The SF-400 partition inserters from Wayne Automation cycle once every second and travel 96.5cm vertically. Every up-down cycle accurately inserts solid fibre or corrugated partitions into cartons that hold bottles and plastic containers ready for shipment. To maintain repeatable accuracy round the clock at these high speeds, they use servomotors connected to backlash-free Zero-Max CD couplings.
These couplings damp out shock and vibration from the inserters' vertical reciprocating and intermittent motion and maintain insertion accuracy cycle after cycle.
'To operate without problems, conventional vertical inserters require near perfect fibre or corrugated partitions,' said Jay Bachman, VP of Engineering for Wayne.
'In contrast, the SF-400 inserters have designed-in features, including servo drive systems, that help deal with less than perfect materials'.
'Unlike conventional systems which rely on gravity during the insertion process, the SF-400 maintains complete insertion control from the time the partition is picked off the magazine until is fully inserted into the case'.
'This ensures correct partition placement into the case every cycle'.
The drive system for the vertical inserter mechanism is powered by an Allen Bradley servomotor connected to a planetary reduction gearbox.
The motor transmits torque to the inserter via a floating shaft Zero-Max CD coupling configuration connected at both ends to two gearboxes.
These gearboxes are connected to two timing belt drive pulley gearboxes.
The combination of both intermittent and reciprocating motions at 1000rev/min (96.5cm one-way travel for every one second cycle) is demanding on the system's drive train.
Torque loads are a big factor in this setup with cyclical peak torques approaching 60% of the motor torque with vertical load lift up to 90kg.
A coupling design was needed that would handle these forces and one that could be positioned at both ends of the two gearboxes to equalise tension on both timing belts.
The firm chose the Zero-Max CD 6F30-AC floating shaft coupling.
The SF-400 coupling application is unique because of the 71cm span from one coupling's outer connecting hub to the second coupling's outer hub.
Also, this setup is a test of each coupling's composite disc design integrity that has a rated torque of 90Nm.
While the CD coupling disc pack transmits torque similar to any conventional coupling, it does a better job of dampening backlash and shock without coupling fatigue, which can occur in a fast-moving, high torque system such as the SF-400.
The disc pack at each shaft end resists fatigue through its open arm disc design.
Made of highly durable composite material, the disc pack absorbs any shock from the servomotor's intermittent motion while maintaining a zero backlash condition.
Also, the coupling's disc design and hub configuration provide support for the floating shaft component without imposing excessive radial loads on the connected equipment and bearings.
Inverters/servo controls/gearmotors in catalogue
Nord Gear, the manufacturer of high-performance gearboxes, gearmotors and associated drive electronics, has released a new 'Electronic Products' catalogue. Nord's experience with countless applications and system set-ups is the basis of continuous and innovative product research and development, which is reflected in the new catalogue. The catalogue contains details of the company's inverters, servo controllers, gearmotors with integral inverters and motor switches.
There is also a range of accessories, from braking resistors and line filters to output chokes and communication systems such as Profibus and CANbus.
Among the range of inverters are the NordAC vector mc inverters for cabinet installation.
These are microprocessor controlled, voltage source DC link inverters, designed to control three-phase asynchronous motors.
They offer many control modes and options, efficient drive control, convenient operation, minimal space requirement and high operational dependability.
Nord Gear also offers expert advice, whatever the nature of the application, from designing control processes, to starting a system from scratch.
There is also a range of accessories, from braking resistors and line filters to output chokes and communication systems such as Profibus and CANbus.
Among the range of inverters are the NordAC vector mc inverters for cabinet installation.
These are microprocessor controlled, voltage source DC link inverters, designed to control three-phase asynchronous motors.
They offer many control modes and options, efficient drive control, convenient operation, minimal space requirement and high operational dependability.
Nord Gear also offers expert advice, whatever the nature of the application, from designing control processes, to starting a system from scratch.
Planetary wheel drives offer an off-road edge
The demands to reduce size and weight, and yet achieve improved price/performance ratios, are familiar to designers of mobile equipment, worldwide. In their attempts to meet these demands, designers have focused on the area of drive systems, seeking simpler and more efficient alternatives to the conventional axle drive systems that are still used widely. Increasingly, engineers are finding the answers to their questions in this area with planetary wheel and track drives.
The reason for this lies with the planetary design.
Comprising several smaller planetary gears around an input pinion (instead of one larger gear running to one side), this arrangement offers a number of major advantages including: high efficiency - usually 97-98% per stage; reduced size - planetaries facilitate multiple reduction stages in a very compact space; and increased reliability - the result of a design that reduces radial loads.
In addition, because the torque being transmitted at any time in a planetary is shared between multiple sets of teeth on the primary drive pinion, torque capability is greatly increased.
Brevini has developed the planetary principle, proven in its range of industrial gearboxes, into highly compact wheel and track drives.
