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.
Modular geared motors promise cost savings
The new Hydromec range of helical geared motors from Lenze can deliver significant cost savings in light to medium duty applications such as conveyors, feeders, pumps, mixers and food processing machinery. Covering powers from 90W to 4.0kW, the Hydromec geared motors offer advantages from the aluminium casing design, plus lubrication for life and ATEX compliance. The aluminium alloy gear housings mean less machining and lower purchase costs.
As well as offering a cosmetic match to aluminium framed motors, the gearbox housings do not require painting, which means a small cost saving for many applications.
Problems with oil leakage are avoided through vacuum impregnation of the casings.
An additional advantage of the aluminium design is weight reduction.
The modularity of the Hydromec range with the options to bolt flanges and feet to the gear housing results in short delivery times for a wide range of models, and customers benefit from only paying for the parts they need.
Bolt on input flanges can be to IEC or NEMA specification, and together with shaft reducers permit two or three motor frame sizes to be fitted to a single gearbox housing.
Bolt on output flanges are available, but customers can opt for face mounting without flanges to further reduce costs.
The bolt on feet are available in configurations to match the dimensions of nine other geared motor ranges on the market, so making spares replacements an easy decision.
The Hydromec range covers motor powers from 90W to 4kW, mostly with four-pole motors, and typical output speeds are 23-250rev/min.
A full range of speeds from 11 to 1800rev/min is also possible.
Gearboxes are available in five sizes and with one-, two- or three-stage designs.
The ability to achieve a ratio of 61 in two-stage gearboxes will save money from some customers, and for larger ratios, the three stage version is compact and also cost attractive.
Output torques range from 30 to 460Nm.
Hydromec geared motors are well suited to inverter variable speed control.
The low cost and simple Lenze smd inverter is an ideal partner.
The variable speed range can be optimised by increasing the full speed setting up to 70Hz, representing about 2000rev/min.
This means a speed range of more than 3:1 and continuous rated duty can be achieved without the cost of adding a force ventilation blower.
Hydromech is sold and supported by Lenze group in Europe and a 2-year warranty is offered.
Gearboxes are lubricated for life with synthetic oil.
A further advantage is the possibility to achieve ATEX standards for a minimal surcharge.
As well as offering a cosmetic match to aluminium framed motors, the gearbox housings do not require painting, which means a small cost saving for many applications.
Problems with oil leakage are avoided through vacuum impregnation of the casings.
An additional advantage of the aluminium design is weight reduction.
The modularity of the Hydromec range with the options to bolt flanges and feet to the gear housing results in short delivery times for a wide range of models, and customers benefit from only paying for the parts they need.
Bolt on input flanges can be to IEC or NEMA specification, and together with shaft reducers permit two or three motor frame sizes to be fitted to a single gearbox housing.
Bolt on output flanges are available, but customers can opt for face mounting without flanges to further reduce costs.
The bolt on feet are available in configurations to match the dimensions of nine other geared motor ranges on the market, so making spares replacements an easy decision.
The Hydromec range covers motor powers from 90W to 4kW, mostly with four-pole motors, and typical output speeds are 23-250rev/min.
A full range of speeds from 11 to 1800rev/min is also possible.
Gearboxes are available in five sizes and with one-, two- or three-stage designs.
The ability to achieve a ratio of 61 in two-stage gearboxes will save money from some customers, and for larger ratios, the three stage version is compact and also cost attractive.
Output torques range from 30 to 460Nm.
Hydromec geared motors are well suited to inverter variable speed control.
The low cost and simple Lenze smd inverter is an ideal partner.
The variable speed range can be optimised by increasing the full speed setting up to 70Hz, representing about 2000rev/min.
This means a speed range of more than 3:1 and continuous rated duty can be achieved without the cost of adding a force ventilation blower.
Hydromech is sold and supported by Lenze group in Europe and a 2-year warranty is offered.
Gearboxes are lubricated for life with synthetic oil.
A further advantage is the possibility to achieve ATEX standards for a minimal surcharge.
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.
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.
Customised gearbox aids extraterrestrial search
The second stage of an upgrade project has seen Cone Drive working with Dangel Robots and Machinery to provide another specialist solution for the world famous WM Keck Observatory at the summit of Hawaii's Mauna Kea. Cone Drive had already been involved in a successful project to replace exterior mounted worm boxes in 2004 and this time returned with additional expertise provided by its sister company David Brown to upgrade the shutter motion of the world's largest optical and infra-red telescope. The latest stage of the project involved installation of new drives for the two massive shutters on the dome that encloses the Keck I telescope.
