Designed to handle seating and unseating force of high-pressure gate and globe valves found in power plants, MT Series is available in torque ranges to 8,000 lb-ft and thrust ranges to 325,000 lb. With ductile iron bevel gears and thrust base housings, units withstand elevated process temperatures. Operator stem nut is shouldered in drive sleeve to capture thrust forces within thrust housing without transferring forces to torque housing.
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Product line optimized to deliver reliable performance in power industry valve applications
DALLAS - September 29, 2005 - Flowserve Corp., a global provider of fluid motion and control products and services, announces the launch of the Limitorque Actuation Systems MT series of bevel gear operators. The MT series operators are optimized to deliver reliable performance in power industry valve applications.
Designed as a superior combination of a bevel gear operator torque housing with a new thrust base design, the MT series is ideally suited for torque-seated valve applications and applications involving elevated process temperatures. MT series bevel gears and thrust base housings are made of ductile iron.
The MT series features robust thrust bearings and drive sleeve/stem nut design. These combine to offer the most rugged bevel gear operator available for handling the seating and unseating forces of high-pressure gate and globe valves found in power plants around the world. The MT operator stem nut is shouldered in the drive sleeve to capture thrust forces within the thrust housing without transferring those forces to the torque housing.
Available in torque ranges to 8,000 ft-lb and thrust ranges to 325,000 lb., the MT series provides high efficiency and strong design for every application. When motorized by the Limitorque MX, SMB or L120 series electric actuators, the MT series offers flexibility for a wide range of valve opening and closing times.
"With the MT series, Flowserve once again leads the market with its product offerings for the power industry," says Earnest Carey, manager, product management, Flowserve Flow Control, Limitorque Actuation Systems. "Backed by our unsurpassed sales and service support, the MT series is further evidence of Flowserve's unwavering commitment to deliver the technology needed for reliable power plant valve operation today and in the years to come."
Foul Weather Gear protects workers from harsh conditions
ncluded in GLoWEAR[R] High-Visibility Apparel line, rain and thermal foul weather gear shields workers from rain, sleet, snow, cold, and wind. Rain jacket, rain pant, thermal jacket, thermal pant, and 4-in-1 jacket with detachable sleeves have polyester weatherproof outer shell that uses breathable PU material and ANSI 107-certified 3M(TM) Scotchlite(TM) reflective tape. Rain gear has polyester mesh lining, and thermal pieces feature 100 g 3M(TM) Thinsulate(TM) lining.
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New Gear Keeps Workers Safe, Comfortable In Harsh Weather Conditions
ST. PAUL, Minn. (September 12, 2005) - Ergodyne today introduced new rain and thermal foul weather gear to its popular line of GLoWEAR[R] High-Visibility Apparel. The new gear shields workers from rain, sleet, snow, cold, and wind while keeping them conspicuous on the job with high-visibility, ANSI-certified materials. Breathable fabrics and a high-quality design ensure a comfortable fit, allowing workers to move freely on the job site.
The new collection includes a rain jacket, rain pant, thermal jacket, thermal pant, and a 4-in-1 jacket with detachable sleeves. Each item has a polyester weatherproof outer shell that uses a breathable PU material and ANSI 107-certified 3M(TM) Scotchlite(TM) reflective tape. The rain gear has a polyester mesh lining and the thermal pieces feature a 100-gram 3M(TM) Thinsulate(TM) lining. All of the jackets are Class 3-certified and the pants are Class-E certified.
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New Gear Keeps Workers Safe, Comfortable In Harsh Weather Conditions
ST. PAUL, Minn. (September 12, 2005) - Ergodyne today introduced new rain and thermal foul weather gear to its popular line of GLoWEAR[R] High-Visibility Apparel. The new gear shields workers from rain, sleet, snow, cold, and wind while keeping them conspicuous on the job with high-visibility, ANSI-certified materials. Breathable fabrics and a high-quality design ensure a comfortable fit, allowing workers to move freely on the job site.
The new collection includes a rain jacket, rain pant, thermal jacket, thermal pant, and a 4-in-1 jacket with detachable sleeves. Each item has a polyester weatherproof outer shell that uses a breathable PU material and ANSI 107-certified 3M(TM) Scotchlite(TM) reflective tape. The rain gear has a polyester mesh lining and the thermal pieces feature a 100-gram 3M(TM) Thinsulate(TM) lining. All of the jackets are Class 3-certified and the pants are Class-E certified.
Textron Acquires ALSTOM Gears; Acquisition Establishes Preferred Supplier Relationship and Enhances Technological Offerings
Textron Inc. (NYSE:TXT) announced today the acquisition of U.K.-based ALSTOM Gears, part of ALSTOM, a leading supplier of components, systems and services to the world's energy and transport infrastructure markets. ALSTOM Gears manufactures and sells a range of gears and gearboxes, including high-speed epicyclic and parallel shaft gearboxes, for the industrial, rail and marine industries. The acquisition will be fully integrated into Textron's Power Transmission Products business, part of the company's Fluid & Power Systems Group. For the fiscal year-ended March 1999, ALSTOM Gear's revenues were approximately $10 million. Terms of the transaction were not disclosed.
"Textron's acquisition of ALSTOM Gears further strengthens our power transmission capabilities, adding a range of technologically advanced gearbox systems to our existing product brands, including David Brown, Cone Drive and Textron Industrial gears," said Textron Fluid & Power Systems President Bob Geckle. "Furthermore, the acquisition establishes a multi-year preferred supplier agreement for Textron with ALSTOM for power transmission products," he added.
With approximately $1 billion in annualized revenues and locations in 23 countries, Textron's Fluid & Power Systems Group is a leading manufacturer of mechanical power transmission, motion control, fluid handling and electronic systems and components. The Fluid & Power Systems Group is part of Textron's $4 billion Industrial Segment.
"Textron's acquisition of ALSTOM Gears further strengthens our power transmission capabilities, adding a range of technologically advanced gearbox systems to our existing product brands, including David Brown, Cone Drive and Textron Industrial gears," said Textron Fluid & Power Systems President Bob Geckle. "Furthermore, the acquisition establishes a multi-year preferred supplier agreement for Textron with ALSTOM for power transmission products," he added.
With approximately $1 billion in annualized revenues and locations in 23 countries, Textron's Fluid & Power Systems Group is a leading manufacturer of mechanical power transmission, motion control, fluid handling and electronic systems and components. The Fluid & Power Systems Group is part of Textron's $4 billion Industrial Segment.
Expert system for selecting speed reduction components for a power transmission
This paper describes the development of an expert system that will allow for the concurrent consideration and analysis of the many facets of product constraints, particularly function and manufacturability, at the early stages of power transmission development. The Power Transmission Design Assistant methodology is based on the concept of directed refinement, where the product and analysis methodology become less abstract as more information is given. This allows for analysis and guidance throughout the product development process. The methodology has been demonstrated on a small-scale, semi-automatic tool. The tool was the foundation for a larger tool that incorporates expert rules to help optimize power transmission component design.
Power transmission systems are a crucial component in many types of machinery. Mechanical power transmissions are used in products such as food mixers, automobiles, and aircraft. The power transmission design problem involves deciding the input, intermediate components, and their layout for a required motion, force, or torque output. With the increased popularity of computer-based design tools, many difficult engineering problems, such as power transmission design, can be eased, which allows engineers to spend more time optimizing the product.
A partial listing of the various components involved in power transmission is shown in Figure 1. Power transmission can be achieved by either electrical, mechanical, or hydraulic means; however, most transmission systems are designed for mechanical, rotary applications. Power transmission of rotary systems typically consists of components such as shafts, bearings, gears, pulleys, sprockets, chains, belts, connectors, and fasteners. These elements can be prepackaged to meet a specific design goal, or they may be individual elements that the designer selects to meet a need. In either case, each has its own design criteria and constraints.
In the past, optimization of power transmission systems involved achieving the following interdependent functional requirements in an iterative, trial-and-error approach:
Geometry-Are there space limitations between elements, especially moving and stationary components? What is the relationship between input and output locations?
Kinematics-What is the direction of motion of the input and output transmission components? Is it at constant speed or is it transient?
Kinetics-What are the forces and torques present in the system?
Speeds-What are the required input and output speeds and forces?
Design adequacy-Once the loads and speeds are known, are the stresses, vibrations, and weights within acceptable limits?
However, after functional optimization occurs, the product is often still suboptimal in terms of cost, especially when life cycle costs are considered. The main reason for the suboptimal result is that the trade-offs between the requirements are often impossible to consider manually. It is necessary to develop a set of design tools to tackle this complex problem and integrate the many areas of the life cycle cost into a set of optimal solutions.
The iterative nature of the product development process implies that a considerable amount of time is spent repeating common but sometimes difficult tasks. If, as in power transmissions, there are a substantial number of functional constraints, these tasks become even more difficult. The process of finding optimal solutions to design problems is usually difficult and is often abandoned in favor of a quick solution that works but may not be optimal. The difficulty may simply be a result of computational ability to solve for the optimal solution or lack of a metric for deciding the optimal solution.
Engineers must be able to make correct engineering decisions early in the product development process to maintain profitability and competitiveness. The consequences of poor decision making include increased development time, increased time to market, pressure from internal groups who depend on the design decisions, and increased change order costs. Decisions or changes made later in the product development are more costly because they have greater repercussions. It is therefore advantageous to make decisions as early in the product's design as possible. The major hindrance to achieving this is the lack of quantitative knowledge on which to base these decisions.
In recent years, computer-aided engineering (CAE) has been used to relieve some of the pressures on design decisions. CAE is used to size components, evaluate products, and perform low-level design tasks. CAE has mostly been used to automate complicated and repetitive mathematical tasks; however, automation of these mathematical tasks usually requires information about product parameters that is not available early in the product development process. Currently, such design automation software falls into one of several categories: CAD-based design for manufacturability/design for assembly (DFM/DFA)1,2
Power transmission systems are a crucial component in many types of machinery. Mechanical power transmissions are used in products such as food mixers, automobiles, and aircraft. The power transmission design problem involves deciding the input, intermediate components, and their layout for a required motion, force, or torque output. With the increased popularity of computer-based design tools, many difficult engineering problems, such as power transmission design, can be eased, which allows engineers to spend more time optimizing the product.
A partial listing of the various components involved in power transmission is shown in Figure 1. Power transmission can be achieved by either electrical, mechanical, or hydraulic means; however, most transmission systems are designed for mechanical, rotary applications. Power transmission of rotary systems typically consists of components such as shafts, bearings, gears, pulleys, sprockets, chains, belts, connectors, and fasteners. These elements can be prepackaged to meet a specific design goal, or they may be individual elements that the designer selects to meet a need. In either case, each has its own design criteria and constraints.
In the past, optimization of power transmission systems involved achieving the following interdependent functional requirements in an iterative, trial-and-error approach:
Geometry-Are there space limitations between elements, especially moving and stationary components? What is the relationship between input and output locations?
Kinematics-What is the direction of motion of the input and output transmission components? Is it at constant speed or is it transient?
Kinetics-What are the forces and torques present in the system?
Speeds-What are the required input and output speeds and forces?
Design adequacy-Once the loads and speeds are known, are the stresses, vibrations, and weights within acceptable limits?
However, after functional optimization occurs, the product is often still suboptimal in terms of cost, especially when life cycle costs are considered. The main reason for the suboptimal result is that the trade-offs between the requirements are often impossible to consider manually. It is necessary to develop a set of design tools to tackle this complex problem and integrate the many areas of the life cycle cost into a set of optimal solutions.
The iterative nature of the product development process implies that a considerable amount of time is spent repeating common but sometimes difficult tasks. If, as in power transmissions, there are a substantial number of functional constraints, these tasks become even more difficult. The process of finding optimal solutions to design problems is usually difficult and is often abandoned in favor of a quick solution that works but may not be optimal. The difficulty may simply be a result of computational ability to solve for the optimal solution or lack of a metric for deciding the optimal solution.
Engineers must be able to make correct engineering decisions early in the product development process to maintain profitability and competitiveness. The consequences of poor decision making include increased development time, increased time to market, pressure from internal groups who depend on the design decisions, and increased change order costs. Decisions or changes made later in the product development are more costly because they have greater repercussions. It is therefore advantageous to make decisions as early in the product's design as possible. The major hindrance to achieving this is the lack of quantitative knowledge on which to base these decisions.
In recent years, computer-aided engineering (CAE) has been used to relieve some of the pressures on design decisions. CAE is used to size components, evaluate products, and perform low-level design tasks. CAE has mostly been used to automate complicated and repetitive mathematical tasks; however, automation of these mathematical tasks usually requires information about product parameters that is not available early in the product development process. Currently, such design automation software falls into one of several categories: CAD-based design for manufacturability/design for assembly (DFM/DFA)1,2
Techno trucks: Roush racing
I'n a western suburb of Detroit, the Roush Racing NASCAR Craftsman Truck teams have been busy all winter preparing for the 1999 season opener in Homestead, Florida. The snow-shrouded shop could be mistaken for any other factory in a row of commercial buildings that line the service drive of a major expressway leading into downtown Detroit. But inside lies one of the most organized and complete shops in racing.
Don't tell Jack Roush that NASCAR teams must be located in the Carolinas to be competitive. The Roush truck teams have been extremely successful operating right out of Michigan, thank you, with third and eighth place overall standings in the 1998 series, almost identical to 1997. And don't tell Roush he has to purchase his chassis, engines or other components from someone in the South. If it can be done at all, it can be done well by Roush Racing.
Perhaps this formula has been the secret to the success of Roush's NASCAR teams over the last few years. (Roush Racing campaigns five Winston Cup and two Busch Grand National cars, in addition to the trucks.)
Part of the credit, however, must be given to the vast amount of technology used in this operation. Everywhere I looked I saw laptop computers used for reference and data recording. Nothing is left to human memory or the possibility of miscommunication.
The Teams
The two truck teams consist of the No. 50 Grainger Ford, driven by Greg Biffle, and the No. 99 Exide Battery Ford, now piloted by Mike Bliss for 1999.
I was given a shop tour by Matt Chambers, Crew Chief for the No. 99 truck and Randy Goss, Crew Chief for the No. 50 truck. I asked them what it was like, working in close proximity to another team.
"The two teams eat their lunches together and share information and communication. It keeps everybody together," said Goss. "It's an advantage."
"Randy and I work together closely, comparing notes and finding out what works and what doesn't," Chambers added. "It saves us a lot of time." Chambers prefers working in the NASCAR Truck Series rather than the Winston Cup or Busch Grand National cars. He's been on Winston Cup and Grand National teams and thinks the trucks are the best, "especially here with Roush. This is the best team I've been on," he continued, "and I find it's a lot of fun. In Winston Cup, there's tremendous pressure to please sponsors. We know we still have to make them happy,' but the pressure doesn't seem as bad in the Truck Series. We're also very fortunate to have great sponsors, as well as great ownership."
"We still have fun," Goss chimed in. "We race hard and take it seriously, but we still enjoy ourselves. Plus, when we leave home, we know we've got a chance to win. Some teams can't say that, and it takes all the fun out of it."
The huge facility is large enough to house both teams, with plenty of space for several built-up trucks, plus the offices and fabricating and storage areas. There's even a "wall" area for practicing pit stops. Each team has bays to work on five or six trucks that are in various stages of completion. Located in the fabricating area is a machine shop, a shop where oil pans and coolers are made, a shop for making headers, a chassis-building section and a shop to create the steel body shells. Outside, the transport trucks for each team wait to be loaded for the trip to Homestead.
Technology Abounds
I visited with Kevin Caparella, an experienced shock man who builds the shock absorbers for both teams. He creates a computer profile of each track on the schedule, compares it to last year's results and prebuilds the shocks for each truck accordingly. Caparella says short tracks with higher banks, like Bristol, create his biggest problems, because "a lot is happening in a short distance"-lots of bumps and turns. He then prepares several sets of shocks for each of the two trucks, which can then be fine-tuned at the track during testing and qualifying.
Caparella logs the mileage of each component and records the changes on his laptop computer. He inspects the shocks after every race and rebuilds them after three races. He uses a dynamometer that's specially made for testing and proofing the shocks before returning them to action. Again, the dynamics of each shock are recorded on his laptop for later reference.
Brian Hoye builds the transmissions and differentials for the truck teams. He has 22 Jerico four-speed gearboxes in his inventory and prebuilds several boxes prior to each race. Hoye usually prepares a tranny and two spare boxes for each truck, while the parts truck hauls two extra units, just in case. Having eight transmissions for the two trucks gives him the flexibility to rebuild quickly at the track to suit the driver's needs.
Don't tell Jack Roush that NASCAR teams must be located in the Carolinas to be competitive. The Roush truck teams have been extremely successful operating right out of Michigan, thank you, with third and eighth place overall standings in the 1998 series, almost identical to 1997. And don't tell Roush he has to purchase his chassis, engines or other components from someone in the South. If it can be done at all, it can be done well by Roush Racing.
Perhaps this formula has been the secret to the success of Roush's NASCAR teams over the last few years. (Roush Racing campaigns five Winston Cup and two Busch Grand National cars, in addition to the trucks.)
Part of the credit, however, must be given to the vast amount of technology used in this operation. Everywhere I looked I saw laptop computers used for reference and data recording. Nothing is left to human memory or the possibility of miscommunication.