The wheel drives are used widely on such vehicles as agricultural machines, access platforms, fork lift trucks, sweepers and low speed wheeled vehicles; and the track drive units are specifically designed for use on tracked vehicles, such as excavators and earthmoving machines, weighing from 1.5 to 40t.
Both the wheel and track drive units permit a much neater and more compact design solution than axle drives and provide greater clearance for rough terrain vehicles.
The wheel drives offer the ability to accept directly mounted standard wheel rims and packaged hydraulic motors; and the track units are designed to mount inside the track sprockets of vehicles.
The wheel drive units employ the highly efficient combination of a planetary gear unit and high-speed hydraulic motor.
This combination is much more economical than using large slow-speed hydraulic motors on their own, and offers significant operating advantages.
In the event of hydraulic fluid contamination only the inexpensive package motor need be replaced, and this can be removed and refitted in minutes.
And the gearbox/ motor combination is capable of the very low speeds required when, for example, inching vehicles into position.
The wide range of ratios available with the wheel drive units makes it easy for designers of mobile plant to adapt the reduction unit to the most suitable hydraulic transmission.
In addition, further flexibility is provided by the ability of the wheel drives to accommodate the mounting of all types of orbit, geared and axial piston type hydraulic motors into their universal input.
Also included in the comprehensive design specification is a mechanical disconnect device.
This is manually operated from the hub end-plate and enables a vehicle to be towed in an emergency.
The reason for this lies with the planetary design.
Comprising several smaller planetary gears around an input pinion (instead of one larger gear running to one side), this arrangement offers a number of major advantages including: high efficiency - usually 97-98% per stage; reduced size - planetaries facilitate multiple reduction stages in a very compact space; and increased reliability - the result of a design that reduces radial loads.
In addition, because the torque being transmitted at any time in a planetary is shared between multiple sets of teeth on the primary drive pinion, torque capability is greatly increased.
Brevini has developed the planetary principle, proven in its range of industrial gearboxes, into highly compact wheel and track drives.
The wheel drives are used widely on such vehicles as agricultural machines, access platforms, fork lift trucks, sweepers and low speed wheeled vehicles; and the track drive units are specifically designed for use on tracked vehicles, such as excavators and earthmoving machines, weighing from 1.5 to 40t.
Both the wheel and track drive units permit a much neater and more compact design solution than axle drives and provide greater clearance for rough terrain vehicles.
The wheel drives offer the ability to accept directly mounted standard wheel rims and packaged hydraulic motors; and the track units are designed to mount inside the track sprockets of vehicles.
The wheel drive units employ the highly efficient combination of a planetary gear unit and high-speed hydraulic motor.
This combination is much more economical than using large slow-speed hydraulic motors on their own, and offers significant operating advantages.
In the event of hydraulic fluid contamination only the inexpensive package motor need be replaced, and this can be removed and refitted in minutes.
And the gearbox/ motor combination is capable of the very low speeds required when, for example, inching vehicles into position.
The wide range of ratios available with the wheel drive units makes it easy for designers of mobile plant to adapt the reduction unit to the most suitable hydraulic transmission.
In addition, further flexibility is provided by the ability of the wheel drives to accommodate the mounting of all types of orbit, geared and axial piston type hydraulic motors into their universal input.
Also included in the comprehensive design specification is a mechanical disconnect device.
This is manually operated from the hub end-plate and enables a vehicle to be towed in an emergency.
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.
Planetary Gear"...
We see from your search that you're looking for information on the term "Planetary Gear", and we have a large number of manufacturers' news releases and technical articles here on Manufacturingtalk which will be of interest. Let me be your guide.
Start with the news release Harmonic Drive gear systems used extensively from Harmonic Drive UK, which we summarised at the time by saying "Gears and gear mechanisms are probably one of the oldest mechanical technologies known to mankind.". Earlier in the week, we featured the news release Al extrusions automatically deburred economically from RSA Entgrat- u. Trenn-Systeme: "A deburring system with different automation levels uses a tool like a surface wire brush and is driven by a planetary gear reduces deburring to round 3s per end face.".
In September 2006, we covered the news from Neuhaus concerning its Compact winch, puller - take a look at Compact unit added to winch range which says: "With a compact design and all-up weight of approximately 30kg, this unit provides a pulling capacity of 530kgf on the fifth rope layer, with a full 800kgf on the first layer.".
Take a look also at the news release from Delta Line Europe UK, Standard drive motors offered within one week, as well as Torque and force sensors used in drives from Alpha Calibration Services, and Gear oils for specialised applications from Kluber Lubrication GB.
Start with the news release Harmonic Drive gear systems used extensively from Harmonic Drive UK, which we summarised at the time by saying "Gears and gear mechanisms are probably one of the oldest mechanical technologies known to mankind.". Earlier in the week, we featured the news release Al extrusions automatically deburred economically from RSA Entgrat- u. Trenn-Systeme: "A deburring system with different automation levels uses a tool like a surface wire brush and is driven by a planetary gear reduces deburring to round 3s per end face.".