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea
Motorised gearbox has flexible configurations
Ondrives has launched a new DC motorised worm and wheel reduction gearbox into its 2005 product range. They are fitted with high end 24V DC motors which when operating at 12V DC ensure good torque and speed characteristics. They are available in ratios from 10:1 to 120:1 as standard with fitted motors.
Thanks to the quality of the motors, Ondrives is able to offer variations on this, including encoders and brakes fitted to these motors.
This allows Ondrives to offer gearboxes tailored to more specific applications, capable of moulding their products to specific needs.
The gearboxes and motors are also available to purchase as separate components, allowing total flexibility for customers' applications.
Ondrives can also design and supply the gearboxes to accept customers' motors.
Suitable applications include medical and pharmaceutical industries, scanning machines and general OEM work.
They are always available to purchase in small or large volume quantities
Thanks to the quality of the motors, Ondrives is able to offer variations on this, including encoders and brakes fitted to these motors.
This allows Ondrives to offer gearboxes tailored to more specific applications, capable of moulding their products to specific needs.
The gearboxes and motors are also available to purchase as separate components, allowing total flexibility for customers' applications.
Ondrives can also design and supply the gearboxes to accept customers' motors.
Suitable applications include medical and pharmaceutical industries, scanning machines and general OEM work.
They are always available to purchase in small or large volume quantities
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.
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.
Complementing this device is the additional option of an integral multiple-disc negative parking brake, which is spring applied and hydraulically released.
This functions as an emergency fail-to-safe brake should the hydraulic pressure fail and is an important safeguard for access vehicles, as they are sometimes manoeuvred with the platform fully raised.
Where the nature of the application is more heavy duty, wheel drives give way to track units.
These, in common with wheel drives, are rotary-case-type planetary units that use multiple gear stages to reduce size.
They are available with integrated hydraulic motors, which are either axial piston or orbital types, and can be fitted with options such as brakes and a disconnect device to aid towing.
Thanks to the inherent capacity of planetary gear trains to deliver high reduction ratios in small packages and to transmit several times the torque of similarly sized, conventional gear units, the integrated track drive package is remarkably compact and lightweight, and requires little installation space.
In addition, the planetary drive is around 98% efficient and, critically, is able to provide extremely low speeds without any loss of efficiency.
A recent application highlighting the operational benefits of planetary wheel drives is in beet harvesting.
Dennis Van Arkel, Sales Manager at Brevini Benelux explains: 'Beet harvesting is a tough, arduous and generally very dirty process; environmental conditions are rarely optimal, with harvesting machines having to work either in rain-sodden, muddy fields, or in extremely dry conditions where dust poses a constant problem to equipment'.
'Obviously, these conditions place a premium on the performance of power transmission equipment used in the operation of the harvesters'.
'Yet despite all the rigours, Brevini has established a supply partnership with manufacturers of beet harvesters, based on quality, reliability and after sales service, which goes back nearly two decades'.
Brevini supplies Agrifac/WKM and Vervaet, the market leaders in Holland, with wheel drives for use on their beet harvesters.
Both companies use the drives for several reasons.
First, because they are wheel mounted in a package with a hydraulic motor, they permit a much simpler design solution than axle drives, and provide improved clearance over rough ground.
Secondly, the absence of an axle means that manufacturers have the flexibility to fit ultrawide terra tyres to spread loading over a wider area.
Thirdly, with no standard axle to consider, the space under the harvester is free and can be used to transport beets from front to back of the equipment.
Forthly, the flexibility as regards brakes: the wheel drives can be supplied fully equipped with dynamic disc and parking brakes enabling the harvester manufacturer to conform easily to the specific laws in each country where the equipment is sold.
In another application of mobile planetary technology, Richard Larrington is making its giant dumper trucks lighter and more manoeuvrable using Brevini track drives.
The Brevini units enable the track-driven Predator vehicles to turn on the spot and transport 20t of peat across steep and unstable terrain at speeds in excess of 8km/h.
Thanks to an innovative design, the Predator can transport peat up and down 20-degree inclines and boggy terrain with loads in excess of 20t - more than four times that of conventional tractors.
