In a marketplace where power to size to weight ratios are now all important, this product is claimed to set new boundaries. Available in two lengths (44 and 54mm), the 25GST 82 and 25GT 82 motors benefit from the most powerful magnets available on the market, designed into an optimised magnetic circuit.
The compact 25GST delivers a continuous 27W and a permanent torque of 32mNm.
The 54mm long 25GT delivers 40W and a permanent torque of 43mNm.
The life of DC motors is always a subjective issue; however these motors are fitted with the Rotafente commutation system, which is ideally suited to applications requiring high continuous and peak torques, where high current densities have to be commutated, thus giving longer motor life.
All motors are fitted with an industry proven fibre wrapped high temperature coil, with preloaded ball bearings and a rugged stator structure; which enables the motors to have a very long working life in the harshest of environments typically around ambient temperatures ranging from -30 to +125C.
Their mechanical time constants and power to weight ratios are market leaders, and are ideally suited to applications in the medical device, medical diagnostics equipment, textile machines and automation equipment market segments.
Delta Line Europe offers a complete range of front end and rear end options which include a full range of customised gearboxes, spur and planetary gearboxes, brakes, encoders and an optional integrated RFI filter.
New gear systems offer higher strength
The Davall Spiradrive is a right-angled/offset drive, consisting of a gear and pinion. The pinion has fewer teeth than the gear and is of parallel or tapered screw form. The gear is a face type similar to a hypoid-offset spiral bevel.
This arrangement offers a wide range of gear ratios, with a greater number of continuously meshing teeth (than for a worm gear of similar size), resulting in higher strength and smoothness of action from a compact design.
Also, mounting requirements for Spiradrive are not as critical as for bevel or hypoid gears, ensuring maximum accuracy and positive backlash control.
Spiradrive is available in a standard range of gearboxes (motorised and overload protected), loose gear sets, or custom-designed and manufactured to specification.
This arrangement offers a wide range of gear ratios, with a greater number of continuously meshing teeth (than for a worm gear of similar size), resulting in higher strength and smoothness of action from a compact design.
Also, mounting requirements for Spiradrive are not as critical as for bevel or hypoid gears, ensuring maximum accuracy and positive backlash control.
Spiradrive is available in a standard range of gearboxes (motorised and overload protected), loose gear sets, or custom-designed and manufactured to specification.
Square design range is cost-effective alternative
Brown Group has a new range of square design worm reduction units. The BW-Q range of gearboxes is available in single-reduction, double-reduction and helical-worm formats, and all units are interchangeable with other leading square design makes. The units are available with 30-150mm centres with a ratio of 7:1 to 100:1 for single reduction and up to 10,000:1 in double reduction.
The gears are designed with an increased-width phosphor-bronze worm wheel to give extra strength, longer life and increased input power and output torque capacity.
This square design range complements the existing worm and helical gear range but can also be viewed as an extremely cost-effective alternative.
The gears are designed with an increased-width phosphor-bronze worm wheel to give extra strength, longer life and increased input power and output torque capacity.
This square design range complements the existing worm and helical gear range but can also be viewed as an extremely cost-effective alternative.
GWS right angle gearbox upgrade from Parvalux
Parvalux is continuously adding to its range of motors and motor gear units. The latest unit is the compact and powerful GWS right angle gearbox with a speed range of 0.5-26 rpm with torques up to 200Nm. The GWS gearbox has an envelope size of approximately 151(h) x 142(w) x 142(d) mm and is fitted, in its natural form, with a 25mm dia x 76mm long shaft incorporating a 6mm wide x 63mm long keyway.
Mounting is by means of four m10 tapped holes in the base of the gearbox or M6 x 19mm deep on the flange.
To complement the GWS unit, Parvalux offers a versatile range of permanent magnet motors as well as induction motors.
Such combinations of motors and GWS gearboxes have enabled Parvalux to provide industry with units that offer power in a compact design.
Typical applications for the GWS gearbox include traction units, winch and hoist motor gearboxes, conveyor drives, turntables and welding manipulator drives.
Mounting is by means of four m10 tapped holes in the base of the gearbox or M6 x 19mm deep on the flange.
To complement the GWS unit, Parvalux offers a versatile range of permanent magnet motors as well as induction motors.
Such combinations of motors and GWS gearboxes have enabled Parvalux to provide industry with units that offer power in a compact design.
Typical applications for the GWS gearbox include traction units, winch and hoist motor gearboxes, conveyor drives, turntables and welding manipulator drives.
Stock gearsets cut machine downtime
Gearbox Direct now holds a huge range of matched worm and wheel gearsets in stock. The gearsets are interchangeable with most leading brands of gearbox. The service is aimed mainly at large maintenance departments and commercial gearbox repairers and rebuilders, who will benefit from ex-stock availability and top quality worm gear sets that can be easily modified to suit virtually all gearboxes.
The service reduces the time for repairs from anything between 4 and 6 weeks to a matter of hours.
The speed of supply and variation available should help overcome the problems faced everyday by gearbox rebuilders and repairers.
In many instances these concerns are frustrated in their efforts to provide fast gearbox rebuilds by the waiting time for original parts, typically 4 to 6 weeks.
Gearbox Direct's versatile worm gearsets are designed to overcome this problem.
They can be easily modified to suit virtually all gearbox types with comparable ratios and centre distances, simply by matching both ends of the extended, unfinished shafts.
This can be undertaken by the repairer/rebuilder or by Gearbox Direct itself.
The comprehensive range of "off-the-shelf" gearsets is available in ratios from 5:1 to 70:1 and centres from 5 to 14in".
Special worms and wheels can also be manufactured to customer specifications.
For maximum efficiency and reliability, all the gearshafts are made from case-hardened alloy steel with ground involute-helicoids profiles.
The worm wheels are manufactured from centrifugally cast phosphor bronze.
Gearbox Direct will also manufactures made to order gearboxes and gearsets for non-standard applications.
The service reduces the time for repairs from anything between 4 and 6 weeks to a matter of hours.
The speed of supply and variation available should help overcome the problems faced everyday by gearbox rebuilders and repairers.
In many instances these concerns are frustrated in their efforts to provide fast gearbox rebuilds by the waiting time for original parts, typically 4 to 6 weeks.
Gearbox Direct's versatile worm gearsets are designed to overcome this problem.
They can be easily modified to suit virtually all gearbox types with comparable ratios and centre distances, simply by matching both ends of the extended, unfinished shafts.
This can be undertaken by the repairer/rebuilder or by Gearbox Direct itself.
The comprehensive range of "off-the-shelf" gearsets is available in ratios from 5:1 to 70:1 and centres from 5 to 14in".
Special worms and wheels can also be manufactured to customer specifications.
For maximum efficiency and reliability, all the gearshafts are made from case-hardened alloy steel with ground involute-helicoids profiles.
The worm wheels are manufactured from centrifugally cast phosphor bronze.
Gearbox Direct will also manufactures made to order gearboxes and gearsets for non-standard applications.
Lighter bevel helicals thanks to aluminium casings
Leading power transmission specialists Motovario have extended their range of bevel helicals to include two new larger sizes and more small sizes made with lightweight aluminium universal mounting casings. The larger sizes are designed for new markets, such as bulk material handling, conveyors and agitator/mixer applications where a robust cast iron casing is required with high torques and slow speeds through to lighter duties where the low weight of the aluminium casing lends itself for mounting directly on the drive shaft. The bevel helical range compliments Motovario's worm gearbox range with the added benefit of high efficiency at 96 per cent.
Motovario have been particularly successful with their bevel helical range due to the efficiency for electronic variable speed drives.
Although a bevel helical unit is more expensive than a wormbox, when the efficiency and required motor power are taken into account, they are cost effective, especially with electrical variable speed drives, since smaller controllers can be utilised.
"The reason why the small end of the market has been developed is that, with the development of high efficiency motors and the environmental needs to save energy, bevel helicals are going to be a main gearbox requirement in the 21st century," said Steve Horsfall, Managing Director of Motovario Ltd, based in Rushock, near Droitwich.
"Motovario is extending and developing its range of bevel helicals with an eye on the future.
The aluminium casings make them more cost effective.
"The iron age has passed and people now accept aluminium as not only being lightweight but also as a strong material such as used in lunar modules and new top of the range cars."
Features: - 8 sizes - Ratios from M.6/1 - Power ratings from 0.12KW to 30KW Inputs to suit any standard IEC, ac or dc motor Close coupled motor versions Foot mounting or flange mounting versions with hollow output bore or solid output shaft options
Motovario have been particularly successful with their bevel helical range due to the efficiency for electronic variable speed drives.
Although a bevel helical unit is more expensive than a wormbox, when the efficiency and required motor power are taken into account, they are cost effective, especially with electrical variable speed drives, since smaller controllers can be utilised.
"The reason why the small end of the market has been developed is that, with the development of high efficiency motors and the environmental needs to save energy, bevel helicals are going to be a main gearbox requirement in the 21st century," said Steve Horsfall, Managing Director of Motovario Ltd, based in Rushock, near Droitwich.
"Motovario is extending and developing its range of bevel helicals with an eye on the future.
The aluminium casings make them more cost effective.
"The iron age has passed and people now accept aluminium as not only being lightweight but also as a strong material such as used in lunar modules and new top of the range cars."
Features: - 8 sizes - Ratios from M.6/1 - Power ratings from 0.12KW to 30KW Inputs to suit any standard IEC, ac or dc motor Close coupled motor versions Foot mounting or flange mounting versions with hollow output bore or solid output shaft options
Catalogue has more than 3500 stock gear products
More than 3500 stock gear products are detailed in the new KHK catalogue, several of which are new to this 3008 publication. It features sections on spur, helical, mitre, bevel, screw, worm and internal gears as well as CP racks and pinions. Newcomers include Fairloc hub acetal spur gears, sintered metal spur gears, tapered pinions and racks, high ratio hypoid gears and spiral bevel gearboxes for both right-angle and inline drive applications.
Civil engineer wins marine gearbox
Simon Alsop of York was the winner of a brand new, two-speed PRM StepDrive gearbox in a free-to-enter competition organised by Newage Transmissions earlier in the year. Alsop had his name drawn first from more than 200 entries to the StepDrive promotion, which was run by Newage to coincide with its participation at the London International Boat Show in January. Alsop, a 26-year-old civil engineer, intends to install his prise - along with another StepDrive unit - to his twin engined Fairline Targa 29 within the next few weeks.
'StepDrives have been designed specifically for use with the Volvo diesel engines in my boat, so I am particularly pleased to have won this competition', says Alsop.
'A friend of mine has another Fairline Targa, which is powered by twin V6 petrol engines'.
'This currently outperforms my boat by quite a margin, so I'm looking forward to being able to match his performance much more closely once my StepDrives are fitted'.
The novel two-speed automatic gearboxes significantly improve boat acceleration by providing a reduction ratio of around 25% in addition to their direct drive top gear.
They are installed entirely within the centre section of Duoprop units and are ideal for use with turbocharged engines such as Volvo Penta AD31 and 41 series; as well as supercharged units up to the KAD44.
'From the computer simulations we've run, we expect Simon's Fairline to show at least a 30% improvement in acceleration, enabling it to get onto the plane far quicker than at present', says Newage Marine Sales Manager Jamie Pratt.
'Simon's boat is berthed at Naburn Marina in York, and much of his cruising is done on inland waterways'.
'As a result, Stepdrive's other advantages, such as better low speed manoeuvrability, reduced emissions and noise, will also be extremely beneficial to him', he adds.
'I was seriously considering buying a pair of StepDrives for my boat anyway', continues Alsop: 'Their whole concept is very impressive'.
'What's more, Newage has ensured that they are extremely well designed - reflecting the company's pedigree of producing rugged and dependable gearboxes for boats with engines rated at up to 620hp'.
'StepDrives have been designed specifically for use with the Volvo diesel engines in my boat, so I am particularly pleased to have won this competition', says Alsop.
'A friend of mine has another Fairline Targa, which is powered by twin V6 petrol engines'.
'This currently outperforms my boat by quite a margin, so I'm looking forward to being able to match his performance much more closely once my StepDrives are fitted'.
The novel two-speed automatic gearboxes significantly improve boat acceleration by providing a reduction ratio of around 25% in addition to their direct drive top gear.
They are installed entirely within the centre section of Duoprop units and are ideal for use with turbocharged engines such as Volvo Penta AD31 and 41 series; as well as supercharged units up to the KAD44.
'From the computer simulations we've run, we expect Simon's Fairline to show at least a 30% improvement in acceleration, enabling it to get onto the plane far quicker than at present', says Newage Marine Sales Manager Jamie Pratt.
'Simon's boat is berthed at Naburn Marina in York, and much of his cruising is done on inland waterways'.
'As a result, Stepdrive's other advantages, such as better low speed manoeuvrability, reduced emissions and noise, will also be extremely beneficial to him', he adds.
'I was seriously considering buying a pair of StepDrives for my boat anyway', continues Alsop: 'Their whole concept is very impressive'.
'What's more, Newage has ensured that they are extremely well designed - reflecting the company's pedigree of producing rugged and dependable gearboxes for boats with engines rated at up to 620hp'.
Extra-large gearbox handles heavy-duty servos
A new, extra-large servo-gearbox for heavy-duty applications has been launched in the UK by Motor Technology of Stockport. The new Dynabox XL, from Girard Transmissions, delivers up to 8000Nm of torque with backlash as low as 0.5arc-min and with ratios of up to 90:1. It is the newest addition to the existing range of Dynabox servo gearboxes which are all maintenance free with a right-angled, space-saving configuration.
Like the other gearboxes in the range, the Dynabox XL has two levels of precision to suit different applications.
The first is "medium precision", where backlash is fixed at 5arc-min; the second is "expert precision", where the backlash is adjustable to less than 0.5arc-min.
The new gearbox can accommodate input speeds from 4000rev/min (continuous) to 6000rev/min (peak), and can handle axial and radial loading of over 70,000N.
It is available in three frame sizes (125, 160 and 200mm) and is supplied with a choice of either a hollow or solid input shaft.
Like the other gearboxes in the range, the Dynabox XL has two levels of precision to suit different applications.
The first is "medium precision", where backlash is fixed at 5arc-min; the second is "expert precision", where the backlash is adjustable to less than 0.5arc-min.
The new gearbox can accommodate input speeds from 4000rev/min (continuous) to 6000rev/min (peak), and can handle axial and radial loading of over 70,000N.
It is available in three frame sizes (125, 160 and 200mm) and is supplied with a choice of either a hollow or solid input shaft.
Novel high-tech design for planetary gear
The new PH series satisfies market requirements for low-backlash planetary gears with higher torsional stiffness and stability together with a longer operational life for the output shaft bearings. The internal workings of this compact design draw on the proven technology of helical cut gears in existing planetary gearboxes. The output shaft is designed as a flange according to ISO9409.
As a result it is possible to directly bolt on pinions, gearbelt pulleys, transmission shafts, rotary actuators, or rotary tables.
Expensive shaft hub connections such as shrink discs are no longer necessary.
The gearbox series consists of six sizes with torques from 100 to 6000Nm.
Exact gear ratios can be selected in the range of 5 to 100.
The standard model already has a backlash of 3arc-min, and can be easily reduced to 1arc-min.
These characteristics of the new PH planetary gear series are especially suited to drive solutions demanding the highest standards for smooth running, precision and reliability
As a result it is possible to directly bolt on pinions, gearbelt pulleys, transmission shafts, rotary actuators, or rotary tables.
Expensive shaft hub connections such as shrink discs are no longer necessary.
The gearbox series consists of six sizes with torques from 100 to 6000Nm.
Exact gear ratios can be selected in the range of 5 to 100.
The standard model already has a backlash of 3arc-min, and can be easily reduced to 1arc-min.
These characteristics of the new PH planetary gear series are especially suited to drive solutions demanding the highest standards for smooth running, precision and reliability
Size 23 in-line planetary gearbox launched
API Portescap an API Motion company are pleased to announce the IP57B which is a second generation product offering Integer ratios, low backlash, the ratio of 10:1 in a single stage and low cost. These improved gearboxes of 40Nm peak torque give stock ratios from 5 to 100:1, plus five other standard ratios and 34 optional ratios. This is all contained within 57mm square x 54 to 79mm long depending on the ratio.
The gearboxes come with adapters and an 'Easyfit' clamp on pinion for off the shelf flexibility or direct fit for a cost effective solution in OEM volumes.
The gearbox can be fitted to any type of motor, but its prime use with a brushed and brushless DC and Stepper motor for the Factory Automation, Medical, Process Control, Scientific Instruments, Security and Access, and Semi-Conductor manufacturing machines.
