We’re seeing less paint waste, fewer defects, and more consistent performance overall. The seamless integration with our existing OTSON systems made the upgrade even easier.”
— Production Manager, Leading Automotive Manufacturer

Case Study 2: Aerospace Component Coatings

Challenge:
An aerospace company specializing in the production of aircraft components needed a pump capable of handling high-viscosity, corrosion-resistant coatings. Their previous gear pump struggled to maintain consistent flow, leading to uneven application and potential coating defects, which are critical in the aerospace industry.

Solution:
The company replaced their existing pump with the OTS-50-V3-HT gear pump, specifically designed to handle high-viscosity industrial coatings like epoxies and polyurethanes. The 7:1 gearbox allowed the pump to deliver the necessary torque to move thicker materials at high pressure.

Outcome:

25% improvement in coating uniformity, ensuring even distribution on complex aircraft components.
Significant reduction in material waste, with the pump delivering only the necessary amount of coating.
Better surface protection, resulting in longer-lasting components and fewer quality control issues.

Testimonial:
“The OTSON gear pump delivered exactly what we needed—consistent, reliable performance even with thick coatings. The improved transfer efficiency and coating quality have been crucial in meeting our aerospace industry standards.”
— Operations Director, Aerospace Manufacturer

Case Study 3: Bicycle Frame Manufacturing

Challenge:
A leading bicycle manufacturer was facing challenges applying different coatings to both aluminum and carbon fiber frames. They required a versatile gear pump capable of switching between waterborne primers and high-viscosity powder coatings.

Solution:
The company opted for the OTS-50-V6-XT gear pump, which could seamlessly handle both low-viscosity and high-viscosity coatings by adjusting the VFD settings on the motor. This allowed for flexible operation and efficient coating application across different frame materials.

Outcome:

20% increase in production efficiency, as the OTS-50 pump easily transitioned between different coating types without downtime.
Consistent finishes across all frame materials, improving product quality and customer satisfaction.
Lower maintenance costs, with the wear-resistant materials of the OTS-50 pump extending its operational life.

Testimonial:
“OTSON’s OTS-50 gear pump has made a noticeable difference in our production line. We’re able to coat different frame materials more efficiently, with less downtime and improved quality. The durability of the pump means we’re not constantly dealing with repairs.”
— Plant Manager, Bicycle Manufacturer

Case Study 4: Woodworking and Furniture Manufacturer

Challenge:
A high-end furniture manufacturer needed a solution to apply thick lacquers and stains to large surface areas of wooden furniture. Their previous pump struggled to maintain consistent flow, leading to streaks, uneven finishes, and material waste.

Solution:
The company installed the OTS-50-V6-HT pump, designed to handle high-viscosity materials and provide even coverage on wide surfaces. The pump’s precise control ensured that the coatings were applied evenly, resulting in a smooth and high-quality finish.

Outcome:

50% reduction in coating defects, leading to a higher-quality final product.
Reduced material waste, with the pump delivering only the necessary amount of lacquer or stain.
Higher customer satisfaction due to the improved quality of finishes.

Testimonial:
“We’ve seen a dramatic improvement in our finish quality since installing the OTSON gear pump. The even flow and consistent pressure have made a big difference in the final look of our products, and we’re using less material in the process.”
— Production Supervisor, Furniture Manufacturer

Summary of Key Benefits from Real-World Applications:

Higher transfer efficiency, reducing material waste and lowering costs.
Improved product quality, with fewer defects and more uniform finishes.
Reduced downtime, with less need for maintenance and easier integration with existing systems.
Versatile handling of different coating types, from low-viscosity waterborne paints to high-viscosity industrial coatings.
Increased production efficiency, helping customers meet tight deadlines while maintaining quality standards.

Why These Case Studies Matter:

These examples demonstrate how the OTS-50 Gear Pump Line helps businesses across different industries improve their fluid handling and coating processes. Whether replacing competitor gear pumps or upgrading existing OTSON systems, the OTS-50 series delivers measurable improvements in both performance and cost savings.

Contact us

We look forward to working with you to enhance the performance of your paint shop and help you achieve your goals. Contact us today to learn more about our products and services and also the latest addition iOTSON Paint Shop Technologies.