The Teams
The two truck teams consist of the No. 50 Grainger Ford, driven by Greg Biffle, and the No. 99 Exide Battery Ford, now piloted by Mike Bliss for 1999.
I was given a shop tour by Matt Chambers, Crew Chief for the No. 99 truck and Randy Goss, Crew Chief for the No. 50 truck. I asked them what it was like, working in close proximity to another team.
"The two teams eat their lunches together and share information and communication. It keeps everybody together," said Goss. "It's an advantage."
"Randy and I work together closely, comparing notes and finding out what works and what doesn't," Chambers added. "It saves us a lot of time." Chambers prefers working in the NASCAR Truck Series rather than the Winston Cup or Busch Grand National cars. He's been on Winston Cup and Grand National teams and thinks the trucks are the best, "especially here with Roush. This is the best team I've been on," he continued, "and I find it's a lot of fun. In Winston Cup, there's tremendous pressure to please sponsors. We know we still have to make them happy,' but the pressure doesn't seem as bad in the Truck Series. We're also very fortunate to have great sponsors, as well as great ownership."
"We still have fun," Goss chimed in. "We race hard and take it seriously, but we still enjoy ourselves. Plus, when we leave home, we know we've got a chance to win. Some teams can't say that, and it takes all the fun out of it."
The huge facility is large enough to house both teams, with plenty of space for several built-up trucks, plus the offices and fabricating and storage areas. There's even a "wall" area for practicing pit stops. Each team has bays to work on five or six trucks that are in various stages of completion. Located in the fabricating area is a machine shop, a shop where oil pans and coolers are made, a shop for making headers, a chassis-building section and a shop to create the steel body shells. Outside, the transport trucks for each team wait to be loaded for the trip to Homestead.
Technology Abounds
I visited with Kevin Caparella, an experienced shock man who builds the shock absorbers for both teams. He creates a computer profile of each track on the schedule, compares it to last year's results and prebuilds the shocks for each truck accordingly. Caparella says short tracks with higher banks, like Bristol, create his biggest problems, because "a lot is happening in a short distance"-lots of bumps and turns. He then prepares several sets of shocks for each of the two trucks, which can then be fine-tuned at the track during testing and qualifying.
Caparella logs the mileage of each component and records the changes on his laptop computer. He inspects the shocks after every race and rebuilds them after three races. He uses a dynamometer that's specially made for testing and proofing the shocks before returning them to action. Again, the dynamics of each shock are recorded on his laptop for later reference.
Brian Hoye builds the transmissions and differentials for the truck teams. He has 22 Jerico four-speed gearboxes in his inventory and prebuilds several boxes prior to each race. Hoye usually prepares a tranny and two spare boxes for each truck, while the parts truck hauls two extra units, just in case. Having eight transmissions for the two trucks gives him the flexibility to rebuild quickly at the track to suit the driver's needs.
Tech & Trends; Alfa Romeo Solves 'Tiptronic' FoibleEngaging the 'logic' gear to improve manual automatic transmissions
Fiat SpA's Alfa Romeo acts on an astute insight into one ergonomic problem that, to now, has vexed the new breed of sequential-shift automatic transmissions: the gear lever offers the driver no perception of which gear is being used.
Many drivers of automatic-transmission vehicles equipped with a "manual" sequential-shift function - often called "Tiptronic" after the system name coined by early adopter Porsche AG - have complaints. They say the lackof aural and tactile feedback from the driveline - combined with a gear lever that remains centrally situated regardless of which gear is being employed - makes it difficult to discern one gear from the next.
This is particularly a problem for sequential-shift automatics hooked to larger-displacement, 6- or 8-cyl. engines that are too refined to give much seat-of-the-pants indication about gear selection. Drivers of sequential-shift automatics thus must drive by the tachometer or peer at a usually too-small digital gear indicator located in the gauge cluster.
Alfa Romeo solves the problem with its all-new "Q-System" 4-speed automatic for the 156: its manual-function "quadrant" effectively replicates that of a manual transmission (see diagram), with the four forward speeds arranged in the standard "H" pattern.
Rather than simply moving - or "tipping" - the gear lever forward or backward sequentially for up- or down-shifts, the Q-System's gears can be selected much like those of a manual transmission, with no need to move sequentially from one gear to the next. And because it's an automatic at heart, the Q-System, like all sequential-shift gearboxes, of course doesn't require a clutch.
Most important, the Q-System's gear lever, by moving through a distinct H-pattern, provides the driver with a quick visual confirmation of which gear is engaged. In effect, the Q-System provides for much more intuitive information about gear selection than a Tiptronic-style gear lever.
In addition, a digital display placed in the tachometer offers a readout of which gear is engaged - the only indicator with most other sequential-shift systems.
The Q-System was designed as the automatic transmission for the Alfa 156 after its launch with only manual transmissions, which means Alfa Romeo was able to engineer the H-pattern for the shifter from the onset; most sequential-shift automatics were designed to make use of an already existing automatic transmission's gear selector and console housings, making it more difficult - and costly - to incorporate a manual-transmission-replicating gearlever and shift "pattern."
Many drivers of automatic-transmission vehicles equipped with a "manual" sequential-shift function - often called "Tiptronic" after the system name coined by early adopter Porsche AG - have complaints. They say the lackof aural and tactile feedback from the driveline - combined with a gear lever that remains centrally situated regardless of which gear is being employed - makes it difficult to discern one gear from the next.
This is particularly a problem for sequential-shift automatics hooked to larger-displacement, 6- or 8-cyl. engines that are too refined to give much seat-of-the-pants indication about gear selection. Drivers of sequential-shift automatics thus must drive by the tachometer or peer at a usually too-small digital gear indicator located in the gauge cluster.
Alfa Romeo solves the problem with its all-new "Q-System" 4-speed automatic for the 156: its manual-function "quadrant" effectively replicates that of a manual transmission (see diagram), with the four forward speeds arranged in the standard "H" pattern.
Rather than simply moving - or "tipping" - the gear lever forward or backward sequentially for up- or down-shifts, the Q-System's gears can be selected much like those of a manual transmission, with no need to move sequentially from one gear to the next. And because it's an automatic at heart, the Q-System, like all sequential-shift gearboxes, of course doesn't require a clutch.
Most important, the Q-System's gear lever, by moving through a distinct H-pattern, provides the driver with a quick visual confirmation of which gear is engaged. In effect, the Q-System provides for much more intuitive information about gear selection than a Tiptronic-style gear lever.
In addition, a digital display placed in the tachometer offers a readout of which gear is engaged - the only indicator with most other sequential-shift systems.
The Q-System was designed as the automatic transmission for the Alfa 156 after its launch with only manual transmissions, which means Alfa Romeo was able to engineer the H-pattern for the shifter from the onset; most sequential-shift automatics were designed to make use of an already existing automatic transmission's gear selector and console housings, making it more difficult - and costly - to incorporate a manual-transmission-replicating gearlever and shift "pattern."
Maintenance management: Smart methods (cont.)
Note: This column is a continuation of the December, February, and April P&P maintenance columns by Christer Idhammar discussing smart corrective maintenance methods. This month, he covers some techniques in preventive and corrective maintenance for beginning to advanced readers.
MICROCANS TECHNOLOGY IS THE closest thing to a paperless maintenance system I have seen. The MicroCan is a stainless steel container about the size of a dime with a thickness of about three dimes. Inside the container is a microchip that stores information. With a handheld probe, you can touch the MicroCan and read information from it, or you can add information it.
This technology has been used for many years in security systems, car locks, maintenance management, and other applications. Many years ago, I saw a MicroCan fastened in a cow's ear. This triggered my curiosity and led me to develop a demonstration route system for preventive maintenance that was used for training and idea creation in training programs. Today, many companies are using MicroCan technology in their maintenance departments-especially for lubrication and inspection routes.
The applications for this technology are limited only by our imaginations. I have introduced it to many maintenance software suppliers without success. They apparently do not see its benefits and say that they have other solutions, including bar codes and other technology. However, bar codes can easily be damaged or painted over.The biggest obstacle with software suppliers is most probably a resistance to change.
The MicroCan technology is so effective that I am convinced we will see more and more of it in the future. If you are interested in learning more about it, you can contact Dallas Semiconductor in Dallas, Texas, and ask for a demonstration kit. We can also give you names of lubrication suppliers offering this system as part of their services.
HYGROSCOPIC BREATHERS AND FILTERS. Poor filtration and moisture in hydraulic systems and lubrication systems are costing the pulp and paper industry millions of dollars. If you keep hydraulic fluids cool and clean, hydraulic systems -to the contrary belief of American industrywill not leak as much as they do in most U.S. pulp and paper mills. If hydraulic fluids and lubrication oils are kept clean from particles bigger than five microns and there is no water content in the systems, components in these systems will have much longer life.
If you use silica-filled filters as breathers on hydraulic systems and, for example, gearboxes, you will eliminate one source of contamination. Desiccant bag filters will dry the air entering the system and filter out particles down to one micron. An indicator will change color when it is time to change the unit. More information is available from Des-Case Corp. in White House,Tenn.
I talked with a pulp and paper maintenance manager in a mill I worked with for many years. This mill used to have problems with the short life-about eight months-of small gears driving its big rotating filters and washers.After trying to solve the problem with other types of oil, the lubrication team modified the gears so that it was easy to connect a mobile filter. They also put hygroscopic filters on the gears. They have now been running the gears for six years without a problem!
HIGH INTENSITY LIGHT. We recently followed up on the results of a PM/ECCM (preventive maintenance/essential care condition monitoring) program that was implemented in two pulp and paper mills. They both used cost avoidance reports to follow up on results. A conservative estimate showed that, in both mills, savings were about ten times the cost of implementing the program in the first six months.
Most of these savings came from avoiding production losses. In one mill, 80% of all work in a shutdown was the result of inspections instead of short notice work orders. Also, one mill followed up on the methods used to identify potential problems. It showed that 73% of identified problems were detected by use of high intensity light and that another 15% were detected by the use of strobe lights. Before the program was implemented, sporadic "when-we-have-time" inspections were done using flashlights. In the initial training, the inspector trainees were introduced to better lights with a light beam of l000w. They discovered that this opened up a new world when they inspected equipment, especially when it was performed in conjunction with detailed cleaning of components.
MICROCANS TECHNOLOGY IS THE closest thing to a paperless maintenance system I have seen. The MicroCan is a stainless steel container about the size of a dime with a thickness of about three dimes. Inside the container is a microchip that stores information. With a handheld probe, you can touch the MicroCan and read information from it, or you can add information it.
This technology has been used for many years in security systems, car locks, maintenance management, and other applications. Many years ago, I saw a MicroCan fastened in a cow's ear. This triggered my curiosity and led me to develop a demonstration route system for preventive maintenance that was used for training and idea creation in training programs. Today, many companies are using MicroCan technology in their maintenance departments-especially for lubrication and inspection routes.
The applications for this technology are limited only by our imaginations. I have introduced it to many maintenance software suppliers without success. They apparently do not see its benefits and say that they have other solutions, including bar codes and other technology. However, bar codes can easily be damaged or painted over.The biggest obstacle with software suppliers is most probably a resistance to change.
The MicroCan technology is so effective that I am convinced we will see more and more of it in the future. If you are interested in learning more about it, you can contact Dallas Semiconductor in Dallas, Texas, and ask for a demonstration kit. We can also give you names of lubrication suppliers offering this system as part of their services.
HYGROSCOPIC BREATHERS AND FILTERS. Poor filtration and moisture in hydraulic systems and lubrication systems are costing the pulp and paper industry millions of dollars. If you keep hydraulic fluids cool and clean, hydraulic systems -to the contrary belief of American industrywill not leak as much as they do in most U.S. pulp and paper mills. If hydraulic fluids and lubrication oils are kept clean from particles bigger than five microns and there is no water content in the systems, components in these systems will have much longer life.
If you use silica-filled filters as breathers on hydraulic systems and, for example, gearboxes, you will eliminate one source of contamination. Desiccant bag filters will dry the air entering the system and filter out particles down to one micron. An indicator will change color when it is time to change the unit. More information is available from Des-Case Corp. in White House,Tenn.
I talked with a pulp and paper maintenance manager in a mill I worked with for many years. This mill used to have problems with the short life-about eight months-of small gears driving its big rotating filters and washers.After trying to solve the problem with other types of oil, the lubrication team modified the gears so that it was easy to connect a mobile filter. They also put hygroscopic filters on the gears. They have now been running the gears for six years without a problem!
HIGH INTENSITY LIGHT. We recently followed up on the results of a PM/ECCM (preventive maintenance/essential care condition monitoring) program that was implemented in two pulp and paper mills. They both used cost avoidance reports to follow up on results. A conservative estimate showed that, in both mills, savings were about ten times the cost of implementing the program in the first six months.
Most of these savings came from avoiding production losses. In one mill, 80% of all work in a shutdown was the result of inspections instead of short notice work orders. Also, one mill followed up on the methods used to identify potential problems. It showed that 73% of identified problems were detected by use of high intensity light and that another 15% were detected by the use of strobe lights. Before the program was implemented, sporadic "when-we-have-time" inspections were done using flashlights. In the initial training, the inspector trainees were introduced to better lights with a light beam of l000w. They discovered that this opened up a new world when they inspected equipment, especially when it was performed in conjunction with detailed cleaning of components.
Ikona to Exhibit New Gearing Products at Permian Basin International Oil Show
Ikona Gear International, Inc. (OTCBB: IKGI) ("Ikona"), an innovator in compact, lightweight, gearing systems solutions, announced today that it will be exhibiting its new gearing products for the oil industry at the upcoming 2006 Permian Basin International Oil Show.
Billed as "The World's Largest Inland Petroleum Exposition," the show will be held at the Ector County Coliseum Complex in Odessa, Texas on October 17, 18 and 19, 2006. Ikona will be located at booth E 23 and will exhibit dedicated oil & gas field machinery product designs for mud pump drives and drawworks.
Ikona COO George Stefan will attend the Odessa show with Ikona's Vice President of Business Development, Vladimir Scekic. Visitors to the Ikona booth at the Odessa show are invited to talk with Ikona's senior management team, access printed materials, and watch animated presentations of Ikona products.
"Our compact and lightweight products offer reduced maintenance requirements, competitive prices, and the best warranty in the industry -- six months longer than the competition," said Stefan. "This helps drilling companies with reducing their capital investments, operating costs, and rig relocation costs.
"As a direct result of the contacts established at the Global Petroleum Show in Calgary, AB, June 13-15, 2006, we received our first oil & gas orders, which currently are either delivered or in process of manufacturing for delivery in December 2006 and January 2007. We have successfully delivered two complete prototype gearboxes within 9 weeks from receipt of the order against an industry standard of 12 to 14 weeks delivery, thus demonstrating Ikona's superior time-to-market abilities and the strength of our supply chain."
About the Permian Basin Show
The Permian Basin International Oil Show, Inc. brings together people from every phase of the petroleum industry. Oil & Gas Leaders come to Odessa, Texas from every corner of the world to learn about the latest technology, the newest equipment, and to transact business and renew friendships. For more information go to
About Ikona Gear International, Inc.
Ikona Gear is a knowledge-based company focused on the design and manufacture of innovative and patented solutions for gearing and power transmission applications, a $100 billion market. The Ikona gear system is better, stronger, more precise and generally superior to standard gearing systems. The Company's unique, patented technology is ideally suited for deep ratio, weight and size constrained applications where often it is the only solution. The Ikona gear technology is the only technology that enables internal gear-sets with only one tooth difference, resulting in a much higher meshing of gears, and significantly higher gear ratios -- very important factors, especially in plastic gearing solutions.
Billed as "The World's Largest Inland Petroleum Exposition," the show will be held at the Ector County Coliseum Complex in Odessa, Texas on October 17, 18 and 19, 2006. Ikona will be located at booth E 23 and will exhibit dedicated oil & gas field machinery product designs for mud pump drives and drawworks.
Ikona COO George Stefan will attend the Odessa show with Ikona's Vice President of Business Development, Vladimir Scekic. Visitors to the Ikona booth at the Odessa show are invited to talk with Ikona's senior management team, access printed materials, and watch animated presentations of Ikona products.
"Our compact and lightweight products offer reduced maintenance requirements, competitive prices, and the best warranty in the industry -- six months longer than the competition," said Stefan. "This helps drilling companies with reducing their capital investments, operating costs, and rig relocation costs.
"As a direct result of the contacts established at the Global Petroleum Show in Calgary, AB, June 13-15, 2006, we received our first oil & gas orders, which currently are either delivered or in process of manufacturing for delivery in December 2006 and January 2007. We have successfully delivered two complete prototype gearboxes within 9 weeks from receipt of the order against an industry standard of 12 to 14 weeks delivery, thus demonstrating Ikona's superior time-to-market abilities and the strength of our supply chain."
About the Permian Basin Show
The Permian Basin International Oil Show, Inc. brings together people from every phase of the petroleum industry. Oil & Gas Leaders come to Odessa, Texas from every corner of the world to learn about the latest technology, the newest equipment, and to transact business and renew friendships. For more information go to
About Ikona Gear International, Inc.