The gearboxes come with adapters and an 'Easyfit' clamp on pinion for off the shelf flexibility or direct fit for a cost effective solution in OEM volumes.
The gearbox can be fitted to any type of motor, but its prime use with a brushed and brushless DC and Stepper motor for the Factory Automation, Medical, Process Control, Scientific Instruments, Security and Access, and Semi-Conductor manufacturing machines.
Rigid axle units aimed at 3 and 5 tonne vehicles
A re-developed range of heavy duty rigid axle units for off-highway and construction site vehicle applications has been announced by Coventry-based mechanical driveline equipment specialist, Newage Transmissions Ltd. The first two models in the series, the 215 and 415, are nominally designed for 3 and 5 tonne vehicle types. Each unit features double reduction gearing, with a 14.8:1 drive ratio as standard.
In addition, all axles in the new range will be available with integral transfer gearboxes for hydrostatic drives - providing overall reduction ratios of: 22.64, 26.10 and 31.52:1.
According to Newage's Technical Director, Clive Rayner: "These two new units are the forerunners of our next generation of versatile, high efficiency driveline equipment.
They are designed on a modular basis to ensure maximum commonality of parts.
This, in turn, means reduced development and manufacturing costs, as well as even better availability of units and spares."
"We believe that by extending the new range to suit vehicles up to 10 tonnes, we shall have products ideally suited to a much wider range of construction site and off-highway applications," he added.
Both new models incorporate integrated oil-immersed disc brakes and transmit drive to the wheels via inboard planetary reduction units and fully floating half shafts.
Offered with three wheel track widths, 215 and 415 series axles are rated at maximum loads of 3200kg and 5200kg and provide nominal output torques at their two wheels of 6,460Nm and 13,222Nm respectively, based on the standard reduction ratio of 14.8:1.
Both new units are available with an optional handbrake and can be supplied with a comprehensive range of input flange and wheel mounting configurations.
With a precision engineering pedigree spanning more than 70 years, Coventry-based Newage Transmissions Ltd is one of the UK's leading designers and manufacturers of high efficiency mechanical drive-line equipment.
The company's products - which are backed by certification to BSI standards - encompass heavy duty gearboxes, axles and transfer boxes for off-road dumper vehicles, as well as its world-renowned PRM marine gearbox range.
Newage also supplies finished products for a wide variety of new generation, special purpose vehicles in addition to sub-contract services for leading manufacturing organisations, including AGCO Massey Ferguson, Case and Lansing Linde.
In addition, all axles in the new range will be available with integral transfer gearboxes for hydrostatic drives - providing overall reduction ratios of: 22.64, 26.10 and 31.52:1.
According to Newage's Technical Director, Clive Rayner: "These two new units are the forerunners of our next generation of versatile, high efficiency driveline equipment.
They are designed on a modular basis to ensure maximum commonality of parts.
This, in turn, means reduced development and manufacturing costs, as well as even better availability of units and spares."
"We believe that by extending the new range to suit vehicles up to 10 tonnes, we shall have products ideally suited to a much wider range of construction site and off-highway applications," he added.
Both new models incorporate integrated oil-immersed disc brakes and transmit drive to the wheels via inboard planetary reduction units and fully floating half shafts.
Offered with three wheel track widths, 215 and 415 series axles are rated at maximum loads of 3200kg and 5200kg and provide nominal output torques at their two wheels of 6,460Nm and 13,222Nm respectively, based on the standard reduction ratio of 14.8:1.
Both new units are available with an optional handbrake and can be supplied with a comprehensive range of input flange and wheel mounting configurations.
With a precision engineering pedigree spanning more than 70 years, Coventry-based Newage Transmissions Ltd is one of the UK's leading designers and manufacturers of high efficiency mechanical drive-line equipment.
The company's products - which are backed by certification to BSI standards - encompass heavy duty gearboxes, axles and transfer boxes for off-road dumper vehicles, as well as its world-renowned PRM marine gearbox range.
Newage also supplies finished products for a wide variety of new generation, special purpose vehicles in addition to sub-contract services for leading manufacturing organisations, including AGCO Massey Ferguson, Case and Lansing Linde.
Overload clutch gets its own website
A new website aims to help design engineers and industrial distributors select the Centric Clutch overload clutch that is best for a given application. Commonly used in applications such as paper converting, packaging, wastewater treatment, braking and material handling, these products offer valuable machine design benefits. The new www.CentricClutch.com features downloadable product guides and application information for Centric Clutch mechanical and pneumatic centrifugal overload clutch products.
Technical data and product specifications for a variety of models can be accessed easily with the click of a mouse.
And a special section offers important considerations and helpful guidelines for selecting a Centric Clutch.
Overload clutches provide design advantages such as machine protection and reduced repair time during jamming load conditions.
Centric clutches offer an accurate method of resetting the torque without operator intervention.
A single position clutch will reengage in the exact rotational position each time - often necessary for system timing in bottling, packaging, paper converting and other similar applications.
Overload clutches provide consistent torque levels after many overloads.
At very low speeds, systems can develop a large amount of unnecessary torque that can damage drive system components (shafts, gearboxes, chains, couplings, etc.) in the advent of a jam.
A torque limiter will restrict the torque to the set level and extend system component life.
Technical data and product specifications for a variety of models can be accessed easily with the click of a mouse.
And a special section offers important considerations and helpful guidelines for selecting a Centric Clutch.
Overload clutches provide design advantages such as machine protection and reduced repair time during jamming load conditions.
Centric clutches offer an accurate method of resetting the torque without operator intervention.
A single position clutch will reengage in the exact rotational position each time - often necessary for system timing in bottling, packaging, paper converting and other similar applications.
Overload clutches provide consistent torque levels after many overloads.
At very low speeds, systems can develop a large amount of unnecessary torque that can damage drive system components (shafts, gearboxes, chains, couplings, etc.) in the advent of a jam.
A torque limiter will restrict the torque to the set level and extend system component life.
Marine propulsion control unit set for show debut
The PRM Marine Propulsion Control (MPC) unit, an all-new system providing full electronic control over engine throttle and gear engagement, will be launched by Newage Transmissions as part of the company's presentation on stand 1.310 at the METS International Marine Equipment Trade Show (taking place in Amsterdam between 15th and 17th November 2005). Providing soft gear engagement - for improved comfort, increased vessel control and reduced component wear - the MPC system also features a trolling capability (variable propeller speed at constant engine revs) and the automatic adjustment of engine power to match the demands of engine-driven ancillaries, such as power take off (PTO) units. Designed specifically for PRM series marine transmissions, the new system is suitable for use with both mechanical and electronically controlled engines.
The unit's fully interlocked, closed loop control provides stable gearbox output speeds under all engine load conditions.
In addition, it allows the sizing of hydraulic pumps and accessories to be optimised enabling the use of more powerful ancillary equipment in many applications.
Further features of the new system include programmable software to enable the system to be tailored to individual application requirements, and the availability of single, twin or fly-bridge controls, whose operation is synchronised through the unit's electronic control system.
For added safety, the new MPC unit also offers a full manual override in the event of an onboard electrical failure.
Other high efficiency PRM marine transmissions equipment to be displayed at METS will include lightweight, all mechanical units designed for the rapidly-expanding pleasure craft and light commercial market; heavy duty PRM 750 workboat transmissions; and the company's recently introduced top-of-the range PRM 1750 gearboxes for use with engines rated at up to 457kW.
With a maximum torque capacity of 1750Nm, this heavy duty unit is available in both shallow or deep gearcase configurations, with a range of standard ratios from 1.22:1 to 4.90:1.
Like other PRM gearboxes, the latest model features a dual countershaft design that enables full input power to be transmitted in both ahead or astern.
As a result, units are equally suitable for left or right hand propeller rotations - as well as multiple engine installations.
They also carry Lloyd's approved commercial ratings and are backed by a full two year warranty and the company's worldwide dealer and customer support network.
The unit's fully interlocked, closed loop control provides stable gearbox output speeds under all engine load conditions.
In addition, it allows the sizing of hydraulic pumps and accessories to be optimised enabling the use of more powerful ancillary equipment in many applications.
Further features of the new system include programmable software to enable the system to be tailored to individual application requirements, and the availability of single, twin or fly-bridge controls, whose operation is synchronised through the unit's electronic control system.
For added safety, the new MPC unit also offers a full manual override in the event of an onboard electrical failure.
Other high efficiency PRM marine transmissions equipment to be displayed at METS will include lightweight, all mechanical units designed for the rapidly-expanding pleasure craft and light commercial market; heavy duty PRM 750 workboat transmissions; and the company's recently introduced top-of-the range PRM 1750 gearboxes for use with engines rated at up to 457kW.
With a maximum torque capacity of 1750Nm, this heavy duty unit is available in both shallow or deep gearcase configurations, with a range of standard ratios from 1.22:1 to 4.90:1.
Like other PRM gearboxes, the latest model features a dual countershaft design that enables full input power to be transmitted in both ahead or astern.
As a result, units are equally suitable for left or right hand propeller rotations - as well as multiple engine installations.
They also carry Lloyd's approved commercial ratings and are backed by a full two year warranty and the company's worldwide dealer and customer support network.
Brushless motors with integrated speed controller
Parvalux introduces a new range of DC brushless motors with optional integrated drive electronics. These next generation motor solutions are designed to meet today's needs for cost effective, compact, versatile and maintenance free motors. The Parvalux 'ParvaDrive' range can be supplied as an integrated motor and drive package, or as a motor only with the option of a separate controller.
Using modern materials and the latest design and manufacturing techniques, ParvaDrive motors offer a significant price advantage over similar products from other manufacturers.
They provide a highly reliable and low cost motor solution suitable for many OEM applications.
The range includes motor diameters of 42mm, 60mm and 86mm with up to four different stack lengths available in each frame size.
They have a torque range of 0.1Nm up to 2.1Nm continuous (20W to 800W) from a single input voltage of 12V to 48V (other voltages available on request).
Speed control is by means of an analogue input reference from a controller or PLC (Programmable Logic Controller), or alternatively by means of a speed control potentiometer.
Rated to IP55 (splash proof) and designed to meet European and International specifications, the motors feature rare earth magnets, and UL specified components.
The optional integrated two quadrant controller housed in the rear of the motor allows speed control in either direction and the use of SMT (Surface Mount Technology) components provides a reliable and compact package that is housed inside the motor.
ParvaDrive units can also be integrated with the extensive range of Parvalux gearboxes which include worm and wheel, planetary, spur and multi-spur to provide a huge range of torques and output speeds to suit every application.
ParvaDrive motors are available from stock in a range of voltages and torque ratings and are part of a much wider range of AC and DC motors and gearboxes.
Parvalux specialise in the design and supply of individual motor and gearbox solutions up to 650W.
Evaluation units can be quickly provided for new applications and all orders are turned around with the minimum of delay. Request a free brochure from Parvalux Electric Motors....
Using modern materials and the latest design and manufacturing techniques, ParvaDrive motors offer a significant price advantage over similar products from other manufacturers.
They provide a highly reliable and low cost motor solution suitable for many OEM applications.
The range includes motor diameters of 42mm, 60mm and 86mm with up to four different stack lengths available in each frame size.
They have a torque range of 0.1Nm up to 2.1Nm continuous (20W to 800W) from a single input voltage of 12V to 48V (other voltages available on request).
Speed control is by means of an analogue input reference from a controller or PLC (Programmable Logic Controller), or alternatively by means of a speed control potentiometer.
Rated to IP55 (splash proof) and designed to meet European and International specifications, the motors feature rare earth magnets, and UL specified components.
The optional integrated two quadrant controller housed in the rear of the motor allows speed control in either direction and the use of SMT (Surface Mount Technology) components provides a reliable and compact package that is housed inside the motor.
ParvaDrive units can also be integrated with the extensive range of Parvalux gearboxes which include worm and wheel, planetary, spur and multi-spur to provide a huge range of torques and output speeds to suit every application.
ParvaDrive motors are available from stock in a range of voltages and torque ratings and are part of a much wider range of AC and DC motors and gearboxes.
Parvalux specialise in the design and supply of individual motor and gearbox solutions up to 650W.
Evaluation units can be quickly provided for new applications and all orders are turned around with the minimum of delay. Request a free brochure from Parvalux Electric Motors....
Gearbox drops in to upgrade test rig
ZF Industrial has supplied a custom Graessner gearbox for testing apparatus used to simulate airflow through new engine components to the Rolls Royce sponsored Aeronautical Research Unit at Loughborough University. In order to drive the test rig compressor system and provide the correct results, the replacement gearbox needed to produce output speeds of 5000rev/min. As the original gearbox was no longer manufactured, ZF supplied a PowerGear unit with a custom lubrication system as a drop-in replacement, which offered high performance operation and extended wear life.
In continued efforts to reduce emissions and fuel consumption from modern aeroplanes, Rolls Royce Aerospace sponsors the Aeronautical Research Unit at Loughborough University.
To improve the performance of the combustor units in gas turbine engines, Bill Rasmussen and his team operate a test rig which simulates airflow over and through new component designs.
By artificially recreating engine conditions, cooling, quality of airflow, the efficiency of air/fuel mixing can be monitored and the results used to develop higher performance engines.
The test rig itself consists of compressor disk assembly driven by 81kW motor and 4:1 ratio gearbox operating through 90 degrees.
To test engine hardware such as fuel injectors and diffusers, the rig requires input speeds of 5000rev/min to the compressor system in order to create an accurate simulation of airflow through a jet engine.
'We were previously relying on a bevel gearbox from another manufacturer for the application, which had begun to run hot due to oil starvation', explains Rasmussen.
'When we made initial enquires, we were informed that the unit had been discontinued, we then had difficulty finding a suitable replacement until we contacted ZF, whose range of gearboxes promised the high levels performance required as well as direct compatibility'.
David Morgan, the ZF Sales Engineer in charge of the project, recommended a P240H Graessner PowerGear unit fitted with a bespoke oil feed system as the optimum solution.
'The Graessner unit acted as a drop-in replacement and provided the high speeds and levels of accuracy required to drive the compressor blades and produce the precise airflow needed for accurate results'.
'The forced through oil lubrication system keeps the gearbox cool despite the high output speeds while contributing to a longer wear life'.
'Originally designed for compact machine tool applications, the PowerGear unit occupied minimal space in the small cellar room where the test rig drive assembly is situated, allowing for simple fitting and easier maintenance'.
'The housing and flanges of the PowerGear units are made of spheroidal graphite iron for maximum rigidity and the use of high quality taper roller bearings allows a high axial and radial load capacity, making them ideal for the test rig applications'.
Options available include two-, three- and four-way shaft configurations and gear ratios ranging from 1:1 to 5:1.
With Gleason bevel gearing providing high levels of efficiency (98%), and a parameter optimised gear tooth contact pattern that promotes uniform load distribution, the units are able to offer high levels of torque (up to 7800Nm) compared with their diminutive size. Request a free brochure from ZF Great Britain....
In continued efforts to reduce emissions and fuel consumption from modern aeroplanes, Rolls Royce Aerospace sponsors the Aeronautical Research Unit at Loughborough University.
To improve the performance of the combustor units in gas turbine engines, Bill Rasmussen and his team operate a test rig which simulates airflow over and through new component designs.
By artificially recreating engine conditions, cooling, quality of airflow, the efficiency of air/fuel mixing can be monitored and the results used to develop higher performance engines.
The test rig itself consists of compressor disk assembly driven by 81kW motor and 4:1 ratio gearbox operating through 90 degrees.
To test engine hardware such as fuel injectors and diffusers, the rig requires input speeds of 5000rev/min to the compressor system in order to create an accurate simulation of airflow through a jet engine.
'We were previously relying on a bevel gearbox from another manufacturer for the application, which had begun to run hot due to oil starvation', explains Rasmussen.
'When we made initial enquires, we were informed that the unit had been discontinued, we then had difficulty finding a suitable replacement until we contacted ZF, whose range of gearboxes promised the high levels performance required as well as direct compatibility'.
David Morgan, the ZF Sales Engineer in charge of the project, recommended a P240H Graessner PowerGear unit fitted with a bespoke oil feed system as the optimum solution.
'The Graessner unit acted as a drop-in replacement and provided the high speeds and levels of accuracy required to drive the compressor blades and produce the precise airflow needed for accurate results'.
'The forced through oil lubrication system keeps the gearbox cool despite the high output speeds while contributing to a longer wear life'.
'Originally designed for compact machine tool applications, the PowerGear unit occupied minimal space in the small cellar room where the test rig drive assembly is situated, allowing for simple fitting and easier maintenance'.