The secret of the Predator's superior performance is two large rubberised tracks that spread the load over a large surface area and allow the vehicle to turn 360 degrees on the spot.
The tracks are driven by a pair of Brevini two-stage reduction drive systems, which provide the levels of torque control required to power and position the machine that can weigh in excess of 43t when fully loaded.
Jon Snaith, Sales Manager at Brevini UK explains: 'The steep and boggy terrain on which the vehicle was designed to operate, required the drive system to be track rather than wheel based as traditional tractors would often 'dig in', even when carrying less than a quarter of the load'.
'Also, in order to maximise the load carrying capacity of the Predator, the machine itself was designed to be as light as possible without compromising strength, making a two stage reduction wheel drive system a vast improvement over heavier axel based or larger direct drive systems'.
The drive units themselves consist of hydraulic motors integrated with Brevini planetary gearboxes, making them small enough to fit inside the Predator's tracks.
The compact motors produce rotational speeds of up to 2750rev/min, which is geared down to ratio of 40:1 by the Brevini boxes, providing levels of torque that can reach 38,000Nm.
Despite the high gearing, the Predator is capable of an impressive 13km/h unloaded and 8km/h at full carrying capacity.
As the Brevini track units are designed for use on large farm machinery such as crop harvesters, a dual braking function is provided as standard, thus enabling the Larrington Predator to be stopped hydrostatically using fluid pressure, and dynamically, via a disc brake inside the gearbox, which holds the vehicle while stationary.
This is an especially important feature when the machines are exported to countries where legislation requires dual braking in order for the vehicle to be road legal.
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.
Complementing this device is the additional option of an integral multiple-disc negative parking brake, which is spring applied and hydraulically released.
This functions as an emergency fail-to-safe brake should the hydraulic pressure fail and is an important safeguard for access vehicles, as they are sometimes manoeuvred with the platform fully raised.
Where the nature of the application is more heavy duty, wheel drives give way to track units.
These, in common with wheel drives, are rotary-case-type planetary units that use multiple gear stages to reduce size.
They are available with integrated hydraulic motors, which are either axial piston or orbital types, and can be fitted with options such as brakes and a disconnect device to aid towing.
Thanks to the inherent capacity of planetary gear trains to deliver high reduction ratios in small packages and to transmit several times the torque of similarly sized, conventional gear units, the integrated track drive package is remarkably compact and lightweight, and requires little installation space.
In addition, the planetary drive is around 98% efficient and, critically, is able to provide extremely low speeds without any loss of efficiency.
A recent application highlighting the operational benefits of planetary wheel drives is in beet harvesting.
Dennis Van Arkel, Sales Manager at Brevini Benelux explains: 'Beet harvesting is a tough, arduous and generally very dirty process; environmental conditions are rarely optimal, with harvesting machines having to work either in rain-sodden, muddy fields, or in extremely dry conditions where dust poses a constant problem to equipment'.
'Obviously, these conditions place a premium on the performance of power transmission equipment used in the operation of the harvesters'.
'Yet despite all the rigours, Brevini has established a supply partnership with manufacturers of beet harvesters, based on quality, reliability and after sales service, which goes back nearly two decades'.
Brevini supplies Agrifac/WKM and Vervaet, the market leaders in Holland, with wheel drives for use on their beet harvesters.
Both companies use the drives for several reasons.
First, because they are wheel mounted in a package with a hydraulic motor, they permit a much simpler design solution than axle drives, and provide improved clearance over rough ground.
Secondly, the absence of an axle means that manufacturers have the flexibility to fit ultrawide terra tyres to spread loading over a wider area.
Thirdly, with no standard axle to consider, the space under the harvester is free and can be used to transport beets from front to back of the equipment.
Forthly, the flexibility as regards brakes: the wheel drives can be supplied fully equipped with dynamic disc and parking brakes enabling the harvester manufacturer to conform easily to the specific laws in each country where the equipment is sold.
In another application of mobile planetary technology, Richard Larrington is making its giant dumper trucks lighter and more manoeuvrable using Brevini track drives.
The Brevini units enable the track-driven Predator vehicles to turn on the spot and transport 20t of peat across steep and unstable terrain at speeds in excess of 8km/h.
Thanks to an innovative design, the Predator can transport peat up and down 20-degree inclines and boggy terrain with loads in excess of 20t - more than four times that of conventional tractors.
The secret of the Predator's superior performance is two large rubberised tracks that spread the load over a large surface area and allow the vehicle to turn 360 degrees on the spot.