Ikona Gear is a knowledge-based company focused on the design and manufacture of innovative and patented solutions for gearing and power transmission applications, a $100 billion market. The Ikona gear system is better, stronger, more precise and generally superior to standard gearing systems. The Company's unique, patented technology is ideally suited for deep ratio, weight and size constrained applications where often it is the only solution. The Ikona gear technology is the only technology that enables internal gear-sets with only one tooth difference, resulting in a much higher meshing of gears, and significantly higher gear ratios -- very important factors, especially in plastic gearing solutions.
New Breakthrough Mobil Industrial Gear Lubricants Designed to Maximize Performance
Mobilgear 600 XP Series Delivers Exceptional Protection to Reduce Wear and Increase Customers' Productivity
FAIRFAX, Va. -- ExxonMobil today announced that the new Mobilgear 600 XP Series of premium industrial gear oils will be introduced worldwide. Formulated to deliver exceptional, long-lasting protection for industrial gearboxes, Mobilgear 600 XP can help industrial companies become more competitive in global markets by raising their productivity.
"Gearbox technology has advanced significantly in recent years. As a result, maintenance professionals are demanding higher-performance gear oils that can enhance the durability and performance of gearboxes," said Jeff Biamonte, ExxonMobil's global industrial advisor. "At the same time, gear industry groups, gearbox and equipment manufacturers continue to introduce new specifications and equipment designs which impose ever higher demands on gear lubricants."
With its advanced and balanced formulation, Mobilgear 600 XP delivers exceptional performance over the long haul, even under the most demanding operating conditions, surpassing the industry's most demanding specifications, such as Flender BA Table 7300 A, DIN 51517 Part 3 and AGMA 9005 E02.
Mobilgear 600 XP is formulated to minimize wear and enhance the performance of all critical gearbox components - including gears, bearings and seals.
By providing exceptional wear protection, Mobilgear 600 XP helps control micropitting and other forms of gear wear. Its balanced formulation improves bearing and corrosion protection while remaining compatible with commonly used gearbox sealing materials. Furthermore, Mobilgear 600 XP is designed to significantly reduce the formation of oil degradation by-products that often lead to frequent oil changes.
Robert Errichello, a gear failure analysis expert and head of GEARTECH consulting firm based in the United States, stated, "All gear metallurgies are susceptible to wear, and without the appropriate lubrication, this can lead to machine failure. Gear oils need to have basestocks and additives that are properly balanced to protect against micropitting, macropitting, scuffing and corrosion."
"Maintenance and production professionals continue to seek ways to increase productivity and reduce costs by maximizing the reliability of their equipment. Mobilgear 600 XP offers them a huge advance in this quest," said Dr. Tim Nadasdi, ExxonMobil's product technical advisor.
FAIRFAX, Va. -- ExxonMobil today announced that the new Mobilgear 600 XP Series of premium industrial gear oils will be introduced worldwide. Formulated to deliver exceptional, long-lasting protection for industrial gearboxes, Mobilgear 600 XP can help industrial companies become more competitive in global markets by raising their productivity.
"Gearbox technology has advanced significantly in recent years. As a result, maintenance professionals are demanding higher-performance gear oils that can enhance the durability and performance of gearboxes," said Jeff Biamonte, ExxonMobil's global industrial advisor. "At the same time, gear industry groups, gearbox and equipment manufacturers continue to introduce new specifications and equipment designs which impose ever higher demands on gear lubricants."
With its advanced and balanced formulation, Mobilgear 600 XP delivers exceptional performance over the long haul, even under the most demanding operating conditions, surpassing the industry's most demanding specifications, such as Flender BA Table 7300 A, DIN 51517 Part 3 and AGMA 9005 E02.
Mobilgear 600 XP is formulated to minimize wear and enhance the performance of all critical gearbox components - including gears, bearings and seals.
By providing exceptional wear protection, Mobilgear 600 XP helps control micropitting and other forms of gear wear. Its balanced formulation improves bearing and corrosion protection while remaining compatible with commonly used gearbox sealing materials. Furthermore, Mobilgear 600 XP is designed to significantly reduce the formation of oil degradation by-products that often lead to frequent oil changes.
Robert Errichello, a gear failure analysis expert and head of GEARTECH consulting firm based in the United States, stated, "All gear metallurgies are susceptible to wear, and without the appropriate lubrication, this can lead to machine failure. Gear oils need to have basestocks and additives that are properly balanced to protect against micropitting, macropitting, scuffing and corrosion."
"Maintenance and production professionals continue to seek ways to increase productivity and reduce costs by maximizing the reliability of their equipment. Mobilgear 600 XP offers them a huge advance in this quest," said Dr. Tim Nadasdi, ExxonMobil's product technical advisor.
New Breakthrough Mobil Industrial Gear Lubricants Designed to Maximize Performance
Mobilgear 600 XP Series Delivers Exceptional Protection to Reduce Wear and Increase Customers' Productivity
FAIRFAX, Va. -- ExxonMobil today announced that the new Mobilgear 600 XP Series of premium industrial gear oils will be introduced worldwide. Formulated to deliver exceptional, long-lasting protection for industrial gearboxes, Mobilgear 600 XP can help industrial companies become more competitive in global markets by raising their productivity.
"Gearbox technology has advanced significantly in recent years. As a result, maintenance professionals are demanding higher-performance gear oils that can enhance the durability and performance of gearboxes," said Jeff Biamonte, ExxonMobil's global industrial advisor. "At the same time, gear industry groups, gearbox and equipment manufacturers continue to introduce new specifications and equipment designs which impose ever higher demands on gear lubricants."
With its advanced and balanced formulation, Mobilgear 600 XP delivers exceptional performance over the long haul, even under the most demanding operating conditions, surpassing the industry's most demanding specifications, such as Flender BA Table 7300 A, DIN 51517 Part 3 and AGMA 9005 E02. Mobilgear 600 XP is formulated to minimize wear and enhance the performance of all critical gearbox components - including gears, bearings and seals.
By providing exceptional wear protection, Mobilgear 600 XP helps control micropitting and other forms of gear wear. Its balanced formulation improves bearing and corrosion protection while remaining compatible with commonly used gearbox sealing materials. Furthermore, Mobilgear 600 XP is designed to significantly reduce the formation of oil degradation by-products that often lead to frequent oil changes.
Robert Errichello, a gear failure analysis expert and head of GEARTECH consulting firm based in the United States, stated, "All gear metallurgies are susceptible to wear, and without the appropriate lubrication, this can lead to machine failure. Gear oils need to have basestocks and additives that are properly balanced to protect against micropitting, macropitting, scuffing and corrosion."
"Maintenance and production professionals continue to seek ways to increase productivity and reduce costs by maximizing the reliability of their equipment. Mobilgear 600 XP offers them a huge advance in this quest," said Dr. Tim Nadasdi, ExxonMobil's product technical advisor.
FAIRFAX, Va. -- ExxonMobil today announced that the new Mobilgear 600 XP Series of premium industrial gear oils will be introduced worldwide. Formulated to deliver exceptional, long-lasting protection for industrial gearboxes, Mobilgear 600 XP can help industrial companies become more competitive in global markets by raising their productivity.
"Gearbox technology has advanced significantly in recent years. As a result, maintenance professionals are demanding higher-performance gear oils that can enhance the durability and performance of gearboxes," said Jeff Biamonte, ExxonMobil's global industrial advisor. "At the same time, gear industry groups, gearbox and equipment manufacturers continue to introduce new specifications and equipment designs which impose ever higher demands on gear lubricants."
With its advanced and balanced formulation, Mobilgear 600 XP delivers exceptional performance over the long haul, even under the most demanding operating conditions, surpassing the industry's most demanding specifications, such as Flender BA Table 7300 A, DIN 51517 Part 3 and AGMA 9005 E02. Mobilgear 600 XP is formulated to minimize wear and enhance the performance of all critical gearbox components - including gears, bearings and seals.
By providing exceptional wear protection, Mobilgear 600 XP helps control micropitting and other forms of gear wear. Its balanced formulation improves bearing and corrosion protection while remaining compatible with commonly used gearbox sealing materials. Furthermore, Mobilgear 600 XP is designed to significantly reduce the formation of oil degradation by-products that often lead to frequent oil changes.
Robert Errichello, a gear failure analysis expert and head of GEARTECH consulting firm based in the United States, stated, "All gear metallurgies are susceptible to wear, and without the appropriate lubrication, this can lead to machine failure. Gear oils need to have basestocks and additives that are properly balanced to protect against micropitting, macropitting, scuffing and corrosion."
"Maintenance and production professionals continue to seek ways to increase productivity and reduce costs by maximizing the reliability of their equipment. Mobilgear 600 XP offers them a huge advance in this quest," said Dr. Tim Nadasdi, ExxonMobil's product technical advisor.
New utility vehicle from Kubota - utility equipment
Kubota Tractor Corp., Torrance, Calif., has announced the development of its first utility vehicle, the RTV900. Designed for general purpose, worksite, turf and recreational applications, the new unity vehicle is available in four configurations and incorporates the same technology used on the company's tractors, which have been sold in the U.S. for more than 30 years.
Kubota entered the utility vehicle market based on the growing trends of utility vehicles and the resources it already had to produce the vehicles, said James Burnside, product manager at Kubota. "We are going to grow this business. This is going to be big growth for Kubota this year."
After three years in development, Kubota began production on the vehicles in Gainesville, Ga. Full production was slated to begin in January.
While the company may have aimed for commonality between its new utility vehicle and its tractors in many areas, Burnside said the Kubota D902 diesel engine was designed specifically for the RTV900 utility vehicle. The three-cylinder, OHV, liquid-cooled engine has an 898 cc displacement on a bore and stroke of 2.83 in. x 2.90 in. and is rated 21.6 hp. The engine features a half float valve cover with a rubber ring gasket to seal and isolate vibration and reduce noise throughout the crankcase, the company said. Engine cooling is provided by a Denso radiator.
The vehicle's ground drive is a hydrostatic transmission (HST) system that incorporates a shaft-driven pump, mounted to the engine block, that de livers power to a single motor. Kubota built the RTV900 vehicle's HST from the design used in its tractors. "We used the knowledge that we know on hydrostatic and tractors and built a hydrostatic transmission to function in a utility vehicle," said Burnside.
In order for the HST to provide the same low-end torque as Kubota's tractors, a second variable displacement motor is driven off the main pump. Hydraulic flow is provided to this motor through a swashplate that automatically opens when the system senses the HST is beyond its limit, the company said. Hydraulic flow can also be manually directed to the second motor by selecting the low gear range. A foot-operated pedal controls gear selection by changing the gear ratio in the trans mission through a clutchless gear shift. Vehicle operation is also available in mid- and high-speed modes.
Both two- and four-wheel drive is standard on the vehicle, "because we already make our own transmission, gears and gearboxes for all our four-wheel drive tractors," said Burnside. "To take it out of the vehicle was insignificant." Four-wheel drive is activated by a single lever inside the cab.
An independent suspension is mounted to the front axle and rear semi-independent suspension is mounted to the rear axle. The rear axle has a flexible bend to achieve semi-independent movement in the Titan International Inc. tires. Tire options include four-ply turf, six-ply knobby, heavy-duty or ATV
Also taken from its tractor line, is Kubota's power steering and wet disc brakes. The power steering is driven off the engine by a hydraulic cylinder. The brakes prevent free-wheeling during downhill travel, the company said. Additional braking is achieved by a rear wheel, hand lever parking brake.
The four configurations of the RTV900 vehicle include a general purpose model used for light labor with the option of knobby, turf or heavy-duty tires. The work site model features a hydraulic bed lift, grill guard and heavy-duty tires for application in general construction projects. The turf model, with the same features as the work site model, has a rear remote valve to run hydraulic implements for golf and landscape projects and turf style tires. The camo model is designed for the sportsman with protective grill guard, ATV tires and real tree camouflage coloring. All other models are available in Kubota's signature orange color.
Kubota entered the utility vehicle market based on the growing trends of utility vehicles and the resources it already had to produce the vehicles, said James Burnside, product manager at Kubota. "We are going to grow this business. This is going to be big growth for Kubota this year."
After three years in development, Kubota began production on the vehicles in Gainesville, Ga. Full production was slated to begin in January.
While the company may have aimed for commonality between its new utility vehicle and its tractors in many areas, Burnside said the Kubota D902 diesel engine was designed specifically for the RTV900 utility vehicle. The three-cylinder, OHV, liquid-cooled engine has an 898 cc displacement on a bore and stroke of 2.83 in. x 2.90 in. and is rated 21.6 hp. The engine features a half float valve cover with a rubber ring gasket to seal and isolate vibration and reduce noise throughout the crankcase, the company said. Engine cooling is provided by a Denso radiator.
The vehicle's ground drive is a hydrostatic transmission (HST) system that incorporates a shaft-driven pump, mounted to the engine block, that de livers power to a single motor. Kubota built the RTV900 vehicle's HST from the design used in its tractors. "We used the knowledge that we know on hydrostatic and tractors and built a hydrostatic transmission to function in a utility vehicle," said Burnside.
In order for the HST to provide the same low-end torque as Kubota's tractors, a second variable displacement motor is driven off the main pump. Hydraulic flow is provided to this motor through a swashplate that automatically opens when the system senses the HST is beyond its limit, the company said. Hydraulic flow can also be manually directed to the second motor by selecting the low gear range. A foot-operated pedal controls gear selection by changing the gear ratio in the trans mission through a clutchless gear shift. Vehicle operation is also available in mid- and high-speed modes.
Both two- and four-wheel drive is standard on the vehicle, "because we already make our own transmission, gears and gearboxes for all our four-wheel drive tractors," said Burnside. "To take it out of the vehicle was insignificant." Four-wheel drive is activated by a single lever inside the cab.
An independent suspension is mounted to the front axle and rear semi-independent suspension is mounted to the rear axle. The rear axle has a flexible bend to achieve semi-independent movement in the Titan International Inc. tires. Tire options include four-ply turf, six-ply knobby, heavy-duty or ATV
Also taken from its tractor line, is Kubota's power steering and wet disc brakes. The power steering is driven off the engine by a hydraulic cylinder. The brakes prevent free-wheeling during downhill travel, the company said. Additional braking is achieved by a rear wheel, hand lever parking brake.
The four configurations of the RTV900 vehicle include a general purpose model used for light labor with the option of knobby, turf or heavy-duty tires. The work site model features a hydraulic bed lift, grill guard and heavy-duty tires for application in general construction projects. The turf model, with the same features as the work site model, has a rear remote valve to run hydraulic implements for golf and landscape projects and turf style tires. The camo model is designed for the sportsman with protective grill guard, ATV tires and real tree camouflage coloring. All other models are available in Kubota's signature orange color.
Gear Grinder rough and finish grinds gears in one setup
Built on mineral-filled cast polymer base, 6-axis GS:G2 produces gears from 1-12 in. dia, employs near net-shaped or hobbed gears, and requires 15 min of setup. Machine requires users to install proper tooling and enter part form, dress, and grind parameters into control in order to start-up new jobs, while menu-driven screens and Gear Smart(TM) Programming facilitate operation. Product features dual wheel machining and infinitely variable wheel speeds and feeds.
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Sometimes a new machine is just destined to happen. Markets evolve, new technologies emerge, and an experienced machine tool builder seizes the opportunity. The result: the right machine, at the right time, at the right price.
Drake Manufacturing in Warren, OH is putting the finishing touches on a highly productive 6-axis gear grinder that will be grinding quality parts after just 15-minutes of setup. Best part is - like Drake's other gear and thread manufacturing machines - it's priced to provide high return on investment for the job shop owner as well as the large, automotive supplier.
Drake is best known for its line of CNC gear hobbers, thread and worm grinders, rack mills and bore grinders. The GS:G2 is a machine that blends the best of Drake's specialty grinding and gear making expertise.
As the basis of competition in the power transmission and speed reducer markets increasingly shifts toward quiet operation and efficiency, more and more manufacturers are calling for precision ground gears. The Drake GS:G2 enables manufacturers to source near net-shaped or hobbed gears from low-cost suppliers and still control the final product quality. "This is a high value-added grinder, that with minimal capital outlay, can help our customers remain globally competitive for years to come," said Stig Mowatt-Larssen, Drake's Manager of Research and Development.
A flexible grinder
The GS:G2 has the flexibility and capability to handle a variety of grinding roles: job shop work, manufacturing cell environments, high volume grinding - even prototype work. Fast changeovers with menu-driven setup screens-no more change gears or dressing thread wheels-make it easy to switch from job to job.
Ideal customers for the Drake GS:G2 are manufacturers and suppliers of industrial, off-highway and heavy equipment power transmissions, speed reducers, and gearboxes. Actually, anyone who is producing gears and has wanted ground gears but thought an affordable gear grinder was unobtainable is a potential customer. Drake Manufacturing Services made CNC thread grinders affordable 20 years ago and is now working to do the same in gear grinding. "We want to take the mystery out of gear grinding and make that technology widely available and less intimidating," said Michael Hughes, Systems Engineer at Drake.
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Sometimes a new machine is just destined to happen. Markets evolve, new technologies emerge, and an experienced machine tool builder seizes the opportunity. The result: the right machine, at the right time, at the right price.