'The housing and flanges of the PowerGear units are made of spheroidal graphite iron for maximum rigidity and the use of high quality taper roller bearings allows a high axial and radial load capacity, making them ideal for the test rig applications'.
Options available include two-, three- and four-way shaft configurations and gear ratios ranging from 1:1 to 5:1.
With Gleason bevel gearing providing high levels of efficiency (98%), and a parameter optimised gear tooth contact pattern that promotes uniform load distribution, the units are able to offer high levels of torque (up to 7800Nm) compared with their diminutive size. Request a free brochure from ZF Great Britain....
Transmission company on show in Amsterdam
Newage Transmissions is aiming to build on recent export successes through its participation at Europe's premier marine equipment exhibition, METS 2001, which takes place in Amsterdam between 13th-15th November. The company's presentation on Stand 10.10522 will feature examples from its full range of high efficiency PRM series marine transmissions. Models on show will include PRM 80, 120 and 150 units, designed for the rapidly-expanding pleasure craft and light commercial market; heavy duty PRM 750 workboat transmissions; and the company's top-of-the range PRM 1500 gearboxes for use with engines rated at up to 500hp.
In addition, Newage will be highlighting its series of ancillary marine equipment, including trolling valves and power take-off units.
"PRM units are already the gearboxes of choice for the overwhelming majority of Britain's inland waterway craft, with more than 80 per cent market share," says Marine Sales Manager, Ian Oliver.
"Their reputation for durability, reliability and in-service performance has seen them specified for an increasingly diverse range of applications over recent months, from pleasure craft to fishing vessels and passenger ferries.
"As one of the most important shows on our exhibition calendar, METS 2001 provides us with the ideal opportunity to further develop our overseas marine equipment sales."
In addition, Newage will be highlighting its series of ancillary marine equipment, including trolling valves and power take-off units.
"PRM units are already the gearboxes of choice for the overwhelming majority of Britain's inland waterway craft, with more than 80 per cent market share," says Marine Sales Manager, Ian Oliver.
"Their reputation for durability, reliability and in-service performance has seen them specified for an increasingly diverse range of applications over recent months, from pleasure craft to fishing vessels and passenger ferries.
"As one of the most important shows on our exhibition calendar, METS 2001 provides us with the ideal opportunity to further develop our overseas marine equipment sales."
Novel gearbox installed in Brixham boat
Newage Transmissions' first production StepDrive unit - an automatic two-speed marine gearbox that dramatically improves the performance of boats equipped with Volvo Penta diesel engines - has been installed in a 25ft Lema Clon motor boat based at Brixham. The installation marks the new gearbox's successful completion of exhaustive rig testing and sea trials designed to simulate many years of normal pleasure craft operation. StepDrive units are self-contained gearboxes that can be retrofitted to Volvo Duoprop 290 drive legs.
They are installed entirely within the centre section of the Duoprop unit and are ideal for use with turbocharged engines such as Volvo Penta AD31 and 41 series; as well as supercharged units up to the KAD44.
In operation, StepDrive gearboxes automatically change from low to high ratio at a predetermined engine speed.
This is optimised during installation to the individual boat and engine combination.
When the boat decelerates again, low gear is engaged as the engine speed falls below 1500rev/min.
Installed on the Lema Clon with a 150hp AD31 engine and DP-E driveleg, the Newage StepDrive unit has fully justified its makers claims that it typically increases boat performance by 25%.
"In timed test runs, some vessels have achieved massive 40% improvements in 0-20 knot times", reports Newage's Marine Sales Manager, Jamie Pratt.
"However, by providing an additional reduction ratio of around 25%, StepDrive units not only boost overall performance, but provide the benefits of reduced creep speed, emissions and noise when manoeuvring in busy marinas or restricted waterways".
"In some cases, they will also enable the original propellers to be replaced; so that the vessel's improved handling and fuel economy characteristics can be combined with an even higher top speed".
StepDrive installations will normally be completed in a day, with further in-water commissioning required to set the optimum gear change point.
All units carry a two-year warranty and are available nation-wide through the following six regional installations centres: DB Marine of Cookham, BA Peters in Chichester, Maldon-based Volspec, Marine Engineering Looe of East Looe, Southampton-based RK Marine, and Abersoch Land and Sea in Pwllheli.
They are installed entirely within the centre section of the Duoprop unit and are ideal for use with turbocharged engines such as Volvo Penta AD31 and 41 series; as well as supercharged units up to the KAD44.
In operation, StepDrive gearboxes automatically change from low to high ratio at a predetermined engine speed.
This is optimised during installation to the individual boat and engine combination.
When the boat decelerates again, low gear is engaged as the engine speed falls below 1500rev/min.
Installed on the Lema Clon with a 150hp AD31 engine and DP-E driveleg, the Newage StepDrive unit has fully justified its makers claims that it typically increases boat performance by 25%.
"In timed test runs, some vessels have achieved massive 40% improvements in 0-20 knot times", reports Newage's Marine Sales Manager, Jamie Pratt.
"However, by providing an additional reduction ratio of around 25%, StepDrive units not only boost overall performance, but provide the benefits of reduced creep speed, emissions and noise when manoeuvring in busy marinas or restricted waterways".
"In some cases, they will also enable the original propellers to be replaced; so that the vessel's improved handling and fuel economy characteristics can be combined with an even higher top speed".
StepDrive installations will normally be completed in a day, with further in-water commissioning required to set the optimum gear change point.
All units carry a two-year warranty and are available nation-wide through the following six regional installations centres: DB Marine of Cookham, BA Peters in Chichester, Maldon-based Volspec, Marine Engineering Looe of East Looe, Southampton-based RK Marine, and Abersoch Land and Sea in Pwllheli.
PRM marine gearbox range on show in Southampton
Four models from Newage Transmissions well-known PRM marine gearbox range will form the centrepiece of the company's presentation on Stand 84 at the Seawork Marine Equipment Show in Southampton between 19-21st June 2001. Developed specifically to meet the needs of commercial fishing vessel and work boat users, the PRM 500, 750, 1000 and 1500 models on show provide the ideal choice for a wide variety of applications with engines rated at up to 500 hp. All PRM gearboxes feature a dual countershaft design that enables full input power to be transmitted in both ahead or astern.
As a result, units are equally suitable for left or right hand propeller rotations - as well as multiple engine installations.
They also carry Lloyd's approved commercial ratings and are backed by a full two year warranty and the company's world-wide dealer and customer support network.
In addition, PRM marine gearboxes are offered with a comprehensive range of ancillary equipment, including trolling valves and clutched or direct-drive power take-offs.
"Our transmissions' in-service reliability, durability and low maintenance have helped to establish them as the units of choice for the majority of Britain's leisure boat owners," reports Newage's Marine Sales Manager, Ian Oliver.
"They are currently specified on more than 80 per cent of all new inland waterway craft."
As a result, units are equally suitable for left or right hand propeller rotations - as well as multiple engine installations.
They also carry Lloyd's approved commercial ratings and are backed by a full two year warranty and the company's world-wide dealer and customer support network.
In addition, PRM marine gearboxes are offered with a comprehensive range of ancillary equipment, including trolling valves and clutched or direct-drive power take-offs.
"Our transmissions' in-service reliability, durability and low maintenance have helped to establish them as the units of choice for the majority of Britain's leisure boat owners," reports Newage's Marine Sales Manager, Ian Oliver.
"They are currently specified on more than 80 per cent of all new inland waterway craft."
Miniature motors come with big specifications
A continuous power rating of no less than 70W is offered by 30mm diameter ironless-rotor DC motors in the new 30GT range from miniature motor and gearbox expert Portescap. These tiny motors, which are just 62mm long, combine their high power/size ratio with extended operating life, thanks to the use of high-quality graphite-copper brushgear and precision ball bearings. Portescap 30GT motors are currently offered, as standard, for use on 24 or 48V supplies.
The typical maximum operating speed for all models is 11,000rev/min, with 24V units capable of developing continuous torques of up to 83mNm, a figure which rises to 104mNm for 48V motors.
All 30GT motors can operate well in excess of their rated torque for short periods.
Benefits of the Portescap ironless technology used in these new motors include low friction, low starting voltage, absence of iron losses, good thermal dissipation and a linear torque-speed characteristic.
All of these factors facilitate the use of the units in high-performance drive and servo systems.
Their high efficiency means that they are also an ideal choice for applications in battery-powered equipment.
To complement its small, but powerful, 30GT ironless-rotor motors, Portescap offers an extensive range of standard and custom miniature gearboxes.
Designed for simple and speedy attachment to the motor, these gearboxes are available in both spur and planetary versions, with a wide range of reduction ratios.
• Delta Line Europe UK: contact details and other news
• Other news in Precision Motors and Gears
The typical maximum operating speed for all models is 11,000rev/min, with 24V units capable of developing continuous torques of up to 83mNm, a figure which rises to 104mNm for 48V motors.
All 30GT motors can operate well in excess of their rated torque for short periods.
Benefits of the Portescap ironless technology used in these new motors include low friction, low starting voltage, absence of iron losses, good thermal dissipation and a linear torque-speed characteristic.
All of these factors facilitate the use of the units in high-performance drive and servo systems.
Their high efficiency means that they are also an ideal choice for applications in battery-powered equipment.
To complement its small, but powerful, 30GT ironless-rotor motors, Portescap offers an extensive range of standard and custom miniature gearboxes.
Designed for simple and speedy attachment to the motor, these gearboxes are available in both spur and planetary versions, with a wide range of reduction ratios.
• Delta Line Europe UK: contact details and other news
• Other news in Precision Motors and Gears
70W continuous power from small DC motor
A continuous power rating of no less than 70 watts is offered by 30mm diameter ironless-rotor DC motors in the new 30GT range from miniature motor and gearbox supplier Portescap. These tiny motors, which are just 62mm long, combine their high power/size ratio with extended operating life, thanks to the use of high-quality graphite-copper brushgear and precision ball bearings. Portescap 30GT motors are currently offered, as standard, for use on 24V or 48V supplies.
Custom motors for other supply voltages are, however, available to order.
The typical maximum operating speed for all models is 11,000 rpm, with 24V units capable of developing continuous torques of up to 83 mNm, a figure which rises to 104 mNm for 48V motors.
All 30GT motors can operate well in excess of their rated torque for short periods.
Benefits of the Portescap ironless technology used in these new motors include low friction, low starting voltage, absence of iron losses, good thermal dissipation and a linear torque-speed characteristic.
All of these factors facilitate the use of the units in high-performance drive and servo systems.
Their high efficiency means that they are also an ideal choice for applications in battery-powered equipment.
To complement its small, but powerful, 30GT ironless-rotor motors, Portescap offers an extensive range of standard and custom miniature gearboxes.
Designed for simple and speedy attachment to the motor, these gearboxes are available in both spur and planetary versions, with a wide range of reduction ratios.
Portescap is a subsidiary of the Danaher Motion Components Group, a part of the multinational Danaher Corporation, and is a world leader in the development and manufacture of motion control products.
Custom motors for other supply voltages are, however, available to order.
The typical maximum operating speed for all models is 11,000 rpm, with 24V units capable of developing continuous torques of up to 83 mNm, a figure which rises to 104 mNm for 48V motors.
All 30GT motors can operate well in excess of their rated torque for short periods.
Benefits of the Portescap ironless technology used in these new motors include low friction, low starting voltage, absence of iron losses, good thermal dissipation and a linear torque-speed characteristic.
All of these factors facilitate the use of the units in high-performance drive and servo systems.
Their high efficiency means that they are also an ideal choice for applications in battery-powered equipment.
To complement its small, but powerful, 30GT ironless-rotor motors, Portescap offers an extensive range of standard and custom miniature gearboxes.
Designed for simple and speedy attachment to the motor, these gearboxes are available in both spur and planetary versions, with a wide range of reduction ratios.
Portescap is a subsidiary of the Danaher Motion Components Group, a part of the multinational Danaher Corporation, and is a world leader in the development and manufacture of motion control products.
Conveyor upgrade is ahead of schedule
David Brown is ahead of time with its management contract to overhaul and upgrade the massive conveying system at Australia's Yallourn power station in Victoria - in turn part of a huge scheme that involves diverting the Morwell River and upgrading and modernising Yallourn mine. With the two year contract for Yallourn Energy (now called TRUenergy Yallourn) stipulating completion of 15 conveyor drive assemblies by September 2006, the company has already completed that number as well as two gearbox spares in a clear demonstration of its asset management capabilities as well as its widely recognised technical prowess. Extra work was also required following a serious fire in December 2005 that necessitated the urgent refurbishment and relocation of a number of drive conveyors in order to keep Yallourn operating.
Concurrent with this urgent work was the refurbishment of critical drive gearboxes on a large overburden dredger which was undergoing upgrade at the same time - David Brown once again pulled out all of the stops to assist Yallourn Energy at this difficult time.
Each of the 25 year old conveyor drive assemblies comprise a 370 or 610kW electric motor, gearbox, brake and fluid coupling, to absorb shock loading of the conveyors, all mounted on a base plate.
Whereas the gearboxes, of various origins, were transported from Melbourne and overhauled at David Brown's own facilities at Bulli, New South Wales, the work on motors and couplings was subcontracted.
The smooth running of the project therefore demonstrates the project management skills and QA knowledge of David Brown's management team and workforce.
Yallourn Energy had initially approached David Brown early in 2004 when the process of site visits and tendering was initiated.
On signature of the contract in the following December the real work began which required fortnightly meetings on-site to ensure the smooth running of the project.
The principal's requirements of stringent QA documentation, refurbishment to EOM standard or better, full load testing off site plus incorporation of condition monitoring devices on all refurbished equipment were challenges met by David Brown.
David Brown has also undertaken additional refurbishment works on the Yallourn overburden dredger drives, all based on the main contract terms and conditions.
'The Yallourn contract has been a very steep learning curve for us', commented David Brown Project Manager Geoff Kinniburgh.
'We were confident that we had all of the necessary experience and expertise but quite frankly we had never handled a project of this scale and importance before'.
'In completing the project successfully and ahead of time, I believe we have built a real reputation for ourselves in the field of asset management that will stand us in good stead for the future'.
In fact, as the two-year project approaches completion, David Brown is confident that it will be able to negotiate a possible extra 6-year renewal having demonstrated a much greater degree of ownership of Yallourn problems and challenges than previous asset management companies.
Yallourn W power station, located 160km east of Melbourne, provides 24% of Victoria's power and 8% of the national requirement, and the adjacent open cut brown coal mine is the second largest in Australia with available reserves sufficient to meet the projected needs of the power station until 2032.
To allow unimpeded access to the coal field a project was begun five years ago to divert the Morwell River and was recently completed on time.
The 3.5km diversion is an impressive feat of modern engineering in itself and cost Au $122 million (over GBP 50 million).
The mine upgrade and modernisation programme was also undertaken in the five year period and involved works to fixed conveyor plant and infrastructure that totalled an additional Au $50 million (GBP 20 million).
Concurrent with this urgent work was the refurbishment of critical drive gearboxes on a large overburden dredger which was undergoing upgrade at the same time - David Brown once again pulled out all of the stops to assist Yallourn Energy at this difficult time.
Each of the 25 year old conveyor drive assemblies comprise a 370 or 610kW electric motor, gearbox, brake and fluid coupling, to absorb shock loading of the conveyors, all mounted on a base plate.
Whereas the gearboxes, of various origins, were transported from Melbourne and overhauled at David Brown's own facilities at Bulli, New South Wales, the work on motors and couplings was subcontracted.
The smooth running of the project therefore demonstrates the project management skills and QA knowledge of David Brown's management team and workforce.
Yallourn Energy had initially approached David Brown early in 2004 when the process of site visits and tendering was initiated.
On signature of the contract in the following December the real work began which required fortnightly meetings on-site to ensure the smooth running of the project.
The principal's requirements of stringent QA documentation, refurbishment to EOM standard or better, full load testing off site plus incorporation of condition monitoring devices on all refurbished equipment were challenges met by David Brown.
David Brown has also undertaken additional refurbishment works on the Yallourn overburden dredger drives, all based on the main contract terms and conditions.
'The Yallourn contract has been a very steep learning curve for us', commented David Brown Project Manager Geoff Kinniburgh.
'We were confident that we had all of the necessary experience and expertise but quite frankly we had never handled a project of this scale and importance before'.
'In completing the project successfully and ahead of time, I believe we have built a real reputation for ourselves in the field of asset management that will stand us in good stead for the future'.
