Motorized Pulleys offer integrated shaft encoder

BDL motorized pulleys allow conveyor system operators to synchronize product movements. Shaft encoders utilize SKF or SNR pulse outputs to monitor motorized pulley movement and control conveyor belt speed, position, torque, and rotational direction. Accurate conveyor belt movements, up to [+ or -]0.0002 in. at speeds of 19-500 fpm, are achievable. Mounted with 2 brackets, pulleys range from 3.18-12.6 in. in diameter with face widths from 7.8-67 in.

Motorized pulleys with integrated shaft encoders, that allow conveyor system operators to accurately synchronize product movements, are available from BDL America, Wilmington, N.C. The encoders utilize either SKF or SNR pulse outputs to precisely monitor motorized pulley movement to control conveyor belt speed, position, torque and rotational direction. The motorized pulleys have been successfully applied in applications requiring properly timed conveyor movement, such as: positioning, dispensing, adjusting, cutting, tape winding, pick and place operations, and constant speed applications, among others.

The encoders are hermetically sealed within a stainless steel housing, eliminating the possibility of external influences and providing an extremely reliable control system. Accurate conveyor belt movements up to [+ or -]0.0002-inches at speeds of 19 to 500 fpm are achievable with the motorized pulley and integrated encoder design. The motorized pulleys are protected from dust and moisture, meeting class IP66 and IP67 standards.

The integrated encoders are available on the complete line of BDL motorized pulleys ranging from diameters of 3.18 to 12.6 inches, and face widths from 7.8 to 67 inches. Power from the motor is transmitted through the gearbox which is coupled to a geared rim fixed to the drum and housing.

Mounted with just two (2) brackets, there is no need for multiple parts - and multiple vendors. Ordering and installation are quick and easy requiring less than half the time needed to install external drives. The motorized pulley requires no external component maintenance.

Motorized pulleys in the BDL family feature durable steel gears with precision cut and honed teeth - reducing noise levels to only 50dB to meet OSHA requirements. Efficient and reliable, the motors run at 96 percent efficiency, saving up to 32 percent (unloaded) and 47 percent (loaded) on power consumption when compared to exposed drives.

Industrial Gear Oils help prolong gear life

Mineral-based Shell Omala, suited for highly loaded gearboxes operating under normal temperatures, exhibits water separation properties critical for operations in wet environments. Formulated for harsh industrial environments, Shell Omala HD synthetic oil is based on PAO and other select additives and exhibits thermal and oxidative stability. Synthetic Shell Tivela S is designed for enclosed, sealed-for-life or worm-helical gear units operating at higher temperatures.

Shell lubricants companies have launched a revitalized range of mineral and synthetic industrial gear oils for the US market. Shell Omala, Shell Omala HD and Shell Tivela S gear oils, have been specially formulated to help prolong gear life and reduce unscheduled downtime, which can help industrial companies reduce their overall operating costs.

The revitalized range of Shell gear oils has been developed to meet the challenges placed on modern gear systems, which are becoming increasingly sophisticated, smaller and designed to run longer. In a recent survey conducted by Shell of US industrial companies, 50% of respondents said that industrial gearboxes were one of their most critical components, while 30% said that they had experienced a lubricant related gearbox failure within the last 12 months.

Darren Cross, Shell's Industrial Lubricants Sector Marketing Manager, explains: "Today's industrial environment is more demanding than ever with trends towards smaller equipment and commercial pressures to raise throughput. The result is equipment needs to be able to run at higher operating temperatures, handle increased loads and cope with exposure to water and other contaminants. In these tough conditions, operators need a gear oil that is designed to tackle the problems that can affect operational efficiency. Shell has invested heavily in lubricants R&D to ensure that we can provide a revitalized range of gear oils for the US that meets these new challenges."

Transmission considerations: beyond the manual gearbox

As far as the majority of European drivers are concerned, the only transmission worth considering is the manual, which accounts for four out of every five gearboxes found in new cars sold in the region. There are two key factors in this dominance: (1) the extra cost in purchase price of automatic transmissions; (2) the in-built prejudice against automatics. The typical European driver still believes that not having a shift stick dilutes control of the car. "In Europe, if a customer can obtain an air conditioning system or light-alloy sports wheels for the same extra cost as an automatic transmission, the majority choose the other options," said Dr--Ing Gerhard Wagner, group vice president, ZF in his plenary speech at the Innovative Automotive Transmissions conference organized by the Car Training Institute in Berlin at the beginning of December 2005. "However, it should be noted that the extra cost charged for an automatic transmission is not in any way related to their manufacturing costs. Instead, the whole issue is governed by the pricing policy of the vehicle manufacturers which still determines that some items of equipment are cost options."

