The Redimount system permits machine and component manufacturers to select the most compatible combination motors and gearheads fit for each application.

Ensuring absolute concentricity between the gearhead pinion shaft and the motor shaft, the system comes with a self-centring hub feature. This leads to eliminating the possibility of excessive wear on components during operation, according to the company.

Other key benefits of the Redimount gearhead mounting system include enabling gearheads and the mounting system to be stocked separately. As the gearheads and the mounting system are stocked separately, associated costs are also being reduced.

Another useful feature is that all of the Thomson Micron gearheads will be using an identical Redimount system. This will make sure that the components will always be compatible.

Redimount’s pre-assembled pinion rejects the need for the need for a pinion positioning process which is rather time-consuming. It also removes the frequent source of error that occurs resulting brought by the motor mounting.

With the Redimount system, the gearhead and motor can be mounted quickly in just a few steps.

Thomson’s linear drive units are supplied with the Redimount system on standard so that users may specify any servo motor less any additional expense.

The length of the drive block will remain unmodified as the Redimount adapter flange is tailored to the dimensions of the provided motor. This spares engineers from any mounting position problems on their subsequent motor replacements.

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Zero-Max Crown gear drives feature long-life, precision hardened and ground ball bearings handling speeds up to 2,000 rpm in most operating environments. The internal gears are permanently mounted to the shafts with locking pins. This provides a resilient and durable connection for use in heavy load applications while requiring no maintenance.

Zero-Max ensures their drives are predictably smooth operating, and similar model sizes have identical performance characteristics when designed into multiple drive setups. To accomplish this, Zero-Max drives are hand-shimmed and hand-assembled for perfect bearing and gear alignment. The drives are pre-lubricated during assembly, then completely enclosed in a heavy-duty anodized aluminum housing.  This design ensures that internal gears stay permanently aligned, lubricated and free of contamination from outside debris.

Zero-Max Crown drives are ideal for a wide range of machine applications including food processing, packaging and material handling systems. Available in many sizes and models, they are ideal for a wide range of horsepower, torque and shaft speed requirements. Standard two and three way models are available with 1:1 and 2:1 speed ratios in shaft diameter combinations of 3/8, 1/2, 5/8 and 3/4 inch.

For more information, visit www.zero-max.com.

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With 8 gear ratios available (16:1 to 643:1), the brushed DC MG16B gear motor series develops a range of rated torques from 1.42 oz-in. at 800 rpm to 42.5 oz-in. at 17 rpm.  Using the same gearboxes, the brushless DC LB16MG gear motor series (with integrated driver) generates 1.42 oz-in. at 710 rpm to 42.5 oz-in. at 18 rpm.

Available input voltages for the MG16B include 6, 12 and 24 VDC and 6 and 12 VDC for the brushless LB16MG version. Nidec Copal also provides a lower cost HG16 series of 16mm gear motors using resin planetary gears.

For more information, email info@nidec-copal-usa.com or visit www.nidec-copal-usa.com.

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Maximum permissible torque is increased by up to two times the level of conventional AC motor gearheads. If the load condition changes, the gearhead’s strength can easily accommodate it and there is no need to increase the size of the motor or gearhead. Specific torque is dependent on frame size.

The motor’s strength is due to its rigid case, a proprietary side-panel construction and an optimized gear design. The larger diameter bearing serves to extend its useful life.

For more information about the V-Series, visit: http://www.orientalmotor.com/products/ac-motors/v-series.html

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Model No. MMP D22-376D-24V GRA60-032 BR-005 accepts any 24VoltDCsource, including battery or solar power. Measuring just 2.24 inches in diameter and 7.2 inches long, including the brake, this robust Gear Motor comes with a keyed output shaft of 14 mm diameter and 25 mm long. It can easily mounted as it features four “face mount” M5.5 threaded holes, spaced equally on a 52 mm Dia. B.C.

This reversible gear motor delivers a 3.3 Nm (29 lb. in.) torque output, at 230 rpm. Weighing around six pounds, the compact gear motor offers an efficient design that requires only four Amps at 25 Volts DC to produce its Full Load Torque. This translates into very low noise operation, long battery charge and reduced costs for related drive electronics.

The model’s integral failsafe “holding” brake measures only 2.25 inches in diameter, as well as operates on similar supply voltage as the motor.

Rated with “IP 54” protection level, the DC Gear Motor’s unique design makes it suitable for operation in hazardous environments. Variable speed control can be achieved with the company’s compatible speed controls, Model MMP 20A-24V-RSP or MMP 25A-24V.

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A number of devices use gears in some mechanical arrangement and these devices go by a number of names, depending on the branding of the manufacturer. Here is a look at some of the more common terms.

Gear reducers
Gear reducers, also known as speed reducers, are a component of many mechanical, electrical, and hydraulic motors. Essentially it is a gear or series of gears combined in such a manner to alter the torque of a motor. Typically, the torque increases in direct proportion to the reduction of rotations per unit of time.

Speed reducers come in two varieties: base mounted and shaft mounted. The shaft-mounted type, in turn, has two variations. One is truly shaft mounted in that it is supported entirely by the input shaft of the drive machine, with torque reaction absorbed by a special link. The other is mounted to the driven-machine housing so the input shaft does not absorb reducer weight or torque reaction. By AGMA definition, the term “speed reducer” is applied to units operating at pinion speeds below 3,600 rpm or pitch-line velocities below

5,000 fpm. Reducers operating at speeds higher than these are called “high-speed units.” Catalog ratings and engineering specifications for speed reducers are generally based on AGMA standards.

There are as many types of speed reducers as there are types of gears. Worm gear reducers are used in low to moderate horsepower applications. They offer low initial cost, high ratios, and high output torque in a small package, along with a higher tolerance for shock loading then helical gear reducers. The ratio of a worm gear set is the ratio of the number of teeth in the gear to the number of threads (starts or leads) on the worm.

Helical reducers are used in higher horsepower applications where long-term operational efficiency is more important than initial cost. The ratio of a helical or bevel gear set is simply the number of teeth in the larger gear divided by the number of teeth in the smaller gear.

Spur gear reducers have a gear wheel with radial teeth parallel to the axle. In bevel and spiral bevel gears, the gear wheel meshes with another at an angle between 90o and 180o.

Gearhead
A gearhead is often another term for gear reducer; however, it does not limit the unit’s function to speed reduction. Gearheads are mainly used wherever an application calls for high torque at low speed. It reduces a load’s reflected mass inertia, which makes accelerating heavy loads easier, enabling a design to use a smaller motor.

Gearheads come in a variety of styles from basic spur gearheads to more complex planetary gearheads and harmonic-type gearheads, each with their own characteristics and suitable applications.

In some applications, gearhead backlash may become an issue. In this case, consider using a gearhead with low backlash or zero backlash.

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Planetary gears
Planetary gears consist of one or more outer gears, or planet gears, revolving about a central, or sun gear. Typically, the planet gears are mounted on a movable arm or carrier that may rotate relative to the sun gear. These systems often use an outer ring gear or annulus, which meshes with the planet gears.

The gear ratio in this type of system is not obvious, particularly because there are several ways in which an input rotation can be converted into an output rotation.

Typically, one of these three gear wheels is held stationary; one is an input providing power to the system, while another is an output, receiving power from the system. The ratio of input rotation to output rotation is dependent upon the number of teeth in each gear, and upon which component is held stationary.

Planetary gears offer several advantages over parallel axis gears. These include high power density, the ability to achieve a large reduction in a small volume, multiple kinematic combinations, pure torsional reactions, and coaxial shafting. The disadvantages include high bearing loads, inaccessibility, and design complexity.

