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.
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.
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 gearboxes. Request a free brochure from Ondrives/Rino Industries....
The new ranges added include hardened plain and flanged jig bushes, manual leadscrew actuators, miniature grooved steel thrust bearings and low-backlash inline taper gearboxes. Request a free brochure from Ondrives/Rino Industries....
High precision gears can be made to order
Holroyd is harnessing the DIN 2 capabilities of its new 'smart' GTG2 gear grinder to provide a bespoke service for high precision helical/spur gears in diameters up to 350mm and 160mm gear face width. The new service meets the market need for ever increasing accuracy of small volume, high precision gears in aerospace and high performance automotive applications, industrial optics and custom designed industrial products. 'The helical service is a complement to our existing and well proven high precision wormgear business', says Paul Hannah, Holroyd Sales Director.
'Using the newly introduced GTG2 machine, we can grind even small batches of helical/spur gears to DIN 2 levels of quality with some features achieving DIN 1'.
'This sort of performance means that our service is ideal for providing items such as master gears for prototyping, timing gears for use in aerospace applications and helical gears for use in high performance automotive gearboxes and oil pumps'.
'What differentiates our service in a competitive market is that we provide a package of design advice and manufacturing which not only ensures the highest levels of precision, but also optimises gear performance'.
One of the major problems in helical gear manufacture is predicting actual stresses.
This is important because the more pressure on the gear teeth, the more risk there is of pitting (macro or micro) and eventual gear failure.
Says Hannah: 'We address this problem with unique stress prediction software, which was developed by Holroyd engineers, and enables us to optimise gear design, with profile and lead modifications to achieve the optimum contact conditions for low noise and high strength'.
'The software, however, is only one part of the package'.
'Crucially, we must be able to replicate the profile derived from software on a gear grinding machine'.
'On conventional machines this can be difficult, but the GTG2 is designed with just this capability'.
'It's onboard scanning probe and dresser compensation enables us to replicate, faithfully, any lead and profile modification from our prediction software to minimise contact stress and pitting'.
In addition to profile modification, users of Holroyd's new gear service also benefit from the additional features of the GTG2 machine, which uses form grinding rather than the generation method.
Besides higher productivity from single wheels, form grinding offers improved flexibility for flank and root profiles, and produces a better (quieter) surface texture, with reduced risk of thermal damage.
The machine also has a unique method of compensating for 'helical twist', an unwelcome condition that occurs when helical gears are 'lead crowned' to reduce transmission errors which often occur when the gears experience misalignments or deflections under load.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
Besides giving the desirable 'relief' to the helix, this gives an undesirable 'lean' to the profile where the crowning is greatest.
In many applications.
this deviation is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is possible with the GTG2.
It is achieved by calculating additional motions of the grinding wheel and controlling them during the grinding operation using Holroyd's unique software.
This modifies the angle of inclination of the grinding wheel during the grinding operation, either alone or in combination with other axis deviations.
The result is better tooth contact during meshing, giving improvements in load bearing and transmission accuracy, ie smoother, more durable gears.
Developed in collaboration with the respected Gear Design Unit at Newcastle University, Holroyd's machine is the first CNC gear grinder to be designed, produced and marketed in the UK, and is believed to be the only gear grinding system available which uses a continuously variable wheel angle in this way.
Patents are pending, and the machine is now available for sale.
Summing-up the benefits of the new service, Paul Hannah stressed Holroyd's unrivalled experience in designing and manufacturing grinding machines for the global market - the same machines that Holroyd uses for its own bespoke gear production.
'Holroyd is unique, in that we not only manufacture bespoke worm and helical gears and rotors, but also make the machine tools, which produce these components'.
'This complementary operating strategy means that we are, in essence, always our own customer, a situation that provides an ongoing database of manufacturing experience, benefiting users of Holroyd products worldwide'. Request a free brochure from Holroyd....
'Using the newly introduced GTG2 machine, we can grind even small batches of helical/spur gears to DIN 2 levels of quality with some features achieving DIN 1'.
'This sort of performance means that our service is ideal for providing items such as master gears for prototyping, timing gears for use in aerospace applications and helical gears for use in high performance automotive gearboxes and oil pumps'.
'What differentiates our service in a competitive market is that we provide a package of design advice and manufacturing which not only ensures the highest levels of precision, but also optimises gear performance'.
One of the major problems in helical gear manufacture is predicting actual stresses.
This is important because the more pressure on the gear teeth, the more risk there is of pitting (macro or micro) and eventual gear failure.
Says Hannah: 'We address this problem with unique stress prediction software, which was developed by Holroyd engineers, and enables us to optimise gear design, with profile and lead modifications to achieve the optimum contact conditions for low noise and high strength'.
