| Sample Product | Electronic Suspended Pedal | |
| Industry | Agriculture | |
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Application |
Farm Equipment | |
| Materials | RTP (Reinforced Thermoplastic) |
| Pedals are critical components across various industries—including automotive, industrial, and medical sectors—playing a vital role in controlling power, speed, and operational functions. The quality, durability, and performance of these pedals directly impact the safety and efficiency of the systems they support. In the automotive sector especially, even a minor defect in a pedal or lever can pose serious safety risks. |
Layana's Capabilities: Injection Molding, Overmolding & Assembly
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Layana adheres strictly to IATF 16949 standards, ensuring the highest level of quality and safety in producing safety-critical parts like pedals, especially automobile-related. We implement rigorous quality management systems throughout the manufacturing process, from design and material selection to production and final inspection. |
Layana's key practices on safety part management include:
- Advanced Risk Management: Utilizing Failure Mode and Effects Analysis (FMEA) to identify potential risks early in the design and manufacturing stages.
- Strict Traceability Measures: Tracking each component through every phase of production for accountability and quality assurance.
- Regular Audits: Conducting internal and external audits to ensure compliance with the latest IATF standards and continuously improve manufacturing processes.
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| Item/Type | Vertical Injection Machinery | Horizontal Injection Machinery |
|---|---|---|
| Tonnage Range | From 35T to 250T | From 60T to 200T |
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Maximum Product Size |
INCH: 8.5 x 11 x 6 MILLMETER: 216 x 279 x 150 |
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Maximum Product Weight |
0.1g~500g | |
| Preciseness |
Mold: ± 0.005mm Product: ± 0.03~0.05mm |
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Design for Manufacture (DFM)
Utilizing advanced mold flow analysis software, we meticulously assess critical aspects such as flow balance, hub analysis, and venting line design. |
Process Failure Mode and Effects Analysis (PFMEA) PFMEA includes stringent material control through rigorous inspections and meticulous equipment management to ensure optimal performance. |
Surface Texture
Whether you require intricate engraving based on your specifications or alternative texture patterns for validation, we deliver exceptional results. |
The Types of Pedals
Automotive Pedals
- Accelerator Pedals
- Brake Pedals
- Clutch Pedals (usage decreasing due to automatic transmissions)
These pedals require precise design and manufacturing to meet stringent safety and performance standards.
- Cars: In the era of new mobility, reducing vehicle weight is crucial for improving fuel efficiency and performance, especially in heavier electric vehicles (EVs). Layana specializes in insert molding and overmolding techniques, leveraging expertise in bi-material manufacturing. Their plastic and metal engineering teams collaborate to produce lightweight yet robust pedal solutions.
- Trucks: Heavy-duty trucks require pedals that can endure extreme conditions, including frequent use and harsh environments. Layana manufactures high-strength plastic pedals designed for extended durability, offering full pedal assemblies or subassemblies for seamless integration with vehicle systems. This allows clients to efficiently bring their latest pedal designs into production while maintaining high performance standards.
Off-Road, Construction, and Operational Vehicles
Off-road and heavy-duty vehicles—such as agricultural tractors, ATVs, 4x4 trucks, military vehicles, excavators, cranes, bulldozers, forklifts, and aircraft tugs—operate in demanding environments where ruggedness and reliability are critical. Layana delivers advanced pedal solutions tailored to these tough conditions, using high-performance materials like high-strength polymers reinforced with glass fiber.
Key features include:
- Maximum Durability and Resilience: Optimized plastic injection molding processes ensure pedals can withstand heavy loads, dirt, moisture, and extreme temperatures.
- Precision Engineering: Producing pedals that are lightweight yet durable, maintaining reliability even under harsh operational conditions.
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Semi Truck Pedals |
Agriculture Vehicle Pedals |
Off-Road Vehicle Pedals |
Commercial Vehicle Pedals |
Utility Vehicle Pedals |
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Industrial: pedals serve as key control mechanisms in machinery and automation equipment, allowing hands-free operation. These pedals must be designed for superior durability to withstand continuous use in demanding environments.
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Machine Controls: Layana manufactures pedals for critical medical equipment, such as surgical tools and diagnostic devices, where flawless performance is essential. For example, dental pedals allow dentists to control equipment while keeping both hands free for procedures.
Materials Used in Pedal Manufacturing
Selecting the right materials is critical, affecting performance, durability, and safety. Layana offers a variety of materials for different pedal types:
Metal Pedals
- Materials: Carbon steel, stainless steel, lightweight aluminum.
- Manufacturing: Forging or precision metal stamping.
- Applications: Ideal for medical machinery requiring enhanced strength and durability.
Plastic Pedals
- Materials: Advanced polymers like Polyamide (PA), Polycarbonate (PC), Polyoxymethylene (POM), reinforced with glass fiber or other hardening agents
- Manufacturing: Cutting-edge plastic injection molding techniques
- Advantages:
- Lightweight yet durable
- Corrosion-resistant
- Able to withstand extreme temperatures and environmental conditions
- Lightweight yet durable
- Applications: Suited for demanding automotive and heavy-industrial applications where weight reduction is crucial.
Bi-Material Pedals
- Combination of Metal and Plastic: Utilizing insert molding or overmolding processes
- Benefits:
- Ideal balance between strength and weight
- Combines durability of metal with lightweight properties of plastic
- Ideal balance between strength and weight
- Applications: Suitable for a wide range of applications, from off-road vehicles to automated industrial systems.
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Metal Pedals |
Plastic Pedals |
Bi-material pedals |
Layana's Commitment to Green Manufacturing
In addition to delivering high-performance pedal solutions, Layana is dedicated to sustainable and environmentally conscious manufacturing. Our Green Factory Certification and Green Building Gold Level Certification reflect our commitment to eco-friendly practices, including:
- Energy Efficiency: Implementation of ISO 50001 energy management systems to reduce energy consumption across all operations.
- Waste Reduction: Advanced production techniques minimize material waste, contributing to a smaller environmental footprint.
- Water Conservation: Innovative rainwater recycling systems reduce water usage in our facilities.
- Emission Reduction: Programs aimed at minimizing CO₂ emissions, validated by our ISO 14064 Greenhouse Gas Certification.
By choosing Layana, clients not only receive superior pedal components but also contribute to a more sustainable future.
Frequently Asked Questions (FAQ)
1. Does Layana commercialize pedals?
2. How can Layana help manufacture pedals?
3. What is the difference between safety parts and standard parts?
| Aspect | Safety Parts | Normal Parts |
|---|---|---|
| Regulatory Compliance | Strict industry standards, third-party certification, full traceability | General industry standards or internal guidelines |
| Inspection Frequency | Multiple stages, increased frequency, continuous monitoring (SPC) | Inspections at key points, random sampling |
| Testing Methods | Advanced tests (crash, fatigue, destructive testing) | Basic dimensional checks, functional and visual inspection |
| Documentation and Traceability | Detailed records, full traceability | Less detailed documentation |
| Failure Tolerance | Zero-defect tolerance | Minor cosmetic or non-critical defects may be allowed |
| Supplier and Process Audits | Strict audits, regular reassessments, full process control | Less frequent and comprehensive audits |
| Rework and Scrap Policies | Rework often not allowed; defective parts are scrapped | Rework allowed if defects are minor |