In a planetary gearbox arrangement, one advantage is power transmission efficiency, which is typically 3% per stage. Thus, a high proportion of the energy transmitted through the gearbox is used rather than wasted on mechanical losses inside the gearbox.

Planetary gearbox arrangements distribute load efficiently too. The transmitted load is shared between multiple planets, which greatly increases torque density. The more planets in the system, the greater load ability and the higher the torque density. This arrangement is also very stable due to the even distribution of mass and increased rotational stiffness.

Strain wave gearing
Strain wave gearing is an approach to speed reduction using metal elasticity (deflection) of the gear to reduce speed. (Strain wave gearing is also known as Harmonic drives–a registered trademark term of Harmonic Drive Systems Inc.) The benefits of using this approach include zero backlash, high torque, compact size, and positional accuracy.

A strain wave gear is comprised of three components: Wave Generator, Flexspline, and Circular Spline.

The Wave Generator is an assembly of a bearing and a steel disk called a Wave Generator plug. The outer surface of the Wave Generator plug has an elliptical shape machined to a precise specification. A specially designed ball bearing is pressed around this bearing plug causing the bearing to conform to the same elliptical shape of the Wave Generator plug. The Wave Generator is typically used as the input member, usually attached to a servomotor.

Strain wave gearing uses the metal elasticity of gears to reduce speed. The teeth of the Flexspine and Circular Spline are engaged near the major axis of the ellipse and disengage at the minor axis of the ellipse. The elastic radial deformation acts like a very stiff spring to compensate for space between the teeth that would otherwise increase backlash.

The Flexspline is a thin-walled steel cup. Its geometry allows the walls of the cup to be radically compliant, yet remain torsionally stiff since the cup has a large diameter. Gear teeth are machined into the outer surface near the open end of the cup (near the “brim”). The Flexspline is usually the output member of the mechanism.

The cup has a rigid boss at one end to provide a rugged mounting surface. The Wave Generator is inserted inside the Flexspline so that the bearing is at the same axial location as the Flexspline teeth. The Flexspline wall near the brim of the cup conforms to the same elliptical shape of the bearing. This causes the teeth on the outer surface of the Flexspline to conform to this elliptical shape. Effectively, the Flexspline now has an elliptical gear pitch diameter on its outer surface.

The Circular Spline is a rigid circular steel ring with teeth on the inside diameter. It is usually attached to the housing and does not rotate. Its teeth mesh with those of the Flexspline. The tooth pattern of the Flexspline engages the tooth profile of the Circular Spline (circular) along the major axis of the ellipse. This engagement is like an ellipse inscribed concentrically within a circle. Mathematically, an inscribed ellipse will contact a circle at two points. However, the gear teeth have a finite height. So there are actually two regions (instead of two points) of tooth engagement. Roughly 30% of the teeth are engaged at all times.

The pressure angle of the gear teeth transforms the output torque’s tangential force into a radial force acting on the Wave Generator bearing. The teeth of the Flexspline and Circular Spline are engaged near the major axis of the ellipse, and disengaged at the minor axis of the ellipse.

The Flexspline has two less teeth than the Circular Spline. Thus, every time the Wave Generator rotates one revolution, the Flexspline and Circular Spline shift by two teeth. The gear ratio is calculated by:

Number of Flexspline Teeth / (Number of Flexspline Teeth – Number of Circular Spline Teeth)

The tooth engagement motion (kinematics) of the strain wave gear is different than that of planetary or spur gearing. The teeth engage in a manner that allows up to 30% of the teeth (60 teeth for a 100:1 gear ratio) to be engaged at all times. This contrasts with maybe 6 teeth for a planetary gear, and 1 or 2 teeth for a spur gear.

In addition, the kinematics enable the gear teeth to engage on both sides of the tooth flank. Since backlash is defined as the difference between the tooth space and tooth width, this difference is zero in strain wave gearing.

As part of the design, the gearteeth of the Flexspline are preloaded against those of the Circular Spline at the major axis of the ellipse. They are preloaded such that the stresses are well below the material’s endurance limit.

In the gear as the gear teeth wear, this elastic radial deformation acts like a very stiff spring to compensate for space between the teeth that would otherwise cause an increase in backlash. This allows the performance to remain constant over the life of the gear.

Strain wave gearing offers high torque/weight and torque/volume ratios. The lightweight construction and single stage gear ratios of up to 160:1 allows the gears to be used in applications requiring minimum weight or volume. Small motors can exploit the large mechanical advantage of a 160:1 gear ratio to create a compact, lightweight, and low cost package.

A new tooth profile for strain wave gearing has become available in the last few years. This “S” tooth design allows more gear teeth to engage. The effect is to double torsional stiffness, double peak torque ratings, and lengthen operational life.

The “S” tooth form does not use the involute curve of a tooth. Instead, it uses a series of pure convex and concave circular arcs that match the loci of engagement points dictated by theoretical and CAD analysis.

The increased root filet radius makes the “S” tooth much stronger than an involute curve gear tooth. It will resist higher bending (tension) loads while maintaining a safe stress margin.

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This reversible gear motor delivers an output that is rated for 15.3 Nm (136 lb. in.) torque, at 35 rpm. Although it comes in a compact package — weighing only around four pounds — the efficient design of the gear motor requires only 7.2 Amps at 12 Volts DC to produce its Full Load Torque, and translate into remarkably low noise operation, long life battery charge and reduced costs for related drive electronics. The company also offers motor windings for 24 Volts, 28 Volts, 36 Volts, 42 Volts, 48 Volts, 60 Volts and 90 Volts.

The gear motor’s innovative design is rated “IP 54” protection level, making it suitable for operation in harsh environments. Variable speed control can be achieved with the company’s fully compatible Speed Controls, Model MMP 20A-12V-RSP or MMP 25A-12V.

Typical options offered by the company include Failsafe Brakes, Servo Motors with integral Optical Encoders, Analog Tachometers and various Planetary Gearheads.

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When compared with the conventional STOBER K1 helical bevel gear unit version, the new KL1 supplies increased torque density of well over 100 percent. The size reduction for the KL was achieved by a newly designed, 2-stage gear set geometry. The housing dimensions of the two sizes illustrate the new shape factor. In the KL1 version, the length is 113.5 mm, the width 81mm and the depth 90 mm; this represents a volume of only 0.83 liters.

The KL2 is 143.5 mm long, 98 mm wide and 108 mm deep, which makes its volume only 1.52 liters. This compact housing also gives a significant weight reduction, which is an advantage for drive dynamics, particularly on traveling axes.

Input speeds of up to 6,000 rpm are possible in cyclic operation with a torque range up to 65 Nm. The highly stiff, compact and symmetrical design requires no offset because the unit looks virtually the same on either side. On the output side, the new right-angle gear unit offers various options for output shafts and mounting methods, including solid shafts with and without keys, and hollow output shafts with and without keys. Output shafts are available in carbon and stainless steel.

Motors from other suppliers can be fitted using an adapter with a backlash-free coupling that features thermal length compensation. Both sizes are available in all the different versions.

www.stober.com

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At 2.0 rpm, this reversible gearmotor delivers an output of 443 lb. in. (50 Nm) torque. Although it weighs only 4.5 pounds, this compact gearmotor offers an efficient design that requires only 3.6 Amps at 24 V DC to produce its Full Load Torque. This translates into very low noise operation, long life battery charge and lower costs for related drive electronics.

Rated with IP 54 protection level, the gearmotor’s unique design makes it suitable for operation in harsh environments. Its fully compatible speed controls — Model MMP 20A-24V-RSP or MMP 25A-24V help the gearmotor accomplish variable speeds.