In fact, as the two-year project approaches completion, David Brown is confident that it will be able to negotiate a possible extra 6-year renewal having demonstrated a much greater degree of ownership of Yallourn problems and challenges than previous asset management companies.
Yallourn W power station, located 160km east of Melbourne, provides 24% of Victoria's power and 8% of the national requirement, and the adjacent open cut brown coal mine is the second largest in Australia with available reserves sufficient to meet the projected needs of the power station until 2032.
To allow unimpeded access to the coal field a project was begun five years ago to divert the Morwell River and was recently completed on time.
The 3.5km diversion is an impressive feat of modern engineering in itself and cost Au $122 million (over GBP 50 million).
The mine upgrade and modernisation programme was also undertaken in the five year period and involved works to fixed conveyor plant and infrastructure that totalled an additional Au $50 million (GBP 20 million).
Synthetic grease for washing machine transmissions
Some washing machine manufacturers are designing new planetary gearboxes using plastic gear materials. Others maintain conventional, cut-metal, spur gear designs. However, if they rely on standard petroleum oils to lubricate those gears, they all have two things in common: leakage concerns and the added cost of seals and gaskets.
Using Nye lubricants synthetic greases can solve both problems.
Although synthetic greases may cost more than petroleum oils, it delivers large ROIs by eliminating oil seals, gaskets, silicone sealants and associated manufacturing costs - and the cost of damage control if the transmission leaks oil on a customer's brand new hardwood floor.
Nye Lubricants supplies greases for plastic gearing, cut and powered metal gears, cut metal and plastic gearing, plastic gearing and light-duty clutch mechanisms.
Newgate Simms is the exclusive UK distributor for Nye Lubricants.
Using Nye lubricants synthetic greases can solve both problems.
Although synthetic greases may cost more than petroleum oils, it delivers large ROIs by eliminating oil seals, gaskets, silicone sealants and associated manufacturing costs - and the cost of damage control if the transmission leaks oil on a customer's brand new hardwood floor.
Nye Lubricants supplies greases for plastic gearing, cut and powered metal gears, cut metal and plastic gearing, plastic gearing and light-duty clutch mechanisms.
Newgate Simms is the exclusive UK distributor for Nye Lubricants.
Brevini integrates Posiva Drives
Designers, OEMs, and plant and process engineers are set to benefit from a wider range of solutions to their power transmission problems, following the integration into the International Brevini Group of Posiva Drives. As part of this integration, Posiva will change its name and in future will trade as PIV Drives UK. The UK incorporation follows the purchase, in 2002, of Posiva's German parent company, by Brevini Ruduttori.
It brings together the activities of Brevini UK and PIV Drives UK under the control of Guiseppe Galli, General Manager of Brevini's UK operation, which is based at a new purpose built facility in Warrington.
The partnering of the two UK companies is essentially seamless for customers as PIV is remaining at its base in Scunthorpe, Lincolnshire.
"The coming together of Brevini and PIV in the UK is good news for our customers", said Guiseppe Galli.
"The complementary product ranges offered by the two companies means that we are able to offer solutions to a wider range of industrial power transmission applications.
Moreover, our newly synergised operations mean that - more than ever - we will be able to provide the latest concepts in gear technology to solve the most complex of drive problems cost effectively for our customers".
The product ranges allied by the integration of Brevini and PIV are both top of their class in terms of quality, efficiency and flexibility.
The high torque, compact size, and low weight advantages of Brevini's planetary gearboxes mean that they are increasingly the first choice in industrial and process applications, having dominated in the mobile sector for a number of years.
The versatility in design and flexibility in the number of options available mean that Brevini's planetary range is suitable for use in a wide range of industries.
These include materials handling, water treatment, quarrying, food processing, waste disposal (crushers), marine (winches), steel, mining, agriculture, machine tools and construction.
PIV's helical, bevel helical and spiral bevel gearboxes are market leaders for design, quality, power/weight ratio and price per kilowatt.
The company' s experience is second to none and the recent introduction of the modular Posired 2 range of helical and bevel helical gears has revolutionised the market, enabling gear problems to be solved "off the shelf" with considerable savings potential for the user.
It brings together the activities of Brevini UK and PIV Drives UK under the control of Guiseppe Galli, General Manager of Brevini's UK operation, which is based at a new purpose built facility in Warrington.
The partnering of the two UK companies is essentially seamless for customers as PIV is remaining at its base in Scunthorpe, Lincolnshire.
"The coming together of Brevini and PIV in the UK is good news for our customers", said Guiseppe Galli.
"The complementary product ranges offered by the two companies means that we are able to offer solutions to a wider range of industrial power transmission applications.
Moreover, our newly synergised operations mean that - more than ever - we will be able to provide the latest concepts in gear technology to solve the most complex of drive problems cost effectively for our customers".
The product ranges allied by the integration of Brevini and PIV are both top of their class in terms of quality, efficiency and flexibility.
The high torque, compact size, and low weight advantages of Brevini's planetary gearboxes mean that they are increasingly the first choice in industrial and process applications, having dominated in the mobile sector for a number of years.
The versatility in design and flexibility in the number of options available mean that Brevini's planetary range is suitable for use in a wide range of industries.
These include materials handling, water treatment, quarrying, food processing, waste disposal (crushers), marine (winches), steel, mining, agriculture, machine tools and construction.
PIV's helical, bevel helical and spiral bevel gearboxes are market leaders for design, quality, power/weight ratio and price per kilowatt.
The company' s experience is second to none and the recent introduction of the modular Posired 2 range of helical and bevel helical gears has revolutionised the market, enabling gear problems to be solved "off the shelf" with considerable savings potential for the user.
Choose the most appropriate drive for the job
Electronic servo drives are certainly in vogue. For many design engineers, they are the preferred choice for systems which synchronise and co-ordinate the movement and position of fast moving components. Clearly they have an important contribution to make but they are not necessarily the right choice for all applications.
A mechanical solution may not be as technically exciting but in many cases it can be more reliable, more accurate and far more cost efficient in the long run.
Mechanical drives are often seen as old fashioned and low tech.
In truth they are the subject of much development.
The fact is mechanical drives are increasingly getting better and those at the quality end of the scale are now able to deliver even greater accuracy and reliability.
More accurate machining of components, more durable materials, higher quality bearings, new methods of heat treatment, and heating which effectively eliminates any distortion - all these elements have contributed to the significant improvement.
The electronic drive is often sold on the basis of it being more accurate than its mechanical counterpart.
Certainly mediocre quality mechanical drives may be inferior but those at the higher end of the quality scale can far exceed the accuracy of the electronic drive.
The main benefit of a largely mechanical system - one comprising line shafts and bevel gear boxes - is that its accuracy is maintained throughout the system.
Basically, what you put in at one end, you get out the other! Within one revolution a mechanical drive will always repeat itself, it will always return to its original position.
Of course the transmission error of a geared system must be considered, but this can be measured.
It is a known quantity for which compensation can be made if necessary.
In a multi-stage process driven by electronic drives, the relationship between the position of the product and various elements of the machine is fed back to the controller by a variety of peripheral sensors.
The system is therefore far more complicated and often servo motors cannot respond fast enough to achieve the required degree of accuracy.
By its very nature, an electronic drive system will only respond to where the product was in relation to the drive, not where it is.
There are however, applications where a single electronic drive offers advantages over a single mechanical drive.
If you need fast response and where the application involves changes in motion, the electronic drive is the best choice.
It is ideal for replacing cams and for applications which require high torque for fast acceleration and braking.
However, if the whole system requires high torque, the electronic drive and motor will need to be large and may be very expensive.
In this case a motor/gearbox solution will produce high torque far more cost-effectively.
Electronic drives are also limited when it comes to providing high torque at low speed; gearbox speed reduction is the only viable solution.
Electronic drives are often chosen for machines used to produce or process a number of different products.
Stored set-up data can be quickly called-up to re-set the machine with changed parameters.
But an electronic drive does not always have to be the foregone conclusion.
Speed modulation gearboxes are increasingly being used in packaging machines and in particular cartoning machines.
These gearboxes allow adjustments to be made in machine set-up to accommodate different carton sizes at a much lower cost than having all components being driven and controlled electronically.
Notably, the speed modulation gearbox offers considerable benefit over traditional systems comprising gearboxes, line shafts and chains.
Adjusting such a mechanical system would take upwards of 45 minutes.
Systems using speed modulation gearboxes, with a manual adjustment, may take just two minutes to set up.
Although the cost of servo drives is certainly reducing, they remain expensive in relation to mechanical drives.
One of the main cost penalties is the programming back-up they require.
In fairness, the majority of good servo drive manufacturers do offer this service but help is not always readily at hand in the middle of the night shift! Also when problems occur in an electronically driven system it can be difficult to know where to start.
A largely mechanical system is much more simple and user-friendly.
A problem is easier to track down.
A mechanical solution may not be as technically exciting but in many cases it can be more reliable, more accurate and far more cost efficient in the long run.
Mechanical drives are often seen as old fashioned and low tech.
In truth they are the subject of much development.
The fact is mechanical drives are increasingly getting better and those at the quality end of the scale are now able to deliver even greater accuracy and reliability.
More accurate machining of components, more durable materials, higher quality bearings, new methods of heat treatment, and heating which effectively eliminates any distortion - all these elements have contributed to the significant improvement.
The electronic drive is often sold on the basis of it being more accurate than its mechanical counterpart.
Certainly mediocre quality mechanical drives may be inferior but those at the higher end of the quality scale can far exceed the accuracy of the electronic drive.
The main benefit of a largely mechanical system - one comprising line shafts and bevel gear boxes - is that its accuracy is maintained throughout the system.
Basically, what you put in at one end, you get out the other! Within one revolution a mechanical drive will always repeat itself, it will always return to its original position.
Of course the transmission error of a geared system must be considered, but this can be measured.
It is a known quantity for which compensation can be made if necessary.
In a multi-stage process driven by electronic drives, the relationship between the position of the product and various elements of the machine is fed back to the controller by a variety of peripheral sensors.
The system is therefore far more complicated and often servo motors cannot respond fast enough to achieve the required degree of accuracy.
By its very nature, an electronic drive system will only respond to where the product was in relation to the drive, not where it is.
There are however, applications where a single electronic drive offers advantages over a single mechanical drive.
If you need fast response and where the application involves changes in motion, the electronic drive is the best choice.
It is ideal for replacing cams and for applications which require high torque for fast acceleration and braking.
However, if the whole system requires high torque, the electronic drive and motor will need to be large and may be very expensive.
In this case a motor/gearbox solution will produce high torque far more cost-effectively.
Electronic drives are also limited when it comes to providing high torque at low speed; gearbox speed reduction is the only viable solution.
Electronic drives are often chosen for machines used to produce or process a number of different products.
Stored set-up data can be quickly called-up to re-set the machine with changed parameters.
But an electronic drive does not always have to be the foregone conclusion.
Speed modulation gearboxes are increasingly being used in packaging machines and in particular cartoning machines.
These gearboxes allow adjustments to be made in machine set-up to accommodate different carton sizes at a much lower cost than having all components being driven and controlled electronically.
Notably, the speed modulation gearbox offers considerable benefit over traditional systems comprising gearboxes, line shafts and chains.
Adjusting such a mechanical system would take upwards of 45 minutes.
Systems using speed modulation gearboxes, with a manual adjustment, may take just two minutes to set up.
Although the cost of servo drives is certainly reducing, they remain expensive in relation to mechanical drives.
One of the main cost penalties is the programming back-up they require.
In fairness, the majority of good servo drive manufacturers do offer this service but help is not always readily at hand in the middle of the night shift! Also when problems occur in an electronically driven system it can be difficult to know where to start.
A largely mechanical system is much more simple and user-friendly.
A problem is easier to track down.
Updated website for motor supplier
In addition, the complete range of Premotec gearboxes is also featured - with spur and planetary versions available.
Detailed data sheets can be easily downloaded on all the above product types including fully productionised, mature products in the range plus recently launched part numbers from the brushless and coreless motor families.
The site will be regularly updated as new products are launched.
Of particular interest to customers requiring long-life, simple operation and fully integrated electronic controls will be the recently extended BL58 motor family which now includes products from 35 to 70 watts in a variety of stack lengths.
The smaller, BL48 family now includes motors with or without electronic control of speed and tacho signal.
Versions are available in 8 and 12 watts.
The site is very easy to use with each page uploading quickly so that no time is wasted waiting for your valuable information to arrive.
As well as providing detailed data on the Premotec range of products, there is also an introduction to Premotec, it's products and capabilities.
Detailed data sheets can be easily downloaded on all the above product types including fully productionised, mature products in the range plus recently launched part numbers from the brushless and coreless motor families.
The site will be regularly updated as new products are launched.
Of particular interest to customers requiring long-life, simple operation and fully integrated electronic controls will be the recently extended BL58 motor family which now includes products from 35 to 70 watts in a variety of stack lengths.
The smaller, BL48 family now includes motors with or without electronic control of speed and tacho signal.
Versions are available in 8 and 12 watts.
The site is very easy to use with each page uploading quickly so that no time is wasted waiting for your valuable information to arrive.
As well as providing detailed data on the Premotec range of products, there is also an introduction to Premotec, it's products and capabilities.
Geared products have ATEX compliance covered
ATEX directive 94/9/EC (also known as ATEX 95 or ATEX 100A) and the CE Marking Directive came into force in all EC member states from 1st July, and compliance is compulsory for anyone designing, manufacturing or selling equipment for use in potentially explosive atmospheres. The directive covers electrical and nonelectrical equipment and is not only relevant to obvious industry sectors such as oil and gas and chemical manufacturing.
It also impacts on a range of other areas endangered by potentially explosive atmospheres created by the presence of flammable gases, vapours, mists or dusts.
These may include plants handling cereal, animal feed, paper, wood, coal and flour, or locations where solvents are used extensively.
David Brown, a Textron Power Transmission company, is now equipped to provide full Ex compliant badging and certification where required for its range of standard gearboxes and geared motors, through self certification as allowed by the directive.
Products that meet the requirements of the ATEX Directive are marked by the manufacturer with the CE Mark and the Ex mark, along with the name and location of the manufacturer, designation of series or type, serial number, year of construction, Ex symbol followed by equipment group and category.
David Brown standard gearboxes can be supplied against Group 2 or 3 for surface industries; ATEX defines categories of equipment specified by their protection characteristics.
It also designates the hazardous location zones where they can be used: Zones 1 and 2 for gases, vapours and mists; Zones 21 and 22 for dusts.
David Brown Engineering has for some time been supplying mechanical products to meet the ATEX requirements in anticipation of enforcement.
The company has undertaken a programme of risk assessment and product evaluation in preparation for the ATEX enforcement as part of a wider TPT initiative, with special attention devoted to the installation and maintenance protocols.
Commercial Manager for Standard Products Richard Irons, who has been closely involved with the ATEX programme, explains: "Safety is a vital element in the design and manufacture of all our products, and as a matter of course we pay particular attention to critical areas such as lubrication and surface temperatures.
Service factors are an additional consideration to maintain the ATEX standard, so we insist that maintenance schedules and installation procedures, such as electrical grounding, are followed precisely
It also impacts on a range of other areas endangered by potentially explosive atmospheres created by the presence of flammable gases, vapours, mists or dusts.
These may include plants handling cereal, animal feed, paper, wood, coal and flour, or locations where solvents are used extensively.
David Brown, a Textron Power Transmission company, is now equipped to provide full Ex compliant badging and certification where required for its range of standard gearboxes and geared motors, through self certification as allowed by the directive.
Products that meet the requirements of the ATEX Directive are marked by the manufacturer with the CE Mark and the Ex mark, along with the name and location of the manufacturer, designation of series or type, serial number, year of construction, Ex symbol followed by equipment group and category.
David Brown standard gearboxes can be supplied against Group 2 or 3 for surface industries; ATEX defines categories of equipment specified by their protection characteristics.
It also designates the hazardous location zones where they can be used: Zones 1 and 2 for gases, vapours and mists; Zones 21 and 22 for dusts.
David Brown Engineering has for some time been supplying mechanical products to meet the ATEX requirements in anticipation of enforcement.
The company has undertaken a programme of risk assessment and product evaluation in preparation for the ATEX enforcement as part of a wider TPT initiative, with special attention devoted to the installation and maintenance protocols.
Commercial Manager for Standard Products Richard Irons, who has been closely involved with the ATEX programme, explains: "Safety is a vital element in the design and manufacture of all our products, and as a matter of course we pay particular attention to critical areas such as lubrication and surface temperatures.