Drake Manufacturing in Warren, OH is putting the finishing touches on a highly productive 6-axis gear grinder that will be grinding quality parts after just 15-minutes of setup. Best part is - like Drake's other gear and thread manufacturing machines - it's priced to provide high return on investment for the job shop owner as well as the large, automotive supplier.
Drake is best known for its line of CNC gear hobbers, thread and worm grinders, rack mills and bore grinders. The GS:G2 is a machine that blends the best of Drake's specialty grinding and gear making expertise.
As the basis of competition in the power transmission and speed reducer markets increasingly shifts toward quiet operation and efficiency, more and more manufacturers are calling for precision ground gears. The Drake GS:G2 enables manufacturers to source near net-shaped or hobbed gears from low-cost suppliers and still control the final product quality. "This is a high value-added grinder, that with minimal capital outlay, can help our customers remain globally competitive for years to come," said Stig Mowatt-Larssen, Drake's Manager of Research and Development.
A flexible grinder
The GS:G2 has the flexibility and capability to handle a variety of grinding roles: job shop work, manufacturing cell environments, high volume grinding - even prototype work. Fast changeovers with menu-driven setup screens-no more change gears or dressing thread wheels-make it easy to switch from job to job.
Ideal customers for the Drake GS:G2 are manufacturers and suppliers of industrial, off-highway and heavy equipment power transmissions, speed reducers, and gearboxes. Actually, anyone who is producing gears and has wanted ground gears but thought an affordable gear grinder was unobtainable is a potential customer. Drake Manufacturing Services made CNC thread grinders affordable 20 years ago and is now working to do the same in gear grinding. "We want to take the mystery out of gear grinding and make that technology widely available and less intimidating," said Michael Hughes, Systems Engineer at Drake.
Motorized Pulleys offer integrated shaft encoder
BDL motorized pulleys allow conveyor system operators to synchronize product movements. Shaft encoders utilize SKF or SNR pulse outputs to monitor motorized pulley movement and control conveyor belt speed, position, torque, and rotational direction. Accurate conveyor belt movements, up to [+ or -]0.0002 in. at speeds of 19-500 fpm, are achievable. Mounted with 2 brackets, pulleys range from 3.18-12.6 in. in diameter with face widths from 7.8-67 in.
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Motorized pulleys with integrated shaft encoders, that allow conveyor system operators to accurately synchronize product movements, are available from BDL America, Wilmington, N.C. The encoders utilize either SKF or SNR pulse outputs to precisely monitor motorized pulley movement to control conveyor belt speed, position, torque and rotational direction. The motorized pulleys have been successfully applied in applications requiring properly timed conveyor movement, such as: positioning, dispensing, adjusting, cutting, tape winding, pick and place operations, and constant speed applications, among others.
The encoders are hermetically sealed within a stainless steel housing, eliminating the possibility of external influences and providing an extremely reliable control system. Accurate conveyor belt movements up to [+ or -]0.0002-inches at speeds of 19 to 500 fpm are achievable with the motorized pulley and integrated encoder design. The motorized pulleys are protected from dust and moisture, meeting class IP66 and IP67 standards. The integrated encoders are available on the complete line of BDL motorized pulleys ranging from diameters of 3.18 to 12.6 inches, and face widths from 7.8 to 67 inches. Power from the motor is transmitted through the gearbox which is coupled to a geared rim fixed to the drum and housing.
Mounted with just two (2) brackets, there is no need for multiple parts - and multiple vendors. Ordering and installation are quick and easy requiring less than half the time needed to install external drives. The motorized pulley requires no external component maintenance.
Motorized pulleys in the BDL family feature durable steel gears with precision cut and honed teeth - reducing noise levels to only 50dB to meet OSHA requirements. Efficient and reliable, the motors run at 96 percent efficiency, saving up to 32 percent (unloaded) and 47 percent (loaded) on power consumption when compared to exposed drives.
The motor's compact design eliminates all external parts, such as: motors, gearboxes, chains or belts, pillow block bearings and associated guards. Virtually maintenance-free, the units only require an oil change after 50,000 hours of operation and the oil change can be performed without removing the motorized pulley from the conveyor.
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Motorized pulleys with integrated shaft encoders, that allow conveyor system operators to accurately synchronize product movements, are available from BDL America, Wilmington, N.C. The encoders utilize either SKF or SNR pulse outputs to precisely monitor motorized pulley movement to control conveyor belt speed, position, torque and rotational direction. The motorized pulleys have been successfully applied in applications requiring properly timed conveyor movement, such as: positioning, dispensing, adjusting, cutting, tape winding, pick and place operations, and constant speed applications, among others.
The encoders are hermetically sealed within a stainless steel housing, eliminating the possibility of external influences and providing an extremely reliable control system. Accurate conveyor belt movements up to [+ or -]0.0002-inches at speeds of 19 to 500 fpm are achievable with the motorized pulley and integrated encoder design. The motorized pulleys are protected from dust and moisture, meeting class IP66 and IP67 standards. The integrated encoders are available on the complete line of BDL motorized pulleys ranging from diameters of 3.18 to 12.6 inches, and face widths from 7.8 to 67 inches. Power from the motor is transmitted through the gearbox which is coupled to a geared rim fixed to the drum and housing.
Mounted with just two (2) brackets, there is no need for multiple parts - and multiple vendors. Ordering and installation are quick and easy requiring less than half the time needed to install external drives. The motorized pulley requires no external component maintenance.
Motorized pulleys in the BDL family feature durable steel gears with precision cut and honed teeth - reducing noise levels to only 50dB to meet OSHA requirements. Efficient and reliable, the motors run at 96 percent efficiency, saving up to 32 percent (unloaded) and 47 percent (loaded) on power consumption when compared to exposed drives.
The motor's compact design eliminates all external parts, such as: motors, gearboxes, chains or belts, pillow block bearings and associated guards. Virtually maintenance-free, the units only require an oil change after 50,000 hours of operation and the oil change can be performed without removing the motorized pulley from the conveyor.
An introduction to SMALL MODELS
When you were a kid, did you ever dream of controlling your rubber-powered creations? And now, do you wish that you could build a plane in your living room while watching TV? Micro models take up less space than their larger counterparts, can be less expensive, take less time to build and can even be flown indoors! So what are you waiting for? Read on to see how easy it is to join the fun.
The field of micro RC models is rapidly developing, with new products and dealers showing up almost daily. For our purposes, "micro" refers to planes that weigh 2 ounces or less and that use radio and power systems that don't weigh more than 1 ounce combined. Another characteristic of the micro model is that it can use a single Li-poly cell for power. There are a variety of ready-to-fly models available from several dealers as well as quite a selection of kits designed for micro RC. Meanwhile, many modelers have had fine success converting small, rubber-band-powered models to micro RC. A good selection of plans is available for scratch-builders, ranging from simple stick fuselage models to more elaborate scale projects. A good start for plan projects are the Model Airplane News downloads, and many others are available from rcstore.com. Meanwhile, a number of modelers have successfully resized plans from older magazines at photocopy stores that have this capability.
Assuming you have selected the model, let's go over some of the equipment options available and look at a few features and compatibility.
RADIO GEAR
Receivers. Several types of receiver are currently being produced for the micro market. In general, all of them incorporate an electronic speed control (ESC) for small brushed motors. The ratings on these ESC circuits vary, so you need to make sure that the ESC can handle the motor selected. All of the current receivers are designed to operate from a single Li-poly cell (or equivalent voltage, if you're using Ni-Cd or NiMH batteries). At least one of the receivers, the Plantraco HXF900, operates on the 90OMHz frequency band, which eliminates all conflicts with equipment on lower frequencies (of course, you must use Plantraco's matching HFX900 transmitter). Several of the receivers are relatively wide band, and to function without interference, they require that adjacent channels not be in use. Others are narrowband and can operate safely in a crowded environment.
Most of the available receivers can drive actuators directly, while several have outputs that can drive servos. A few are capable of handling brushless motors' speed controls along with other features. The market is changing rapidly, so it pays to compare features and prices.
Actuators. In general, all of the actuators being produced for the micro market are designed along the same lines and operate in the same way. A coil is wired to a special driver in the receiver, in which a proportional voltage is generated depending on the transmitter-stick position. A magnet pivots within this coil and moves in response to the changing voltage. With the proper centering setup, the movement of the magnet is truly proportional to the transmitter stick. The primary difference in these actuators is their size. The smallest weigh only a few tenths of a gram and produce very light forces. Larger units can weigh several grams and operate the controls on larger or faster models.
The field of micro RC models is rapidly developing, with new products and dealers showing up almost daily. For our purposes, "micro" refers to planes that weigh 2 ounces or less and that use radio and power systems that don't weigh more than 1 ounce combined. Another characteristic of the micro model is that it can use a single Li-poly cell for power. There are a variety of ready-to-fly models available from several dealers as well as quite a selection of kits designed for micro RC. Meanwhile, many modelers have had fine success converting small, rubber-band-powered models to micro RC. A good selection of plans is available for scratch-builders, ranging from simple stick fuselage models to more elaborate scale projects. A good start for plan projects are the Model Airplane News downloads, and many others are available from rcstore.com. Meanwhile, a number of modelers have successfully resized plans from older magazines at photocopy stores that have this capability.
Assuming you have selected the model, let's go over some of the equipment options available and look at a few features and compatibility.
RADIO GEAR
Receivers. Several types of receiver are currently being produced for the micro market. In general, all of them incorporate an electronic speed control (ESC) for small brushed motors. The ratings on these ESC circuits vary, so you need to make sure that the ESC can handle the motor selected. All of the current receivers are designed to operate from a single Li-poly cell (or equivalent voltage, if you're using Ni-Cd or NiMH batteries). At least one of the receivers, the Plantraco HXF900, operates on the 90OMHz frequency band, which eliminates all conflicts with equipment on lower frequencies (of course, you must use Plantraco's matching HFX900 transmitter). Several of the receivers are relatively wide band, and to function without interference, they require that adjacent channels not be in use. Others are narrowband and can operate safely in a crowded environment.
Most of the available receivers can drive actuators directly, while several have outputs that can drive servos. A few are capable of handling brushless motors' speed controls along with other features. The market is changing rapidly, so it pays to compare features and prices.
Actuators. In general, all of the actuators being produced for the micro market are designed along the same lines and operate in the same way. A coil is wired to a special driver in the receiver, in which a proportional voltage is generated depending on the transmitter-stick position. A magnet pivots within this coil and moves in response to the changing voltage. With the proper centering setup, the movement of the magnet is truly proportional to the transmitter stick. The primary difference in these actuators is their size. The smallest weigh only a few tenths of a gram and produce very light forces. Larger units can weigh several grams and operate the controls on larger or faster models.
New utility vehicle from Kubota - utility equipment
Kubota Tractor Corp., Torrance, Calif., has announced the development of its first utility vehicle, the RTV900. Designed for general purpose, worksite, turf and recreational applications, the new unity vehicle is available in four configurations and incorporates the same technology used on the company's tractors, which have been sold in the U.S. for more than 30 years.
Kubota entered the utility vehicle market based on the growing trends of utility vehicles and the resources it already had to produce the vehicles, said James Burnside, product manager at Kubota. "We are going to grow this business. This is going to be big growth for Kubota this year."
After three years in development, Kubota began production on the vehicles in Gainesville, Ga. Full production was slated to begin in January.
While the company may have aimed for commonality between its new utility vehicle and its tractors in many areas, Burnside said the Kubota D902 diesel engine was designed specifically for the RTV900 utility vehicle. The three-cylinder, OHV, liquid-cooled engine has an 898 cc displacement on a bore and stroke of 2.83 in. x 2.90 in. and is rated 21.6 hp. The engine features a half float valve cover with a rubber ring gasket to seal and isolate vibration and reduce noise throughout the crankcase, the company said. Engine cooling is provided by a Denso radiator The vehicle's ground drive is a hydrostatic transmission (HST) system that incorporates a shaft-driven pump, mounted to the engine block, that de livers power to a single motor. Kubota built the RTV900 vehicle's HST from the design used in its tractors. "We used the knowledge that we know on hydrostatic and tractors and built a hydrostatic transmission to function in a utility vehicle," said Burnside.
In order for the HST to provide the same low-end torque as Kubota's tractors, a second variable displacement motor is driven off the main pump. Hydraulic flow is provided to this motor through a swashplate that automatically opens when the system senses the HST is beyond its limit, the company said. Hydraulic flow can also be manually directed to the second motor by selecting the low gear range. A foot-operated pedal controls gear selection by changing the gear ratio in the trans mission through a clutchless gear shift. Vehicle operation is also available in mid- and high-speed modes.
Both two- and four-wheel drive is standard on the vehicle, "because we already make our own transmission, gears and gearboxes for all our four-wheel drive tractors," said Burnside. "To take it out of the vehicle was insignificant." Four-wheel drive is activated by a single lever inside the cab.
An independent suspension is mounted to the front axle and rear semi-independent suspension is mounted to the rear axle. The rear axle has a flexible bend to achieve semi-independent movement in the Titan International Inc. tires. Tire options include four-ply turf, six-ply knobby, heavy-duty or ATV
Also taken from its tractor line, is Kubota's power steering and wet disc brakes. The power steering is driven off the engine by a hydraulic cylinder. The brakes prevent free-wheeling during downhill travel, the company said. Additional braking is achieved by a rear wheel, hand lever parking brake.
The four configurations of the RTV900 vehicle include a general purpose model used for light labor with the option of knobby, turf or heavy-duty tires. The work site model features a hydraulic bed lift, grill guard and heavy-duty tires for application in general construction projects. The turf model, with the same features as the work site model, has a rear remote valve to run hydraulic implements for golf and landscape projects and turf style tires. The camo model is designed for the sportsman with protective grill guard, ATV tires and real tree camouflage coloring. All other models are available in Kubota's signature orange color.
Kubota entered the utility vehicle market based on the growing trends of utility vehicles and the resources it already had to produce the vehicles, said James Burnside, product manager at Kubota. "We are going to grow this business. This is going to be big growth for Kubota this year."
After three years in development, Kubota began production on the vehicles in Gainesville, Ga. Full production was slated to begin in January.
While the company may have aimed for commonality between its new utility vehicle and its tractors in many areas, Burnside said the Kubota D902 diesel engine was designed specifically for the RTV900 utility vehicle. The three-cylinder, OHV, liquid-cooled engine has an 898 cc displacement on a bore and stroke of 2.83 in. x 2.90 in. and is rated 21.6 hp. The engine features a half float valve cover with a rubber ring gasket to seal and isolate vibration and reduce noise throughout the crankcase, the company said. Engine cooling is provided by a Denso radiator The vehicle's ground drive is a hydrostatic transmission (HST) system that incorporates a shaft-driven pump, mounted to the engine block, that de livers power to a single motor. Kubota built the RTV900 vehicle's HST from the design used in its tractors. "We used the knowledge that we know on hydrostatic and tractors and built a hydrostatic transmission to function in a utility vehicle," said Burnside.
In order for the HST to provide the same low-end torque as Kubota's tractors, a second variable displacement motor is driven off the main pump. Hydraulic flow is provided to this motor through a swashplate that automatically opens when the system senses the HST is beyond its limit, the company said. Hydraulic flow can also be manually directed to the second motor by selecting the low gear range. A foot-operated pedal controls gear selection by changing the gear ratio in the trans mission through a clutchless gear shift. Vehicle operation is also available in mid- and high-speed modes.
Both two- and four-wheel drive is standard on the vehicle, "because we already make our own transmission, gears and gearboxes for all our four-wheel drive tractors," said Burnside. "To take it out of the vehicle was insignificant." Four-wheel drive is activated by a single lever inside the cab.
An independent suspension is mounted to the front axle and rear semi-independent suspension is mounted to the rear axle. The rear axle has a flexible bend to achieve semi-independent movement in the Titan International Inc. tires. Tire options include four-ply turf, six-ply knobby, heavy-duty or ATV
Also taken from its tractor line, is Kubota's power steering and wet disc brakes. The power steering is driven off the engine by a hydraulic cylinder. The brakes prevent free-wheeling during downhill travel, the company said. Additional braking is achieved by a rear wheel, hand lever parking brake.
The four configurations of the RTV900 vehicle include a general purpose model used for light labor with the option of knobby, turf or heavy-duty tires. The work site model features a hydraulic bed lift, grill guard and heavy-duty tires for application in general construction projects. The turf model, with the same features as the work site model, has a rear remote valve to run hydraulic implements for golf and landscape projects and turf style tires. The camo model is designed for the sportsman with protective grill guard, ATV tires and real tree camouflage coloring. All other models are available in Kubota's signature orange color.
American Gear Manufacturers Association
The American Gear Manufacturers Association (AGMA) will sponsor an exhibit pavilion for its members at the 2008 IFPE--International Exposition for Power Transmission. AGMA will also promote the show as an IFPE 2008 supporting organization. IFPE 2008 will be held March 11-15, 2008, at the Las Vegas Convention Center in Las Vegas, Nev., and will be North America's largest exposition and technical conference for hydraulic, pneumatic, electrical and mechanical power transmission components, systems and controls. AGMA members primarily manufacture gears, gearboxes, flexible couplings or mechanical power transmission equipment or components; supply machine tools, cutting tools and other capital equipment to the gear manufacturing industry; or offer supplies or services such as gear blanks, lubricants, heat treating and grinding.