In September 2006, we covered the news from Neuhaus concerning its Compact winch, puller - take a look at Compact unit added to winch range which says: "With a compact design and all-up weight of approximately 30kg, this unit provides a pulling capacity of 530kgf on the fifth rope layer, with a full 800kgf on the first layer.".
Take a look also at the news release from Delta Line Europe UK, Standard drive motors offered within one week, as well as Torque and force sensors used in drives from Alpha Calibration Services, and Gear oils for specialised applications from Kluber Lubrication GB.
3D images aid gearbox evaluation
Ondrives of Chesterfield started using AutoCAD LT in 1997 and has steadily progressed over the past few years enabling it to accurately produce 2D scale drawings in dwg and dxf formats. These early successes ensured the company upgraded to the latest released CAD when it became available. Ondrives now has a 3D solution in the shape of Solidworks Plus which enables its engineers to draw 3D images and assemblies of the company's gearboxes helping to produce photorealistic images and 2/3D drawings for customer evaluation.
Images can be imported and exported in all major formats, including dwg, dxf, bmp, jpg and many others.
An additional feature is that images can be published in either html or e-drawing formats.
E-drawings can then be e-mailed and contain embedded software within the file which allows the customer to view and print the subject.
In addition to viewing a 2D image, the customer will also be able to view a 3D colour image which can be seen in animation sequence and can be stopped and fully rotated in any direction by the user.
The html version offers similar functionality but at a reduced file size.
This is because it uses viewer software which is available at no cost and may be downloaded from the Solidworks website.
Request free introductory details about products from Ondrives/Rino Industries....
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Images can be imported and exported in all major formats, including dwg, dxf, bmp, jpg and many others.
An additional feature is that images can be published in either html or e-drawing formats.
E-drawings can then be e-mailed and contain embedded software within the file which allows the customer to view and print the subject.
In addition to viewing a 2D image, the customer will also be able to view a 3D colour image which can be seen in animation sequence and can be stopped and fully rotated in any direction by the user.
The html version offers similar functionality but at a reduced file size.
This is because it uses viewer software which is available at no cost and may be downloaded from the Solidworks website.
Request free introductory details about products from Ondrives/Rino Industries....
• Ondrives/Rino Industries: contact details and other news
• Other news in Gears, brakes, couplings and engines
• Email this news to a colleague
• Send us a blank email now to get the Editor’s free regular email newsletter
• RSS news feed for Ondrives/Rino Industries
• RSS news feed for Gears, brakes, couplings and engines
Programme responds to power industry demands
The need for a massive increase in power generation to meet the demands of South Africa's growing economy is also driving an advanced customer service programme by David Brown Engineering to deliver improvements in gear technology for power stations. David Brown is playing an important part in the upgrading of existing power stations to boost efficiency and ensure plant availability, and bringing back into service smaller power stations mothballed during the 1990s. The timetable of improvement and recommissioning is a demanding one necessary to keep pace with the country's power needs, and David Brown, part of Textron Fluid and Power, has developed a special rapid response customer service package to deliver a rolling programme of plant inspection, refurbishment and improvement.
The David Brown rapid response package has been designed through a six sigma 'green belt' project to integrate with the challenging timetable and uses priority work scheduling and Kanban agile manufacturing and supply protocol to ensure component parts are available and heavy duty gearboxes used on coal crushers are refurbished and delivered back to the client on time.
The project has initially involved power stations at Duvha and Kriel; each has four boilers and each boiler is served by up to seven massive Babcock E-mill crusher units which pulverise the coal to ensure rapid combustion.
The crushers are served by 25 tonne horizontal bevel helical gear units with vertical outputs, many of which were originally designed and manufactured by David Brown South Africa.
Some of these units have operated for up to 160,000 hours life, and to ensure continued reliability and performance David Brown personnel are stripping down the original units and, depending on the size of the mill, replacing the thrust bearings and reinforcing the ductile iron casings with an extra thrust plate to handle the massive loading of the bearings.
Another power station at Grootvlei that was mothballed more than 12 years ago is now being brought back into service and David Brown is inspecting and where necessary refurbishing the gearboxes.
Heavy-duty screw jacks lift performance
Austria's annual Bregenz Festival on the eastern shore of Lake Constance is world renowned for its spectacular opera productions and is held in two lakeside theatres. Whereas the indoor theatre is home to more traditional performances, the floating stage on the lake - the Seebuhne - is known for its imaginative sets that require a high level of technical support. As all scene changes at this al fresco theatre are undertaken in full view of the audience there is little room for error.
Therefore when specifying mechanical lifting systems to effect set movement theatre engineers had to be especially careful in their selection.