Service factors are an additional consideration to maintain the ATEX standard, so we insist that maintenance schedules and installation procedures, such as electrical grounding, are followed precisely
Marine gearbox is affordable alternative
The PRM 1750, Newage Transmissions' highest capability marine gearbox to date, will form the centrepiece of the company's joint presentation with its distributor, Albatross Marine, on Stand 31 at the Seawork 2005 international boat show - to be held in Southampton between 14th and 16th June. With a maximum torque capacity of 1750Nm, the PRM 1750 is suitable for engines rated at up to 457kW and is available in both shallow or deep gearcase configurations, with standard ratios from 1.22:1 to 4.90:1. Units also have integral SAE housings and can be supplied with trolling valve and clutched power take-off (PTO) options, enabling them to meet the widest variety of commercial and pleasure workboat applications.
The new transmission has been developed as an affordable and reliable alternative to twin disc, self changing gears, capitol and other drop centre gearboxes.
It features a twin countershaft design that is compatible with both left or right hand propeller rotations, making the transmission equally suitable for single or twin engine installations.
The PRM 1750 also uses maintenance-free, self-adjusting, oil-operated multiple-disc clutches for reliability and in-service performance, and allows maximum input torque to be transmitted continuously in either direction at speeds of up to 2500rev/min.
The use of lubricating oil of the same viscosity as the engine eliminates the need for automatic transmission fluid and ensures rapid response to control movements.
The gearcase is manufactured from high grade cast iron, which is internally ribbed for extra rigidity and strength, and the gearbox's operating lever has a positive neutral detent for use with proprietary single lever remote control operating systems.
In addition, the PRM 1750's oil pump and hydraulic control valves are mounted externally for easy access and servicing.
Further Newage gearboxes for commercial fishing vessel and work boat applications to be featured at Seawork 2005 will include PRM 500, 750, 1000 and 1500 models.
These are suitable for engines from 245 to 500hp and, in common with other Newage marine gearbox designs, have output shafts that can be rotated continuously in neutral, eliminating the need for a propshaft brake when running with an engine shut down.
As an additional safeguard, they also incorporate a mechanical lockup device that will enable the vessel to be brought safely back to port in the unlikely event of hydraulic failure.
The new transmission has been developed as an affordable and reliable alternative to twin disc, self changing gears, capitol and other drop centre gearboxes.
It features a twin countershaft design that is compatible with both left or right hand propeller rotations, making the transmission equally suitable for single or twin engine installations.
The PRM 1750 also uses maintenance-free, self-adjusting, oil-operated multiple-disc clutches for reliability and in-service performance, and allows maximum input torque to be transmitted continuously in either direction at speeds of up to 2500rev/min.
The use of lubricating oil of the same viscosity as the engine eliminates the need for automatic transmission fluid and ensures rapid response to control movements.
The gearcase is manufactured from high grade cast iron, which is internally ribbed for extra rigidity and strength, and the gearbox's operating lever has a positive neutral detent for use with proprietary single lever remote control operating systems.
In addition, the PRM 1750's oil pump and hydraulic control valves are mounted externally for easy access and servicing.
Further Newage gearboxes for commercial fishing vessel and work boat applications to be featured at Seawork 2005 will include PRM 500, 750, 1000 and 1500 models.
These are suitable for engines from 245 to 500hp and, in common with other Newage marine gearbox designs, have output shafts that can be rotated continuously in neutral, eliminating the need for a propshaft brake when running with an engine shut down.
As an additional safeguard, they also incorporate a mechanical lockup device that will enable the vessel to be brought safely back to port in the unlikely event of hydraulic failure.
Harmonic Drive sets up shop in the UK
Harmonic Drive has been a leading manufacturer and supplier of precision gears and actuators for more than 30 years in Europe. The company's core competences lie in the development, production and marketing of gear component sets, servo actuators, gearboxes or custom-made motion control systems which are manufactured at its facility and headquarters in Limburg (near Frankfurt), Germany. For many years the Heason Technologies Group was Harmonic Drive's sales partner in the UK and responsible for the sales and marketing of its products.
However, the continuous expansion of the company and its product range, coupled with positive UK business development, has necessitated the foundation of a new sales subsidiary, enabling Harmonic Drive to provide its specific knowhow directly to UK customers.
The company's new office is located at the Staffordshire Technology Park in Stafford, close to the M6 motorway between Manchester and Birmingham, at the heart of the UK manufacturing industry.
This is the first of a number of major investments in both personnel and facilities by Harmonic Drive over the coming months.
As a 100% daughter of Harmonic Drive AG, the UK company can now offer direct customer support by a local UK sales team.
"Customer care, short reaction time and intensive engineering support are the most important objectives for us", says Graham Mackrell, Sales Director of Harmonic Drive UK.
"Harmonic Drive UK aims to offer an improved level of services to all customers, now having the benefit of direct contact to specialist staff at our manufacturing plant in Germany".
"We will also try to offer customers some cost savings and shorter delivery times, where possible, associated with the purchase of products directly from the manufacturer", adds Mackrell.
However, the continuous expansion of the company and its product range, coupled with positive UK business development, has necessitated the foundation of a new sales subsidiary, enabling Harmonic Drive to provide its specific knowhow directly to UK customers.
The company's new office is located at the Staffordshire Technology Park in Stafford, close to the M6 motorway between Manchester and Birmingham, at the heart of the UK manufacturing industry.
This is the first of a number of major investments in both personnel and facilities by Harmonic Drive over the coming months.
As a 100% daughter of Harmonic Drive AG, the UK company can now offer direct customer support by a local UK sales team.
"Customer care, short reaction time and intensive engineering support are the most important objectives for us", says Graham Mackrell, Sales Director of Harmonic Drive UK.
"Harmonic Drive UK aims to offer an improved level of services to all customers, now having the benefit of direct contact to specialist staff at our manufacturing plant in Germany".
"We will also try to offer customers some cost savings and shorter delivery times, where possible, associated with the purchase of products directly from the manufacturer", adds Mackrell.
Gearbox options make for flexible gearmotors
Following the launch of the new generation of helical geared motors from Leroy Somer, Industrial Motors and Gears is stocking inline, right angle and shaft mount gearboxes. Designed to exceed the demands of today's industrial applications, the new 3000 range consists of modular helical-geared motors. The CB3000 range is already in stock for same-day build an delivery.
The Orthobloc series (delivering its output via helical bevel gears) will be introduced over the next month to further extend the range.
The Poulibloc PB range of shaft mount speed reducers is also available 'off the shelf'.
Whatever the version, the advanced design of the 3000 range delivers up to 30% more torque than similar-sised competitors.
Dust and damp ingress protection has been improved, and a redesigned removable panel gives easy access for inspection and preventative maintenance.
A variety of mounting options are available for maximum versatility, including MI mounting with integral motor, MU universal mounting using a standard B5 IEC motor and AP input shaft with optional AP/AD antirunback.
A key feature of the 3000 range is its modularity: a unique integral mounting allows the same MI motor to be used on all three gearbox series, reducing the number of spare parts required.
The same Leroy-Somer integrated motors can also now be used across the entire 3000 range, making them the ideal choice for a wide variety of applications including ATEX dust, ATEX gas, variable speed, food and beverage and many others.
A wide variety of mounting configurations combine with various drive options for maximum versatility.
The Orthobloc series (delivering its output via helical bevel gears) will be introduced over the next month to further extend the range.
The Poulibloc PB range of shaft mount speed reducers is also available 'off the shelf'.
Whatever the version, the advanced design of the 3000 range delivers up to 30% more torque than similar-sised competitors.
Dust and damp ingress protection has been improved, and a redesigned removable panel gives easy access for inspection and preventative maintenance.
A variety of mounting options are available for maximum versatility, including MI mounting with integral motor, MU universal mounting using a standard B5 IEC motor and AP input shaft with optional AP/AD antirunback.
A key feature of the 3000 range is its modularity: a unique integral mounting allows the same MI motor to be used on all three gearbox series, reducing the number of spare parts required.
The same Leroy-Somer integrated motors can also now be used across the entire 3000 range, making them the ideal choice for a wide variety of applications including ATEX dust, ATEX gas, variable speed, food and beverage and many others.
A wide variety of mounting configurations combine with various drive options for maximum versatility.
Mechanical help for steppers and servos
Total Motion Systems can supply a range of mechanical equipment to complement its stepper and servomotor systems. A series of high precision planetary gearboxes with ratios from 3:1 to 400:1 gives torque outputs up to 3500Nm from input speeds of up to 6000rev/min. Backlash options range from 30 down to 1arc-min, and the gearboxes can be fitted with flanges to suit almost any motor.
Linear actuators and tables are available with ballscrew and belt driven variants.
These can be fitted with stepper or servomotors to give accurate linear positioning.
The ballscrew electric cylinder range is available in ISO frames 32, 50, 80, 100 and 125 and can produce thrusts of up to 44.5kN and variable speeds up to 2m/s.
Positioning tables are available with strokes up to 2m, and can move payloads up to 1000kg at up to 0.5m/s.
Higher loads and longer strokes are available in a range of high payload linear actuators.
All these linear products can be used as single-axis systems, or can be linked together to produce multi-axis gantries.
The TMS mechanical range is further enhanced by a series of stepper-motor-driven rotary tables.
Among their features are indexing repeatability to 12arc-sec, load capacities to 90kg and 360-degree continuous travel.
Table diameters up to 305mm are available.
Also available are linear and rotary manually driven tables and slides.
The linear slides range in size from 11 to 150mm wide with travels up to 305mm and have load capacities from 25g to 100kg.
Rotary tables have load capacities up to 90kg and diameters up to 305mm.
Linear actuators and tables are available with ballscrew and belt driven variants.
These can be fitted with stepper or servomotors to give accurate linear positioning.
The ballscrew electric cylinder range is available in ISO frames 32, 50, 80, 100 and 125 and can produce thrusts of up to 44.5kN and variable speeds up to 2m/s.
Positioning tables are available with strokes up to 2m, and can move payloads up to 1000kg at up to 0.5m/s.
Higher loads and longer strokes are available in a range of high payload linear actuators.
All these linear products can be used as single-axis systems, or can be linked together to produce multi-axis gantries.
The TMS mechanical range is further enhanced by a series of stepper-motor-driven rotary tables.
Among their features are indexing repeatability to 12arc-sec, load capacities to 90kg and 360-degree continuous travel.
Table diameters up to 305mm are available.
Also available are linear and rotary manually driven tables and slides.
The linear slides range in size from 11 to 150mm wide with travels up to 305mm and have load capacities from 25g to 100kg.
Rotary tables have load capacities up to 90kg and diameters up to 305mm.
Harmonic Drive sets up shop in the UK
Harmonic Drive has been a leading manufacturer and supplier of precision gears and actuators for more than 30 years in Europe. The company's core competences lie in the development, production and marketing of gear component sets, servo actuators, gearboxes or custom-made motion control systems which are manufactured at its facility and headquarters in Limburg (near Frankfurt), Germany. For many years the Heason Technologies Group was Harmonic Drive's sales partner in the UK and responsible for the sales and marketing of its products.
However, the continuous expansion of the company and its product range, coupled with positive UK business development, has necessitated the foundation of a new sales subsidiary, enabling Harmonic Drive to provide its specific knowhow directly to UK customers.
The company's new office is located at the Staffordshire Technology Park in Stafford, close to the M6 motorway between Manchester and Birmingham, at the heart of the UK manufacturing industry.
This is the first of a number of major investments in both personnel and facilities by Harmonic Drive over the coming months.
As a 100% daughter of Harmonic Drive AG, the UK company can now offer direct customer support by a local UK sales team.
"Customer care, short reaction time and intensive engineering support are the most important objectives for us", says Graham Mackrell, Sales Director of Harmonic Drive UK.
"Harmonic Drive UK aims to offer an improved level of services to all customers, now having the benefit of direct contact to specialist staff at our manufacturing plant in Germany".
"We will also try to offer customers some cost savings and shorter delivery times, where possible, associated with the purchase of products directly from the manufacturer", adds Mackrell.
However, the continuous expansion of the company and its product range, coupled with positive UK business development, has necessitated the foundation of a new sales subsidiary, enabling Harmonic Drive to provide its specific knowhow directly to UK customers.
The company's new office is located at the Staffordshire Technology Park in Stafford, close to the M6 motorway between Manchester and Birmingham, at the heart of the UK manufacturing industry.
This is the first of a number of major investments in both personnel and facilities by Harmonic Drive over the coming months.
As a 100% daughter of Harmonic Drive AG, the UK company can now offer direct customer support by a local UK sales team.
"Customer care, short reaction time and intensive engineering support are the most important objectives for us", says Graham Mackrell, Sales Director of Harmonic Drive UK.
"Harmonic Drive UK aims to offer an improved level of services to all customers, now having the benefit of direct contact to specialist staff at our manufacturing plant in Germany".
"We will also try to offer customers some cost savings and shorter delivery times, where possible, associated with the purchase of products directly from the manufacturer", adds Mackrell.
Gearbox is crucial to satellite success
The recent successful launch and subsequent solar array deployment of the Eur 2 billion (GBP 1.2 billion) Envisat satellite depended on a 4in-diameter gearbox, created by David Brown Engineering. The gearbox controlled the deployment of the satellite's crucial power-generating solar array. The Envisat environmental monitoring satellite is the largest satellite yet launched by ESA (the European Space Agency).
It boosts Europe's capacity to take part in the study of the Earth and its environment by supporting critical research programmes on global warming and climate change issues.
The satellite depends for power on a giant solar array capable of generating up to 8kW of electricity.
The solar array design was termed 'flatpack', because it was folded away during the launch.
Once the satellite was stationed in orbit the Flatpack was deployed using a battery operated electric motor in combination with a cable pulley system, with power routed through the David Brown Engineering gearbox.
Control is effected by an epicyclic gear train of a two stage sun and triple planet wheel arrangement giving an overall ratio of 38:1.
Fokker Space, the contractor for the solar array has a 100% record of successful solar array deployments and chose David Brown as a partner in the confidence that the gear specialist would help maintain this record.
Phil Dalton, Technical Sales Manager for David Brown Engineering said: "The small gearbox only had to operate once but it had to work with absolute certainty in a harsh environment and following the stresses imposed by a rocket launch.
In space, on a satellite orbiting at this distance above the earth, there are, of course, no opportunities for repair and servicing!".
Every component on the satellite is critical in terms of its weight and size.
An extra gram of weight on a mechanical component means one less gram for the satellite's monitoring equipment, likewise components and equipment must be balanced millimetre for millimetre.
The gearbox therefore had to produce the maximum power to weight ratio with the lowest possible space envelope.
David Brown engineered a gearbox which can be held in the palm of a hand, and yet was entirely capable of deploying the 70m2 solar array from its position folded within the body of the satellite to full deployment and 'snap-locked' into position.
On behalf of Fokker Space, Wim den Haak, Product Assurance Manager said: "I congratulate David Brown on the successful deployment of the solar array which was possible thanks to the co-operation between our companies during the development and manufacturing of this complicated solar array".
Phil Dalton of David Brown Engineering said: "This contract is a major success for David Brown, showing, as it does, the capability the company possesses to manufacture bespoke gearboxes capable of producing maximum torque in the most challenging environment and with absolute reliability.
It also demonstrates the underlying strength of the David Brown portfolio, encompassing gearboxes used in everything from military vehicles and ships, to power plants and industrial machinery".
The gearbox was originally designed by Alvis Transmissions, a company which David Brown purchased in 1998.
Development continued during the handover period.
David Brown is supplying similar gearboxes to another European Space Agency project, this being the METOP series of weather and climate monitoring satellites, the first of which is scheduled for launch in 2005.
It boosts Europe's capacity to take part in the study of the Earth and its environment by supporting critical research programmes on global warming and climate change issues.
The satellite depends for power on a giant solar array capable of generating up to 8kW of electricity.
The solar array design was termed 'flatpack', because it was folded away during the launch.
Once the satellite was stationed in orbit the Flatpack was deployed using a battery operated electric motor in combination with a cable pulley system, with power routed through the David Brown Engineering gearbox.
Control is effected by an epicyclic gear train of a two stage sun and triple planet wheel arrangement giving an overall ratio of 38:1.
Fokker Space, the contractor for the solar array has a 100% record of successful solar array deployments and chose David Brown as a partner in the confidence that the gear specialist would help maintain this record.
Phil Dalton, Technical Sales Manager for David Brown Engineering said: "The small gearbox only had to operate once but it had to work with absolute certainty in a harsh environment and following the stresses imposed by a rocket launch.