The tracks are driven by a pair of Brevini two-stage reduction drive systems, which provide the levels of torque control required to power and position the machine that can weigh in excess of 43t when fully loaded.
Jon Snaith, Sales Manager at Brevini UK explains: 'The steep and boggy terrain on which the vehicle was designed to operate, required the drive system to be track rather than wheel based as traditional tractors would often 'dig in', even when carrying less than a quarter of the load'.
'Also, in order to maximise the load carrying capacity of the Predator, the machine itself was designed to be as light as possible without compromising strength, making a two stage reduction wheel drive system a vast improvement over heavier axel based or larger direct drive systems'.
The drive units themselves consist of hydraulic motors integrated with Brevini planetary gearboxes, making them small enough to fit inside the Predator's tracks.
The compact motors produce rotational speeds of up to 2750rev/min, which is geared down to ratio of 40:1 by the Brevini boxes, providing levels of torque that can reach 38,000Nm.
Despite the high gearing, the Predator is capable of an impressive 13km/h unloaded and 8km/h at full carrying capacity.
As the Brevini track units are designed for use on large farm machinery such as crop harvesters, a dual braking function is provided as standard, thus enabling the Larrington Predator to be stopped hydrostatically using fluid pressure, and dynamically, via a disc brake inside the gearbox, which holds the vehicle while stationary.
This is an especially important feature when the machines are exported to countries where legislation requires dual braking in order for the vehicle to be road legal.
Customised gearbox aids extraterrestrial search
The second stage of an upgrade project has seen Cone Drive working with Dangel Robots and Machinery to provide another specialist solution for the world famous WM Keck Observatory at the summit of Hawaii's Mauna Kea. Cone Drive had already been involved in a successful project to replace exterior mounted worm boxes in 2004 and this time returned with additional expertise provided by its sister company David Brown to upgrade the shutter motion of the world's largest optical and infra-red telescope. The latest stage of the project involved installation of new drives for the two massive shutters on the dome that encloses the Keck I telescope.
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea.
Each telescope stands eight storeys tall and weighs 300 tonnes, yet operates with nanometre precision, probing the deepest regions of the universe.
The dome and shutters for the Keck II telescope were originally built using Cone gearboxes in 1995 and they are still performing today.
Cone Drive provided a 'drop in' solution to replace the reducers on the shutters for the Keck I telescope that was built in 1991.
The original reducers were undersized and causing maintenance problems.
Seal leaks were of special concern because of the low temperatures and dry air at such high altitude.
The observatory presents obvious maintenance problems and the aim was to find a replacement reducer that would require minimum modification at the summit, and which offered an increased service factor and improved seal arrangement.
For the final stage of the project four David Brown G14 gearboxes with a ratio of 41.6:1 were added to the 14 previously installed Cone custom 8.000in centre distance HP double enveloping worm reducer units with a special ratio of 9.75:1.
Modified shafting, housings, mounting flanges and keeper plates were provided to mount the gearboxes and connect them together.
The gearboxes incorporate taconite seal arrangements on both input and output shafts.
Oil expansion chambers were supplied to provide sealed units since the gearboxes change attitude as the shutters move up and down over the dome.
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea.
Each telescope stands eight storeys tall and weighs 300 tonnes, yet operates with nanometre precision, probing the deepest regions of the universe.
The dome and shutters for the Keck II telescope were originally built using Cone gearboxes in 1995 and they are still performing today.
Cone Drive provided a 'drop in' solution to replace the reducers on the shutters for the Keck I telescope that was built in 1991.
The original reducers were undersized and causing maintenance problems.
Seal leaks were of special concern because of the low temperatures and dry air at such high altitude.
The observatory presents obvious maintenance problems and the aim was to find a replacement reducer that would require minimum modification at the summit, and which offered an increased service factor and improved seal arrangement.
For the final stage of the project four David Brown G14 gearboxes with a ratio of 41.6:1 were added to the 14 previously installed Cone custom 8.000in centre distance HP double enveloping worm reducer units with a special ratio of 9.75:1.
Modified shafting, housings, mounting flanges and keeper plates were provided to mount the gearboxes and connect them together.
The gearboxes incorporate taconite seal arrangements on both input and output shafts.
Oil expansion chambers were supplied to provide sealed units since the gearboxes change attitude as the shutters move up and down over the dome.