It was vital that the chosen system should provide smooth, speedy, reliable and above all safe positioning of the high loads involved.
Furthermore it had to deliver a consistent performance in all weathers and require little or no maintenance.
Zimm lifting systems, available in the UK from HepcoMotion, have been used by the festival theatre complex since its inception in 1997.
Four Zimm 250kN screw jacks were initially specified to raise and lower the scenery platform a distance of 1790mm typically with a static load of 27t and a dynamic load of 17t.
The equipment is driven by a 22kW three-phase motor, the output of which is transmitted via connecting shafts to the four screw jacks equipped with bevel gears.
These heavy-duty screw jacks are supplied as standard with a safety nut with a sensor that detects wear in the thread in excess of 20% of the screw pitch.
It also has a rotation sensor that responds to the failure of any of the transmission components.
In the event of a problem the load is therefore brought safely to a standstill.
The success of this application led to four further Zimm screw jacks being ordered - size 50kN - for the connecting passageway between the floating stage and the festival theatre.
A lifting distance of 3450mm was required for this platform and the system had to withstand 12t of static load and 8t of dynamic load.
In view of the length of travel involved Zimm engineers suggested the load on the gearbox spindles should be applied under tension not pressure.
This allowed the dimensions of the lifting systems to be considerable smaller.
As a result the mechanism not only cost less to buy but also to install.
The proven performance and reliability of the permanently installed Zimm systems have led to them several units being kept for specific production tasks.
These 'extras' were used extensively in the highly acclaimed stage settings for La Boheme in the 2001-02 season.
Last year, in West Side Story, they were also responsible for lifting a stage flat weighing 22t along a 50m bridge against a substantial wind force that can occur at any time across the lake.
The current production, Verdi's Il Trovatore, has also benefited from this technology.
Zimm screw jacks are available in a range of capacities from 500N to 500kN complete with gearboxes, motors and connecting shafts
Therefore when specifying mechanical lifting systems to effect set movement theatre engineers had to be especially careful in their selection.
It was vital that the chosen system should provide smooth, speedy, reliable and above all safe positioning of the high loads involved.
Furthermore it had to deliver a consistent performance in all weathers and require little or no maintenance.
Zimm lifting systems, available in the UK from HepcoMotion, have been used by the festival theatre complex since its inception in 1997.
Four Zimm 250kN screw jacks were initially specified to raise and lower the scenery platform a distance of 1790mm typically with a static load of 27t and a dynamic load of 17t.
The equipment is driven by a 22kW three-phase motor, the output of which is transmitted via connecting shafts to the four screw jacks equipped with bevel gears.
These heavy-duty screw jacks are supplied as standard with a safety nut with a sensor that detects wear in the thread in excess of 20% of the screw pitch.
It also has a rotation sensor that responds to the failure of any of the transmission components.
In the event of a problem the load is therefore brought safely to a standstill.
The success of this application led to four further Zimm screw jacks being ordered - size 50kN - for the connecting passageway between the floating stage and the festival theatre.
A lifting distance of 3450mm was required for this platform and the system had to withstand 12t of static load and 8t of dynamic load.
In view of the length of travel involved Zimm engineers suggested the load on the gearbox spindles should be applied under tension not pressure.
This allowed the dimensions of the lifting systems to be considerable smaller.
As a result the mechanism not only cost less to buy but also to install.
The proven performance and reliability of the permanently installed Zimm systems have led to them several units being kept for specific production tasks.
These 'extras' were used extensively in the highly acclaimed stage settings for La Boheme in the 2001-02 season.
Last year, in West Side Story, they were also responsible for lifting a stage flat weighing 22t along a 50m bridge against a substantial wind force that can occur at any time across the lake.
The current production, Verdi's Il Trovatore, has also benefited from this technology.
Zimm screw jacks are available in a range of capacities from 500N to 500kN complete with gearboxes, motors and connecting shafts
High torque/high speed gearboxes save energy costs
Neeter Drives 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: 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.
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.
The overall torque range is from 25Nm to 5200Nm with input speeds up to 6500 rev/min.
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.
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.
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.
The overall torque range is from 25Nm to 5200Nm with input speeds up to 6500 rev/min.
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.
Ram-type borer cuts machining lead-times
The GBP 1.4 million investment by RWE Power International, TSG Ferrybridge in what is probably the largest and most sophisticated ram-type horizontal boring and milling machine in Europe, a 16m X-axis capacity Union PCR 150 ram-type machine with live spindle and head changing supplied by Ward CNC of Sheffield, is generating equally massive benefits at the West Yorkshire, UK, site - in one case, the one-hit machining from solid of a large gearbox coupling, the machine has slashed lead times from seven weeks down to an amazing seven days. 'Indeed, compared to the two ageing machines it replaces, the new Union is completing in a single shift what used to take a week on the two older Union borers it has replaced,' says process co-ordinator Craig Bill, who adds that the machine has provided the company with an unprecedented level of milling and boring capability and flexibility, with which any other UK company, at least, cannot compete. With complementary Y and Z axes traverses of 4000mm and 1000mm, respectively, plus a 700mm W-axis (spindle) stroke, coupled with twin 40- and 24-tool toolchangers and axis feed rates and rapids of 5-15000mm/min and 15m/min, respectively, the machine can accommodate workpiece loadings of 70,000kg on a traversing and rotating CNC table, so clearly has the capacity to satisfy every machining situation likely to come its way.