Gear Grinder rough and finish grinds gears in one setup
Built on mineral-filled cast polymer base, 6-axis GS:G2 produces gears from 1-12 in. dia, employs near net-shaped or hobbed gears, and requires 15 min of setup. Machine requires users to install proper tooling and enter part form, dress, and grind parameters into control in order to start-up new jobs, while menu-driven screens and Gear Smart(TM) Programming facilitate operation. Product features dual wheel machining and infinitely variable wheel speeds and feeds.
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Sometimes a new machine is just destined to happen. Markets evolve, new technologies emerge, and an experienced machine tool builder seizes the opportunity. The result: the right machine, at the right time, at the right price.
Drake Manufacturing in Warren, OH is putting the finishing touches on a highly productive 6-axis gear grinder that will be grinding quality parts after just 15-minutes of setup. Best part is - like Drake's other gear and thread manufacturing machines - it's priced to provide high return on investment for the job shop owner as well as the large, automotive supplier.
Drake is best known for its line of CNC gear hobbers, thread and worm grinders, rack mills and bore grinders. The GS:G2 is a machine that blends the best of Drake's specialty grinding and gear making expertise.
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Sometimes a new machine is just destined to happen. Markets evolve, new technologies emerge, and an experienced machine tool builder seizes the opportunity. The result: the right machine, at the right time, at the right price.
Drake Manufacturing in Warren, OH is putting the finishing touches on a highly productive 6-axis gear grinder that will be grinding quality parts after just 15-minutes of setup. Best part is - like Drake's other gear and thread manufacturing machines - it's priced to provide high return on investment for the job shop owner as well as the large, automotive supplier.
Drake is best known for its line of CNC gear hobbers, thread and worm grinders, rack mills and bore grinders. The GS:G2 is a machine that blends the best of Drake's specialty grinding and gear making expertise.
Right-angle drives have all applications covered
Davall Stock Gears has released a new series of right angle drives, a worm and worm-wheel gear speed reducer. The series comprises seven standard sizes of gearbox, with reduction ratios between 7:1 and 102:1, power ratings from 0.12 to 4kW, which can provide 15 to 850Nm output torque. The reduction ratios can be increased significantly when mounting two reducers together to provide up to 9792:1 in a combination unit.
The core product is based around a simple, sealed for life, modular design, comprising of an innovative two piece aluminium casing, vacuum impregnated (to seal and protect) with Resinol RT, ground and case hardened alloy steel worm and a bronze alloy wheel.
The high-speed input shaft is supported with two oversized bearings, ideal for frequent start or reversing applications, whilst the slower speed shaft has oversized bearings to accommodate maximum output bore (or shaft) diameters, and the housing is sealed using high temperature nitrile seals.
Critical exterior surfaces are precision machined to enable a variety of mounting accessories to be attached, for example, either an IEC or NEMA C flange motor adapter, output torque arm.
The series has been developed to provide as many additional engineering features as might be required to design a drive, without the necessary delay and expense of a custom gearbox.
The product range is suitable for use in all applications, and is also available on request, either certified to ATEX Category 2 and ATEX Category 3 or with stainless steel components for food environments.
Designed primarily for the European market, metric configuration, there is the unusual option of standard products focused toward the significant North American market, based around imperial dimensions.
After market service is available through a global network of distributors and agents.
The series has been developed to replicate the critical dimensions of other popular gearboxes currently available.
The core product is based around a simple, sealed for life, modular design, comprising of an innovative two piece aluminium casing, vacuum impregnated (to seal and protect) with Resinol RT, ground and case hardened alloy steel worm and a bronze alloy wheel.
The high-speed input shaft is supported with two oversized bearings, ideal for frequent start or reversing applications, whilst the slower speed shaft has oversized bearings to accommodate maximum output bore (or shaft) diameters, and the housing is sealed using high temperature nitrile seals.
Critical exterior surfaces are precision machined to enable a variety of mounting accessories to be attached, for example, either an IEC or NEMA C flange motor adapter, output torque arm.
The series has been developed to provide as many additional engineering features as might be required to design a drive, without the necessary delay and expense of a custom gearbox.
The product range is suitable for use in all applications, and is also available on request, either certified to ATEX Category 2 and ATEX Category 3 or with stainless steel components for food environments.
Designed primarily for the European market, metric configuration, there is the unusual option of standard products focused toward the significant North American market, based around imperial dimensions.
After market service is available through a global network of distributors and agents.
The series has been developed to replicate the critical dimensions of other popular gearboxes currently available.
Two speed clutches feature on combination lathe
The effectiveness of ZF Industrial's two-speed products in providing improved performance from machine tools has been underlined recently with the adoption by Colchester, part of 600 Group, of ZF two speed clutches on what is claimed to be the world's most technically advanced combination lathe. The lathe is the new Combi K, which was unveiled for the first time at MACH 2000. Designed for manual, electronic and full CNC operation, the Combi K is a two-axis machine offering a host of innovative features, not least its unique 30 degree slant bed design, which puts an end to swarf debris accumulation and the damage that it can cause.
The design of the Combi K is a true synergy of ergonomics, technical innovation, flexibility and cost effectiveness.
The machine is modular in concept to allow for any size of bed length, and employs only high performance "lean turn" components in an integrated approach that allows cost compression.
One of the key components in this lean turn approach is ZF's gearless, self-contained two-speed clutch/pulley unit assembly, which in combination with a custom-developed, wide range, high performance motor offers a 20:1 constant power band.
"The ZF two speed clutch provides us with a convenient and inexpensive way of achieving a two speed machine with a wider spread of power and without the added cost and complexity of gears," say Colchester's Technical Director, Peter Cook.
"The system is more cost effective, quieter, more reliable, and certainly more time efficient for the operator as the time for changing speed ranges is considerably reduced.
"Colchester is the latest machine tool manufacturer to realise the cost and convenience benefits of our two speed products," commented ZF's Account Manager, Rob Pearson.
"The products are the ideal OEM component for modern machine tools.
They provide full power across the widest range of speeds, are compact and easy to install, are essentially maintenance free and remove the need to use large, and expensive, motors - and gearboxes."
"In addition to two speed clutches, the range also includes a two speed gearbox which is being used by many machine tool manufacturers across the world.
These are being increasingly adopted because they provide constant power across the speed range of a machine tool, right down to a common base speed of 375rpm.
This enables machine tool builders to standardise on their machine construction, and to reduce costs and build times, because the same mechanical arrangement can always to be used, irrespective of the maximum speed requirement.
The design of the Combi K is a true synergy of ergonomics, technical innovation, flexibility and cost effectiveness.
The machine is modular in concept to allow for any size of bed length, and employs only high performance "lean turn" components in an integrated approach that allows cost compression.
One of the key components in this lean turn approach is ZF's gearless, self-contained two-speed clutch/pulley unit assembly, which in combination with a custom-developed, wide range, high performance motor offers a 20:1 constant power band.
"The ZF two speed clutch provides us with a convenient and inexpensive way of achieving a two speed machine with a wider spread of power and without the added cost and complexity of gears," say Colchester's Technical Director, Peter Cook.
"The system is more cost effective, quieter, more reliable, and certainly more time efficient for the operator as the time for changing speed ranges is considerably reduced.
"Colchester is the latest machine tool manufacturer to realise the cost and convenience benefits of our two speed products," commented ZF's Account Manager, Rob Pearson.
"The products are the ideal OEM component for modern machine tools.
They provide full power across the widest range of speeds, are compact and easy to install, are essentially maintenance free and remove the need to use large, and expensive, motors - and gearboxes."
"In addition to two speed clutches, the range also includes a two speed gearbox which is being used by many machine tool manufacturers across the world.
These are being increasingly adopted because they provide constant power across the speed range of a machine tool, right down to a common base speed of 375rpm.
This enables machine tool builders to standardise on their machine construction, and to reduce costs and build times, because the same mechanical arrangement can always to be used, irrespective of the maximum speed requirement.
Range comprises 133 standard gear products
As its latest all-product catalogue confirms, Japan's leading manufacturer of gear products, KHK, continues to expand its range. This new publication introduces several new products and reinforces KHK's status as a comprehensive single source supplier. The full KHK product programme is supplied in the UK by sole distributor RA Rodriguez from whom the new KHK 3009 product guide and technical databook is also now available.
The 382-page book has been designed for easy reference and to complement the company's web-based catalogue.
The range now comprises 133 standard gear products and more than 4000 individual items.
Several new additions appear in this issue including an expanded range of racks, three types of bevel gearboxes and a new K-clamp for spur gears.
The 382-page book has been designed for easy reference and to complement the company's web-based catalogue.
The range now comprises 133 standard gear products and more than 4000 individual items.
Several new additions appear in this issue including an expanded range of racks, three types of bevel gearboxes and a new K-clamp for spur gears.
Igus (UK) can provide a multitude of high-performance plastic bearing alternatives for the automotive industry. Igus tailor-made materials and solutio
The new MCA range of brushless maintenance-free servomotors comprises 19 models across frame size 56 to 112, with a choice between natural ventilation and forced cooling. Standard options are brakes, resolvers, encoders and plug or terminal box connection. Enclosure is to IP54 but can be readily upgraded to IP65 on request.
Compared to synchronous motors, asynchronous models are more robust and the MCA series has particularly high overload capacities from five to more than ten times nominal torque.
Costs are lower as the construction does not use expensive rare-earth magnets.
Sizes are generally larger which leads to higher inertias and a performance that is less dynamic but still suiting most applications.
A further advantage is the ability to run at high speeds through field weakening, up to 8000rev/min on the MCA range.
Rated output torques range from 2 to 55Nm at speeds of 2000 to 4000rev/min.
The addition of a rear mounted blower increases the torque on a given frame size by a factor of two or more.
Lenze offers UL conformity as standard for the North American market, and a full range of pre-assembled system cables to speed installation.
An almost infinite range of solutions can be specified by combining MCA motors with Lenze G-motion gearboxes.
These include inline planetary gears with rated outputs up to 1000Nm, as well as helical and right-angle bevel designs.
Gear ratios are possible between 1.6 and 412.
Many combinations can be built from stock parts for fast delivery, and low backlash of typically 6-10arc-min is available.
Compared to synchronous motors, asynchronous models are more robust and the MCA series has particularly high overload capacities from five to more than ten times nominal torque.
Costs are lower as the construction does not use expensive rare-earth magnets.
Sizes are generally larger which leads to higher inertias and a performance that is less dynamic but still suiting most applications.
A further advantage is the ability to run at high speeds through field weakening, up to 8000rev/min on the MCA range.
Rated output torques range from 2 to 55Nm at speeds of 2000 to 4000rev/min.
The addition of a rear mounted blower increases the torque on a given frame size by a factor of two or more.
Lenze offers UL conformity as standard for the North American market, and a full range of pre-assembled system cables to speed installation.
An almost infinite range of solutions can be specified by combining MCA motors with Lenze G-motion gearboxes.
These include inline planetary gears with rated outputs up to 1000Nm, as well as helical and right-angle bevel designs.
Gear ratios are possible between 1.6 and 412.
Many combinations can be built from stock parts for fast delivery, and low backlash of typically 6-10arc-min is available.
Plastic bearings offer automotive alternatives
Igus (UK) can provide a multitude of high-performance plastic bearing alternatives for the automotive industry. Igus tailor-made materials and solutions deliver a longer life at a lower cost with bearings designed for specific automotive applications, including: convertible tops; door hinges; chassis (shock absorbers, brakes and control arms); seats (lift links, headrests and gears); windscreen wipers; steering systems (both shaft and column); foot pedals; gearboxes; and engine compartments (variable air intake, EGR, belt tensioner and throttle valve). Igus' Iglidur suite of plastic plain bearings offers customers the choice of more than 6000 imperial and metric bearings from stock.
Iglidur plastic bearings are a convenient, cost-effective alternative to bronze, metal-backed and custom injection-moulded bearings.
All Iglidur bearings are self-lubricating and maintenance-free.
The plastic-based construction eliminates corrosion and delivers better vibration dampening than metal bearings.
Some Igus bearings that are designed for automotive applications include Iglidur H2 and H4 plain bearings, which are ideal for under-the-bonnet automotive applications, where extreme temperatures and harsh chemicals are common.
Iglidur GLW is an economical solution for mass production.
Iglidur J is well suited for applications with quick, short rotations such as seat adjustment and mirror actuators.
Igus works with its customers to find the right solution for each individual application.
Organisations that use Iglidur bearings in their automotive applications will receive the following technical advantages: high temperatures during the e-coating process enable bearings to recalibrate for a low-clearance fit; low-clearance bearings, designed to meet specified housing bore and shaft tolerances; preloaded bearings for equalising tube tolerances on pedal systems; bearings that provide vibration damping in transmission control forks; and self-lubricating bearings which are dirt-resistant in the suspension system.
All customers will receive research and development, application assistance, production installation and worldwide logistics.
Iglidur plastic bearings are a convenient, cost-effective alternative to bronze, metal-backed and custom injection-moulded bearings.
All Iglidur bearings are self-lubricating and maintenance-free.
The plastic-based construction eliminates corrosion and delivers better vibration dampening than metal bearings.
Some Igus bearings that are designed for automotive applications include Iglidur H2 and H4 plain bearings, which are ideal for under-the-bonnet automotive applications, where extreme temperatures and harsh chemicals are common.
Iglidur GLW is an economical solution for mass production.
Iglidur J is well suited for applications with quick, short rotations such as seat adjustment and mirror actuators.
Igus works with its customers to find the right solution for each individual application.
Organisations that use Iglidur bearings in their automotive applications will receive the following technical advantages: high temperatures during the e-coating process enable bearings to recalibrate for a low-clearance fit; low-clearance bearings, designed to meet specified housing bore and shaft tolerances; preloaded bearings for equalising tube tolerances on pedal systems; bearings that provide vibration damping in transmission control forks; and self-lubricating bearings which are dirt-resistant in the suspension system.
All customers will receive research and development, application assistance, production installation and worldwide logistics.
Lubricants save money at brickworks
A success story for Sovereign Lubricants and Seals concerns the manufacturing of bricks and the associated machinery that is subject to harsh conditions. All companies involved in this business experience the same problems with machinery wearing out quickly due to poor or inadequate lubrication, A brickworks that has been using Omega since 1983 has proven that quality lubricants make a noticeable difference to wear and tear on plant and equipment and in turn increase productivity results. The brickworks first started using Omega 690 gear oil in January 1983 and after trials is now running Omega 690 in most of its gearboxes.
There are hardly any failures these days and the firm saves about 10% on energy.
The boxes run quieter and the oil lasts longer.
For the past 23 years, the brickworks has used Omega 71 high temperature grease in its kiln fan bearings, which are subjected to extreme heat.
The product has let the firm save on maintenance costs.
It also uses this product on its screen bearings which are in a very dusty and wet environment.
It had big problems finding a suitable high temperature lubricant for its kiln car bearings for many years until Sovereign introduced it to the Omega 35 in November 1994.
This product has been a success in handling the very high under car temperatures.
Sometimes the temperatures are as high as 350C in certain hotspots and this would melt or harden other greases and the bearings would seize.
Now it only uses 10kg of Omega 35 per year to grease all its kiln cars, saving thousands of pounds per year in staff hours and cost of grease as it only greases once per year.
It has also saved money on not having to replace seized bearings.
Finally, it uses Omega 73 on all its open gears.
The Chief Engineer at the brickworks, which is based in South Yorkshire, said: '23 years of satisfaction'.
There are hardly any failures these days and the firm saves about 10% on energy.
The boxes run quieter and the oil lasts longer.
For the past 23 years, the brickworks has used Omega 71 high temperature grease in its kiln fan bearings, which are subjected to extreme heat.
The product has let the firm save on maintenance costs.
It also uses this product on its screen bearings which are in a very dusty and wet environment.
It had big problems finding a suitable high temperature lubricant for its kiln car bearings for many years until Sovereign introduced it to the Omega 35 in November 1994.
This product has been a success in handling the very high under car temperatures.
Sometimes the temperatures are as high as 350C in certain hotspots and this would melt or harden other greases and the bearings would seize.
Now it only uses 10kg of Omega 35 per year to grease all its kiln cars, saving thousands of pounds per year in staff hours and cost of grease as it only greases once per year.
It has also saved money on not having to replace seized bearings.
Finally, it uses Omega 73 on all its open gears.
The Chief Engineer at the brickworks, which is based in South Yorkshire, said: '23 years of satisfaction'.
Rotary actuator range expands its coverage
applications where dynamic force demands are below 100Nm. Conversely, the Model 17 is a modular maintenance-free design engineered for high torque, high load environments.
Application potential for both designs is wide and varied.
For example, the Crab 17 has been adopted by the electricity supply industry.
Manufactures of high power switching gear are using the actuator to provide the motive power for high reliability, remote controlled motorised switches, which automatically ensure distribution continuity by bypassing line faults.
Model 05 rotary actuators result from the development of a new, patented Swedish seat recliner technology, which has been successfully applied in the automotive industry.
Car seat applications demand low cost, high impact strength and easy operation (electric or manual).