The company’s typical options include Failsafe Brakes, Servo Motors with integral Optical Encoders, Analog Tachometers and Planetary Gearheads that comes with standard ratios ranging between 3:1 and 2653:1 as well as standard or low backlash precision gearing. It also offers various Motor Winding Options that include 28V, 12V, 48V, 36V, 90V and 60 Volts DC.

Midwest also offers standard ancillary equipment such as DC Servomotors, DC power supplies, Motor Speed Controls, PWM Servo Amplifiers, Linear Actuators and a vast array of DC gear-motors.

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The SPK+ 210 / 240 hypoid gear has an output shaft and offers:

- Torques up to 4500 Nm

- Ratios up to i=10000

The TPK+ 300 / 500 hypoid gear has an output flange and offers:

- Torques up to 4500 Nm

- Ratios up to i=10000

www.wittenstein-us.com

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Offered in six standard, off-the-shelf versions, the new gearmotors employs 1/20 PS (37.3 W) AC motors that can be easily operated from either 230V or 115V, 50Hz or 60Hz power sources. Delivering gear ratios ranging between 10:1 and 494:1, the gearmotors provide output speeds between 181 and four RPM, and maximum continuous torque ratings of 50 in. lbs (5.65 Nm).

The integral gear reducers and totally enclosed non ventilated (TENV) permanent split capacitor (PSC) AC motors are reversible, and also feature all-position face mounting with an overhung load capacity of 50 pound (22.7 kg.).

“These Bison drop-in replacements for VW14 AC gearmotors feature permanent split capacitor four-pole motors that operate at half the speed of the competitive units they replace. With corresponding gear ratio changes, this result in a quieter, longer life gearmotor,” Bison Gear Application Engineering Supervisor Clayton Hinkle said.

“An engineered resin first-stage gear further contributes to quiet operation which makes these gearmotors ideal in such applications as foodservice equipment, automated displays, peristaltic pumps, business machines, ticket dispensers and even pellet stoves.”

Available with CSA and U.L. recognition as standard, the new VWDIR14 AC parallel shaft gearmotors can be also provided to OEM’s with CE recognition.

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The new BLDC motors feature a wide selection range for power, speed, torque and size. Motors include continuous power up to 400W, speeds between 1,500 and 6,100 RPM, and motor constants up to 15 ounce per square root Watt (103 mNm per square root Watt). Maximum torque constants feature up to 198 oz.-in./A (1400 mNm/A). The six new models include two round and four square designs with lengths ranging from 41 to 114mm. Motors can be ordered with a factory-mounted optical or magnetic encoder and can also be fitted with electro-mechanical fail-safe power off brakes.

Compatible gearboxes feature Spur, Planetary and Worm styles with torques from 0.4 to 120 Nm. The BDE30 and BDE40 external drives are offered in 6A or 14A max respectively. Internal drives are offered on BLDC motors that feature power ranges from 40 to 100W. A wide range of accessories are also available.

The new motor control solution is suitable for a wide range of applications in the medical and industrial markets. Specific uses include automation for endoscopy, x-ray and dental equipment, robotic pool equipment, peristaltic pumps, access control, printing and bill boards.

For more information, visit www.crouzet.com.

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“These gearmotors offer ideal solutions for applications in industrial automation, automatic doors and windows, vending, packaging and many others,” said Intecno’s General Manager Moreno Ferrari.

The BLDC brushless micro gearmotors are available in three different sizes, and feature low voltage power supply of 24 VDC. The motors deliver a torque that range between 0.425 in-lbs (0.05Nm) and 3.80 in-lbs (0.43Nm).

“These motors are low voltage which optimizes safety in the work place, particularly in applications where the worker could be in direct contact with the motor,” added Ferrari.

For low cost and compactness, the motors have been equipped with Hall Sensors and can be supplied with an external drive control or an integrated control (IE version).

The motors right angle worm gearboxes are available in two sizes CM30 (30 mm center to center distance) and CM26 (26 mm center to center distance). Its ratios range from 5:1 up to 100:1.

Users can customize the planetary gearboxes to the application due to the possibility of utilizing plastic, metal or material mix versions. The motor is also offered in low noise (LN) version, which minimizes the gearbox noise and making it ideal for medial applications.

The company’s planetary gearboxes offer a vast array of reduction ratios, which range between 3.7: 1 (1 stage) and 2076:1 (4 stages). The planetary gearboxes are maintenance-free since they have already been lubricated with grease.

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The Falk V-Class incorporates the latest advances in materials technology, engineering design, and manufacturing processes to produce a tough, reliable gearbox for demanding applications. These advancements, coupled with innovative mounting and cooling accessories, provide a reliable, sustainable gearbox. Features are built into the drive to provide maximum uptime in a smaller drive at a lower total cost of ownership (TCO).

One of the most distinguishable features of the Falk V-Class is the housing. The heavy-duty, horizontally split housing design incorporates advanced gearing, optimized through the latest materials and technologies, to provide maximum performance under load. The housing shape and features were designed through the use of Computational Fluid Dynamics (CFD), to enhance the drive’s superior thermal dissipation qualities.

Additional features were built into the Falk V-Class to increase productivity and profitability. The drive incorporates exclusive Magnum no-leak seals with oil drain backs and purgeable grease chamber to eliminate oil leaks. An optional, eco-friendly DuraPlate™ cooling system requires no water or electricity to operate and provides optimal cooling to fully use the unit’s torque density.

Rexnord offers standardized monitoring and lubrication packages, 24/7 customer support, readily available spare parts, and a product services team that offers onsite support, in addition to a 36-month warranty.

Learn more about the Falk V-Class at www.rexnord.com and www.falkv-class.com.

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Coming from the company’s well-established portfolio of tin-can stepper products, PFG25G gearhead stepper motor is suitable for medical device industry’s projects that demand for high torque motor but have limited space.

The gearhead stepper motor is offered both in unipolar and bipolar winding and features 24 steps or 48 steps per revolution. Depending on the device’s step number and winding, Nippon’s gearhead stepper motor offers a rated voltage of either five volts or 12 volts. It also delivers a resistance ranging from 15 ohms and 122 ohms, a holding torque that stands between 8 mNom and 12 mNom. Weighting 35 grams, the PFG25G stepper motor’s other remarkable features include a starting pulse of 490 pps or 790 pps, a maximum torque of 100 mNom and a motor diameter of 25 mm.

Nippon’s PFG25G stepper motor offers customers the choice of more than 20 gearhead ratios, starting from 6/25 to 1/300. Depending on the motor’s gear ratio, it produces a maximum torque of between 20 mNom and 100 mNom.

Just like the rest of Nippon Pulse stepper motor products, the company offers customers the option to customize their PFG25G motor to meet their individual need. The Nippon Pulse factory and model shop can add longer lead wires, connectors, ball bearings, customized flanges, pinions and many other motor options.

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The gearheads feature 300 series Stainless Steel external housings for maximum corrosion resistance, and are IP67 protected to provide reliable operation and long life in environments subject to caustic cleaning chemicals and high-pressure washdown.  The external housing is round with no external seams to eliminate the potential for bacteria collection or ingress, which would otherwise result in interior damage, compromised performance and shortened operating life.

AquaTRUE Planetary Gearheads are available in 60, 80, 120 and 160 mm frame sizes, with ratios from 3:1 to 10:1, torque capacity up to 876 Nm and precision to 13 arc-min. Their robust construction and performance attributes make them well suited for use in washdown and/or corrosive environments such as meat/poultry slicing, beverage dispensing, medical hygienic and pharmaceutical applications, among others.