Geared motors take disconnect clutch onboard
The GKK series from Lenze are geared motors with a manually operated clutch that disconnects the motor and gears from the output shaft. Designed for conveyors and particularly electric overhead monorail conveyors, the GKK range is designed with high radial load capacity at the output shaft, suiting heavy overhung loads. Monorail overhead conveyor systems create a flexible and efficient means of transportation for factory materials handling through their high level of automation.
The control and drive technology of a monorail overhead conveyor comprises the following elements: signal and energy transmission using brush gear or by means of induction systems; decentralised motor control for the entire motion control of the carriage, including speed control, monitoring of the motor, separation monitoring, data transmission and diagnostic options; and the geared motor with clutch for manual carriage advance.
The Lenze geared motors in monorail overhead conveyor systems for light load applications are available in two sizes (GKK04 and GKK05) with permissible radial loads up to 5600 and 8000N and torques up to 70 and 160Nm, respectively.
Motors can be supplied at 42 or 400V with optional spring operated brakes.
With their compact dimensions and ability to absorb high radial forces, the geared motors are well suited to monorail overhead conveyors.
The helical bevel teeth achieve a high degree of efficiency for matching torque to speed.
The monorail overhead conveyor geared motors correspond to the BDI directive 3543 (C1 standard).
They incorporate a reliable mechanical clutch that can be used to interrupt the flow of power between the output shaft of the gearbox and the drive shaft of the motor.
The clutch lever is located on the opposite side to the motor.
Both disengagement and re-engagement is possible with the motor running.
Operators may disconnect the clutch to move a conveyor trolley by hand, for example, to a parking position.
This is easily done without back driving the gearbox or the need to override brake motors.
This design also allows the geared motor to be used in ground-level conveyors.
In addition to the flange-mounted design, the gearboxes are also available with threaded bores on the top and bottom, providing flexible mounting options.
In service the drive can be disassembled quickly without removing the running wheel.
This reduces downtime and thus costs.
The development of the monorail overhead conveyor (EHB) geared motors is based on an established design from the GKR range of bevel gearboxes using helical bevel gearing that has a high efficiency of 96%.
As well as saving energy compared to worm and wheel alternatives, the lower energy requirements mean that the cost of installing power cabling is lower.
In rail transportation systems that run across entire factories, decentralised motor control systems represent the link between the monorail overhead conveyor and the higher level automation technology.
They provide the necessary intervention options, the flow of data and transparency for the installation.
The system is equally suited to simple tasks as to more complex tasks.
Examples of this are the control of several motors on a single carriage, infinitely variable speed control with frequency inverters or the separation control system, which regulates the distance between the carriages.
All the data relevant to automatic operation, such as the position of the carriage, can be transmitted directly by means of collector wires or inductive systems.
With geared motors and decentralised motor control systems, Lenze offers a complete drive system for monorail overhead conveyors.
With these co-ordinated components, interface problems are a thing of the past.
In addition, different conveyor delivery rates, travel profiles or transport speeds can be configured much faster and more precisely.
The control and drive technology of a monorail overhead conveyor comprises the following elements: signal and energy transmission using brush gear or by means of induction systems; decentralised motor control for the entire motion control of the carriage, including speed control, monitoring of the motor, separation monitoring, data transmission and diagnostic options; and the geared motor with clutch for manual carriage advance.
The Lenze geared motors in monorail overhead conveyor systems for light load applications are available in two sizes (GKK04 and GKK05) with permissible radial loads up to 5600 and 8000N and torques up to 70 and 160Nm, respectively.
Motors can be supplied at 42 or 400V with optional spring operated brakes.
With their compact dimensions and ability to absorb high radial forces, the geared motors are well suited to monorail overhead conveyors.
The helical bevel teeth achieve a high degree of efficiency for matching torque to speed.
The monorail overhead conveyor geared motors correspond to the BDI directive 3543 (C1 standard).
They incorporate a reliable mechanical clutch that can be used to interrupt the flow of power between the output shaft of the gearbox and the drive shaft of the motor.
The clutch lever is located on the opposite side to the motor.
Both disengagement and re-engagement is possible with the motor running.
Operators may disconnect the clutch to move a conveyor trolley by hand, for example, to a parking position.
This is easily done without back driving the gearbox or the need to override brake motors.
This design also allows the geared motor to be used in ground-level conveyors.