Also, for reliability, they require minimum moving parts and a lubricated-for-life design.
To meet this design brief, the 05 actuators comprise two planetary gearboxes, which provide a final gear ratio equal to their difference.
Thus, high ratios can be achieved with a simple design and few moving parts.
As standard, Crab 05 units feature chrome-plated steel components which suit dry, indoor applications.
However, for more demanding environments, SKF can manufacture customised solutions.
Model 05 actuators are primarily designed for exposure to torque.
Key specifications include: a maximum static output torque 800Nm (flange) and 40Nm (sun gear); maximum dynamic output torque 100Nm; maximum radial force 200N; gear ratio 56:1 or 57:1; and maximum input speed 300rev/min.
Operating temperature range is 5 to 40C.
Moving to the Crab 17, priorities switch to design flexibility and modularity within a compact, high torque, high load unit.
Regarding flexibility, in addition to a wide choice of standard motors, gears, connectors and output shaft configurations, customers can also opt for bespoke elements such as custom machined outputs.
Model 17 actuators can be used as load-bearing elements of machine designs without the need for additional bearing arrangements.
The aluminium housing is prelubricated, sealed-for-life and maintenance-free.
Requiring just four mounting bolts, the actuators can be used in extremes of temperature and humidity.
Specifications include: maximum instantaneous output torque 200Nm; maximum axial load 5000N; maximum angular speed 180deg/s; and backlash +/-0.25deg
Application potential for both designs is wide and varied.
For example, the Crab 17 has been adopted by the electricity supply industry.
Manufactures of high power switching gear are using the actuator to provide the motive power for high reliability, remote controlled motorised switches, which automatically ensure distribution continuity by bypassing line faults.
Model 05 rotary actuators result from the development of a new, patented Swedish seat recliner technology, which has been successfully applied in the automotive industry.
Car seat applications demand low cost, high impact strength and easy operation (electric or manual).
Also, for reliability, they require minimum moving parts and a lubricated-for-life design.
To meet this design brief, the 05 actuators comprise two planetary gearboxes, which provide a final gear ratio equal to their difference.
Thus, high ratios can be achieved with a simple design and few moving parts.
As standard, Crab 05 units feature chrome-plated steel components which suit dry, indoor applications.
However, for more demanding environments, SKF can manufacture customised solutions.
Model 05 actuators are primarily designed for exposure to torque.
Key specifications include: a maximum static output torque 800Nm (flange) and 40Nm (sun gear); maximum dynamic output torque 100Nm; maximum radial force 200N; gear ratio 56:1 or 57:1; and maximum input speed 300rev/min.
Operating temperature range is 5 to 40C.
Moving to the Crab 17, priorities switch to design flexibility and modularity within a compact, high torque, high load unit.
Regarding flexibility, in addition to a wide choice of standard motors, gears, connectors and output shaft configurations, customers can also opt for bespoke elements such as custom machined outputs.
Model 17 actuators can be used as load-bearing elements of machine designs without the need for additional bearing arrangements.
The aluminium housing is prelubricated, sealed-for-life and maintenance-free.
Requiring just four mounting bolts, the actuators can be used in extremes of temperature and humidity.
Specifications include: maximum instantaneous output torque 200Nm; maximum axial load 5000N; maximum angular speed 180deg/s; and backlash +/-0.25deg
Geared motors excite packaging machine makers
Lenze is an official distributor for Panasonic, one of the largest motor manufacturers in the world. Panasonic developed the G-series range of geared motors which cover powers from 6 to 90W. These units are now established in the worldwide market with a reputation for quality, value and long life.
The PPMA show held in September 2005 at the Birmingham NEC proved the popularity of the range with many of the displayed machines using the G-series range.
The G-series range of geared motors are designed for single- and three-phase supply, the single-phase units are suitable for fixed speed running in a power range of 6 to 90W.
The three-phase motors ranging from 25-90W have two versions, 230V ideal for variable speed control with an inverter and the 400V version designed for fixed speed running.
All 6 to 40W models are all self cooled, and the 60 to 90W units are supplied with a cooling fan.
The G-series geared motors are available as standard induction, quick reversible or braked motors.
Standard induction motors are highly efficient and quite in operation.
The same high quality design and basic construction is used throughout the range.
All motors are four-pole with a nominal speed of 1500rev/min at 50Hz.
Quick reversible motors have a plate attached to the end of the rotor which is constantly under friction via four cylindrical brake pads and springs.
The resulting braking torque is continuously applied to the motor even during motor running.
When power is removed, this friction results in faster stopping of the motor.
The brakes in the braked motor models release when power is turned on leaving no residual torque, so when the motor is switched off the brake engages.
The gearboxes are available in standard ratios of 3:1 to 200:1 and use a combination of helical and spur gears for high speed efficient running.
Where high rations and lower speeds are required, an intermediate decimal gearbox is available.
If variable speed is required the 230V three-phase geared motors can be used with the Panasonic Micro-Inverter.
This combination offers excellent speed/torque characteristics and good dynamic motor performance.
Other inverters with higher functionality can be used, for example the Lenze smd with its unique memory chip which contains the entire drive and motor configuration and can be easily removed and replaced for fast and efficient program changes, saving time and money.
With the G-series suitable for conveyor, food machinery, packaging, pumps, labelling and test equipment applications, it's no wonder that many of the packaging industry's top manufacturers include the G-series in show machinery.
The PPMA show held in September 2005 at the Birmingham NEC proved the popularity of the range with many of the displayed machines using the G-series range.
The G-series range of geared motors are designed for single- and three-phase supply, the single-phase units are suitable for fixed speed running in a power range of 6 to 90W.
The three-phase motors ranging from 25-90W have two versions, 230V ideal for variable speed control with an inverter and the 400V version designed for fixed speed running.
All 6 to 40W models are all self cooled, and the 60 to 90W units are supplied with a cooling fan.
The G-series geared motors are available as standard induction, quick reversible or braked motors.
Standard induction motors are highly efficient and quite in operation.
The same high quality design and basic construction is used throughout the range.
All motors are four-pole with a nominal speed of 1500rev/min at 50Hz.
Quick reversible motors have a plate attached to the end of the rotor which is constantly under friction via four cylindrical brake pads and springs.
The resulting braking torque is continuously applied to the motor even during motor running.
When power is removed, this friction results in faster stopping of the motor.
The brakes in the braked motor models release when power is turned on leaving no residual torque, so when the motor is switched off the brake engages.
The gearboxes are available in standard ratios of 3:1 to 200:1 and use a combination of helical and spur gears for high speed efficient running.
Where high rations and lower speeds are required, an intermediate decimal gearbox is available.
If variable speed is required the 230V three-phase geared motors can be used with the Panasonic Micro-Inverter.
This combination offers excellent speed/torque characteristics and good dynamic motor performance.
Other inverters with higher functionality can be used, for example the Lenze smd with its unique memory chip which contains the entire drive and motor configuration and can be easily removed and replaced for fast and efficient program changes, saving time and money.
With the G-series suitable for conveyor, food machinery, packaging, pumps, labelling and test equipment applications, it's no wonder that many of the packaging industry's top manufacturers include the G-series in show machinery.
"Mounting Flanges"...
We see from your search that you're looking for information on the term "Mounting Flanges", and we have a large number of manufacturers' news releases and technical articles here on Engineeringtalk which will be of interest. Let me be your guide.
Start with the news release Tank heaters reduce wear in hydraulic systems from KTR Couplings, which we summarised at the time by saying "The viscosity of the hydraulic fluid is a main parameter for the long lifetime of a hydraulic system". A few weeks before, we featured the news release Helical geared motors deliver more torque from Leroy Somer: "Designed to exceed the demands of today's industrial applications, the new 3000 range consists of three modular families of helical-geared motors.".
In September 2006, we covered the news from Elite Thermal Engineering concerning its OCP-055 - take a look at Cold plates extend to OEM applications which says: "Elite Thermal Engineering has extended its cold plate product line to OEM applications.".
Take a look also at the news release from Zeitlauf UK, Flanges make light of gearmotor construction, as well as Control valves for long life and high performance from ARI Armaturen (UK), and Customised gearbox aids extraterrestrial search from David Brown Engineering.
Start with the news release Tank heaters reduce wear in hydraulic systems from KTR Couplings, which we summarised at the time by saying "The viscosity of the hydraulic fluid is a main parameter for the long lifetime of a hydraulic system". A few weeks before, we featured the news release Helical geared motors deliver more torque from Leroy Somer: "Designed to exceed the demands of today's industrial applications, the new 3000 range consists of three modular families of helical-geared motors.".
In September 2006, we covered the news from Elite Thermal Engineering concerning its OCP-055 - take a look at Cold plates extend to OEM applications which says: "Elite Thermal Engineering has extended its cold plate product line to OEM applications.".
Take a look also at the news release from Zeitlauf UK, Flanges make light of gearmotor construction, as well as Control valves for long life and high performance from ARI Armaturen (UK), and Customised gearbox aids extraterrestrial search from David Brown Engineering.
Shaft Collars Hold Tight Face Tolerance
Shaft collars function as mechanical stops, clamps often used on split hubs, bearing faces and as a means for locating components on a variety of equipment including motors, gearboxes, linear actuators, packaging equipment, printing presses, medical devices, and measuring instruments. Shaft collars from Ruland are single point faced to ensure a high level of face to bore perpendicularity. The result is face runout of TIR < .05 mm (.002') on standard collars with even tighter tolerance on bearing locknuts and special designs.
A precise shaft collar face to bore relationship is important for many applications.
It ensures that components are both properly positioned and not tilted on the shaft.
Collar face perpendicularity also ensures even pressure on interfaced components.
Uneven pressure can result in premature failure of components such as bearings.
When shaft collars are subject to shock loads, precise facing reduces the likelihood that the position of the collar will be shifted.
A circular groove indicates the precision face on Ruland shaft collars.
The collars should be installed so that the groove is on the side that will receive shock loads or is against components needing precise positioning or even pressure.
Ruland offers shaft collars in aluminium, black oxide carbon steel and stainless steel, as well as engineered plastic collars.
One- and two-piece clamp-style designs are available with bore sizes from 3mm to 80mm.
Clamp-style shaft collars do not mar the shaft like traditional set-screw types (DIN 705).
Clamp-style collars also have higher holding power because they wrap around the shaft when tightened thus applying compressive stress nearly uniformly on the circumference of the shaft.
Two-piece clamp-style collars have an additional advantage since they can be installed on the shaft without removing other components.
Ruland uses forged socket hardware in all its shaft collars, which allows for higher screw torque and increased holding power.
Shaft collars are part of Ruland's complete product line which also includes rigid couplings with precision honed bores and five types of zero-backlash motion control couplings: beam couplings, bellows couplings, oldham couplings, miniature disc couplings and curved jaw couplings.
A precise shaft collar face to bore relationship is important for many applications.
It ensures that components are both properly positioned and not tilted on the shaft.
Collar face perpendicularity also ensures even pressure on interfaced components.
Uneven pressure can result in premature failure of components such as bearings.
When shaft collars are subject to shock loads, precise facing reduces the likelihood that the position of the collar will be shifted.
A circular groove indicates the precision face on Ruland shaft collars.
The collars should be installed so that the groove is on the side that will receive shock loads or is against components needing precise positioning or even pressure.
Ruland offers shaft collars in aluminium, black oxide carbon steel and stainless steel, as well as engineered plastic collars.
One- and two-piece clamp-style designs are available with bore sizes from 3mm to 80mm.
Clamp-style shaft collars do not mar the shaft like traditional set-screw types (DIN 705).
Clamp-style collars also have higher holding power because they wrap around the shaft when tightened thus applying compressive stress nearly uniformly on the circumference of the shaft.
Two-piece clamp-style collars have an additional advantage since they can be installed on the shaft without removing other components.
Ruland uses forged socket hardware in all its shaft collars, which allows for higher screw torque and increased holding power.
Shaft collars are part of Ruland's complete product line which also includes rigid couplings with precision honed bores and five types of zero-backlash motion control couplings: beam couplings, bellows couplings, oldham couplings, miniature disc couplings and curved jaw couplings.
Better torque output from servo motor brake
Nexen Group has announced the new Eclipse Servo Motor Brake with superior torque output, offering rugged durability for dynamic stopping applications. This brake is an ideal solution for vertical and horizontal holding and braking applications for the packaging and material handling industries. These high-capacity, air-engaged brakes provide 20-50% more stopping torque compared to electric brakes and provide sufficient holding force to stall a servo motor.
Eclipse Servo Motor Brakes also offer improved operating safety and the prevention of premature brake burn-out.
They are designed for cool operation, high efficiency, and less energy consumption.
The flange-mounted Eclipse servo motor brake will fit externally, mounting directly between the servo motor (frequently metric) and industry standard NEMA outputs, such as gearboxes.
All models are available for servo motor frame sizes of two, three, four and five inches.
These brakes offer consistent long-lasting performance with virtually no maintenance needed.
Eclipse Servo Motor Brakes also offer improved operating safety and the prevention of premature brake burn-out.
They are designed for cool operation, high efficiency, and less energy consumption.
The flange-mounted Eclipse servo motor brake will fit externally, mounting directly between the servo motor (frequently metric) and industry standard NEMA outputs, such as gearboxes.
All models are available for servo motor frame sizes of two, three, four and five inches.
These brakes offer consistent long-lasting performance with virtually no maintenance needed.
Couplings suite marine applications
Renold Hi-Tec Couplings has been awarded a contract to supply high performance DCB 838.0 rubber in compression shaft couplings for marine propulsion systems to be installed in a fleet of anchor handling/tug supply vessels. The first of the vessels, the MV JP Laborde, is currently under construction at the Yantai Raffles Shipyard Company in China. The couplings are to be manufactured under ABS Survey and feature oil injection shaft mounting and a drop out feature, which allows access to the motor bearings without the need to move adjacent machinery.
To be operated by Tidewater Marine of New Orleans, each 86m long, dynamically positioned vessel is capable of a bollard pull of over 200t and the ability to handle anchors in depths in excess of 1530m.
The GPS control will keep the vessel constantly on station; the load on the coupling is reversible and highly dynamic.
Renold was awarded the contract by Karl Senner, which is responsible for supplying Reintjes DLG 4447U twin input/single output reduction gear for the five vessels.
The DCB couplings are to be installed in the drive train between each of the Amerimex electric motors and the reduction gearboxes, which in turn drive the azimuth reversible thrusters, which provide the propulsion.
With a maximum torque of 5520kNm, Renold DCB couplings are ideally suited for marine propulsion, power generation and reciprocating compressor applications where fail-safe operation, long life and the control of resonant torsional vibration are essential.
Other benefits derived from using Renold DCB couplings include a misalignment capability and severe shock load protection.
Andrew Broadbent, Sales Manager, Renold Hi-Tec Couplings comments: "Once again the specification of Renold DCB couplings for safety critical marine propulsion systems is fitting testimony to their reliability and fail-safe design principles, while they remain arguably the world's best coupling for noise attenuation and damping
To be operated by Tidewater Marine of New Orleans, each 86m long, dynamically positioned vessel is capable of a bollard pull of over 200t and the ability to handle anchors in depths in excess of 1530m.
The GPS control will keep the vessel constantly on station; the load on the coupling is reversible and highly dynamic.
Renold was awarded the contract by Karl Senner, which is responsible for supplying Reintjes DLG 4447U twin input/single output reduction gear for the five vessels.
The DCB couplings are to be installed in the drive train between each of the Amerimex electric motors and the reduction gearboxes, which in turn drive the azimuth reversible thrusters, which provide the propulsion.
With a maximum torque of 5520kNm, Renold DCB couplings are ideally suited for marine propulsion, power generation and reciprocating compressor applications where fail-safe operation, long life and the control of resonant torsional vibration are essential.
Other benefits derived from using Renold DCB couplings include a misalignment capability and severe shock load protection.
Andrew Broadbent, Sales Manager, Renold Hi-Tec Couplings comments: "Once again the specification of Renold DCB couplings for safety critical marine propulsion systems is fitting testimony to their reliability and fail-safe design principles, while they remain arguably the world's best coupling for noise attenuation and damping
Investment aims improve gearbox quality
Ondrives has once again invested in the latest CMM technology and horizontal machining centre to bring its production facilities to new levels. A Daewoo HC400 seven-pallet horizontal machining centre has been purchased to give greater flexibility to the current gearbox range as well as a Mitutoyo Crysta Apex C-574 co-ordinate measuring machine and accessories to give second-to-none accuracy. These new CMMs are capable of speeds up to 520mm/s with a resolution of 0.0001mm and offer improved accuracy specifications as well as faster movement.
They feature lightweight materials and an innovative machine structure to provide high travel stability and accuracy.
The main attraction of using a co-ordinate measuring machine is the precise nature with which it measures, which will enable Ondrives to control all its output to the highest standard.
One of the benefits of using this machinery is the ability to import 3D CAD models and pick out areas needed for measuring, from which the machine can easily be set up to measure dimensions relative to surfaces.
Parts can be measured with ease of set up and repeatability along with gear measurements down to 0.50 mod.
Ondrives P30 type input worm has been measured for accuracy using a small 0.3mm stylus to give gear measurements to DIN standards.