In space, on a satellite orbiting at this distance above the earth, there are, of course, no opportunities for repair and servicing!".
Every component on the satellite is critical in terms of its weight and size.
An extra gram of weight on a mechanical component means one less gram for the satellite's monitoring equipment, likewise components and equipment must be balanced millimetre for millimetre.
The gearbox therefore had to produce the maximum power to weight ratio with the lowest possible space envelope.
David Brown engineered a gearbox which can be held in the palm of a hand, and yet was entirely capable of deploying the 70m2 solar array from its position folded within the body of the satellite to full deployment and 'snap-locked' into position.
On behalf of Fokker Space, Wim den Haak, Product Assurance Manager said: "I congratulate David Brown on the successful deployment of the solar array which was possible thanks to the co-operation between our companies during the development and manufacturing of this complicated solar array".
Phil Dalton of David Brown Engineering said: "This contract is a major success for David Brown, showing, as it does, the capability the company possesses to manufacture bespoke gearboxes capable of producing maximum torque in the most challenging environment and with absolute reliability.
It also demonstrates the underlying strength of the David Brown portfolio, encompassing gearboxes used in everything from military vehicles and ships, to power plants and industrial machinery".
The gearbox was originally designed by Alvis Transmissions, a company which David Brown purchased in 1998.
Development continued during the handover period.
David Brown is supplying similar gearboxes to another European Space Agency project, this being the METOP series of weather and climate monitoring satellites, the first of which is scheduled for launch in 2005.
Workshop looks at latest gearbox diagnostics
Cranfield University, together with its industrial partners, is hosting a half-day workshop on 'New technology for in-service early differential vibration diagnostics of local tooth damage in gearboxes'. Cranfield University in collaboration with three leading UK industrial partners and funded by the DTI, has experimentally adapted and validated a new condition monitoring technology which will substantially improve gearbox manufacturing, reliability and safety, provide significant reduction of maintenance costs and maintain gearbox quality. The technology is relevant to many applications, such as spur gears, bevel gears, helical gears etc.
It is of high benefit across a number of sectors: defence, aerospace, railway, automotive, power, shipbuilding, oil, gas, food, agricultural, mechanical and civil engineering.
Attendance at the workshop is subsidised by the DTI Basic Technologies for Industrial Applications (BTIA) technology transfer Programme and therefore costs just GBP 25 per delegate.
It is of high benefit across a number of sectors: defence, aerospace, railway, automotive, power, shipbuilding, oil, gas, food, agricultural, mechanical and civil engineering.
Attendance at the workshop is subsidised by the DTI Basic Technologies for Industrial Applications (BTIA) technology transfer Programme and therefore costs just GBP 25 per delegate.
Choose the most appropriate drive for the job
Electronic servo drives are certainly in vogue. For many design engineers, they are the preferred choice for systems which synchronise and co-ordinate the movement and position of fast moving components. Clearly they have an important contribution to make but they are not necessarily the right choice for all applications.
A mechanical solution may not be as technically exciting but in many cases it can be more reliable, more accurate and far more cost efficient in the long run.
Mechanical drives are often seen as old fashioned and low tech.
In truth they are the subject of much development.
The fact is mechanical drives are increasingly getting better and those at the quality end of the scale are now able to deliver even greater accuracy and reliability.
More accurate machining of components, more durable materials, higher quality bearings, new methods of heat treatment, and heating which effectively eliminates any distortion - all these elements have contributed to the significant improvement.
The electronic drive is often sold on the basis of it being more accurate than its mechanical counterpart.
Certainly mediocre quality mechanical drives may be inferior but those at the higher end of the quality scale can far exceed the accuracy of the electronic drive.
The main benefit of a largely mechanical system - one comprising line shafts and bevel gear boxes - is that its accuracy is maintained throughout the system.
Basically, what you put in at one end, you get out the other! Within one revolution a mechanical drive will always repeat itself, it will always return to its original position.
Of course the transmission error of a geared system must be considered, but this can be measured.
It is a known quantity for which compensation can be made if necessary.
In a multi-stage process driven by electronic drives, the relationship between the position of the product and various elements of the machine is fed back to the controller by a variety of peripheral sensors.
The system is therefore far more complicated and often servo motors cannot respond fast enough to achieve the required degree of accuracy.
By its very nature, an electronic drive system will only respond to where the product was in relation to the drive, not where it is.
There are however, applications where a single electronic drive offers advantages over a single mechanical drive.
If you need fast response and where the application involves changes in motion, the electronic drive is the best choice.
It is ideal for replacing cams and for applications which require high torque for fast acceleration and braking.
However, if the whole system requires high torque, the electronic drive and motor will need to be large and may be very expensive.
In this case a motor/gearbox solution will produce high torque far more cost-effectively.
Electronic drives are also limited when it comes to providing high torque at low speed; gearbox speed reduction is the only viable solution.
Electronic drives are often chosen for machines used to produce or process a number of different products.
Stored set-up data can be quickly called-up to re-set the machine with changed parameters.
But an electronic drive does not always have to be the foregone conclusion.
Speed modulation gearboxes are increasingly being used in packaging machines and in particular cartoning machines.
These gearboxes allow adjustments to be made in machine set-up to accommodate different carton sizes at a much lower cost than having all components being driven and controlled electronically.
Notably, the speed modulation gearbox offers considerable benefit over traditional systems comprising gearboxes, line shafts and chains.
Adjusting such a mechanical system would take upwards of 45 minutes.
Systems using speed modulation gearboxes, with a manual adjustment, may take just two minutes to set up.
Although the cost of servo drives is certainly reducing, they remain expensive in relation to mechanical drives.
One of the main cost penalties is the programming back-up they require.
In fairness, the majority of good servo drive manufacturers do offer this service but help is not always readily at hand in the middle of the night shift! Also when problems occur in an electronically driven system it can be difficult to know where to start.
A largely mechanical system is much more simple and user-friendly.
A problem is easier to track down.
Given the right application, there is no longer any reason for an electronic drive to be dismissed on the grounds of unreliability.
They are certainly becoming more reliable.
However, if maintained properly, a mechanical system can be highly reliable and maintain the same level of accuracy over many years.
Again, we need to remember that a mechanical drive will always accurately repeat itself per revolution and that its accuracy can be measured.
This assurance allows an OEM to predict its own product accuracy with full confidence.
So, what of the future.
Will the electronic drive grow in popularity?
Gearless systems may sound Utopian but are they realistic?
The astute design engineer will recognise that whilst the electronic drive has its merits, so does the mechanical drive and a combination of the two in most multi-stage systems is certainly the best bet.
Even in the traditional printing press where the mechanical drive is king, servo drives could certainly play their part.
A typical system could comprise a single drive motor, a line shaft and gearboxes to branch off for all the colours.
A mechanical system is ideal here as print stations can require register accuracies down to less than 0.05mm.
This is well within the capability of a good mechanical drive system.
However, additional processes such as unwind or rewind could benefit by being driven electronically.
A mechanical solution may not be as technically exciting but in many cases it can be more reliable, more accurate and far more cost efficient in the long run.
Mechanical drives are often seen as old fashioned and low tech.
In truth they are the subject of much development.
The fact is mechanical drives are increasingly getting better and those at the quality end of the scale are now able to deliver even greater accuracy and reliability.
More accurate machining of components, more durable materials, higher quality bearings, new methods of heat treatment, and heating which effectively eliminates any distortion - all these elements have contributed to the significant improvement.
The electronic drive is often sold on the basis of it being more accurate than its mechanical counterpart.
Certainly mediocre quality mechanical drives may be inferior but those at the higher end of the quality scale can far exceed the accuracy of the electronic drive.
The main benefit of a largely mechanical system - one comprising line shafts and bevel gear boxes - is that its accuracy is maintained throughout the system.
Basically, what you put in at one end, you get out the other! Within one revolution a mechanical drive will always repeat itself, it will always return to its original position.
Of course the transmission error of a geared system must be considered, but this can be measured.
It is a known quantity for which compensation can be made if necessary.
In a multi-stage process driven by electronic drives, the relationship between the position of the product and various elements of the machine is fed back to the controller by a variety of peripheral sensors.
The system is therefore far more complicated and often servo motors cannot respond fast enough to achieve the required degree of accuracy.
By its very nature, an electronic drive system will only respond to where the product was in relation to the drive, not where it is.
There are however, applications where a single electronic drive offers advantages over a single mechanical drive.
If you need fast response and where the application involves changes in motion, the electronic drive is the best choice.
It is ideal for replacing cams and for applications which require high torque for fast acceleration and braking.
However, if the whole system requires high torque, the electronic drive and motor will need to be large and may be very expensive.
In this case a motor/gearbox solution will produce high torque far more cost-effectively.
Electronic drives are also limited when it comes to providing high torque at low speed; gearbox speed reduction is the only viable solution.
Electronic drives are often chosen for machines used to produce or process a number of different products.
Stored set-up data can be quickly called-up to re-set the machine with changed parameters.
But an electronic drive does not always have to be the foregone conclusion.
Speed modulation gearboxes are increasingly being used in packaging machines and in particular cartoning machines.
These gearboxes allow adjustments to be made in machine set-up to accommodate different carton sizes at a much lower cost than having all components being driven and controlled electronically.
Notably, the speed modulation gearbox offers considerable benefit over traditional systems comprising gearboxes, line shafts and chains.
Adjusting such a mechanical system would take upwards of 45 minutes.
Systems using speed modulation gearboxes, with a manual adjustment, may take just two minutes to set up.
Although the cost of servo drives is certainly reducing, they remain expensive in relation to mechanical drives.
One of the main cost penalties is the programming back-up they require.
In fairness, the majority of good servo drive manufacturers do offer this service but help is not always readily at hand in the middle of the night shift! Also when problems occur in an electronically driven system it can be difficult to know where to start.
A largely mechanical system is much more simple and user-friendly.
A problem is easier to track down.
Given the right application, there is no longer any reason for an electronic drive to be dismissed on the grounds of unreliability.
They are certainly becoming more reliable.
However, if maintained properly, a mechanical system can be highly reliable and maintain the same level of accuracy over many years.
Again, we need to remember that a mechanical drive will always accurately repeat itself per revolution and that its accuracy can be measured.
This assurance allows an OEM to predict its own product accuracy with full confidence.
So, what of the future.
Will the electronic drive grow in popularity?
Gearless systems may sound Utopian but are they realistic?
The astute design engineer will recognise that whilst the electronic drive has its merits, so does the mechanical drive and a combination of the two in most multi-stage systems is certainly the best bet.
Even in the traditional printing press where the mechanical drive is king, servo drives could certainly play their part.
A typical system could comprise a single drive motor, a line shaft and gearboxes to branch off for all the colours.
A mechanical system is ideal here as print stations can require register accuracies down to less than 0.05mm.
This is well within the capability of a good mechanical drive system.
However, additional processes such as unwind or rewind could benefit by being driven electronically.
Motorised gearbox has flexible configurations
Ondrives has launched a new DC motorised worm and wheel reduction gearbox into its 2005 product range. They are fitted with high end 24V DC motors which when operating at 12V DC ensure good torque and speed characteristics. They are available in ratios from 10:1 to 120:1 as standard with fitted motors.
Thanks to the quality of the motors, Ondrives is able to offer variations on this, including encoders and brakes fitted to these motors.
This allows Ondrives to offer gearboxes tailored to more specific applications, capable of moulding their products to specific needs.
The gearboxes and motors are also available to purchase as separate components, allowing total flexibility for customers' applications.
Ondrives can also design and supply the gearboxes to accept customers' motors.
Suitable applications include medical and pharmaceutical industries, scanning machines and general OEM work.
They are always available to purchase in small or large volume quantities. Request a free brochure from Ondrives/Rino Industries....
Thanks to the quality of the motors, Ondrives is able to offer variations on this, including encoders and brakes fitted to these motors.
This allows Ondrives to offer gearboxes tailored to more specific applications, capable of moulding their products to specific needs.
The gearboxes and motors are also available to purchase as separate components, allowing total flexibility for customers' applications.
Ondrives can also design and supply the gearboxes to accept customers' motors.
Suitable applications include medical and pharmaceutical industries, scanning machines and general OEM work.
They are always available to purchase in small or large volume quantities. Request a free brochure from Ondrives/Rino Industries....
Investment provides platform for continued growth
Amongst these is Rotalink, an ISO9001-registered designer and producer of a wide range of miniature AC, iron core DC and stepping motors, spur and planetary gearboxes, linear actuators, encoders, controls and associated mechanical transmission equipment. In the past 6 months alone, Crewkerne based Rotalink has invested more than GBP 0.5 million in new machine tools and manufacturing plant to provide its customers with a faster and more flexible service.
Rotalink has established its success on forging close partnerships with global manufacturing companies for low-cost sourcing of common and higher volume components in combination with its own specialised design and manufacturing expertise to produce exactly what the customer requires.
With a very broad base of customers including several global companies with UK development facilities, Rotalink has found this approach keeps production costs and lead-times to a minimum and that its customers benefit from competitively priced products with a faster, more efficient turnaround from prototype to production.
From the recent investment, the star performer is a new Citizen M32, CNC lathe.
The dual spindle machine is fitted with a gear hobbing attachment capable of producing gears and components up to 32mm diameter.
The new 13-axis fully automated machine features servomotor controlled collet operation, work-piece ejection and magazine bar-feed; the synchronised control system enables fast, front and rear machining.
Using the latest technology means that typical setup times have been significantly reduced and whilst large quantities are often produced on the M32, small quantities can also be accommodated; so smaller production runs, design prototypes and concepts can be produced without high cost to their customers.
Another benefit of its UK manufacturing setup is Rotalink's application and customer support process that has proven to be extremely efficient and widely acclaimed by its customers.
Degree qualified sales engineers handle initial enquiries, directly visit the customer and continue with the project throughout its development phase and beyond to volume manufacture.
They work closely with Rotalink's design and production engineers and in this way, information passes directly between the customer and Rotalink without the costly time delays and potential communication problems that can occur when distributors or UK based sales offices for offshore manufacturers are involved.
The "complete solution" culture extends even further with in-house departments and processes covering coil winding, injection moulding, gear hobbing, soldering, terminating and final assembly.
Indeed, many of Rotalink's customers now specify their requirements well beyond simple components and are supplied customised assemblies to their exact mechanical and electrical interfacing specifications with delivery direct to their production line, exactly when they are required.
Rotalink's customised solutions include mechanical options such as spur and planetary gearboxes, flatted, slotted, threaded or internally tapped shafts, modified mounting arrangements as well as pulleys, leadscrews and other transmission components.
Electrical and electronic options include a wide range of control and drive options, encoder and tacho assemblies and specialised connectors supplied exactly to customer requirements.
Rotalink is confident that its blend of global partnerships and UK manufacturing expertise will continue to provide the platform for its continued growth as a world-class producer of miniature motors, transmission and control products.
Rotalink has established its success on forging close partnerships with global manufacturing companies for low-cost sourcing of common and higher volume components in combination with its own specialised design and manufacturing expertise to produce exactly what the customer requires.
With a very broad base of customers including several global companies with UK development facilities, Rotalink has found this approach keeps production costs and lead-times to a minimum and that its customers benefit from competitively priced products with a faster, more efficient turnaround from prototype to production.
From the recent investment, the star performer is a new Citizen M32, CNC lathe.
The dual spindle machine is fitted with a gear hobbing attachment capable of producing gears and components up to 32mm diameter.
The new 13-axis fully automated machine features servomotor controlled collet operation, work-piece ejection and magazine bar-feed; the synchronised control system enables fast, front and rear machining.
Using the latest technology means that typical setup times have been significantly reduced and whilst large quantities are often produced on the M32, small quantities can also be accommodated; so smaller production runs, design prototypes and concepts can be produced without high cost to their customers.
Another benefit of its UK manufacturing setup is Rotalink's application and customer support process that has proven to be extremely efficient and widely acclaimed by its customers.
Degree qualified sales engineers handle initial enquiries, directly visit the customer and continue with the project throughout its development phase and beyond to volume manufacture.
They work closely with Rotalink's design and production engineers and in this way, information passes directly between the customer and Rotalink without the costly time delays and potential communication problems that can occur when distributors or UK based sales offices for offshore manufacturers are involved.
The "complete solution" culture extends even further with in-house departments and processes covering coil winding, injection moulding, gear hobbing, soldering, terminating and final assembly.
Indeed, many of Rotalink's customers now specify their requirements well beyond simple components and are supplied customised assemblies to their exact mechanical and electrical interfacing specifications with delivery direct to their production line, exactly when they are required.