But Bill also emphasises the machine's ability to quickly and easily utilise and change between different machining modes as the factor that, he says, 'Effectively transforms what is on paper a six-axis milling and boring machine into an unrivalled and highly productive 11-axis machining centre.' Also supplied with the machine by Ward CNC is the automatic accessory changer that comprises: * A linear motor Cytec gyroscopic two-axis milling head with built-in high-speed electro spindle and served by its own dedicated toolchanger.
* A D'Andrea UT5 800S CNC facing and profiling head with 1000mm facing capacity.
The machine specification is further enhanced with the integration of the 70 tonnes loading capacity Eimeldingen heavy-duty rotary and traversing CNC table, extensive floor plates and zoned guarding allowing the machine to be efficiently set up for pendulum or three-zone machining.
Bill emphasises that such has been the impact of the machine specification and the flexibility offered by the accessory changer system, combined with the inherent power and productivity of the Union machine that, as a result, 'We are able to finish machine component features in a single set-up that would have been very difficult, perhaps even impossible, to achieve any other way.' One example of this concerns the production of a hydro power industry 3200mm by 3400mm by 3000mm main inlet valve (weighing 73 tonnes in finished state) and its accompanying 2500mm diameter by 350mm thick main service seal (reverse engineered and machined from stainless steel).
A number of holes are drilled, tapped, counterbored and thread milled in the bore 'outwards'.
'Without the flexibility of using a variety of heads, we would find it very, very hard to produce these features,' Bill confirms.
'When we decided to replace the two old boring machines, we looked at other boring and milling machines and their suppliers,' continues Bill, 'But the Union PCR and Ward CNC won the contract based on a combination of machine capability, capacity and price as well as on Ward CNC's ability to provide the level of support we needed.' Of heavily ribbed design with three-way, backlash-free, heavy-duty compact roller guide system for highly-accurate guidance of the crossslide, the sturdy machine bed is complemented by a similarly constructed box-type column.
The column saddle also features compact roller guides as well as ballscrew drive for transverse movement.
The vertically travelling headstock with axially traversing ram (Z-axis) accommodates the high-precision main spindle system featuring preloaded spindle bearings with lifetime lubrication.
Speed range changes are catered for by a two-step gearbox having hardened and ground helical gears, and a hydrostatic guiding system of the ram with drop compensation in relation to longitudinal displacement, together with an additional mechanical compensation system, ensures high and accurate cutting data.
For example: * X, Y, Z and W axes positioning of +/-0.005mm (up to 800 mm), +/-0.008mm (to 5000mm) and +/-0.012mm (to 10000mm).
* Repeatability of +/-0.003mm.
The Union was installed as part of the RWE npower company's GBP 3.5 million CNC machine tool investment programme last year as the platform for the company's strategic move into the wider arena of sub-contract machining, based around a quick-response machining service for customers in industries such as oil and gas and automotive.
These sectors have been identified by Bill and the TSG Ferrybridge team as ideal to complement and build on the company's core (and established) skills applied since 1974 in the refurbishment of power station equipment, including rotors, valves, pumps and gearboxes and, in particular, turbines and turbine blades.
RWE Power International, TSG Ferrybridge was established as one of three sites to perform such work for power stations within the RWE group, as well as third party sites (basically, the company has worked on equipment at every coal, gas and hydro/wind power station in the UK).
'We were spending a lot of money on turbine blades,' continues Bill, 'And basically reckoned we could save a lot of cash, and produce the blades quicker, if we did it ourselves.' In some cases a single, large turbine blade could cost GBP 36,000.
That is not surprising when it is realised that the leading blade on a large 5m diameter rotor, revolving at 3,500 rev/min, is actually moving at twice the speed of sound - so the blade has to be right.
Since then, the operation has progressed to a GBP 52 million turnover concern, and involves up to 350 people.
Aside from its high-tech turbine blade high-speed machining production facilities - including the development of a innovative and patented 'blade cropping' process - the company has an impressive range of machine tools throughout its three large workshops alongside the Ferrybridge C power station in West Yorkshire.
In conjunction with a general fitting and assembly area - housing press, welding, heat treatment, grit blasting, NDT, grit blasting and 120-tonne gas turbine rotor de-stacking - the light and heavy machine shops accommodate a wide array of CNC machines.