The company states the Mitutoyo Crysta Apex C-574 will be used to monitor standard gear and casing production to ensure quality is maintained, as well as venturing into new areas of design.
Thus expanding on current knowledge and experience, taking Ondrives forward in product development.
The Daewoo HC400 seven-pallet horizontal machining centre offers greater flexibility when machining casings from a horizontal perspective.
It means shorter downtimes and increased productivity, thereby reducing lead times to customers in the long run.
Not only can standard parts be machined in this way, but special designs to customer's requirements can also be quoted for dependant on quantities.
This all means Ondrives customers can look forward to receiving their best ever quality gearboxes and components.
They feature lightweight materials and an innovative machine structure to provide high travel stability and accuracy.
The main attraction of using a co-ordinate measuring machine is the precise nature with which it measures, which will enable Ondrives to control all its output to the highest standard.
One of the benefits of using this machinery is the ability to import 3D CAD models and pick out areas needed for measuring, from which the machine can easily be set up to measure dimensions relative to surfaces.
Parts can be measured with ease of set up and repeatability along with gear measurements down to 0.50 mod.
Ondrives P30 type input worm has been measured for accuracy using a small 0.3mm stylus to give gear measurements to DIN standards.
The company states the Mitutoyo Crysta Apex C-574 will be used to monitor standard gear and casing production to ensure quality is maintained, as well as venturing into new areas of design.
Thus expanding on current knowledge and experience, taking Ondrives forward in product development.
The Daewoo HC400 seven-pallet horizontal machining centre offers greater flexibility when machining casings from a horizontal perspective.
It means shorter downtimes and increased productivity, thereby reducing lead times to customers in the long run.
Not only can standard parts be machined in this way, but special designs to customer's requirements can also be quoted for dependant on quantities.
This all means Ondrives customers can look forward to receiving their best ever quality gearboxes and components.
Mechanical drive components at Interplas
Sister companies Ondrives and Rino Industries are exhibiting jointly at Interplas 2005. The two companies will share Stand 5400 in Hall 5 at the NEC, Birmingham between 4th and 6th October. They will be showing their usual portfolio of mechanical drive components which range from the ever popular gearboxes, couplings, linear motion parts and fasteners to bearings, springs, antivibration parts and various assorted accessories.
There will also be a range of new parts on show for the first time, these range from Rino's new lifting and lashing points, flexible step couplings, tubular connectors and high precision rod ends.
Ondrives offerings include the new Prem6 miniature 90-degree gearbox and motor combination to plain and headed jig bushes.
As ever, the newest edition catalogues and CD-Rom will be available to take away free of charge.
There will also be a range of new parts on show for the first time, these range from Rino's new lifting and lashing points, flexible step couplings, tubular connectors and high precision rod ends.
Ondrives offerings include the new Prem6 miniature 90-degree gearbox and motor combination to plain and headed jig bushes.
As ever, the newest edition catalogues and CD-Rom will be available to take away free of charge.
Couplings feature in cold rolling mill upgrade
Renold Gearflex couplings are playing their part in a major upgrade of Corus' tandem cold rolling mill at Port Talbot in South Wales, a project that will more than double the mill's power handling capability. The five-stand cold rolling mill currently produces up to 1Mt of strip steel a year, which is used in the fabrication of a wide range of items including car bodies and cases for domestic appliances. The upgrade is scheduled to take place in two stages with stage one already completed.
This involved the replacement of three 2.9MW DC motors with three new 6.9MW AC motors and associated gearboxes.
A Renold GF12HDB Gearflex coupling connects the motor to the gearbox.
Additional Renold Gearflex couplings consisting of GF16HDB, GF18HDB and GF20HDBs complete the package, connecting the gearbox output to the pinion box which drives the rollers through which the steel passes.
Commenting on the contract, Martin Slade, Renold Clutches and Couplings' Sales Director said: 'This was an important and prestige order for us to win'.
This involved the replacement of three 2.9MW DC motors with three new 6.9MW AC motors and associated gearboxes.
A Renold GF12HDB Gearflex coupling connects the motor to the gearbox.
Additional Renold Gearflex couplings consisting of GF16HDB, GF18HDB and GF20HDBs complete the package, connecting the gearbox output to the pinion box which drives the rollers through which the steel passes.
Commenting on the contract, Martin Slade, Renold Clutches and Couplings' Sales Director said: 'This was an important and prestige order for us to win'.
Motor range spans millions of options
Parvalux, the UK's leading manufacturer of small geared motors, believes in offering its customers a choice. In fact, when the options of motor type (AC or DC), power rating, torque, voltage, speed, type of fixing, shaft styles and dynamic brakes are taken into account, the result is over 100 million possible combinations. Take fixings for example, in addition to the standard foot mounting, there are also the options of flange, stud or spigot mounting, providing the design engineer with a wide range of methods of attaching motor to machine.
Mounting feet provide a robust and versatile method of attaching a motor or motor/gearbox to the back-plate of the machine.
This fixing method allows motors to be quickly attached and removed from a machine and the fixing feet allow small adjustments to be made to the motors position.
For applications where a suitable fixing surface is not available, customers can specify a spigot (face), flange or stud type fixing.
Flange fixing is common for worm type gearboxes and provides a strong fixing designed to cope with high torques.
The flange is pre-drilled and fully integrated into the body of the gearbox.
It provides a robust and compact method of fixing particularly in applications where space is at a premium.
Spigot mounting is the lowest cost option and provides tapped holes in the body of the motor or gearbox.
Various options are available for the position of the fixing holes and this method provides a compact means to directly mount the motor or gearbox to the machine.
Mounting feet provide a robust and versatile method of attaching a motor or motor/gearbox to the back-plate of the machine.
This fixing method allows motors to be quickly attached and removed from a machine and the fixing feet allow small adjustments to be made to the motors position.
For applications where a suitable fixing surface is not available, customers can specify a spigot (face), flange or stud type fixing.
Flange fixing is common for worm type gearboxes and provides a strong fixing designed to cope with high torques.
The flange is pre-drilled and fully integrated into the body of the gearbox.
It provides a robust and compact method of fixing particularly in applications where space is at a premium.
Spigot mounting is the lowest cost option and provides tapped holes in the body of the motor or gearbox.
Various options are available for the position of the fixing holes and this method provides a compact means to directly mount the motor or gearbox to the machine.
Miniature motors suit all applications
For applications as diverse as medical equipment and robotics, security devices and instrumentation, EMS is now offering the extensive FTB range of high-performance low-profile miniature motors. The motors are available in direct drive versions with torque ratings from 0.05 to 3mNm, and in geared versions with ratings from 50 to 180mNm. All the new motors feature ironless rotors with three flat oval copper coils, which rotate in an axially oriented magnetic field, and which have very small moments of inertia.
This design allows high rates of acceleration to be achieved with minimal flutter, and provides complete freedom from cogging.
In addition, the linear characteristics of the motor make it easy to provide accurate speed control.
The low-profile construction of the motors, which vary in thickness from 5.2 to 8.2mm for direct drive types, and from 12 to 19.1mm for types with gearboxes, makes them an ideal choice for use in modern equipment, where minimum overall size is almost always a prime requirement.
All the motors in the range are available in versions to suit 3 and 6V supplies, with many models available to suit other voltages from 2 to 24V.
Recommend maximum operating speeds for direct drive motors are between 5500 and 10,000rev/min, depending on the motor size.
In addition to FTB motors with integral gearing, EMS also offers compatible spur gearheads for many of the motors in the range.
This design allows high rates of acceleration to be achieved with minimal flutter, and provides complete freedom from cogging.
In addition, the linear characteristics of the motor make it easy to provide accurate speed control.
The low-profile construction of the motors, which vary in thickness from 5.2 to 8.2mm for direct drive types, and from 12 to 19.1mm for types with gearboxes, makes them an ideal choice for use in modern equipment, where minimum overall size is almost always a prime requirement.
All the motors in the range are available in versions to suit 3 and 6V supplies, with many models available to suit other voltages from 2 to 24V.
Recommend maximum operating speeds for direct drive motors are between 5500 and 10,000rev/min, depending on the motor size.
In addition to FTB motors with integral gearing, EMS also offers compatible spur gearheads for many of the motors in the range.
Service for oil and water coolers
ZF Industrial has been awarded the UK distributorship for Habor Oil and Water Coolers and offers a complete service covering supply of spares, complete systems and on and off-site repairs across the UK. The service aims to help customers with existing Habor coolers in CNC machining centres, grinders, broaching machines, lathes, milling and EDM machines reduce maintenance time and costs. Available with or without tanks, the oil coolers provide high levels of cooling capacity with low space requirements while the water coolers maintain the correct temperature of spindles and cutting surfaces without exhausts or tanks.
'The new distributorship deal with Habor is the logical progression for ZF Industrial as we increase our presence in the machine tool market', said ZF Technical Sales Engineer, David Morgan.
'We are well known for supplying gearboxes, brakes and clutches to UK industries and have continued to expand our offering to include the supply of custom high precision gearheads and oil coolers'.
'However, in response to the demands from our customers with existing Habor units fitted to their machines, we now supply both oil and water coolers backed up with extensive stocking of spare parts, a new system specification service, maintenance programme management as well as repairs both on and off site'.
The service from ZF fills a gap in the market where manufacturers may be aware that their current coolers are under performing, but spares, repairs or replacements may not be available in the time scales required to avoid significant impact on output.
With constant demands in manufacturing for increased output and improved accuracy, machinery is operating at higher speeds, making monitoring and controlling the resulting effects of heat on spindles and tools ever more important.
ZF has a range of five oil coolers, which includes the HBO Series units for hydraulic and lubrication oil that control the thermal expansion of spindles in CNC grinding, broaching, punching, woodworking machines and high-speed lathes.
By reducing heat deformation and maintaining spindle centre, the units ensure output quality and a longer service life for the machine.
Compact, easy to fit and available with or without tanks for flexibility, units can provide up to 15,000kcal/hr cooling capacity.
The range of oil coolers also includes the HK series for cooling cutting and grinding liquid in CNC machining centres, grinding machines and laser and cutting machines.
By avoiding increases in operating temperature, the coolers prevent deterioration of the liquid and their open coil design reduces the risk of blockages and potential damage.
The HE series is more for maintaining stability of the fluid in electro discharge machining systems, reducing wastage of the electrode and improving output quality while reducing pollution and risk of fire.
There are four models in the water cooler range providing up to 15,000kcal/hr cooling capacity with a choice fixed temperature control operation of 10 to 40C or differential temperature control of -10 to +10C.
'The new distributorship deal with Habor is the logical progression for ZF Industrial as we increase our presence in the machine tool market', said ZF Technical Sales Engineer, David Morgan.
'We are well known for supplying gearboxes, brakes and clutches to UK industries and have continued to expand our offering to include the supply of custom high precision gearheads and oil coolers'.
'However, in response to the demands from our customers with existing Habor units fitted to their machines, we now supply both oil and water coolers backed up with extensive stocking of spare parts, a new system specification service, maintenance programme management as well as repairs both on and off site'.
The service from ZF fills a gap in the market where manufacturers may be aware that their current coolers are under performing, but spares, repairs or replacements may not be available in the time scales required to avoid significant impact on output.
With constant demands in manufacturing for increased output and improved accuracy, machinery is operating at higher speeds, making monitoring and controlling the resulting effects of heat on spindles and tools ever more important.
ZF has a range of five oil coolers, which includes the HBO Series units for hydraulic and lubrication oil that control the thermal expansion of spindles in CNC grinding, broaching, punching, woodworking machines and high-speed lathes.
By reducing heat deformation and maintaining spindle centre, the units ensure output quality and a longer service life for the machine.
Compact, easy to fit and available with or without tanks for flexibility, units can provide up to 15,000kcal/hr cooling capacity.
The range of oil coolers also includes the HK series for cooling cutting and grinding liquid in CNC machining centres, grinding machines and laser and cutting machines.
By avoiding increases in operating temperature, the coolers prevent deterioration of the liquid and their open coil design reduces the risk of blockages and potential damage.
The HE series is more for maintaining stability of the fluid in electro discharge machining systems, reducing wastage of the electrode and improving output quality while reducing pollution and risk of fire.
There are four models in the water cooler range providing up to 15,000kcal/hr cooling capacity with a choice fixed temperature control operation of 10 to 40C or differential temperature control of -10 to +10C.
New network to distribute geared motors
Lenze has signed up the first member of its new network of geared motor distributors - Transdrive Engineering Services of Oldham. These distributors will offer the StockGears range of Lenze geared motors in their local area, providing a fast and personal service to both users and small machine manufacturers. The StockGears range comprises four models of inline and right-angle geared motors covering the majority of industrial requirements up to 7.5kW.
Transdrive is an independent specialist distributor of drives, motors, gearboxes, clutches and brakes, and has traded for 23 years.
Along with high expertise in geared motors, the company offers 24-hour service, on-site technical support and cabinet building.
Its customers are mainly in the Greater Manchester area and the M62 corridor.
The StockGears range consists of helical, worm and bevel AC geared motors up to 7.5kW and available with fast delivery.
StockGears distributors will also be able to provide service on other requirements such as motors with integrated drive, ATEX motors and larger powers up to 45kW. Request free introductory details about products from Lenze....
Transdrive is an independent specialist distributor of drives, motors, gearboxes, clutches and brakes, and has traded for 23 years.
Along with high expertise in geared motors, the company offers 24-hour service, on-site technical support and cabinet building.
Its customers are mainly in the Greater Manchester area and the M62 corridor.
The StockGears range consists of helical, worm and bevel AC geared motors up to 7.5kW and available with fast delivery.
StockGears distributors will also be able to provide service on other requirements such as motors with integrated drive, ATEX motors and larger powers up to 45kW. Request free introductory details about products from Lenze....
Brook helps lubricant firm flow with seals range
Soverign Lubricants has changed its name to Sovereign Lubricants and Seals and has recruited a Sales Director with over 20 years experience in the industry. David Brook joined the company in February 2006 and has a technical background in providing products to solve sealing problems by designing seals and sealing systems bespoke to individual requirements. Brook is already speaking with the company's major clients to help them solve their sealing and lubrication problems.
The firm has for the past 26 years been the sole UK agent for the Omega range of lubricants.
Steve Chesters, MD of Sovereign Lubricants, said: 'The Omega range has enabled us to offer our customers real world solutions to their lubrication problems'.
'Not only has Omega reduced the customer's maintenance schedules by out-performing previous products, it also allows the typical maintenance manager more time to maintain other areas of plant because the product last that much longer'.
A typical example he said was the Omega 690 gear oil which adheres to the metal surface of the gears in a typical industrial gearbox.
'We have customers who have used this product for over 10 years and still have the original oil in the gearbox', he said.
'This is because it does not drain away or become contaminated like cheaper alternatives, particularly in the food industry where gearboxes are accustomed to being pressure washed thus allowing small amounts of water and moisture to enter into the gears which would in turn contaminate lesser gearbox oils'.
Because Omega 690 does not mix with water, any resulting contaminant can be drained off through the gearbox oil port.
As well as providing lubrication, as part of a continued expansion plan, the company has incorporated a range of seals and sealing products into its portfolio.
O rings, hydraulic seals and seal kits, rotating shaft seals, rubber and engineering plastic parts are available from the company.
'We visit a high proportion of our major clients every week'.
said Chesters.
'They always ask us for seals to accompany the greases and oils that they purchase from us'.
The firm has for the past 26 years been the sole UK agent for the Omega range of lubricants.
Steve Chesters, MD of Sovereign Lubricants, said: 'The Omega range has enabled us to offer our customers real world solutions to their lubrication problems'.
'Not only has Omega reduced the customer's maintenance schedules by out-performing previous products, it also allows the typical maintenance manager more time to maintain other areas of plant because the product last that much longer'.
A typical example he said was the Omega 690 gear oil which adheres to the metal surface of the gears in a typical industrial gearbox.
'We have customers who have used this product for over 10 years and still have the original oil in the gearbox', he said.
'This is because it does not drain away or become contaminated like cheaper alternatives, particularly in the food industry where gearboxes are accustomed to being pressure washed thus allowing small amounts of water and moisture to enter into the gears which would in turn contaminate lesser gearbox oils'.
Because Omega 690 does not mix with water, any resulting contaminant can be drained off through the gearbox oil port.
As well as providing lubrication, as part of a continued expansion plan, the company has incorporated a range of seals and sealing products into its portfolio.
O rings, hydraulic seals and seal kits, rotating shaft seals, rubber and engineering plastic parts are available from the company.
'We visit a high proportion of our major clients every week'.
said Chesters.
'They always ask us for seals to accompany the greases and oils that they purchase from us'.
Heavy duty conveyor indexed by AC geared motor
Alumas, the Lancashire based supplier of modular and bespoke conveyor systems, has just installed a specially designed indexing roller conveyor, capable of holding and transferring up to 90t of press tooling. The end customer, Japanese and American owned Futaba-Tenneco of Burnley, is one of the UK's biggest suppliers of car components to the Japanese car manufacturers. This heavy-duty conveyor is indexed accurately and reliably with three Lenze AC geared motors.
Futaba-Tenneco supplies on a "just in time" basis, and so the ability to make rapid tool changes - several times a day - is of paramount importance.
