4 project planning - sew eurodrive · 2016-07-07 · 4 project planning assistance project planning...

4List of application variablesProject Planning

41Gear Units – 2016

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4 Project Planning Project planning should be performed for all gear units. The data specified in this catalogapplies only if project planning was completed correctly. It is particularly important for gearunits under the following conditions:

• Increased ambient temperatures

• Altitudes > 3280 feet (less convection)

• Gear units > size 87 with small ratios (more heat from oil churning)

• All helical-worm gear units with small ratios and increased ambient temperature

4.1 List of application variables

Your application data is required in order to precisely define the correct drive. Theabbreviations used for project planning are summarized in the following table:

Designation Meaning Unit

namin Minimum output speed [rpm]

namax Maximum output speed [rpm]

Pa at namin Output power at minimum output speed [HP]

Pa at namax Output power at maximum output speed [HP]

Ta at namin Output torque at minimum output speed [lb-in]

Ta at namax Output torque at maximum output speed [lb-in]

FRa Overhung load on gear unit output shaft [lb]

FAa Axial load on gear unit output shaft [lb]

ne Input speed [rpm]

Pm at ne Motor input power [HP]

Te at ne Input torque [lb-in]

Te max Maximum input torque [lb-in]

FRe Overhung load on input of gear unit [lb]

FAe Axial load on input of gear unit [lb]

JLast Mass moment of inertia to be driven [lb-ft2]

R, F, K, S, WM1 - M6

Required gear unit type and mounting position(see chapter, "Mounting positions")

-

IP.. Required degree of protection -

Umg Ambient temperature [°C]

H Installation altitude[ft above sea level]

S.., ..% cdfDuty type and cyclic duration factor (cdf) or exact load cycle can be specified.

-

Z Starting frequency; alternatively, exact load cycle can be specified [1/h]

VBremse Operating voltage of the brake (AT with brake) [V]

TB Required braking torque (AT with brake) [lb-in]

TR Slip torque (AR) [lb-in]

Type of the motors

... Electric motor

... Internal combustion engine

... Hydraulic motor-

4 Project planning assistanceProject Planning

42 Gear Units – 2016

4.2 Project planning assistance

SEW-EURODRIVE’s regional engineers will gladly perform project planning for you. Inaddition, we offer the information in this catalog and complete documentation covering thetopic of drive engineering. The publication "Project Planning for Drives" provides acomprehensive collection of the the most important formulas needed for drive calculation,as well as detailed examples for the most frequently used applications. No doubt, it is a veryvaluable tool for project planning!

You may download "Project Planning for Drives" by scanning the bar code below. Or, youmay go to the following link: www.seweurodrive.com/download/pdf/10522913.pdf

The following catalogs are also available from SEW-EURODRIVE for assistance withproject planning:

• DRE.. Gearmotors (IE2 efficiency)

• DRP.. and DRN.. Gearmotors (IE3 efficiency)

• Synchronous servo gearmotors

• X series Industrial Gear Units

You may request a hard copy of these catalogs by calling SEW-EURODRIVE, or downloadthem from www.seweurodrive.com.

INFORMATION

Online assistance for conveyor, hoisting,and travel drive applications is availablethrough SEW-EURODRIVE’s exclusivePT Pilot® calculator.

Simply enter your drive parameters andlet PT Pilot® do all of the work. Visitwww.ptpilot.com.

4Selection procedureProject Planning


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4.3 Selection procedure

The following flowchart presents a schematic view of the procedure for planning a projectincorporating a gear unit with a component on the input side.

Necessary information regarding the machine to be driven– Technical data and environmental conditions– Positioning accuracy– Travel cycle calculation

Calculation of the application data– Static, dynamic, and regenerative power– Speeds– Torques– Travel diagrams

Gear unit selection– Define gear unit size, gear unit ratio and gear unit type– Check the positioning accuracy– Check the gear unit torque against the load torque for proper service factor

Selecting components on the input side– Specify input type– Check the axial and radial loads on input– Define input size

Options– Monitoring functions (devices, equipment)– Brake (for AT only)– Backstop– Centering shoulder– Motor mounting platform

Make sure that all requirements have been met.

4 Gear efficiency and thermal lossesProject Planning


4.4 Gear efficiency and thermal losses

The efficiency of gear units is mainly determined by the gearing and bearing friction. Thestarting efficiency of a gear unit is always less than its efficiency at operating speed. This isparticularly true for helical-worm and SPIROPLAN® right-angle gear units. Gear units arelisted below in order of highest efficiency to lowest efficiency.