Thomson has available a number of educational webinars for on-demand viewing, including Gearhead Solutions for Washdown Applications that provides participants with practical information on gearhead technologies and their application in food processing and packaging, medical and pharmaceutical, and high pressure washdown applications.  Additional gearhead-related webinars include Planetary Gearheads 101: Basics for Design Engineers and Planetary Gearheads 201: Troubleshooting for Design Engineers.  These two webinars provide an educational overview of planetary gearhead technology, and establish a framework to help users quickly select the right planetary gearhead to reduce design time and optimize machine designs.

Visit www.thomsonlinear.com for more information.

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AquaTrue provides an interesting alternative in the beverage and food processing industry, as well as for other industrial sectors. Manufactured in line with IP69K and IP66/IP67 degrees of protection as standard, AquaTrue can be used in water jet cutting systems, which demand reliable sealing of metal components against chemicals and high water pressure. The gearhead’s design eliminates the concern for any type of corrosion or rust.

AquaTRUE planetary gearheads are ideal in applications including beverage filling machines, food packaging, medical technology equipment, slicing machines in meat processing, pharmaceutical laboratory and production facilities, and in applications with cleaning procedures that use high levels of chemicals or water.

AquaTRUE’s planetary gearheads are offered in sizes of 60 mm, 80 mm, 120 mm and 160 mm. They offer a maximum degree of precision of 13 arc minutes.

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The high-performance servo motors offer high power density in a small installation space and integrate all electrical and mechanical elements into a very compact unit.

Designed with a very small absolute encoder system offering a resolution of 262144 steps per revolution, the system can achieve high precision while occupying lesser space.

The gearboxes are directly mounted on the motor to save installation space, weight and the amount of mass being moved, made possible by a total reconstruction of the motor’s output flange and its adoption to the gearboxes.

The center gear directly rests on the motor shaft and substitutes the input shaft on the gearbox. This kind of mounting eliminates the need for a clamp system, adapter flange or the gearbox input bearing.

Aside from saving approximately 20% in installation space and weight, it also reduces the amount of mass that has to be moved.

Creating high-performance control loops for dynamic applications is also possible even in tight spaces with the small amount of mass and rigid structure.

With gearboxes directly mounted on the motor, it is possible to choose from the standard 8GM40 gearboxes, the economy series 8GM30 gearboxes and the reinforced 8GM50 gearboxes.

The 8GM50 series uses optimized bearings for axial and radial forces for mechanical compatibility with Wittenstein products.

The latest motor series is suited for applications with high demand on torque and dynamics in limited spaces.

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The new online tool helps build upon the CAD selection and part number creation functions for alpha gearboxes by adding:

• Clear and easy to understand visuals representing various part options
• Technical specifications for immediate product review
• Complete drive train selection from gearbox to motor
• Interactive part number creation for complete part number (gearbox+motor)

A key aspect of this redesigned tool is customers will be able to have real-time access to its comprehensive database of standard products and motor data.

WITTENSTEIN has plans for future development of this tool, which includes the addition of rack and pinion, couplings and actuators.  These changes will be added in the coming year.

Click to view a online “how to video”

WITTENSTEIN
www.wittenstein-us.com

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“Typically, motors, gearboxes and controllers are purchased separately,” said Jim McNamara, Application Engineer at Crouzet. “With Crouzet’s new integrated package, customers have a convenient way to purchase all three functions in one product from a single supplier.”

With the addition of this new product, Crouzet has expanded its capabilities. Its product line’s torque range has increased to 120Nm, while its power rating has improved from 80 watts to 205 watts. The product’s planetary models feature speeds from 7 rpm to 627 rpm, while right angle units offer speeds from 44 rpm to 440 rpm. Each 801 model is designed with a standard IP54 sealing and integrated electronics.

The series measures only 57mm square and can easily fit into applications with tight packaging constraints. The product’s sealed packaging enables users to use it even under harsh environments. It also comes with a cast aluminum housing, which optimizes robust operation and durability. Standard models can be modified in Crouzet’s Custom Adaptation Center to suit specific application needs such as higher IP seal ratings, custom mounting options or supplying with no integrated controls.

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The DC-Micromotors series 0816 is available in 3V, 6V and 8V versions, which have an outstanding power-to-volume ratio. The System FAULHABER, a patented ironless rotor, is truly remarkable with its extremely low inertia and low inductivity. Specifications include a no-load speed of up to 17 1000rpm, output power of 0.18W and stall torque of 0.41mNm.

A two-phase Stepper Motor with permanent magnets, the AM0820 is available in 2V, 3V, 5V and has a holding torque of 0.65mNm and 20 full steps per revolution. NdFeB is used as a magnet material to guarantee an excellent size to power ratio. The AM0820 also features two shaft bearings types: preloaded ball and sintered bronze sleeve bearings.

Also available are three all-metal precision gearheads of 08/1, 08/2 and 08/3. The 08/1 planetary gearhead offers user maximum drive torque of 120mNm in intermittent operations and 60mNm in continuous operation. The two additional 08/2 and 08/3 series spur gearheads are available in two executions, convinced with positioning control applications.

The company redefines miniature magnetic encoders with the HEM3-256, providing new possibilities for applications that require miniature motors with encoders. Also available are four resolutions that provide precise positional accuracy and stability control. The encoder is allowed to work with 3V or 5V power sources for low-voltage battery applications. It is also designed for robust reliability with an operating temperature range of -30°C to +85°C, allowing use in extreme applications.

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The Gearhead Express program is part of the online Motioneering service from Thomson-Micron, allowing operators to application-size a right planetary gearhead in a wide range of graded precision bands by entering torque, load, speed and other application requirements to a simple wizard. A list of suitable gearboxes is then presented and the service is finished with their availability under the Gearhead Express program.

The Gearhead Express program encompasses four main Micron TRUE series planetary gearhead lines: UltraTRUE™, DuraTRUE™, ValueTRUE™ and NemaTRUE™.

The UltraTRUE has improved precision to four arc-min through a helical crowned gearing. Its internal gears are directly cut into the housing to reduce slippage and increase torque capacity.

A high-precision planetary gearhead, the DuraTRUE features RediMount system, allowing fast, easy and error-free interfacing to almost any motor.

The Thomson Micron ValueTRUE is a cost version that features a helical crowned gearing. It is available both in right angle and in-line configurations for torques to 2970Nm and ratios up to 100:1.

NemaTRUE planetary gearheads, which are supplied in a combination of standard and metric NEMA sizes, are a low cost series suited in a wide range of applications.

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The new Bodine type 33A5BEPM-WX, permanent magnet DC, 1/11 to ¼ HP (up to 187 Watts), gearmotors (two winding options: rated 12/24 VDC or 90/130 VDC).

The WX gearmotors feature new all-steel gear trains and synthetic lubricants, allowing the WX to produce up to 65% more torque than previous models. The steel gearing is designed to meet or exceed AGMA 9 standards to assure the quiet operation that is expected from Bodine Electric products. The synthetic lubricant improves efficiency and allows these gearmotors to operate in a wide temperature range. Accessories include a bolt-on adaptor to convert the gearhead to 3-point mounting pattern, as well as an “L”-braket for flexible mounting and a IP-44 protection kit. Forty-eight new stock models feature 12 available gear ratios, ranging from 4:1 to 312:1, and rated output speeds from 658 to 2.9 RPM.

A new low-voltage type 33A PMDC motor with a winding rated 12/24 VDC and a standard 90/130 VDC motor are available to power the WX gearhead. Both motors provide high starting torque and linear speed torque characteristics. They feature permanently lubricated ball bearing construction for maintenance-free operation, as well heavy gauge steel housing and copper graphite brushes. The motors are Totally Enclosed, Non-Ventilated (TENV) and contain a Class F rated insulation system. Their windings are resin-impregnated to provide reliable performance in the most demanding applications. The motor armatures are designed to minimize cogging and to operate quietly. “Accessory ready” models allow for easy external mounting of encoders or brakes.