Rotalink's customised solutions include mechanical options such as spur and planetary gearboxes, flatted, slotted, threaded or internally tapped shafts, modified mounting arrangements as well as pulleys, leadscrews and other transmission components.
Electrical and electronic options include a wide range of control and drive options, encoder and tacho assemblies and specialised connectors supplied exactly to customer requirements.
Rotalink is confident that its blend of global partnerships and UK manufacturing expertise will continue to provide the platform for its continued growth as a world-class producer of miniature motors, transmission and control products.
Transmission specialist boosts distributor support
xOEMs can now benefit from having specialist advice on the specification of high performance ZF right angle and planetary gearheads to help improve performance and reduce costs when designing machinery and robotics systems. Previously Sales Manager for AMK Drives and Controls, Logue has many years experience dealing with high performance planetary gearboxes.
His new responsibilities include a dual role as Product Manager for Drive Lines for the ZF range of PG, PGE and WT servo gearheads.
"My new role as Product Manager will enable Drive Lines to provide more focused technical advice and point of contact, to customers with precision power transmission applications", explains Logue.
Drive Lines is well known in the industry for supplying high-volume gearboxes and geared motors for use in machinery where backlash is not critical.
The recent appointment of Patrick Logue further underlines the company's commitment to proving a complete power transmission solution service by increasing support for high performance, low backlash applications.
In addition to the PG and PGE in-line planetary series, Drive Lines also supplies ZF's high performance WT right-angled gearboxes, which mount to any commercial servomotor.
Logue describes their inclusion as "important because Drive Lines can now cover mechanical power and torque ranges required for most industrial motion control applications with a single range".
His new responsibilities include a dual role as Product Manager for Drive Lines for the ZF range of PG, PGE and WT servo gearheads.
"My new role as Product Manager will enable Drive Lines to provide more focused technical advice and point of contact, to customers with precision power transmission applications", explains Logue.
Drive Lines is well known in the industry for supplying high-volume gearboxes and geared motors for use in machinery where backlash is not critical.
The recent appointment of Patrick Logue further underlines the company's commitment to proving a complete power transmission solution service by increasing support for high performance, low backlash applications.
In addition to the PG and PGE in-line planetary series, Drive Lines also supplies ZF's high performance WT right-angled gearboxes, which mount to any commercial servomotor.
Logue describes their inclusion as "important because Drive Lines can now cover mechanical power and torque ranges required for most industrial motion control applications with a single range".
Alliance promises gearing optimisation
In the halcyon days of British engineering most drawing offices could boast an expert on everything, a designer tucked away in the corner whose sole purpose in life was the specification of widgets. Sadly, such days are long gone and usually a single engineer has to have some degree of knowledge across the board from key components to paint specification. The demise of the in-house expert was to some extent offset by the suppliers of components, such as gearboxes, having their own applications engineering teams who were not only expert in their own product but also in their customers machines.
However, this luxury is also being eroded by financial pressures so that fewer and fewer manufacturers are able to offer this service.
The net result of these cutbacks is the loss of innovation and a constant battle to gain a competitive edge by cost cutting, which as any engineer knows eventually leads to self-destruction.
Already most European manufacturers are working on minimum margins and the search for savings further a field in the emerging economies inevitably compromises quality.
Now that prices have been driven to rock bottom there are far greater savings to be made in making better use of the technology available.
In a bold move to offer increased technical support to its customers STM UK has teamed up with Sixsmith Consulting who can provide 30 years of applications experience and specialise in optimising gearbox technology to suit customers requirements.
This represents a substantial investment by the UK company, backed by its Italian principals, but will enable it to focus on the more technical products in their portfolio which have to date remained relatively unknown, even to some of their regular customers.
In particular this includes the GSM range of parallel shaft gearboxes which, although by no means unknown in the UK, have not been promoted directly by the manufacturer, which is obviously able to offer the most competitive pricing.
The standard GSM range of parallel shaft and bevel/helical gearboxes are available with ratios from 3:1 to in excess of 1000:1, can transmit output torques up to 350,000Nm and are well equipped to handle the considerable associated power.
Additionally there are dedicated designs for lifting, elevator and extruder drives and a number of bespoke designs to suit individual market requirements.
Of course not everyone requires such monsters, and so there is also a range of compact modular parallel shaft and right angle units catering for output torques up to 80kNm with ratios from 1.12:1 to 1400:1.
STM has been established in the UK for 15 years offering a broad range of helical and worm gear boxes, geared motors, electronic and mechanical variable speed drives with an unrivalled degree of personalised service.
'There is no place for a 'bad' product in today's market and quality is taken for granted so distributors can only be judged on the level of service they provide'.
Although most will claim customer satisfaction to be paramount not all would send a dedicated van to Germany overnight to meet an 'impossible' delivery as STM UK did recently to avoid disappointing a valued customer.
Paul Sixsmith is better known for promoting planetary gearing and continues to be a firm believer that this technology is under-used especially in the UK.
Sixsmith is however the first to admit that planetary gearboxes are not all things to all men, particularly when high powers are involved or when the length of the gearbox becomes a problem.
'It has always been my policy to put the customer's interests first and propose the best technical solution regardless of product even though this has often led to a loss of business', says Sixsmith.
'Now, with direct access to the STM/GSM range of products I will be able to offer well engineered competitively priced drive solutions whatever the customer's requirements'.
Many people would be amazed how much cost can be taken out of a mechanical transmission by the correct application of the best technology.
This was graphically illustrated in a paper for the Drives and Controls conference some years ago, where the cost of a typical drive was incrementally reduced by 60% by probing deeper and deeper into the application.
Although the benefits of a drive appraisal may be obvious it is a luxury that few can afford, after all: 'if it ain't broke, why fix it?'.
For a limited period therefore, STM UK in conjunction with Sixsmith Consulting is offering a free, no obligation Health Check which, even if it doesn't save you money, will at least confirm that you have the best drive solution on the market.
This offer is also open to the gearbox end users who often fight to keep inefficient outdated drives running and are often ignored by the large manufacturers.
However, this luxury is also being eroded by financial pressures so that fewer and fewer manufacturers are able to offer this service.
The net result of these cutbacks is the loss of innovation and a constant battle to gain a competitive edge by cost cutting, which as any engineer knows eventually leads to self-destruction.
Already most European manufacturers are working on minimum margins and the search for savings further a field in the emerging economies inevitably compromises quality.
Now that prices have been driven to rock bottom there are far greater savings to be made in making better use of the technology available.
In a bold move to offer increased technical support to its customers STM UK has teamed up with Sixsmith Consulting who can provide 30 years of applications experience and specialise in optimising gearbox technology to suit customers requirements.
This represents a substantial investment by the UK company, backed by its Italian principals, but will enable it to focus on the more technical products in their portfolio which have to date remained relatively unknown, even to some of their regular customers.
In particular this includes the GSM range of parallel shaft gearboxes which, although by no means unknown in the UK, have not been promoted directly by the manufacturer, which is obviously able to offer the most competitive pricing.
The standard GSM range of parallel shaft and bevel/helical gearboxes are available with ratios from 3:1 to in excess of 1000:1, can transmit output torques up to 350,000Nm and are well equipped to handle the considerable associated power.
Additionally there are dedicated designs for lifting, elevator and extruder drives and a number of bespoke designs to suit individual market requirements.
Of course not everyone requires such monsters, and so there is also a range of compact modular parallel shaft and right angle units catering for output torques up to 80kNm with ratios from 1.12:1 to 1400:1.
STM has been established in the UK for 15 years offering a broad range of helical and worm gear boxes, geared motors, electronic and mechanical variable speed drives with an unrivalled degree of personalised service.
'There is no place for a 'bad' product in today's market and quality is taken for granted so distributors can only be judged on the level of service they provide'.
Although most will claim customer satisfaction to be paramount not all would send a dedicated van to Germany overnight to meet an 'impossible' delivery as STM UK did recently to avoid disappointing a valued customer.
Paul Sixsmith is better known for promoting planetary gearing and continues to be a firm believer that this technology is under-used especially in the UK.
Sixsmith is however the first to admit that planetary gearboxes are not all things to all men, particularly when high powers are involved or when the length of the gearbox becomes a problem.
'It has always been my policy to put the customer's interests first and propose the best technical solution regardless of product even though this has often led to a loss of business', says Sixsmith.
'Now, with direct access to the STM/GSM range of products I will be able to offer well engineered competitively priced drive solutions whatever the customer's requirements'.
Many people would be amazed how much cost can be taken out of a mechanical transmission by the correct application of the best technology.
This was graphically illustrated in a paper for the Drives and Controls conference some years ago, where the cost of a typical drive was incrementally reduced by 60% by probing deeper and deeper into the application.
Although the benefits of a drive appraisal may be obvious it is a luxury that few can afford, after all: 'if it ain't broke, why fix it?'.
For a limited period therefore, STM UK in conjunction with Sixsmith Consulting is offering a free, no obligation Health Check which, even if it doesn't save you money, will at least confirm that you have the best drive solution on the market.
This offer is also open to the gearbox end users who often fight to keep inefficient outdated drives running and are often ignored by the large manufacturers.
Neodymium magnet technology provides more power
Pittman Lo-Cog 6000 and 8600 series brushed DC motors feature resin bonded, neodymium iron boron magnets, skewed armatures and innovative cartridge brush assemblies for precise control, low magnetic cogging and long life for a wide range of motion control applications. Lo-Cog 6000 and 8600 series motors are aimed at applications requiring the power of an "ironless rotor" or "coreless" motor, without the associated cost. Neodymium magnet technology provides more power than most other DC motors of similar size and suits a wide range of demanding motion control applications such as mass data storage equipment, computer peripherals, office automation, imaging systems and medical diagnostics equipment.
These motors feature a cartridge brush assembly that reduces audible and electrical noise and significantly improves brush life by maintaining optimum brush force throughout the life of the motor.
Skewed windings minimise magnetic cogging, even at low speeds, and windings are resin impregnated for greater reliability in incremental motion applications.
With diamond turned commutators and precision ground stainless steel shafts, these high performance motors feature copper graphite brushes and thanks to their modular construction, are available with a wide range of standard options including alterative brush material, ball bearings for the 6000 series and optical encoders with wide choice of angular resolutions.
For production quantities, windings may be customised to carefully match customers speed and torque characteristics and nonstandard encoders, gearboxes, custom cables, connectors, specialised shafts, pulleys, gears and other mechanical modifications can be easily accommodated.
The 6000 series motors have an effective outside diameter of 22mm and are available in two standard lengths of 32 and 48mm producing maximum continuous torque of 5.7 and 14mNm, respectively.
The 8600 series feature 26mm outside diameter in three lengths of 46, 49 and 55mm with respective continuous torque ratings of 14, 17 and 22mNm.
Both ranges feature no-load speeds between 7000 and 9000rev/min.
The 6000 series is available as part of the MotionExpress fast delivery programme in 6, 12 and 24V versions with "next day" delivery of several variants, some with planetary gearboxes with gear ratios between 4:1 and 169:1.
These motors feature a cartridge brush assembly that reduces audible and electrical noise and significantly improves brush life by maintaining optimum brush force throughout the life of the motor.
Skewed windings minimise magnetic cogging, even at low speeds, and windings are resin impregnated for greater reliability in incremental motion applications.
With diamond turned commutators and precision ground stainless steel shafts, these high performance motors feature copper graphite brushes and thanks to their modular construction, are available with a wide range of standard options including alterative brush material, ball bearings for the 6000 series and optical encoders with wide choice of angular resolutions.
For production quantities, windings may be customised to carefully match customers speed and torque characteristics and nonstandard encoders, gearboxes, custom cables, connectors, specialised shafts, pulleys, gears and other mechanical modifications can be easily accommodated.
The 6000 series motors have an effective outside diameter of 22mm and are available in two standard lengths of 32 and 48mm producing maximum continuous torque of 5.7 and 14mNm, respectively.
The 8600 series feature 26mm outside diameter in three lengths of 46, 49 and 55mm with respective continuous torque ratings of 14, 17 and 22mNm.
Both ranges feature no-load speeds between 7000 and 9000rev/min.
The 6000 series is available as part of the MotionExpress fast delivery programme in 6, 12 and 24V versions with "next day" delivery of several variants, some with planetary gearboxes with gear ratios between 4:1 and 169:1.
Biggest ever catalogue spans 920 pages
Ondrives of Chesterfield has launched its biggest catalogue ever for 2005, with 920 pages. The product range contains all the old favourites as well as some new parts which further enhance the portfolio. gearboxes and coupling ranges remain as popular as ever, with many available off the shelf to suit 'just-in-time' requirements.
The new ranges added include hardened plain and flanged jig bushes, manual leadscrew actuators, miniature grooved steel thrust bearings and low-backlash inline taper
The new ranges added include hardened plain and flanged jig bushes, manual leadscrew actuators, miniature grooved steel thrust bearings and low-backlash inline taper
Wider gear range than ever from Reliance Gear
Along with many other components and assemblies, Reliance Gear Company of Huddersfield have been supplying highly accurate fine pitch gears and gearboxes for use in data transmission and actuation for over 40 years. The company has high precision subcontract and assembly facilities which function alongside a range of standard off the shelf components. It is thus uniquely positioned within the marketplace to supply the design engineer with the exact solution for his requirements.
The standard gear range has pitches ranging from 0.2 to 1.5 mod metric (16-120DP imperial) and includes stainless hardened gears, designed to be used in higher torque, longer life applications and ideal for the medical and aerospace industries.
The gears are designed to be interfaced with all standard components in the Reliance catalogue.
Reliance also have a unique, bi-directional dynamic transmission angle measuring facility which is used for inspection of individual gears during manufacture and for certifying the performance of completed assemblies.
The test results relate directly to the in-service performance requirement suited for high precision applications such as digital scanning, high resolution printing and radar position feedback.
The standard gear range has pitches ranging from 0.2 to 1.5 mod metric (16-120DP imperial) and includes stainless hardened gears, designed to be used in higher torque, longer life applications and ideal for the medical and aerospace industries.
The gears are designed to be interfaced with all standard components in the Reliance catalogue.
Reliance also have a unique, bi-directional dynamic transmission angle measuring facility which is used for inspection of individual gears during manufacture and for certifying the performance of completed assemblies.
The test results relate directly to the in-service performance requirement suited for high precision applications such as digital scanning, high resolution printing and radar position feedback.
In-line helical gearboxes add 5000h life bonus
NBC Group, UK distributors for Italian gearbox manufacturers Varvel, is pleased to announce the launch of the new in-line helical RD series gearbox. Manufactured to ISO 6336/Din 3990 size standards, the key benefit to the consumer is that each unit has been designed around a 15,000 hour life at service factor SF1. Other manufacturers only design around 10,000 hours, thus Varvel offer 50% more life at prices competitive with manufacturers already using the ISO 6336 footprint for their in-line helical units.
There are 5 different size options, offering 28 ratios through 2 and 3 stage reductions.
Powers range from 0.06kW to 9.2kW, ratios from 2.5:1 to 630:1 with output torques from 1.0Nm to 635Nm.
Another key benefit for the consumer is that the units are compatible with standard IEC frame size motors, offering greater flexibility and less expense to the replacement user(no more special motors) and a more familiar territory for the design engineers! The housings are pressure die cast to AISI 12 Cu2Fe, with the gears manufactured in steel 20MnCr5 case hardened.
Varvel have been manufacturing gearboxes since 1955 and currently produce 600 gearboxes daily at their plant in Crespellano in Italy.
A family run firm, they have the ability to offer a flexible, individually orientated service which mirrors that of the NBC Group, who were founded in 1956 and distribute Bearings and Power Transmission products through 4 divisions in the UK - OEM, Export, Distribution(trade only), and the Replacement division.
There are 5 different size options, offering 28 ratios through 2 and 3 stage reductions.
Powers range from 0.06kW to 9.2kW, ratios from 2.5:1 to 630:1 with output torques from 1.0Nm to 635Nm.
Another key benefit for the consumer is that the units are compatible with standard IEC frame size motors, offering greater flexibility and less expense to the replacement user(no more special motors) and a more familiar territory for the design engineers! The housings are pressure die cast to AISI 12 Cu2Fe, with the gears manufactured in steel 20MnCr5 case hardened.
Varvel have been manufacturing gearboxes since 1955 and currently produce 600 gearboxes daily at their plant in Crespellano in Italy.
A family run firm, they have the ability to offer a flexible, individually orientated service which mirrors that of the NBC Group, who were founded in 1956 and distribute Bearings and Power Transmission products through 4 divisions in the UK - OEM, Export, Distribution(trade only), and the Replacement division.