R, F, and K The helical (R), parallel shaft (F) and helical-bevel (K) gear units (excluding K19, K29, K39,K49) contain 100% rolling friction and the highest efficiency. Efficiency depends on thenumber of gear stages: 96% (3-stage), 97% (2-stage) and 98% (1-stage).

K..19 - K..49 These right-angle units contain 2-stage hypoid gearing that combines rolling friction withminor sliding friction. Their efficiency ranges from 90% to 96%, depending on the ratio.Current sizes include K19, K29, K39, and K49.

W - SPIROPLAN® The SPIROPLAN® gear units (W-series) combine rolling friction with some sliding friction,similar to hypoid gearing. The sliding friction induces some loss and lower efficiency than R,F or K gear units, but higher efficiency than a helical-worm (S-series).

The SPIROPLAN® gear units W37 and W47 contain a helical input stage. Therefore, theyhave the highest efficiency of the SPIROPLAN® gear units (>90%), dropping only slightly forlarger ratios.

The efficiency depends on the following factors:

• Gear ratio

• Input speed

• Ambient temperature

S-series The helical-worm (S-series) gear units contain a first stage helical gear set and a secondstage worm set. Various degrees of sliding friction occurs in the worm set, depending on thenumber of starts on the worm gear. Therefore, these gear units have higher losses andlower efficiency than other SEW-EURODRIVE gear units. However, they are stillsignificantly more efficient than single stage worm gear units common in the industry.

The efficiency depends on the following factors:

• Gear ratio (number of starts on worm)

• Input speed

• Ambient temperature

Self-locking Backdriving torques on helical-worm or SPIROPLAN® gear units produce an efficiency of ' = 2 - 1/, which is significantly less than the forward efficiency, . The helical-worm orSPIROPLAN® gear unit is self-locking if the forward efficiency is 0.5, which may occur onsome higher ratios. Therefore, some SPIROPLAN® gear units are dynamically self-locking.

Contact SEW-EURODRIVE if you wish to make technical use of the braking effect of self-locking characteristics.

INFORMATION

Note that the self-locking effect of helical-worm and SPIROPLAN® gear units shouldnot be used as the sole safety function for hoists!

4Gear efficiency and thermal lossesProject Planning


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Run-in phase When gears are initially manufactured, the tooth flanks of helical-worm and SPIROPLAN®

gear units are not 100% smooth. They require a run-in period in order to achieve theirmaximum polish. Therefore, there is a greater friction angle and less efficiency during initialoperation. This effect intensifies with higher gear ratios. To determine the startup efficiency,subtract the following values from the listed efficiency:

The run-in period usually lasts 48 hours. Helical-worm and SPIROPLAN® gear units achievetheir rated efficiency under the following conditions:

• The gear unit has completed the run-in period

• The gear unit has reached nominal operating temperature

• The gear unit contains the recommended lubricant and fill quantity

• The gear unit is operating in the rated load range

Thermal losses In certain gear unit mounting positions (see chapter "Mounting Positions"), the first gearingstage is completely immersed in the lubricant. When the circumferential velocity of the inputstage is high, considerable churning losses occur, especially in larger gear units (> size 87),or with input speeds > 1750 rpm. As a result, the gear unit may have a reduced input HPrating. Substituting synthetic oil and high temperature FKM seals often permits a higheroperating temperature and increases the HP rating.

To keep churning losses to a minimum, use gear units in M1 mounting position wheneverpossible. For more information on gear units with AD input shaft assembly, see page 63.

Helical-Worm

Ratio Range reduction

1-start approx. 50 ... 280 approx. 12 %





SPIROPLAN® W..

Ratio Range reduction

approx. 30 ... 75 approx. 8 %



INFORMATIONFor thermal limitations, you may visit www.ptpilot.com. PT Pilot® uses averageconduction and convection to figure your thermal limitation. It also provides a completequotation, including all motor and gear unit options.

4 Service factor and inertiaProject Planning


4.5 Service factor and inertia

Inertia acceleration factor

The inertia acceleration factor, IAF, is the ratio between the system (load) inertias and themotor inertias. It is an important factor that determines system stability and gear unit servicefactor. It is calculated at the motor shaft, as follows:

Values for Jmot and Jz are available in the motor section of SEW catalogs. Jb is alreadyincluded in the value for Jmot if you select the column for brakemotor. Both Jgear and Japt areoften negligible, especially on smaller gear units.

Jx can be calculated from the application formulas below.

Load classification

There are three load classifications, based upon the inertia acceleration factor:

Contact SEW-EURODRIVE for inertia acceleration factor > 10.