These extend from milling, turning and machining centre capacity through to 25 tonnes vertical borers and large capacity lathes, including a Safop 100 tonnes capacity machine able to handle 17m between centres.
In addition, the company also offers an on-site machining service, which utilises a battery of 'mobile machine tools' to enable customers' fixed plant and equipment to be re-machined, refurbished, repaired or modified in situ.
While the large capacity Safop is currently being targeted to 'partner' the Union PCR to further extend the machines' capabilities by linking the two via existing Unigraphics/Vericut CAD/CAM facility, Craig Bill and the team have other plans for Union, to further reduce lead times and so magnify the enormous savings already being made.
But Bill also emphasises the machine's ability to quickly and easily utilise and change between different machining modes as the factor that, he says, 'Effectively transforms what is on paper a six-axis milling and boring machine into an unrivalled and highly productive 11-axis machining centre.' Also supplied with the machine by Ward CNC is the automatic accessory changer that comprises: * A linear motor Cytec gyroscopic two-axis milling head with built-in high-speed electro spindle and served by its own dedicated toolchanger.
* A D'Andrea UT5 800S CNC facing and profiling head with 1000mm facing capacity.
The machine specification is further enhanced with the integration of the 70 tonnes loading capacity Eimeldingen heavy-duty rotary and traversing CNC table, extensive floor plates and zoned guarding allowing the machine to be efficiently set up for pendulum or three-zone machining.
Bill emphasises that such has been the impact of the machine specification and the flexibility offered by the accessory changer system, combined with the inherent power and productivity of the Union machine that, as a result, 'We are able to finish machine component features in a single set-up that would have been very difficult, perhaps even impossible, to achieve any other way.' One example of this concerns the production of a hydro power industry 3200mm by 3400mm by 3000mm main inlet valve (weighing 73 tonnes in finished state) and its accompanying 2500mm diameter by 350mm thick main service seal (reverse engineered and machined from stainless steel).
A number of holes are drilled, tapped, counterbored and thread milled in the bore 'outwards'.
'Without the flexibility of using a variety of heads, we would find it very, very hard to produce these features,' Bill confirms.
'When we decided to replace the two old boring machines, we looked at other boring and milling machines and their suppliers,' continues Bill, 'But the Union PCR and Ward CNC won the contract based on a combination of machine capability, capacity and price as well as on Ward CNC's ability to provide the level of support we needed.' Of heavily ribbed design with three-way, backlash-free, heavy-duty compact roller guide system for highly-accurate guidance of the crossslide, the sturdy machine bed is complemented by a similarly constructed box-type column.
The column saddle also features compact roller guides as well as ballscrew drive for transverse movement.
The vertically travelling headstock with axially traversing ram (Z-axis) accommodates the high-precision main spindle system featuring preloaded spindle bearings with lifetime lubrication.
Speed range changes are catered for by a two-step gearbox having hardened and ground helical gears, and a hydrostatic guiding system of the ram with drop compensation in relation to longitudinal displacement, together with an additional mechanical compensation system, ensures high and accurate cutting data.
For example: * X, Y, Z and W axes positioning of +/-0.005mm (up to 800 mm), +/-0.008mm (to 5000mm) and +/-0.012mm (to 10000mm).
* Repeatability of +/-0.003mm.
The Union was installed as part of the RWE npower company's GBP 3.5 million CNC machine tool investment programme last year as the platform for the company's strategic move into the wider arena of sub-contract machining, based around a quick-response machining service for customers in industries such as oil and gas and automotive.
These sectors have been identified by Bill and the TSG Ferrybridge team as ideal to complement and build on the company's core (and established) skills applied since 1974 in the refurbishment of power station equipment, including rotors, valves, pumps and gearboxes and, in particular, turbines and turbine blades.
RWE Power International, TSG Ferrybridge was established as one of three sites to perform such work for power stations within the RWE group, as well as third party sites (basically, the company has worked on equipment at every coal, gas and hydro/wind power station in the UK).
'We were spending a lot of money on turbine blades,' continues Bill, 'And basically reckoned we could save a lot of cash, and produce the blades quicker, if we did it ourselves.' In some cases a single, large turbine blade could cost GBP 36,000.
That is not surprising when it is realised that the leading blade on a large 5m diameter rotor, revolving at 3,500 rev/min, is actually moving at twice the speed of sound - so the blade has to be right.
Since then, the operation has progressed to a GBP 52 million turnover concern, and involves up to 350 people.
Aside from its high-tech turbine blade high-speed machining production facilities - including the development of a innovative and patented 'blade cropping' process - the company has an impressive range of machine tools throughout its three large workshops alongside the Ferrybridge C power station in West Yorkshire.
In conjunction with a general fitting and assembly area - housing press, welding, heat treatment, grit blasting, NDT, grit blasting and 120-tonne gas turbine rotor de-stacking - the light and heavy machine shops accommodate a wide array of CNC machines.