In addition to the flange-mounted design, the gearboxes are also available with threaded bores on the top and bottom, providing flexible mounting options.
In service the drive can be disassembled quickly without removing the running wheel.
This reduces downtime and thus costs.
The development of the monorail overhead conveyor (EHB) geared motors is based on an established design from the GKR range of bevel gearboxes using helical bevel gearing that has a high efficiency of 96%.
As well as saving energy compared to worm and wheel alternatives, the lower energy requirements mean that the cost of installing power cabling is lower.
In rail transportation systems that run across entire factories, decentralised motor control systems represent the link between the monorail overhead conveyor and the higher level automation technology.
They provide the necessary intervention options, the flow of data and transparency for the installation.
The system is equally suited to simple tasks as to more complex tasks.
Examples of this are the control of several motors on a single carriage, infinitely variable speed control with frequency inverters or the separation control system, which regulates the distance between the carriages.
All the data relevant to automatic operation, such as the position of the carriage, can be transmitted directly by means of collector wires or inductive systems.
With geared motors and decentralised motor control systems, Lenze offers a complete drive system for monorail overhead conveyors.
With these co-ordinated components, interface problems are a thing of the past.
In addition, different conveyor delivery rates, travel profiles or transport speeds can be configured much faster and more precisely.
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.
'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.
Division focuses power transmission expertise
System integrator and automation equipment specialist Gudel UK has established a new Power Transmissions Division to expand sales of the company's work handling and linear drive components throughout the UK and Ireland. Headed by Mark Howlett, the new division draws on Gudel's 50-year track record of supplying high precision components and systems to customers in industries as diverse as special purpose machinery, automation, nuclear, logistics, warehousing, pharmaceuticals, aerospace, defence, electronics and food processing. At the heart of the new division's range will be Gudel's extensive catalogue of linear and drive technology components - including pinions, racks, rails, rollers, gearboxes, carriages and guideway products.
These enable end users to source a complete drive chain solution for their application from one supplier.
In addition, the new division takes advantage of the company's extensive work handling equipment experience and ongoing investment in advanced manufacturing facilities to provide users with a facility for custom-engineered components and mechanical drive subassemblies.
'Gudel products have a strong reputation for high precision and durability', says Howlett.
'Research shows that they are also among the most competitively priced as well'.
'The establishment of our Power Transmissions Division enables us to offer one of the most comprehensive ranges of drive technology equipment on the market today at extremely cost-effective rates'.
'Furthermore, we are backing our new service with a team of local applications engineering specialists, who will quickly guide users to the most appropriate product for their specific needs'.
'In parallel, our recently introduced 'Fast Developer' tool - available online - allows users to quickly select, configure and order products from our high precision worm gearboxes range'.
'Similarly, our website provides instant access to specifications and fully defined 2D or 3D CAD models of Gudel's products, which can be downloaded on demand to users' desktops'.
'In addition, users can obtain full details of all our precision drive components by requesting our free 360-page product selection guides'.
Gudel's matched drive pinions and straight or helical cut rack units are ideal for machine tool, automation, assembly and special machine building applications that require high speed, high acceleration or accurate positioning of components weighing up to several tonnes.
Steel racks are available in precision cut, precision cut and hardened, or hardened and ground variants capable of withstanding loads of up to 50kN.
Stainless steel alternatives and a variety of special finishes are also offered to combat aggressive or corrosive operating environments.
Gudel also manufactures nylon gears and racks for lighter duty applications.
Gudel's heavy duty plain and Vee rollers and guideways complement the company's rack and pinion drive components.
A selection of ultra-low-backlash planetary, worm gear and bevel drive units is also available - enabling users to engineer complete solutions to their component handling and automation problems.
In addition, the company offers fully automated lubrication systems to ensure high performance, low maintenance installations even under the most demanding operating conditions.
These enable end users to source a complete drive chain solution for their application from one supplier.
In addition, the new division takes advantage of the company's extensive work handling equipment experience and ongoing investment in advanced manufacturing facilities to provide users with a facility for custom-engineered components and mechanical drive subassemblies.
'Gudel products have a strong reputation for high precision and durability', says Howlett.
'Research shows that they are also among the most competitively priced as well'.
'The establishment of our Power Transmissions Division enables us to offer one of the most comprehensive ranges of drive technology equipment on the market today at extremely cost-effective rates'.