Bodine Electric Company
www.bodine-electric.com

Motion Control Tips

Available in both extreme and industrial environment grades, the intelligent servos are capable of generating speeds from 15rpm to 500rpm and torque of 1Nm to 12Nm. They can be controlled through analog signals, pulse-width, serial lines or CANBus, and can accept 12 to 48 Volts of power. Installation can be simplified by a single power/signal cable. With wide power and speed range, the intelligent servos are suitable for robotic arms, retractable landing gear, control surface actuators and drive motors for tracked or wheeled vehicles.

“These servos fill a need for power and reliability above the high-end R/C servos, where virtually no standard products have previously been available,” said Acuity Technologies president Robert Clark. “We started out looking for servos for a Navy UAS but had to build them, due to the lack of selection in speed, power, and form factor.”

For those demanding high reliability, configurable status/error reporting lets monitoring of bus integrity and servo status. The servos can be operated in velocity, position or torque mode, with up to 1,000 per second update rates for high performance human or autopilot control.

The Network Servo Controller offers power distribution and a single serial interface for a network setup of up to 32 servos in a daisy or star chain topology.

Motion Control Tips

The device can be used to replace potentiometer-based angle encoders by combining position and motor feedback in one component or for low-cost servo feedback in rotary and linear actuators. Absolute position feedback is also very useful for machine homing. The device’s multi-turn option consists of an integral rechargeable battery, which maintains full position information for 20 hours if machine power is removed,

Rotalink designs and produces a variety of gearboxes in spur and planetary gearbox designs that feature polymer gears on ball or sintered bearings. The range also consists of ovoid-style gearheads, which include planetary gear assemblies for the output stages and a combination of spur gears for input stages. These are available in a choice of ultra-polymer materials.

The new absolute encoders are included in the company’s latest catalogue, which also features three new ranges of DC motor technologies – brushless, rare earth and heavy case – and new brushless version of the Red Drive motion controller and several gearbox lines.

Motion Control Tips

The new Kollmorgen Automation Suite (KAS) has several key advances, which include a machine throughput of 200m/min, a more compact cabinet with a complete IPC module and total application development time of one week.

Compared with traditional machines, the new device eliminates the need to change the gearwheels and cylinders used for perforating or cross cutting several paper formats due to Kollmorgen’s AKM servo motors and precision gearboxes.

Customized formats can be used in the programmable control unit, while format changeover is performed at the touchscreen display.

“The crucial factor for the decision to go with the Kollmorgen Automation Suite was that the Motion Control, PLC and HMI/SCADA functionalities – in our case on an industrial PC – are available via a single processor. This standard tool allows the cost-effective introduction of company-specific knowhow and tailored solutions for individual applications,” said Jakob Graphic Services design engineering and technical manager. “Furthermore, it radically speeds up programming and commissioning, and increases machine performance.”

Motion Control Tips

The new 2010 GAM Gear catalog includes information on: a new line of low-cost high performance planetary gearboxes (PE-Series), a complete new range of bevel-gear reducers with or without an integrated motor mount (VC-Series and V-Series), a new hollow-shaft-low-cost-hypoid gearbox (DL-DH), and 2 new flange-style gearboxes (right angle DS-DF, and in-line FP-KB).

The 2010 GAM Gear catalog also includes information pertaining to the Linear Slide Kit product (LSK). The LSK is a line of motor mounting kits designed to mount any motor or gearbox to any linear belt or ball screw actuator. The LSK range also includes a unique hollow-output-planetary gearbox designed specifically to mount to linear actuators. GAM provides all engineering and manufacturing for the mating kits and ships within 5 days from order.

GAM Gear, LLC
www.gamweb.com

Motion Control Tips

The unique sensor system permits OEMs to monitor brush wear electronically in order to maintain uninterrupted operation of the PMDC motors or gearmotors. It also removes the guesswork in brush inspection and maintenance. Motors and gearmotors that are equipped with this feature can accommodate built-in EMI filtering and built-in magnetic encoder. The company is already in the process of searching for patent protection for this latest technology. PMDC gearmotors and motors that feature the proprietary design are exclusively available from Bodine Electric Company.

“This is the sort of value-added and innovative design engineering that sets Bodine apart. One of our customers approached us with the challenge of monitoring brush-wear and motor life in a battery- and solar-powered application. We took care of the motor solution with this new technology, and the customer integrated the sensor feedback into his control system,” said Terry Auchstetter Manager of Custom Solutions and Business Development of Bodine Electric.

The sensor system is best suited for remote monitoring of PMDC motors or gearmotors, especially when nobody is standing next to a machine all day.

Motion Control Tips

“Many of our customers have had challenges developing and assembling brackets that connect motors and gearboxes to Festo® actuators,” said Craig Van den Avont, GAM Gear, LLC’s president. “We’re pleased to introduce a motor mount kit and planetary gearbox that comes ready to bolt directly to a Festo actuator.”

The new LSK from GAM is a customized mounting solution designed to connect any motor with a linear actuator. The LSK is also offered in multiple sizes and includes the mounting and coupling hardware.

The new EPL-H is a hollow output planetary gearbox that can directly mounts to any actuator and motor, and is offered in three frame sizes.

“We hope this universal solution will help make mounting to Festo actuators easier,” added Van den Avont. “We’re committed to meeting our customers’ needs as we strive to manufacture custom and universal solutions that make application design a more seamless process.”

Motion Control Tips

• Information on the energy efficient SP+ gearbox – the SP+/L-version (low-friction)
• Technical data on the large SUMO hypoid gearboxes

All updated technical information can be found on product-specific pages at the Wittenstein website (www.wittenstein-us.com). Downloading the electronic version of the new catalog can be done from the Manuals page online.

Motion Control Tips

Easy mounting can be achieved with four ‘face mount’ M5 threaded holes, which is equally spaced on a 40-millimeter diameter B.C. The reversible gearmotor’s output is rated for 310 Lb In continues torque at 2.5 rpm, and 443 Lb. In. Peak. In spite its compact size and weight of approximately four pounds, it is an efficient design, requiring only 0.2 Amps at 12 V DC to generate a Full Load Torque. This translates into a long life battery charge, which is very low in noise operation and lower in costs for related drive electronics. The motor windings for 90, 60, 48, 36, 28 and 24 Volts are also available. The unique design is rated at an IP 54 protection level for harsh environment operations. Variable speed can be achieved with Midwest’s fully compatible speed controls, Model MMP 20A-12V-RSP, or MMP 25A-12V.

Motion Control Tips

Employing modern DSP technology which facilitates implementation of sensorless control algorithms and eliminates the need for position sensors (and associated wiring) required in conventional BLDC motor-control systems, Bison’s new low voltage AUTONOmotor™ parallel shaft gearmotors are offered in eleven standard versions with gear ratios from 5:1 to 215.6:1 and rated output speeds from 470 to 11 RPM with a 10:1 speed range. Speed can be adjusted with either a supplied potentiometer or a 0-5V DC signal. Continuous output torques range from 19 to 300 in-lbs (2.1 to 33.9 N-m). The gearmotors employ all-steel gearing, and oil bath lubrication for optimum design lifetimes.

Ideally suited for foodservice equipment, factory automation, packaging equipment, alternative energy systems, stationary agricultural equipment, and other specialty machinery applications, the eleven new AUTONOmotor™ brushless DC parallel shaft gearmotors are part of Bison Gear’s comprehensive In-Stock, Instant-Ship (ISIS) program that supports Bison’s distribution partners and offers same day shipment for orders received before noon (Central Time).