These extend from milling, turning and machining centre capacity through to 25 tonnes vertical borers and large capacity lathes, including a Safop 100 tonnes capacity machine able to handle 17m between centres.
In addition, the company also offers an on-site machining service, which utilises a battery of 'mobile machine tools' to enable customers' fixed plant and equipment to be re-machined, refurbished, repaired or modified in situ.
While the large capacity Safop is currently being targeted to 'partner' the Union PCR to further extend the machines' capabilities by linking the two via existing Unigraphics/Vericut CAD/CAM facility, Craig Bill and the team have other plans for Union, to further reduce lead times and so magnify the enormous savings already being made.
Small helical gearbox extends manufacturer's range
Nord Gear has unveiled a new, small, 2-stage helical gearbox that is an inexpensive extension, at the low power end, of the existing Nord range of helical gearboxes and gearmotors. Housed in a cast aluminium case of Nord's own Unicase design, the unit is robust but lightweight. Designed to be universally applied, the Unicase design is provided with B14 flanges on both sides of the output end and with machined foot surfaces at three sides.
The gear range is 3.9 to 55, delivering a maximum output torque of 90Nm.
The helical bevel boxes aid energy saving through their higher efficiency, especially when coupled with Nord's new EFF1 motors.
The helical bevel design also reduces wear when compared with less efficient and more commonly used helical worm geared motors.
Nord's helical bevel gearboxes and high efficiency gearmotors are available from the company's new 25,000 ft2 manufacturing facility in Abingdon, Oxfordshire.
The gear range is 3.9 to 55, delivering a maximum output torque of 90Nm.
The helical bevel boxes aid energy saving through their higher efficiency, especially when coupled with Nord's new EFF1 motors.
The helical bevel design also reduces wear when compared with less efficient and more commonly used helical worm geared motors.
Nord's helical bevel gearboxes and high efficiency gearmotors are available from the company's new 25,000 ft2 manufacturing facility in Abingdon, Oxfordshire.
Ultrasonic detectors find leaks and faults
Compressed air is widely used and an effective propellant for many types of machines used in various locations within many industries. Indeed, almost 90% of industries use compressed air in some aspect of their daily use/production. One similarity discovered is that throughout all industry wasted energy in compressed air is quite common.
However compressed air (and other gases) are at the same time a very large cost to the company's budget each year.
It is therefore sensible to continuously inspect the company's air, vacuum or gas installations on a frequent basis.
Portable fault locating detectors are ideally suited, especially in noisy environments, to be used in energy conservation, predictive maintenance and proactive maintenance programmes for leak detection and mechanical inspection.
Logis-Tech Associates has recently introduced to the UK a range of ultrasonic devices for listening to leaks in compressed air and vacuum installations, leaks in tanks etc, and to listen to mechanical noise from for example in ball bearings or other movable parts.
A leakage test may prevent more serious and costly problems from occurring or even show that the installation of a newer larger compressor is unnecessary.
The Logis-Tech EP equipment consists of a very sensitive listening detector where a headphone or an authorised hearing protector with loudspeaker can be connected.
The system works by "listening" at a frequency band that normally is inaudible to humans - from 20kHz and upwards (ultrasound).
Audible noises from the surroundings are filtered off so that the device can be ideally used in a noisy environment.
The Logis-Tech EP equipment can also be used with an ultrasonic transmitter that transmits pulsating ultrasound.
The transmitter is placed inside the item to be examined, which is then closed.
The user can then examine the item from the outside and can easily detect, any leaks.
Air leakage can be defined as consumed air that contributes nothing to production.
In a well-managed system, wasteful air leaks should not exceed 5-10% of net production consumption.
This acceptable leakage still costs the company per year.
Although most engineering and maintenance personnel are aware their operations have air leaks; the biggest problem is they are unable to quantify those air leaks in order to make rational corrective decisions.
This is where a quality compressed air leak-detecting device comes into play.
Since air leaks are a reoccurring problem, it is imperative that plant personnel initiate a regular preventive maintenance programme allowing the detection of these wasteful air leaks.
Ultrasonic sensors detect the disturbance caused by turbulent flow, which is produced by a leak, and because they are sound sensitive, they can be applied to all types of fluid systems.
Detecting air or gas leaks in pressurised tanks, vacuums, boilers, tubing, pipe fittings, flanges, seals and gaskets are all possible.
Specific typical industrial systems include: condensers, furnaces, heat exchangers etc.
The advantage of using these sensors is that they are able to sense a leak in real-time.
During a scan, a user will hear the sound of the leak increase as the sensor passes by the place where it is located.
In the contact, or waveguide mode, leaks in steam traps and valves are also sensed.
Using permanently mounted sensors, valves can be monitored for both the onset of flow, such as in safety relief valves or for flow disruption.