'The software, however, is only one part of the package'.
'Crucially, we must be able to replicate the profile derived from software on a gear grinding machine'.
'On conventional machines this can be difficult, but the GTG2 is designed with just this capability'.
'It's onboard scanning probe and dresser compensation enables us to replicate, faithfully, any lead and profile modification from our prediction software to minimise contact stress and pitting'.
In addition to profile modification, users of Holroyd's new gear service also benefit from the additional features of the GTG2 machine, which uses form grinding rather than the generation method.
Besides higher productivity from single wheels, form grinding offers improved flexibility for flank and root profiles, and produces a better (quieter) surface texture, with reduced risk of thermal damage.
The machine also has a unique method of compensating for 'helical twist', an unwelcome condition that occurs when helical gears are 'lead crowned' to reduce transmission errors which often occur when the gears experience misalignments or deflections under load.
Lead crowning varies the amount of material removed from the flank of a tooth across the face width, by causing the tool motion to deviate from a true helix.
Besides giving the desirable 'relief' to the helix, this gives an undesirable 'lean' to the profile where the crowning is greatest.
In many applications.
this deviation is not of concern, but in high precision and low noise applications it affects gear wheel performance by concentrating loads on particular areas of the teeth during meshing.
Correction of this problem is possible with the GTG2.
It is achieved by calculating additional motions of the grinding wheel and controlling them during the grinding operation using Holroyd's unique software.
This modifies the angle of inclination of the grinding wheel during the grinding operation, either alone or in combination with other axis deviations.
The result is better tooth contact during meshing, giving improvements in load bearing and transmission accuracy, ie smoother, more durable gears.
Developed in collaboration with the respected Gear Design Unit at Newcastle University, Holroyd's machine is the first CNC gear grinder to be designed, produced and marketed in the UK, and is believed to be the only gear grinding system available which uses a continuously variable wheel angle in this way.
Patents are pending, and the machine is now available for sale.
Summing-up the benefits of the new service, Paul Hannah stressed Holroyd's unrivalled experience in designing and manufacturing grinding machines for the global market - the same machines that Holroyd uses for its own bespoke gear production.
'Holroyd is unique, in that we not only manufacture bespoke worm and helical gears and rotors, but also make the machine tools, which produce these components'.
'This complementary operating strategy means that we are, in essence, always our own customer, a situation that provides an ongoing database of manufacturing experience, benefiting users of Holroyd products worldwide'. Request a free brochure from Holroyd....
Powerpack lands Russian river approval
Amp Complect, Newage Transmissions' marine equipment distributor in Moscow, has gained Russian River Authority approval for a fully marinised powerpack to meet the needs of commercial fishing and workboats operating on the country's inland waterway and intercoastal network. Featuring an option of PRM 1000 or PRM 1500 gearboxes, the powerpack is rated at 134kW at 1750rev/min and is the only propulsion system powered by an indigenous engine that has been certified by the Russian waterways authority. Newage Transmissions' Marine Sales Manager Jamie Pratt said: 'More than 30,000 boats are registered with the authority, and each must be equipped with an approved powerpack'.
'The development by our distributor, Amp Complect, provides a reliable and highly cost-effective, approved propulsion system by harnessing the proven efficiency and durability of our gearboxes with the rugged performance of a domestic V8 engine'.
'The unit has already generated a high level of interest from Russian refit specialists and new boat builders alike'.
'This market offers massive potential for our marine products range and, with this in mind, we have already started work on the integration of a more powerful approved marine propulsion package, featuring our heavy-duty PRM 1500 and PRM 1750 gearboxes'.
The PRM 1500 carries type approval and, like other Newage marine gearboxes, uses the firm's dual countershaft design - enabling full power of up to 370kW to be transmitted continuously at 2500rev/min in both ahead or astern.
'The development by our distributor, Amp Complect, provides a reliable and highly cost-effective, approved propulsion system by harnessing the proven efficiency and durability of our gearboxes with the rugged performance of a domestic V8 engine'.
'The unit has already generated a high level of interest from Russian refit specialists and new boat builders alike'.
'This market offers massive potential for our marine products range and, with this in mind, we have already started work on the integration of a more powerful approved marine propulsion package, featuring our heavy-duty PRM 1500 and PRM 1750 gearboxes'.
The PRM 1500 carries type approval and, like other Newage marine gearboxes, uses the firm's dual countershaft design - enabling full power of up to 370kW to be transmitted continuously at 2500rev/min in both ahead or astern.
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 gearboxes. Request a free brochure 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
The new ranges added include hardened plain and flanged jig bushes, manual leadscrew actuators, miniature grooved steel thrust bearings and low-backlash inline taper gearboxes. Request a free brochure 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
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