The new AUTONOmotor™ brushless DC parallel shaft gearmotors are American-made to Bison’s high quality standards in its suburban Chicago facility in order to ensure reliable, long-life operation and a short supply chain for North American customers. In addition, Bison’s Innopreneurial™application and design engineering capabilities to customize the standard models to meet specific OEM needs are readily available.

Bison Gear & Engineering Corp.
www.BisonGear.com

Motion Control Tips

Groschopp’s new NEMA Right Angle Worm Gearboxes with hollow out-put shafts allow options for right, left or dual shaft configurations. RA 40, RA 50, RA 63, RA75 are in stock, the RA 90 and RA 110 will be available in May 2010.

• Six sizes from 40mm-110mm
• Ratios available: 5:1 to 100:1
• Input power, 1/15 to 10 hp
• Torque Range, 5 to 6,000 in/lbs
• Versatile, compact design
• Multiple mounting configurations
• High-quality, lightweight aluminum construction

All gearboxes have high thermal capacity die-cast aluminum housings, designed for exceptionally efficient heat dissipation, resulting in maximum torque output in a highly compact package. All housings are powder-coated, for a durable corrosion-free finish.

The new line of gearboxes feature:

• Flexible product configurations for foot, flange and shaft mounting, with optional torque arm.
• Industry standard NEMA input flanges.
• Lifelong lubrication. Synthetic oil yields a maintenance free highly reliable speed reducer.
• A symmetrical, hollow output shaft. This facilitates gearbox mounting and plug-in shafts for easy assembly and installation.
• Quiet operation and optimum efficiency with ground finished worm shafts and precision machining. (Sizes 90 and 110 are supplied with tapered roller bearings on the worm gear.)

Groschopp
www.groschopp.com

Motion Control Tips

Bison’s new 100mm AC Right Angle Gearmotors are powered by these 115 volt, 60 Hz single-phase TEFC permanent split capacitor motors and offered in six standard versions with gear ratios from 5.2:1 to 50:1 and fixed output speeds from 327 to 28 RPM respectively. Continuous output torques range from 12 to 104 in-lbs (1.4 to 11.8 N-m). The gearmotors are available in an easy-to-mount 3/4″ (19mm) hollow shaft configuration, or can use quickly replaceable single or double output stub shafts and can be either foot or face mounted. In addition, a convenient rear motor shaft extension can be fitted with an optional power-off brake.

Ideally suited for packaging equipment, conveyor systems, foodservice and stationary agricultural equipment, and other specialty machinery applications, the six new 100mm AC Right Angle products are supported by Bison Gear’s In-Stock, Instant-Ship (ISIS) program that supports Bison’s distribution partners and offers same day shipment for orders received before noon (Central Time).

“We believe these compact, high output AC motor designs will find many new applications where space is at a premium, but where motor power cannot be sacrificed,” said Robert Lewton, electrical design engineer at Bison Gear. “This right angle gearmotor offering is the second family of Bison products to benefit from the new 100mm AC motors. This being Bison’s 50th anniversary year, we will continue to expand this innovative new 100mm AC product line and we will follow that up as well with other exciting new products from Bison this year.”

The new 100mm AC Right Angle Gearmotors are American-made to Bison’s high quality standards in its suburban Chicago facility in order to ensure reliable, long-life operation and a short supply chain for North American customers. In addition, Bison’s Innopreneurialâ„¢ application and design engineering capabilities to customize the standard models to meet specific OEM needs are readily available.

Bison Gear & Engineering Corp.
www.BisonGear.com

Motion Control Tips

The latest WX gearhead features rugged, all-steel helical gears exceed or meet AGMA-9 standards for quiet operation and longest life. It also has a synthetic lubrication which allows the gearheads to operate in different temperatures. It can be configured to three-hole mounting pattern through a simple bolt-on adaptor (“Bodine model 0995”).

Also, the gearmotor has 12 new gear ratios with a three-wire reversible, fixed-speed AC motor.

The WX gearhead’s exterior is identical to old W models from Bodine, but its interior has been entirely redesigned. These all-new WX gearmotors has synthetic lubricant and steel helical gears, allowing the gearhead to give up to 50 percent more torque compared to previous models. Its new steel gearing has AGMA 9 standards, or higher, to insure the expected quiet operation from Bodine Electric products. Its synthetic lubricant improves life and allows unvented gearmotors to operate in different temperatures.

The 12 new WX stock models can be configured to feature a three-hole mounting pattern through a simple bolt-on adaptor plate (“Bodine model 0995”). The WX gearhead is the first to be paired with three-wire reversible 34 R from Bodine, motor winding and permanent split capacitor. Its three-wire configuration simplifies connection and reversing the motor’s direction by switching the place of its two leads. Also, new winding can be operated at 50Hz by using a different value run capacitor. The latest 230VAC, 50 or 60Hz, one-phase, three-wire reversible winding is available for custom configurations.

The WX models are made to drive various applications such as commercial appliances, metering devices, packaging equipment and conveyor systems.

Motion Control Tips

Bison’s new 100mm AC Parallel Shaft Gearmotors are powered by these 115 volt, 60 Hz single-phase TEFC permanent split capacitor motors and offered in nine standard versions with gear ratios from 5.0:1 to 215.6:1 and fixed output speeds from 340 to 8 RPM respectively. Continuous output torques range from 16 to 350 in-lbs (1.8 to 39.5 N-m). Ideally suited for foodservice and stationary agricultural equipment, factory automation, conveying and specialty machinery applications, the nine new 100mm AC Parallel Shaft products are supported by Bison Gear’s In-Stock, Instant-Ship (ISIS) program that supports Bison’s distribution partners and offers same day shipment for orders received before noon (Central Time).

“Over the past few years we heard from customers that they were looking for a smaller 1/8 horsepower motor that would help them fit their increasingly smaller machine and equipment envelope, and that’s what drove the development of the new 100mm AC motors,” said Robert Lewton, electrical design engineer at Bison Gear. “This 100mm AC offering is the first of many innovative Bison new product introductions planned for our 50th anniversary year. In the 100mm AC alone, we will be expanding both our electrical and mechanical offerings shortly.”

The new 100mm AC Parallel Shaft Gearmotors are American-made to Bison’s high quality standards in its suburban Chicago facility in order to ensure reliable, long-life operation and a short supply chain for North American customers. In addition, Bison’s Innopreneurial™ application and design engineering capabilities to customize the standard models to meet specific OEM needs are readily available.

Bison Gear & Engineering Corp.
www.BisonGear.com

Motion Control Tips

This powerful, lightweight DC Gear Motor provides benefits for Robotics, Video Monitor Electric Lifts, and Automation Applications.

The output of this ultra-quiet gearmotor is rated for 46 lb-in of continuous 50 RPM torque and 89 IN-LBS Peak. Despite its weight of approximately three pounds and compact size, it is an efficient design, requiring 2.1 A at 28 V DC to generate Full Load Torque. This translates into a long-life battery charge, very quiet operation, and lower cost drive electronics. Also, Motor windings for 12 V, 36 V, 48 V, 60 V and 90 Volts are available. The unit features a True Planetary Gearing with Delrin first stage that allows for nearly silent operation for many interior applications like Monitor lifts and TV Screen, Camera Pan &Tilt axes of Motion and video surveillance.

Its unique design has an IP 54 protection level rating for operation in harsh environments. With Midwest’s fully compatible Speed Controls (“MMP 20A-24V-RSP or Model MMP 25A-24V”), Variable Speed can be accomplished.

Typical options also available from Midwest Motion include Analog Tachometers, Failsafe Brakes, Optical Encoders, and Planetary Gearheads with standard ratios between 3:1 and 2653:1, and low or standard backlash precision gearing. Motor Winding Options include 12 V, 36 V, 48 V, 60 V and 90 Volts DC.

