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'.
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.
Small lightweight motors pack extra power
In a marketplace where power to size to weight ratios are now all important, this product is claimed to set new boundaries. Available in two lengths (44 and 54mm), the 25GST 82 and 25GT 82 motors benefit from the most powerful magnets available on the market, designed into an optimised magnetic circuit.
The compact 25GST delivers a continuous 27W and a permanent torque of 32mNm.
The 54mm long 25GT delivers 40W and a permanent torque of 43mNm.
The life of DC motors is always a subjective issue; however these motors are fitted with the Rotafente commutation system, which is ideally suited to applications requiring high continuous and peak torques, where high current densities have to be commutated, thus giving longer motor life.
All motors are fitted with an industry proven fibre wrapped high temperature coil, with preloaded ball bearings and a rugged stator structure; which enables the motors to have a very long working life in the harshest of environments typically around ambient temperatures ranging from -30 to +125C.
Their mechanical time constants and power to weight ratios are market leaders, and are ideally suited to applications in the medical device, medical diagnostics equipment, textile machines and automation equipment market segments.
Delta Line Europe offers a complete range of front end and rear end options which include a full range of customised gearboxes, spur and planetary gearboxes, brakes, encoders and an optional integrated RFI filter.
The compact 25GST delivers a continuous 27W and a permanent torque of 32mNm.
The 54mm long 25GT delivers 40W and a permanent torque of 43mNm.
The life of DC motors is always a subjective issue; however these motors are fitted with the Rotafente commutation system, which is ideally suited to applications requiring high continuous and peak torques, where high current densities have to be commutated, thus giving longer motor life.
All motors are fitted with an industry proven fibre wrapped high temperature coil, with preloaded ball bearings and a rugged stator structure; which enables the motors to have a very long working life in the harshest of environments typically around ambient temperatures ranging from -30 to +125C.
Their mechanical time constants and power to weight ratios are market leaders, and are ideally suited to applications in the medical device, medical diagnostics equipment, textile machines and automation equipment market segments.
Delta Line Europe offers a complete range of front end and rear end options which include a full range of customised gearboxes, spur and planetary gearboxes, brakes, encoders and an optional integrated RFI filter.
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