Among the key requirements for the conveyor system was the ability to hold up to three complete tool assemblies, each of which can weigh up to 30t, and for these to be indexed along the conveyor as they are loaded and unloaded - in either direction.
The 16.5m-long roller conveyor is 2.3m wide and is driven by three Lenze geared motors.
A helical bevel design was chosen with a high service factor to suit the arduous duty.
The gearboxes contribute to the accuracy of indexing with high efficiency of 95% and low backlash of 7arc-min.
Despite a high output of more than 2600Nm at 7.5rev/min, the gearbox footprint is only 527 x 270mm.
Gary Howard, Futaba-Tenneco's Project Engineer, commented: "We are delighted with the conveyor, and in particular with the service received from Alumas.
The whole system was delivered on schedule, installed during the holidays and training given at 7.30am - between shifts, all with no loss of production.
In fact, we are so pleased that we are considering commissioning a second system which will return used press tools to the tool room".
Alumas, a member of the NIS Group of companies, specialises in modular belt, roller and assembly pallet conveyor systems.
They also supply a wide range of aluminium profiles and assembly elements, available either as individual components, or assembled into frame works, cabinets, guarding, panelling or workbenches.
The geared motors supplied by Lenze are part of the G-motion range which extend up to 45kW with five different gear configurations.
Modularity together with extensive UK stocks means that most requirements can be delivered in a few working days, or even, if required, next day.
Futaba-Tenneco supplies on a "just in time" basis, and so the ability to make rapid tool changes - several times a day - is of paramount importance.
Among the key requirements for the conveyor system was the ability to hold up to three complete tool assemblies, each of which can weigh up to 30t, and for these to be indexed along the conveyor as they are loaded and unloaded - in either direction.
The 16.5m-long roller conveyor is 2.3m wide and is driven by three Lenze geared motors.
A helical bevel design was chosen with a high service factor to suit the arduous duty.
The gearboxes contribute to the accuracy of indexing with high efficiency of 95% and low backlash of 7arc-min.
Despite a high output of more than 2600Nm at 7.5rev/min, the gearbox footprint is only 527 x 270mm.
Gary Howard, Futaba-Tenneco's Project Engineer, commented: "We are delighted with the conveyor, and in particular with the service received from Alumas.
The whole system was delivered on schedule, installed during the holidays and training given at 7.30am - between shifts, all with no loss of production.
In fact, we are so pleased that we are considering commissioning a second system which will return used press tools to the tool room".
Alumas, a member of the NIS Group of companies, specialises in modular belt, roller and assembly pallet conveyor systems.
They also supply a wide range of aluminium profiles and assembly elements, available either as individual components, or assembled into frame works, cabinets, guarding, panelling or workbenches.
The geared motors supplied by Lenze are part of the G-motion range which extend up to 45kW with five different gear configurations.
Modularity together with extensive UK stocks means that most requirements can be delivered in a few working days, or even, if required, next day.
Geared motors are efficient at low speeds
Lenze has extended its range of SW aluminium worm geared motors by introducing a new helical worm series that allows low output speeds of 3-18rev/min. The new gearboxes feature an additional stage, which enables operators to minimise costs and maximise profit. The new PC-SW range, which can be built to order from stock parts, incorporates a helical stage fitted between the motor and the worm gearbox.
This additional module can increase the gear ratio by a factor of three thereby providing low output speeds while maintaining high efficiency levels which, depending on the ratio, can range from 45 to 70%.
Output speeds from four and six-pole motors extend from 3 to 19rev/min, and rated torques can reach 516Nm.
The lower output speeds are produced from standard modules that retain the same output dimensions to those found on Lenze's existing worm geared models.
This minimises manufacturing costs and means the new PC-SW helical motors offer exceptional value for money.
Flexibility is also secured through the modular design of the PC-SW range, which includes standard hollow shaft output and a full range of mounting options, including single/double shafts, torque arms, feet and flanges.
There is also a choice of motors, including one and three-phase drives and braked, flameproof and DC variations.
While commenting on the versatility of the new PC-SW range, Geoff Spear, Marketing Manager at Lenze, also alluded to the motors' competitive price.
"The new helical worm models are adaptable to motor powers ranging from 90W to 750W and they are able to achieve this level of performance by utilising a standard modular design.
This means we can use stock parts to manufacture the PC-SW range and therefore keep costs down.
The result is a keenly priced, highly versatile range of geared motors".
(This was Engineeringtalk's Top Story on 5 September 2002) Request a free brochure from Lenze....
This additional module can increase the gear ratio by a factor of three thereby providing low output speeds while maintaining high efficiency levels which, depending on the ratio, can range from 45 to 70%.
Output speeds from four and six-pole motors extend from 3 to 19rev/min, and rated torques can reach 516Nm.
The lower output speeds are produced from standard modules that retain the same output dimensions to those found on Lenze's existing worm geared models.
This minimises manufacturing costs and means the new PC-SW helical motors offer exceptional value for money.
Flexibility is also secured through the modular design of the PC-SW range, which includes standard hollow shaft output and a full range of mounting options, including single/double shafts, torque arms, feet and flanges.
There is also a choice of motors, including one and three-phase drives and braked, flameproof and DC variations.
While commenting on the versatility of the new PC-SW range, Geoff Spear, Marketing Manager at Lenze, also alluded to the motors' competitive price.
"The new helical worm models are adaptable to motor powers ranging from 90W to 750W and they are able to achieve this level of performance by utilising a standard modular design.
This means we can use stock parts to manufacture the PC-SW range and therefore keep costs down.
The result is a keenly priced, highly versatile range of geared motors".
(This was Engineeringtalk's Top Story on 5 September 2002) Request a free brochure from Lenze....
Extended range of planetary gearheads
A new expanded range of Vogel planetary gearheads that suit most industrial applications is available from Lenze. Vogel is a gearbox specialist that has focused on expanding its planetary product range in response to customer demand for efficient and compact designs. Planetary gearboxes integrate well into energy saving machine designs as efficiencies are typically above 95%.
There are now four ranges of planetary gearheads for torques up to 26000Nm, with ratios from 3 to 345.
These include the low cost MPV range and the high precision MPR that has output shaft backlash of 6arc-min.
On request Vogel can supply reduced backlash below 3arc-min.
A recent addition is the MPG range, which features an output flange instead of a shaft.
This results in a gearbox with particularly compact axial dimensions, well suited to robotic and automation applications.
The smaller Vogel gearheads are frequently used in combination with servomotors.
Lenze offers three ex-stock ranges with their own motors and also servomotors from Panasonic.
There are now four ranges of planetary gearheads for torques up to 26000Nm, with ratios from 3 to 345.
These include the low cost MPV range and the high precision MPR that has output shaft backlash of 6arc-min.
On request Vogel can supply reduced backlash below 3arc-min.
A recent addition is the MPG range, which features an output flange instead of a shaft.
This results in a gearbox with particularly compact axial dimensions, well suited to robotic and automation applications.
The smaller Vogel gearheads are frequently used in combination with servomotors.
Lenze offers three ex-stock ranges with their own motors and also servomotors from Panasonic.
Skew-axis gearing shows its teeth
Spiradrive is the name given to a specific type of skew-axis gearing - gearing in which the axis of the gear and pinion are at right-angles but do not intersect. Spiradrive gears are sometimes referred to as screw-type gearing, this being a general description of the meshing action of the gear and pinion (the equivalent description for spur and bevel gears would be rolling-type gears). Spiradrive gearsets comprise two members, namely a gear and a pinion.
By definition the pinion has fewer teeth (or threads), and is normally the driving member, and the driven member is a face type gear resembling a spiral bevel or hypoid gear.
Spiradrive gears are unusual in that, unlike other forms of gearing such as spur, helical and bevel gears, their design does not involve the use of standard involute tooth shapes and conventional tooth pitch sizes such as diametral pitch (DP) and metric modular pitch (Mod).
A Spiradrive gearset is designed to suit the requirements of the application - the size and shape of the teeth being determined by those requirements.
This unique characteristic enables the designer to exploit Spiradrive in many different ways.
The ability to obtain far higher ratios in a single Spiradrive gear and pinion set, than is possible with any other form of gearing, means that the number of components in the drive can be reduced and hence its overall size and manufacturing cost.
The use of freely available conventional steels, with their high torque transmission capabilities, in place of the less strong and more expensive alloy bronzes, enables the designer to reduce the material cost of the gear package.
The geometry of a Spiradrive gearset is such that, apart from applications where minimal to zero backlash is required, the mounting distance does not have to be controlled to the fine limits required by other gear forms, thus helping to reduce the machining time for the housing and facilitating easier assembly.
Furthermore, the face form of the gear lends itself to high production techniques such as die-casting, sintering, plastic moulding and precision forging, and the pinion can be thread rolled if required in economical batch quantities.
Understanding that Spiradrive gears do not involve the use of standard tooth and pitch sizes, the designer is then able to design into them specific performance characteristics, such as high efficiency, self-locking, reversibility, high strength, exceptionally smooth angular velocity etc.
The permutations of these features are almost unlimited.
A Spiradrive gear generally has 10-12% of its teeth in simultaneous contact with the mating pinion, as opposed to a worm gear which, at the most, has only three teeth in simultaneous contact with its mating worm.
This means that the designer can make the teeth of the Spiradrive gear much smaller than those of the worm gear, as the load being transmitted can be spread over a greater number of teeth.
In turn, this means a reduction in the overall size of the gear envelope.
The generally accepted upper ratio limit for a worm gearset is 90:1.
Above this figure the outside diameter becomes extremely large relative to the outside diameter of the worm, and the designer has to resort to the use of multistage reductions to achieve the required ratio.
This problem does not occur with Spiradrive gears where ratios from 5:1 to 400:1 can be accommodated in a single, well-proportioned gearset Spiradrive pinions have either a tapered or a parallel outside diameter, the choice being dependent on the requirement of the application.
The cylindrical or zero taper angle (ZTA) type can be used for ratios down to 5:1, and is more likely to be used where maximum rigidity is required.
Both types can be used for ratios from 10:1 upwards.
Accurate control of backlash is yet another useful feature of Spiradrive gearing.
Using a tapered pinion, it is possible to attain a zero backlash condition - coarse adjustment is made by moving the gear axially into or out of contact with the pinion, and fine adjustment by moving the pinion into or out of contact with the gear.
In practice the degree of backlash obtained is a function of the accuracy built into the gear and pinion at the manufacturing stage.
When designing a Spiradrive gearset it is essential to know the application for which it is intended, the torque and strength requirements, the quantities required, and the probable lubrication arrangements, as there are many material combinations that can be used.
The most commonly used material for a pinion is hardened steel, but soft steel or brass can be used for lightly loaded applications.
Gear materials range from bronze, which has proved to be the most suitable material for applications involving moderate loads or precision drives, to hardened steel, which is invariably used for heavy duty power transmission applications.
Alternatively, gears required in volume for use on light load, or intermittent running applications can be produced in sintered iron, die-cast aluminium or nylon as those materials are particularly suited to modern high volume production techniques.
The geometry of a Spiradrive gearset is such that a hydrodynamic film tends to build up ahead of the point of contact of the pinion with the gear teeth.
This ensures that the gear teeth always come into contact with freshly lubricated surfaces on the pinion and contributes to the overall the efficiency of the drive.
The use of the correct lubricant is an important consideration when designing a Spiradrive gear drive.
The ideal lubricant for Spiradrive gearsets where both the pinion and the gear are made in hardened steel is extreme pressure (EP) type oil, as used in automotive hypoid drives.
True EP lubricants contain additives such as sulphides, chlorides and phosphates, which combine with the base material of the gearset to form anti-weld compounds.
These compounds, and in particular the sulphur ones, have a low shear strength and a relatively low melting point which prevent welding of the tiny asperities on the contacting tooth surface and thus eliminate metal transference, which on a large scale would obviously result in serious damage.
EP oils can also be used on gearsets comprising a steel pinion and a bronze gear, but a conventional heavy duty worm wheel oil will serve equally as well.
Various greases are available for use on lightly loaded applications and applications where the dissipation of generated heat are not a problem.
Choosing the correct materials and lubricants is a complex subject far too lengthy to discuss here: suffice it to say that a wide choice of materials and lubricants is available providing great design flexibility, economic production and extended operative life.
Davall Gear Company can advise on all aspects of the design of Spiradrive gearsets to suit any given application.
By definition the pinion has fewer teeth (or threads), and is normally the driving member, and the driven member is a face type gear resembling a spiral bevel or hypoid gear.
Spiradrive gears are unusual in that, unlike other forms of gearing such as spur, helical and bevel gears, their design does not involve the use of standard involute tooth shapes and conventional tooth pitch sizes such as diametral pitch (DP) and metric modular pitch (Mod).
A Spiradrive gearset is designed to suit the requirements of the application - the size and shape of the teeth being determined by those requirements.
This unique characteristic enables the designer to exploit Spiradrive in many different ways.
The ability to obtain far higher ratios in a single Spiradrive gear and pinion set, than is possible with any other form of gearing, means that the number of components in the drive can be reduced and hence its overall size and manufacturing cost.
The use of freely available conventional steels, with their high torque transmission capabilities, in place of the less strong and more expensive alloy bronzes, enables the designer to reduce the material cost of the gear package.
The geometry of a Spiradrive gearset is such that, apart from applications where minimal to zero backlash is required, the mounting distance does not have to be controlled to the fine limits required by other gear forms, thus helping to reduce the machining time for the housing and facilitating easier assembly.
Furthermore, the face form of the gear lends itself to high production techniques such as die-casting, sintering, plastic moulding and precision forging, and the pinion can be thread rolled if required in economical batch quantities.
Understanding that Spiradrive gears do not involve the use of standard tooth and pitch sizes, the designer is then able to design into them specific performance characteristics, such as high efficiency, self-locking, reversibility, high strength, exceptionally smooth angular velocity etc.
The permutations of these features are almost unlimited.
A Spiradrive gear generally has 10-12% of its teeth in simultaneous contact with the mating pinion, as opposed to a worm gear which, at the most, has only three teeth in simultaneous contact with its mating worm.
This means that the designer can make the teeth of the Spiradrive gear much smaller than those of the worm gear, as the load being transmitted can be spread over a greater number of teeth.
In turn, this means a reduction in the overall size of the gear envelope.
The generally accepted upper ratio limit for a worm gearset is 90:1.
Above this figure the outside diameter becomes extremely large relative to the outside diameter of the worm, and the designer has to resort to the use of multistage reductions to achieve the required ratio.
This problem does not occur with Spiradrive gears where ratios from 5:1 to 400:1 can be accommodated in a single, well-proportioned gearset Spiradrive pinions have either a tapered or a parallel outside diameter, the choice being dependent on the requirement of the application.
The cylindrical or zero taper angle (ZTA) type can be used for ratios down to 5:1, and is more likely to be used where maximum rigidity is required.
Both types can be used for ratios from 10:1 upwards.
Accurate control of backlash is yet another useful feature of Spiradrive gearing.
Using a tapered pinion, it is possible to attain a zero backlash condition - coarse adjustment is made by moving the gear axially into or out of contact with the pinion, and fine adjustment by moving the pinion into or out of contact with the gear.
In practice the degree of backlash obtained is a function of the accuracy built into the gear and pinion at the manufacturing stage.
When designing a Spiradrive gearset it is essential to know the application for which it is intended, the torque and strength requirements, the quantities required, and the probable lubrication arrangements, as there are many material combinations that can be used.
The most commonly used material for a pinion is hardened steel, but soft steel or brass can be used for lightly loaded applications.
Gear materials range from bronze, which has proved to be the most suitable material for applications involving moderate loads or precision drives, to hardened steel, which is invariably used for heavy duty power transmission applications.
Alternatively, gears required in volume for use on light load, or intermittent running applications can be produced in sintered iron, die-cast aluminium or nylon as those materials are particularly suited to modern high volume production techniques.
The geometry of a Spiradrive gearset is such that a hydrodynamic film tends to build up ahead of the point of contact of the pinion with the gear teeth.
This ensures that the gear teeth always come into contact with freshly lubricated surfaces on the pinion and contributes to the overall the efficiency of the drive.
The use of the correct lubricant is an important consideration when designing a Spiradrive gear drive.
The ideal lubricant for Spiradrive gearsets where both the pinion and the gear are made in hardened steel is extreme pressure (EP) type oil, as used in automotive hypoid drives.
True EP lubricants contain additives such as sulphides, chlorides and phosphates, which combine with the base material of the gearset to form anti-weld compounds.
These compounds, and in particular the sulphur ones, have a low shear strength and a relatively low melting point which prevent welding of the tiny asperities on the contacting tooth surface and thus eliminate metal transference, which on a large scale would obviously result in serious damage.
EP oils can also be used on gearsets comprising a steel pinion and a bronze gear, but a conventional heavy duty worm wheel oil will serve equally as well.
Various greases are available for use on lightly loaded applications and applications where the dissipation of generated heat are not a problem.
Choosing the correct materials and lubricants is a complex subject far too lengthy to discuss here: suffice it to say that a wide choice of materials and lubricants is available providing great design flexibility, economic production and extended operative life.
Davall Gear Company can advise on all aspects of the design of Spiradrive gearsets to suit any given application.
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