A machine or another propellant loses its effectiveness if or when mechanical malfunctions occur.
Often these mean reduced production or at the worst an unintended and expensive production stop.
It is therefore important to be able to quickly locate the mechanical malfunction or in some cases to make a systematic monitoring of essential machine parts to always be able to make a controlled production stop with all the economical advantages this entails.
Also, in this case, the Logis-Tech EP equipment consists of a detector with a headphone or hearing protector where an electronic internal/external sensor (stethoscope sensor or clip) can be connected.
The sensor is used for listening to mechanical noise and only picks up mechanical low frequency vibrations so the stethoscope can also be used in noisy areas.
Within all mechanical operations bearings, pumps, motors, gears, gearboxes and compressors, produce some form of "typical" sound patterns, and a change in these patterns can be detected and analysed.
NASA in the USA paved the way for ultrasonic bearing inspection by demonstrating that ultrasonic monitoring provided the earliest warning of bearing failure.
In addition, conditions such as rubbing and lack of lubrication can also be detected.
The advantage of ultrasonic inspection is the short-wave nature of the signal allows inspectors to easily inspect specific components in operating equipment
However compressed air (and other gases) are at the same time a very large cost to the company's budget each year.
It is therefore sensible to continuously inspect the company's air, vacuum or gas installations on a frequent basis.
Portable fault locating detectors are ideally suited, especially in noisy environments, to be used in energy conservation, predictive maintenance and proactive maintenance programmes for leak detection and mechanical inspection.
Logis-Tech Associates has recently introduced to the UK a range of ultrasonic devices for listening to leaks in compressed air and vacuum installations, leaks in tanks etc, and to listen to mechanical noise from for example in ball bearings or other movable parts.
A leakage test may prevent more serious and costly problems from occurring or even show that the installation of a newer larger compressor is unnecessary.
The Logis-Tech EP equipment consists of a very sensitive listening detector where a headphone or an authorised hearing protector with loudspeaker can be connected.
The system works by "listening" at a frequency band that normally is inaudible to humans - from 20kHz and upwards (ultrasound).
Audible noises from the surroundings are filtered off so that the device can be ideally used in a noisy environment.
The Logis-Tech EP equipment can also be used with an ultrasonic transmitter that transmits pulsating ultrasound.
The transmitter is placed inside the item to be examined, which is then closed.
The user can then examine the item from the outside and can easily detect, any leaks.
Air leakage can be defined as consumed air that contributes nothing to production.
In a well-managed system, wasteful air leaks should not exceed 5-10% of net production consumption.
This acceptable leakage still costs the company per year.
Although most engineering and maintenance personnel are aware their operations have air leaks; the biggest problem is they are unable to quantify those air leaks in order to make rational corrective decisions.
This is where a quality compressed air leak-detecting device comes into play.
Since air leaks are a reoccurring problem, it is imperative that plant personnel initiate a regular preventive maintenance programme allowing the detection of these wasteful air leaks.
Ultrasonic sensors detect the disturbance caused by turbulent flow, which is produced by a leak, and because they are sound sensitive, they can be applied to all types of fluid systems.
Detecting air or gas leaks in pressurised tanks, vacuums, boilers, tubing, pipe fittings, flanges, seals and gaskets are all possible.
Specific typical industrial systems include: condensers, furnaces, heat exchangers etc.
The advantage of using these sensors is that they are able to sense a leak in real-time.
During a scan, a user will hear the sound of the leak increase as the sensor passes by the place where it is located.
In the contact, or waveguide mode, leaks in steam traps and valves are also sensed.
Using permanently mounted sensors, valves can be monitored for both the onset of flow, such as in safety relief valves or for flow disruption.
A machine or another propellant loses its effectiveness if or when mechanical malfunctions occur.
Often these mean reduced production or at the worst an unintended and expensive production stop.
It is therefore important to be able to quickly locate the mechanical malfunction or in some cases to make a systematic monitoring of essential machine parts to always be able to make a controlled production stop with all the economical advantages this entails.
Also, in this case, the Logis-Tech EP equipment consists of a detector with a headphone or hearing protector where an electronic internal/external sensor (stethoscope sensor or clip) can be connected.
The sensor is used for listening to mechanical noise and only picks up mechanical low frequency vibrations so the stethoscope can also be used in noisy areas.
Within all mechanical operations bearings, pumps, motors, gears, gearboxes and compressors, produce some form of "typical" sound patterns, and a change in these patterns can be detected and analysed.
NASA in the USA paved the way for ultrasonic bearing inspection by demonstrating that ultrasonic monitoring provided the earliest warning of bearing failure.
In addition, conditions such as rubbing and lack of lubrication can also be detected.
The advantage of ultrasonic inspection is the short-wave nature of the signal allows inspectors to easily inspect specific components in operating equipment
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