Motion Control Tips

With eight CGSM sizes (2 – 9), Input HP from 1/3 to 125, and Output RPM from 4 – 6 up to 118 – 125, Cleveland Gear is confident that these drives will provide highly reliable service for a variety of different material-handling applications. The shaft mount reducers are suitable for AGMA Class I, II or III service for motor HP’s up to 125 with standard ratios of 15:1 and 25:1.

Twin tapered bushing kits are perfectly sized for CGSM reducers, as well as other manufacturers’ shaft mount drives, with bore diameters from 1 5/16” to 4 15/16”. The kits ensure fast and easy installation and reliable support on both sides of the reducer. All CGC tapered bushing kits come complete with fastening bolts and a full-length key.

Cleveland Gear Company, Inc.
www.clevelandgear.com

Motion Control Tips

The RW8-NEMA23 is made from a CNC machined aluminum block housing, dual ball bearings for shaft support, stainless hardened single piece worm/input shaft and stainless output shaft. It is designed for 24 hour per day operation.

Applications include: food machinery, semiconductor processing, packaging machinery, medical diagnostic equipment, and all sorts of usual and unusual applications.

Rino Mechanical
www.rinomechanical.com/gearbox_miniature.htm

Motion Control Tips

The CG gearhead is paired with Bodine’s most powerful variable speed electric motors, the 48R6, AC inverter-duty, and 42A7 permanent magnet DC motors. This integral gearmotor design allows the CG to deliver up to 1,000 lb-in. of torque, which is nearly twice the torque of any previous Bodine product.

The CG gearmotor features a solid, aluminum cast gearhousing. It can be face-mounted in virtually any position, or mounted with a rigid base. Extra heavy-duty bearings and seals provide reliable operation and long life. Inside the gearhead three-stage, selectively hardened gearing and high performance lubricant insure quiet operation and high output torque. New DC accessory-ready models can be fitted with encoders, other feedback devices, or brakes.

The AC and DC models are the first of Bodine’s product line to be available through their new Quick Delivery program. This program is designed to ship customer orders in small order quantities within two to three working days. Products will be maintained in stock or assembled to order via a quick-turn production cell. Larger order quantities will require lead-time. Expedited delivery options are also available.

Bodine Electric Company
www.Bodine-Electric.com

Motion Control Tips

IP65 protection, food-grade grease, and stainless steel components are some of the features for the range. The washdown option is available as standard for the following alpha products: alpha LP+, alpha SP+, alpha TP+, alpha HG+, alpha SK+, alpha TK+ and alpha V-Drive.

Wittenstein
www.wittenstein-us.com

Motion Control Tips

The 2010 Catalog details Exlar’s selection of solutions for linear and rotary motion control applications. Product families span integrated actuator and motor designs, explosion proof designs, force tube actuators, and servo motor and gearmotors. The catalog and engineering guide additionally details Exlar’s advanced roller screw and stator technology as applied to linear and rotary actuators-with drawings, performance graphs and complete specifications for various configurations and applications. With a wide array of features and capabilities, Exlar offers several robust choices matched to each application’s diverse requirements.

An easy-to-reference engineering section includes definitions and equations for determining move-profile, velocity and acceleration, force, thrust, motor velocity and torque. Also included is a table of factors for converting units of rotary inertia, torque and material densities between English and metric units.

Exlar Corporation
www.exlar.com

Motion Control Tips

The SP Series from Applied Motion Products of Watsonville, CA are NEMA standard 2 phase 1.8 degree hybrid stepper gearmotors which provide high torque in a compact lightweight housing. These offset light duty gearmotors are ideal for rotary indexing and positioning applications.

Available in Nema 17 & Nema 23 frame sizes, the SP Series Stepper Gearmotors produce up to 320 oz-in continuous torque in a cost-effective compact package. 5:1, 10:1 and 18:1 reductions are available.

The SP series feature fast damping and high slew rates for better control in full/half or microstep mode. The torque levels reached with this stepper gearmotor line makes them a cost effective alternative to servo motors in many applications.

Servo2Go.com
www.servo2go.com

Motion Control Tips

JVL also offers complete motion control solutions. This includes a wide range of gears that fit directly on the motors for any application:

Low Cost Planetary
If the application is cost sensitive and high performance is not needed the HMGH series is the right choice.

Worm Gears
If cost is important and a 90° angle is also needed – then Worm gear boxes, the HFOS series, should be the first choice.

High Performance Planetary
When an honest hard working Planetary gear box is needed think of the HTRG series. They provide standard backlash of 15 or 10 arcmin (1+2 stage) and also high precision reduced backlash of either 5 or 3 arcmin.

Backlash free Robot Gears
Combine bearing and backlash free gear box into one ultra compact unit – the HSPG reducer. These gears offer unbeatable specs and performance.

JVL International
www.jvlusa.com

Motion Control Tips

In addition to full product features, benefits, specifications and ordering information, machine builders will find helpful guidelines on where to most effectively apply each technology type, and how to select the optimum product for a given application. Users will also find information on customization and rapid prototyping options.

Portescap
www.portescap.com

Motion Control Tips

“We’ve taken a non-Bison-specific approach in this white paper so that design engineers as well as OEM purchasing authorities will find it helpful, no matter what size or type of gearmotor they may use or who their supplier may be,” said John Morehead, Bison Gear vice president, strategic planning and marketing. “The most important finding, drawing on nearly 50 years experience, is the necessity to involve one’s gearmotor supplier’s application engineers as early as possible in the design process. Inevitably, that ensures the best overall machine performance, durability and cost position.”

Some of the other key issues covered in the white paper include the value of proprietary gearmotor specifications, reasonable lead time expectations for custom engineered prototypes, benefits of an expanding product portfolio, production scalability and value-added opportunities.

The new four-page white paper can be downloaded at BisonGear.com.

Bison Gear & Engineering Corp.
www.BisonGear.com

Motion Control Tips

The U.S. military has demanding requirements for the hardware it needs. Take, for instance, a set of gearboxes built by Excel Gear Inc., Roscoe, Ill, (excelgear.com) for missile launchers on the U.S. Navy’s new DDG1000 series of ships. The gearboxes are drive elements for the servo systems that rotate and elevate the missile launcher. For good servo performance the boxes must meet the Navy’s requirements for stiffness, efficiency, and low backlash.

A prototype was tested using a time consuming manual method. Although satisfactory, the method required careful checking to prevent data entry errors. Requirements for the test system called for high accuracy, elimination of measurement errors, and elimination of data entry errors. The company’s experience automating the test procedures provides a useful design lesson.

After successfully completing the prototypes, Excel Gear president N.K. Chinnusamy, decided the production run needed improved assembly procedures and to automat the test methods. Preload on the bearings was identified as an important factor – too little preload allowed excessive backlash while too much decreases efficiency and generates heat. A measurement accurate enough to size an optimum preload spacer is difficult because before the spacer is in place, the bearing can tip from side to side.

The company manufactured a set of fixtures to prevent bearing tipping and improve the repeatability of the preloads. The fixtures also improved the efficiency of the first production boxes and reduced their backlash from what had been attained in the prototype boxes.

The fixtures were developed to minimized bearing tipping. The fixtures resulted in improved efficiency and lower backlash.

Types of tests

The units called for several tests. For example:

Temperature tests during run-in: The primary sources of heat in the gearbox are seal friction, bearing friction, and oil churning. The heat generated by oil churning distributes throughout the box and dissipates through the case. Seal and bearing friction are concentrated and, if excessive, will cause failure. Temperatures are checked near the bearings on the high-speed shaft, where measurements on the prototype boxes showed the highest temperatures. These areas were also near the seals. Although it isn’t possible to separate the heat generated by the bearings and seals, the seals seem to generate the most heat.