Couplings transmit more torque
Using a traditional keyed fitting to mount pulleys and shaft mounted gearboxes is commonly accepted as a crude method of securing power transmission equipment. But it is time consuming to install and allows fretting corrosion that often leads to difficulties should the unit need to be removed for service or replacement. Using a simple friction bushing type system can alleviate the problem of removal, but does not usually allow for high torque operation.
The new generation of Fenner Taper-Grip addresses both issues; it is engineered to transmit 300% more torque than traditional alternatives and still allow for simple fitting and removal in virtually any condition.
Designed primarily for mounting high power (torque levels up to 38000Nm) Fenner SMSR shaft mounted gearboxes in applications such as conveyors and quarrying equipment, the new Taper-Grip system uses a taper mechanism similar to the Taper-Lock bush.
However, it is in the form of a spiral or thread where an inner bushing engages with the outer sleeve (the hub section) and exerts a clamping force when axial pressure is applied against the spiral taper.
The angle of the taper is finely engineered to allow one face to ride-up on the opposing face and squeeze the inner sleeve along its complete length.
This results in a uniform and very high clamping pressure along the entire length of the assembled bushing, and a very easy removal process - just a tap in the opposite direction.
The inner sleeve is slotted to allow for the radial compression and when released the metal springs back away from the shaft.
Slots also allow for a wide shaft tolerance (tolerances of up to h11 can be accommodated).
Axial pressure exerted against the thread is applied using cap head screws mounted in a collar at one end of the bushing.
The inner bushing is screwed into the hub (only finger pressure required) while the assembly is positioned and locking force then applied by tightening the screws against a hardened collar.
In order to apply the huge clamping force available from Taper-Grip, the cap head screws are finally tightened to the recommended setting using a torque wrench.
In-house testing results showed a 300% increase in the amount of torque that could be transmitted when compared with earlier friction based locking bush designs.
The results complement the introduction of the new range of Fenner SMSR Power Plus shaft mounted gearboxes that actually transmit 50% more torque (up to 280kW) than competitive designs for the same design envelope.
The increased power required a locking system that could ensure the new higher power levels could be delivered to the driven shaft and yet maintains the ease and practicality of a tapered bushing design.
The Taper-Grip system can offer significant advantages when removing a gearbox.
There is a tendency for shaft mounted reducers in some environments to suffer from atmospheric or fretting corrosion and seizing solidly onto the shaft.
This can make removal difficult and time-consuming.
The Taper-Grip system eliminates this problem as the bush is manufactured from high-grade steel to enable high screw tightening torques that, in turn, generate a huge radial force to increase the grip on the driven shaft.
When the bush screws are loosened and the tapers released, there is sufficient clearance within the assembly to permit easy removal.
Because the bush is screwed into the hub, it is inherently safe.
Even if the locking screws are completely removed, it cannot inadvertently fall out during handling.
The new generation of Fenner Taper-Grip addresses both issues; it is engineered to transmit 300% more torque than traditional alternatives and still allow for simple fitting and removal in virtually any condition.
Designed primarily for mounting high power (torque levels up to 38000Nm) Fenner SMSR shaft mounted gearboxes in applications such as conveyors and quarrying equipment, the new Taper-Grip system uses a taper mechanism similar to the Taper-Lock bush.
However, it is in the form of a spiral or thread where an inner bushing engages with the outer sleeve (the hub section) and exerts a clamping force when axial pressure is applied against the spiral taper.
The angle of the taper is finely engineered to allow one face to ride-up on the opposing face and squeeze the inner sleeve along its complete length.
This results in a uniform and very high clamping pressure along the entire length of the assembled bushing, and a very easy removal process - just a tap in the opposite direction.
The inner sleeve is slotted to allow for the radial compression and when released the metal springs back away from the shaft.
Slots also allow for a wide shaft tolerance (tolerances of up to h11 can be accommodated).
Axial pressure exerted against the thread is applied using cap head screws mounted in a collar at one end of the bushing.
The inner bushing is screwed into the hub (only finger pressure required) while the assembly is positioned and locking force then applied by tightening the screws against a hardened collar.
In order to apply the huge clamping force available from Taper-Grip, the cap head screws are finally tightened to the recommended setting using a torque wrench.
In-house testing results showed a 300% increase in the amount of torque that could be transmitted when compared with earlier friction based locking bush designs.
The results complement the introduction of the new range of Fenner SMSR Power Plus shaft mounted gearboxes that actually transmit 50% more torque (up to 280kW) than competitive designs for the same design envelope.
The increased power required a locking system that could ensure the new higher power levels could be delivered to the driven shaft and yet maintains the ease and practicality of a tapered bushing design.
The Taper-Grip system can offer significant advantages when removing a gearbox.
There is a tendency for shaft mounted reducers in some environments to suffer from atmospheric or fretting corrosion and seizing solidly onto the shaft.
This can make removal difficult and time-consuming.
The Taper-Grip system eliminates this problem as the bush is manufactured from high-grade steel to enable high screw tightening torques that, in turn, generate a huge radial force to increase the grip on the driven shaft.
When the bush screws are loosened and the tapers released, there is sufficient clearance within the assembly to permit easy removal.
Because the bush is screwed into the hub, it is inherently safe.
Even if the locking screws are completely removed, it cannot inadvertently fall out during handling.
Power without the price
Neeter Drives' new Powergear range of products have been produced following the increasing technical demands from customers, which has led to the merging of the old Universal and Power Gear ranges, the main technical features of the two older ranges have been taken into account when producing the New range which replaces them. The New Powergear series has been produced to meet with a specific torque-speed spectrum. The advantages of this approach are: * The compact and rigid design assures highest performance at small dimensions and low weight * Lubricated for life, the gearboxes are, depending on their size, maintenance-free, if operated under normal conditions * The high efficiency of the gearbox, 98%, saves energy costs * Housing/Flanges made of spheroidal graphite iron for maximum rigidity * Fretting-free torque transfer using a friction-locked fit between shaft and gear * High quality taper roller bearings taking axial and radial loads and guaranteeing long operational life * Gleason cut gears for high torque ratings * Optimised gear tooth contact pattern during assembly leading to uniform load distribution The units are available in 8 sizes, with 6 standard ratios from 1:1 to 5:1.
Shaft arrangements include 2 way, 3 way and 4 way and are available with solid shafts and hollow output shafts, the units are also available with motor input flanges allowing many standard IEC framed motors to be fitted.
The overall torque range is from 25Nm to 5200Nm with input speeds up to 6500rpm.
For ease of installation the units have been designed, with universal mounting, allowing the units to be mounted from all sides.
Additional accessories include: * Shrink Disc - with hollow shaft extension for friction locked connections.
* Keyless Shafts - for attachment via clamping connections.
* Minimum Backlash - for greater accuracy than already offered as standard.
* Cooling packs - gearboxes fitted with aluminium cooling fins, with or without the addition of an axial fan to provide increased heat dissipation from the unit.
The main advantages of the Powergear design will be found in applications with requirements of high torque at medium to high speeds, robust unit in a small size, useable in any mounting/working position.
Typical applications for the Powergear are angular torque transfer and torque distribution in single, or multiple shaft configuration.
In non-stationary applications where weight is extremely important, the Powergear design is the ideal solution.
For applications requiring a 1:1 ratio unit capable of handling greater torque than the standard Powergear a higher rated 'X-range' is available utilising the same size cases.
For further information on the New Powergear bevel gearboxes or any of our other products, please contact us on +44 (0) 1346 513131 or visit the website at www.neeterdrive.co.uk or www.powerjacks.com Request a free brochure from Power Jacks....
Shaft arrangements include 2 way, 3 way and 4 way and are available with solid shafts and hollow output shafts, the units are also available with motor input flanges allowing many standard IEC framed motors to be fitted.
The overall torque range is from 25Nm to 5200Nm with input speeds up to 6500rpm.
For ease of installation the units have been designed, with universal mounting, allowing the units to be mounted from all sides.
Additional accessories include: * Shrink Disc - with hollow shaft extension for friction locked connections.
* Keyless Shafts - for attachment via clamping connections.
* Minimum Backlash - for greater accuracy than already offered as standard.
* Cooling packs - gearboxes fitted with aluminium cooling fins, with or without the addition of an axial fan to provide increased heat dissipation from the unit.
The main advantages of the Powergear design will be found in applications with requirements of high torque at medium to high speeds, robust unit in a small size, useable in any mounting/working position.
Typical applications for the Powergear are angular torque transfer and torque distribution in single, or multiple shaft configuration.
In non-stationary applications where weight is extremely important, the Powergear design is the ideal solution.
For applications requiring a 1:1 ratio unit capable of handling greater torque than the standard Powergear a higher rated 'X-range' is available utilising the same size cases.
For further information on the New Powergear bevel gearboxes or any of our other products, please contact us on +44 (0) 1346 513131 or visit the website at www.neeterdrive.co.uk or www.powerjacks.com Request a free brochure from Power Jacks....
Transmission specialist boosts distributor support
To further improve support for ZF's WT, PG and PGE servo gearheads, Patrick Logue has joined transmission product specialist Drive Lines Technologies as Sales Engineer for the South of England. OEMs can now benefit from having specialist advice on the specification of high performance ZF right angle and planetary gearheads to help improve performance and reduce costs when designing machinery and robotics systems. Previously Sales Manager for AMK Drives and Controls, Logue has many years experience dealing with high performance planetary gearboxes.
His new responsibilities include a dual role as Product Manager for Drive Lines for the ZF range of PG, PGE and WT servo gearheads.
"My new role as Product Manager will enable Drive Lines to provide more focused technical advice and point of contact, to customers with precision power transmission applications", explains Logue.
Drive Lines is well known in the industry for supplying high-volume gearboxes and geared motors for use in machinery where backlash is not critical.
The recent appointment of Patrick Logue further underlines the company's commitment to proving a complete power transmission solution service by increasing support for high performance, low backlash applications.
In addition to the PG and PGE in-line planetary series, Drive Lines also supplies ZF's high performance WT right-angled gearboxes, which mount to any commercial servomotor.
Logue describes their inclusion as "important because Drive Lines can now cover mechanical power and torque ranges required for most industrial motion control applications with a single range".
Request free introductory details about products from ZF Great Britain...
His new responsibilities include a dual role as Product Manager for Drive Lines for the ZF range of PG, PGE and WT servo gearheads.
"My new role as Product Manager will enable Drive Lines to provide more focused technical advice and point of contact, to customers with precision power transmission applications", explains Logue.
Drive Lines is well known in the industry for supplying high-volume gearboxes and geared motors for use in machinery where backlash is not critical.
The recent appointment of Patrick Logue further underlines the company's commitment to proving a complete power transmission solution service by increasing support for high performance, low backlash applications.
In addition to the PG and PGE in-line planetary series, Drive Lines also supplies ZF's high performance WT right-angled gearboxes, which mount to any commercial servomotor.
Logue describes their inclusion as "important because Drive Lines can now cover mechanical power and torque ranges required for most industrial motion control applications with a single range".
Request free introductory details about products from ZF Great Britain...
Gearbox drops in for engineering-free solution
After a 1975 gearbox seized at Harpenden sewerage works, Thames Water was faced with the choice of having to pay for the original gearboxes to be remanufactured or to replace a large part of the tank's peripheral equipment including the bridge and drive system to fit a modern replacement. For approximately half the cost of these two options, BSL and Brevini have teamed up to design and engineer a modern planetary solution that can be fitted as a direct replacement and meet Thames Water's aim of "no engineering" replacement. Jon Snaith Sales Manager of Brevini UK designed the solution.
He said: "We estimate there are over 100 of these particular 70s style gearboxes driving thickeners and scrapers at sewage works across the UK, many of which will be reaching the end of their operating life".
"We have seen several recently that require attention and the seizure at Harpenden gave us an opportunity to engineer a solution that could be fitted as a like-for-like replacement".
The order was placed on BSL Luton, which has a longstanding relationship with Thames Water and is used to providing maintenance solutions for the water industry.
Several companies were asked to quote for a direct replacement to the Sanderson Heliocentric gearbox but Brevini was the only company that was able to solve the engineering riddle of matching sizes, speed, power output and mounting requirements.
In order to match the fitting requirements Brevini designed and supplied a bespoke engineered flange and end cap for the new assembly.
The splined output pinion was then cut from the original gearbox and fitted to the output shaft of the new five-stage Brevini planetary unit to allow a seamless fit.
The solution means that the original mounting and bridgework, which is sound, can be retained and the new gearbox fitted without any alterations being made.
This was important for Thames Water as the company employs a "no engineering" policy where possible on replacement items in order to control costs.
Compared with the alternatives of having the original ageing gearbox remanufactured which would have involved replacing all worn parts with new parts made from scratch, or dismantling the scraper drive and bridge and adapting them to accommodate a new gearbox or indeed building new ones, the cost of the Brevini engineered solution is at least half that of estimates made for the alternatives.
Meeting strict cost criteria has become an increasingly important facet of most public service and utility engineering projects, making the Brevini solution ideal because it uses up-to-date technology that can be applied with a cost saving.
The savings are not just limited to the purchase and installation cost; Brevini planetary gear reduction stages are 98% efficient and a five-stage reduction can be powered by a very small electric motor.
Using a 0.25kW motor the package delivers an overall efficiency of 87.5%.
This high level of energy efficiency will provide substantial energy savings when compared to the original units.
A second thickener drive at Harpenden that uses the same heliocentric gearbox is also being replaced with a Brevini solution after the tank with the seized gearbox returned to operation.
Now the design solution has been approved and the first one fitted without a hitch, the overall project time for replacements has been reduced drastically compared with the alternatives.
The equipment is only out of action for a matter of days rather than weeks and the commissioning itself is straightforward and relatively simple to complete as no adjustment of the original mountings or drive are required.
Brevini gearboxes are available off the shelf and with engineering support via any one of over 120 BSL branches nationwide.
There are many other Brevini solutions already available for industry specific applications including slewing drives for the water industry, wheel and track drives for the mobile plant industry and for a wide range of general industrial mixing and conveying tasks.
He said: "We estimate there are over 100 of these particular 70s style gearboxes driving thickeners and scrapers at sewage works across the UK, many of which will be reaching the end of their operating life".
"We have seen several recently that require attention and the seizure at Harpenden gave us an opportunity to engineer a solution that could be fitted as a like-for-like replacement".
The order was placed on BSL Luton, which has a longstanding relationship with Thames Water and is used to providing maintenance solutions for the water industry.
Several companies were asked to quote for a direct replacement to the Sanderson Heliocentric gearbox but Brevini was the only company that was able to solve the engineering riddle of matching sizes, speed, power output and mounting requirements.
In order to match the fitting requirements Brevini designed and supplied a bespoke engineered flange and end cap for the new assembly.
The splined output pinion was then cut from the original gearbox and fitted to the output shaft of the new five-stage Brevini planetary unit to allow a seamless fit.
The solution means that the original mounting and bridgework, which is sound, can be retained and the new gearbox fitted without any alterations being made.
This was important for Thames Water as the company employs a "no engineering" policy where possible on replacement items in order to control costs.
Compared with the alternatives of having the original ageing gearbox remanufactured which would have involved replacing all worn parts with new parts made from scratch, or dismantling the scraper drive and bridge and adapting them to accommodate a new gearbox or indeed building new ones, the cost of the Brevini engineered solution is at least half that of estimates made for the alternatives.
Meeting strict cost criteria has become an increasingly important facet of most public service and utility engineering projects, making the Brevini solution ideal because it uses up-to-date technology that can be applied with a cost saving.
The savings are not just limited to the purchase and installation cost; Brevini planetary gear reduction stages are 98% efficient and a five-stage reduction can be powered by a very small electric motor.
Using a 0.25kW motor the package delivers an overall efficiency of 87.5%.
This high level of energy efficiency will provide substantial energy savings when compared to the original units.
A second thickener drive at Harpenden that uses the same heliocentric gearbox is also being replaced with a Brevini solution after the tank with the seized gearbox returned to operation.
Now the design solution has been approved and the first one fitted without a hitch, the overall project time for replacements has been reduced drastically compared with the alternatives.
The equipment is only out of action for a matter of days rather than weeks and the commissioning itself is straightforward and relatively simple to complete as no adjustment of the original mountings or drive are required.
Brevini gearboxes are available off the shelf and with engineering support via any one of over 120 BSL branches nationwide.
There are many other Brevini solutions already available for industry specific applications including slewing drives for the water industry, wheel and track drives for the mobile plant industry and for a wide range of general industrial mixing and conveying tasks.
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