Wagner continued, "The figures quoted in sales brochures for fuel economy, emission levels and 0-100 km/h acceleration times are the next obstacle to overcome when selling a vehicle equipped with an automatic transmission. If these figures are significantly worse than those of a vehicle with a manual transmission, European customers tend as a general rule to favor the manual transmission. As a consequence, the requirement for low fuel consumption and good performance figures form an essential component in any automatic transmission development work."

Things, though, could be about to change in Europe as the transmission has now come into the front line in the carmakers' quest to meet emissions legislation. "The primary requirements and customer benefits underpinning the further development of automatic transmissions," said Wagner, "include a reduction of fuel consumption, a reduction of pollution, vehicle performance improvement, increasing torque capacity, greater comfort, sportiness, noise reduction, resource conservation, and competitiveness."

Clutches, clutch brakes, gearboxes - Mechanical Powertrain Component Report - North American Clutch Co

North American Clutch Co. (Noram) continues to develop its designs of clutches, clutch brakes and mechanical gearboxes for small engine applications. Clutches are designed to fit engines ranging from fractional horsepower up through 50 hp applications. They are available in standard off-the-shelf configurations or designed to fit an OEM'S specific requirement.

Noram centrifugal and mechanical clutches are designed to allow for safe, no-load, quiet starting of power equipment, the company said. Once engaged, the clutches reduce vibration, utilize peak torque for more efficient engine performance and provide overload protection for operator and equipment safety.

The company's reduction gearboxes are designed to fit most small (3/4 in. bore) and medium frame (1 in. bore) four-stroke engines available. Gearboxes are made of rugged aluminum castings, and precision machined gears. Noram's high-torque clutch brake has a variety of uses in the outdoor power equipment marketplace and industrial applications such as pump drives, blowers and agricultural seeders.

Gear Grinder rough and finish grinds gears in one setup

Built on mineral-filled cast polymer base, 6-axis GS:G2 produces gears from 1-12 in. dia, employs near net-shaped or hobbed gears, and requires 15 min of setup. Machine requires users to install proper tooling and enter part form, dress, and grind parameters into control in order to start-up new jobs, while menu-driven screens and Gear Smart(TM) Programming facilitate operation. Product features dual wheel machining and infinitely variable wheel speeds and feeds.

Sometimes a new machine is just destined to happen. Markets evolve, new technologies emerge, and an experienced machine tool builder seizes the opportunity. The result: the right machine, at the right time, at the right price.

Drake Manufacturing in Warren, OH is putting the finishing touches on a highly productive 6-axis gear grinder that will be grinding quality parts after just 15-minutes of setup. Best part is - like Drake's other gear and thread manufacturing machines - it's priced to provide high return on investment for the job shop owner as well as the large, automotive supplier.

Drake is best known for its line of CNC gear hobbers, thread and worm grinders, rack mills and bore grinders. The GS:G2 is a machine that blends the best of Drake's specialty grinding and gear making expertise.

As the basis of competition in the power transmission and speed reducer markets increasingly shifts toward quiet operation and efficiency, more and more manufacturers are calling for precision ground gears. The Drake GS:G2 enables manufacturers to source near net-shaped or hobbed gears from low-cost suppliers and still control the final product quality. "This is a high value-added grinder, that with minimal capital outlay, can help our customers remain globally competitive for years to come," said Stig Mowatt-Larssen, Drake's Manager of Research and Development.

A flexible grinder

The GS:G2 has the flexibility and capability to handle a variety of grinding roles: job shop work, manufacturing cell environments, high volume grinding - even prototype work. Fast changeovers with menu-driven setup screens-no more change gears or dressing thread wheels-make it easy to switch from job to job.

Gearboxes provide torque from 25-5,200 Nm

Lubricated for life, PowerGear Gearboxes are available in 8 sizes, with 6 standard ratios from 1:1-5:1 and efficiencies to 98%. Units feature taper roller bearings, Gleason cut gears, and spheroidal graphite iron housing and flanges. They provide fretting-free torque transfer using friction-locked fit between shaft and gear. Units come with solid or hollow shafts in 2-way, 3-way, and 4-way shaft arrangements, and can be mounted from all sides.

The New PowerGear range of products have been produced following the increasing technical demands from our customers, which has lead 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:

o The compact and rigid design assures highest performance at small dimensions and low weight

o Lubricated for life, the gearboxes are, depending on their size, maintenance-free, if operated under normal conditions

o The high efficiency of the gearbox, 98%, saves energy costs

o Housing/Flanges made of spheroidal graphite iron for maximum rigidity

o Fretting-free torque transfer using a friction-locked fit between shaft and gear

o High quality taper roller bearings taking axial and radial loads and guaranteeing long operational life

o Gleason cut gears for high torque ratings

o Optimized 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. Torque range from 25Nm to 5200Nm with input speeds up to 6500rpm.

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.