Temperatures were recorded for two hours with the box running at maximum speed. After cooling, the test was repeated with the box running in the opposite direction. In the test, temperatures rise rapidly at first and then at a decreasing rate. While the temperatures do not reach equilibrium, in operation the boxes will not run continuously for two hours, and they will reach top speed only intermittently.

Gear-train stiffness: This characteristic, measured with the output shaft locked, is the ratio of the input-shaft motion to the torque applied, in Nm/rad. Torque was applied using a hydraulic actuator with two opposed cylinders driving two racks against a pinion. The racks are held in the pinion by a bushing. This results in friction force opposite to the direction of motion. Because the friction in the hydraulic actuator would cause measurement inaccuracies, the torque is measured between the actuator and the input shaft using a Dataflex 42/1000 torque transducer. This sensor has a capacity of 1,000 Nm in either direction. Torque is determined by measuring the twist in the transducer shaft using rotary encoders in a differential circuit. An encoder rotor is mounted at each end of the shaft. Because the encoder read heads are mounted to the stationary part of the transducer, there are no slip rings. The A-quad-B output from the transducer is converted to a voltage by an encoder electronic box. The voltage output range is 0 to 10V with a no load value of 5V, and the calibration constant is 0.200 Nm/mV. Rotary motion was measured using a 2,000 line rotary encoder (resolution of 0.018° ). Because the input shaft extends through the box, the encoder is mounted on the opposite end of the shaft from the hydraulic actuator. When the box is in operation, a brake is mounted on this end of the shaft.

The A-quad-B output from the encoder is converted to a voltage by the programmable encoder-control box. The range and number of volts per degree can be set depending on the amount of rotation to be measured. The output has a range of 0 to10V. For this test, the output was 8.100° per V and the no-rotation voltage was 5V.

Gear train backlash: Some backlash is necessary to provide running clearance for the gears. Too little backlash results in overheating and premature failure, and too much degrades servo performance. Backlash is determined from the data collected for gear train stiffness.

Breakaway torque: For these boxes, it was low and measured manually using a snap-torque wrench. Although automated tests are usually preferred, a few are so simple that the programming required is not justified. This test, for instance, was the only one not automated.

Gearbox power losses over the full range of speeds: Input torque was measured with the gearbox running at a set of speeds both clockwise and counterclockwise. The torque is a nearly linear function of speed with a small component of stiction. This is preferred in a servo system because it contributes to servo loop damping. Because the torque is nearly a linear function of speed, the power-loss curve is nearly parabolic.

Test equipment

Accompanying images show the test equipment and The test hardware table lists a few of its details. The software used, DASYlab, is a graphical programming language. It is programmed by placing block diagrams representing data collection operations on a screen and connecting them with “wires” to control data flow. In the system used here, processed data is written to disk in a tab-separated format suitable for further analysis using Microsoft Excel.

More detail of the test equipment is listed in the accompanying table

Programming the data collection: The DASYlab block diagram provides an example programming screen. Each block represents an operation on the data such as collecting, scaling, saving to disk, and displaying. This programming method is faster than writing code. For example, the voltage output from the torque transducer, encoder, and thermocouples was connected to the electronic interface box. This box has a built in reference junction for the thermocouples. The device also has digital and analog outputs but these were not used. The interface box scans its inputs and converts from analog to digital values. These are passed to the computer through a USB connection at about 1Hz. This is relatively slow for data acquisition, but more than adequate for these quasistatic tests.

The sample screen shows how DASYlab software is programmed, by running virtual wires from sensors to instruments.

Red curves (not data from a gearbox test) represents data from a typical output while the blue line show a best curve fit. The vertical portion on the zero axis represents backlash. The slope of the blue curve represents gearbox stiffness.

In the DASYlab program, the first box is an input box that “talks” to the hardware and places the input values on its outputs in digital form. Typically this is a special module that works only with particular hardware. Most other boxes do not depend on the type of hardware in the system. The other boxes used are numerical displays, graphical displays, and output boxes to record the data on disk. These boxes have corresponding components on a display screen. This screen can be a virtual instrument, that is, it can look like instruments such as voltmeters, oscilloscopes, and chart recorders. For this test the program converts the inputs to engineering units and displays the values several ways. Digital displays show the current numerical values of inputs.

Another display, an XY-plot, shows rotation on the Y-axis and torque on the X-axis. This feedback gives a preview of results. It can save much time because if something is wrong, such as a broken wire or failed thermocouple, it quickly becomes apparent. The test can be stopped, the problem corrected, and the test resumed. A problem that goes undetected until the data is analyzed wastes the entire test period.

A disadvantage of DASYlab is that this program had to be written with the computer attached to the interface hardware. It would be a great advantage to write the program sitting in front of a desktop computer rather than working in the test area using a laptop.

Details of the analysis

Backlash and Compliance: One advantage of automated data collection is the larger amount of accurate information than can be manually collected in a reasonable period. The additional data gives a better picture of the equipment characteristics than would otherwise be possible. In Backlash and compliance, the red line simulates points collected when the torque was varied from zero to maximum, to minimum, and back to zero three times. (The data shown are not actual values but they are an accurate representation of the type of data collected.) The data showed good consistency and repeatability, which produces confidence in the results. For instance, the blue line shows the curve fitted to the backlash and compliance data. The length of the vertical line at zero-load is reported as backlash. The slope of the lines fitted to the observations is the stiffness. This is a conservative method for determining such values. The normal manual four-point test would have given both lower backlash and compliance numbers. The four-point test uses two torques that are just a little higher than breakaway torque in each direction and two torques that are a quarter to one half of the full load torque.

The encoder (dark disc with cable) works with the automatic system while the inclinometer (meter mounted on the horizontal bar) was used for manual readings. The encoder has better resolution, but a difference between the two devices would quickly show scaling or programming errors.

Converting from manual to automated testing: The first use of an automated system involves debugging because the test system, as well as the tested device, may have problems. An advantage to starting this system was that previous manually collected results were available for reference. Problems with the test system are seen quickly. For the first test, some manual measuring devices were used in parallel with the new test equipment. This either verified the results or showed problems. For example, an incorrect scaling factor was quickly detected and corrected. This illustrates one principle of successful testing: Check the calibration of the test equipment before running the tests.

About the author: William Winterbauer is principal engineer with QED Services and a consultant to Excel Gear Inc.

Excel Gear Inc.
www.excelgear.com

Motion Control Tips

Groschopp’s new IEC RA Gearboxes have hollow out-put allow options for right, left or dual shaft configurations. All nine sizes are in stock and ready to ship in 48 hours or less.

• Nine sizes from 26 mm – 130 mm
• Input Power 0.06 to 7.5kW, 1/15 to 10 hp
• Torque Range 10 to 1050 Nm, 5 to 10,000 in-lbs
• Versatile, Compact Design
• Multiple Mounting Configuration
• High-Quality, Lightweight Aluminum Construction

Sizes RA26 through RA90 have high thermal capacity die-cast aluminum housings, designed for exceptionally efficient heat dissipation, resulting in maximum torque output in a highly compact package. The larger sizes, RA110 and RA130, are cast iron. All housings are powder-coated, for a durable corrosion-free finish.

Tower of power

The new line of gearboxes features:

• flexible product configurations for foot, flange and shaft mounting, with optional torque arm.
• industry standard IEC input flanges.
• permanent synthetic long-life lubrication (sizes RA26-RA90) yields a maintenance-free, highly reliable speed reducer.
• symmetrical hollow output shaft facilitates gearbox mounting and plug-in shafts for easy assembly and installation.
• quiet operation and optimum efficiency with ground finished worm shafts and precision machining.

Groschopp Inc.
www.groschopp.com

Motion Control Tips