'Furthermore, we are backing our new service with a team of local applications engineering specialists, who will quickly guide users to the most appropriate product for their specific needs'.
'In parallel, our recently introduced 'Fast Developer' tool - available online - allows users to quickly select, configure and order products from our high precision worm gearboxes range'.
'Similarly, our website provides instant access to specifications and fully defined 2D or 3D CAD models of Gudel's products, which can be downloaded on demand to users' desktops'.
'In addition, users can obtain full details of all our precision drive components by requesting our free 360-page product selection guides'.
Gudel's matched drive pinions and straight or helical cut rack units are ideal for machine tool, automation, assembly and special machine building applications that require high speed, high acceleration or accurate positioning of components weighing up to several tonnes.
Steel racks are available in precision cut, precision cut and hardened, or hardened and ground variants capable of withstanding loads of up to 50kN.
Stainless steel alternatives and a variety of special finishes are also offered to combat aggressive or corrosive operating environments.
Gudel also manufactures nylon gears and racks for lighter duty applications.
Gudel's heavy duty plain and Vee rollers and guideways complement the company's rack and pinion drive components.
A selection of ultra-low-backlash planetary, worm gear and bevel drive units is also available - enabling users to engineer complete solutions to their component handling and automation problems.
In addition, the company offers fully automated lubrication systems to ensure high performance, low maintenance installations even under the most demanding operating conditions.
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.
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.
Test rig devoted to Indian water project
David Brown Engineering has created a unique test rig at its Huddersfield works to simulate operational loading from the world's largest pumping system as part of a GBP 2.3 million project to supply gearboxes to the Narmada dam project in India. Representatives from India's premier pump manufacturer Kirloskar Brothers visited the works to see the rig in operation - the only one of its kind in the world - and discuss delivery schedules for the gearboxes. David Brown, a Textron Power Transmission company, is supplying 26 single-stage vertical planetary gear units that transmit approximately 4500kW at 200rev/min and are nominally capable of handling a thrust load of over 90t.
They have been designed and engineered to operate in arduous conditions at ambient temperatures of over 45C.
The rig is custom-designed for the Narmada project to subject the gearboxes to no-load and full-load testing.
It was created using two of the gearboxes mounted in a back-to-back configuration; full load torque is applied through a connecting gearbox and the pump thrust is simulated using hydraulic rams.
The first gear units are due for delivery before the end of the year and the remainder will be supplied over the 4-year life of the project.
Roger Leedham, one of the engineering team which designed the rig, comments: "Full load test trialling of the gearbox is important to ensure trouble free installation and running for our customer and the end user.
David Brown is one of the few companies in the world capable of building this sort of test facility in its own factory because of the scale and complexity, but it was a vital element in our success in gaining the business, and is an integral part of the service we offer to clients worldwide".
The Narmada Project canal system in the state of Gujarat will eventually irrigate 1.8 million hectares of land, and meet the drinking water requirements of millions of drought-affected people.
Kirloskar Brothers is building five huge new pumping stations equipped with mammoth concrete volute pumps, which will eventually be capable of lifting some 410,000 litres of water per second to provide irrigation and drinking water to 132 towns and a large number of villages in the drought-affected areas of the Saurashtra region.
They have been designed and engineered to operate in arduous conditions at ambient temperatures of over 45C.
The rig is custom-designed for the Narmada project to subject the gearboxes to no-load and full-load testing.
It was created using two of the gearboxes mounted in a back-to-back configuration; full load torque is applied through a connecting gearbox and the pump thrust is simulated using hydraulic rams.
The first gear units are due for delivery before the end of the year and the remainder will be supplied over the 4-year life of the project.
Roger Leedham, one of the engineering team which designed the rig, comments: "Full load test trialling of the gearbox is important to ensure trouble free installation and running for our customer and the end user.
David Brown is one of the few companies in the world capable of building this sort of test facility in its own factory because of the scale and complexity, but it was a vital element in our success in gaining the business, and is an integral part of the service we offer to clients worldwide".
The Narmada Project canal system in the state of Gujarat will eventually irrigate 1.8 million hectares of land, and meet the drinking water requirements of millions of drought-affected people.
Kirloskar Brothers is building five huge new pumping stations equipped with mammoth concrete volute pumps, which will eventually be capable of lifting some 410,000 litres of water per second to provide irrigation and drinking water to 132 towns and a large number of villages in the drought-affected areas of the Saurashtra region.
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