JxJgearJaptJmotJbJz

= Inertia of all load components reflected to the motor shaft= Inertia of gear unit (ratio dependent)= Inertia of input adapter (AD, AM, AT, AQ)= Inertia of motor without brake= Inertia of the brake on motor shaft (if applicable)= Inertia of the cast iron fan on motor (if applicable)

Linear Motion(Conveyor, Travel Drive, Hoist)

Rotational Motion(Turntable, Solid Cylinder)

WTVmaxDntnm

= Total weight (lbs)= Maximum velocity (feet per minute)= Diameter of turntable or cylinder (in)= Turntable speed (rpm)= Motor full-load speed (rpm)

IAFJgear Japt Jx+ +

Jmot Jb Jz+ +-------------------------------------------------=

Jx

WT39.5-----------

Vmaxnm

---------------- 2

= Jx

WT2

--------- D24------

2

nt

nm--------

2

=

Load Class Type IAF

(I) Uniform IAF 0.2

(II) Moderate Shock 0.2 IAF 3.0

(III) Heavy Shock 3.0 IAF 10

4Service factor and inertiaProject Planning


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SEW service factor, fB

The load from the driven machine imposes a shock on the gear unit. The degree of shockdepends upon the load inertia, motor inertia, daily operating time, and starting frequency.The SEW service factor, fB, considers all of these variables.

Since the method for determining the maximum output torque rating can vary among gearmanufacturers, the required SEW service factor applies to SEW gear units. As such, thisservice factor may differ from an AGMA service factor, or the service factor from anothermanufacturer. However, even when fB=1.0, the SEW gear unit contains an extremely highlevel of safety and reliability in the fatigue strength range.

Service factor is determined from Figure 1 below, using the load classifications I, II, III asdefined on page 46. For proper project planning, the maximum permissible output torque ofthe gear unit (as shown in the selection tables within this catalog) must be greater than theload torque multiplied by the SEW service factor, fB, per the following equation.

Ta = load torque

Tamax = maximum permissible output torque (from gear unit tables)

fB>1.8 can occur with large inertia acceleration factor (>10), high levels of backlash in thetransmission elements, or a large overhung load. Contact SEW-EURODRIVE.

00656BXXFigure 1: SEW service factor fB

* Daily operating time in hours/day** Frequency, Z, is the sum of all load changes within one hour, which includes all

instances of starting, braking, and speed changes. Example: In one hour, a 2-speed motor starts 50 times, switches from low to high speed 50 times, switches from high to low speed 50 times, and stops 50 times. In this case, Z= 200.

Tamax Ta fB

fB

0 200 400 600 800 1200 14001000

24* 16* 8*

0.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Z [1/h] **

(III)

(II)

(I)



Example 1 • Inertia acceleration factor = 2.5

• 14 hours/day operation

• 300 load changes/hour

• R, F, or K-series gear unit required

Using the load classification table: when IAF = 2.5 then,

Load class = II.

From Figure 1: Using the column for 16 hr/day (round up 14 hrs/day) and load class II,

fB = 1.5.

Therefore, the R, F, or K gear unit must have torque rating,

Tamax > (load torque x 1.5)

4Service factor and inertiaProject Planning


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Helical-worm (S-series)

For helical-worm (S-series), two additional service factors, fB1 and fB2, are needed andobtained from Figure 2 below. Contact SEW-EURODRIVE if the temperature < -20°C [-4°F].

• fB1 = Service factor from ambient temperature

• fB2 = Service factor based upon %ED, which is the amount of time the motor is operatingcompared to the time that it is resting.

The total service factor for a helical-worm gear unit becomes:

00657BXXFigure 2: Additional service factors fB1 and fB2

%ED Time under load in min/hr

60--------------------------------------------------------------------- 100=

fB2

-20 0-10 20 40 6020 8030 100%ED

40 50°C

fB1

1.0 0.6

1.2 0.8

1.4 1.0

1.6

1.8

(III)

(II)

(I)

fBtotal fB fB1 fB2=



Example 2 Change example 1 to use a helical-worm gear unit with the additional conditions below.

• Inertia acceleration factor = 2.5 (load class = II

• 14 hours/day operation

• 300 load changes/hour

• Ambient temperature = 40°C

• Time under load = 40 min/hour

• Load Torque = 4200 lb-in

• 29:1 ratio

From Figure 1 using 16 hr/day,

fB = 1.50

Calculate %ED,

ED = 40/60 = 66.7%.

Using Figure 2,

fB1 = 1.40

fB2 = 0.95

The total service factor becomes,

fBtotal = 1.50 1.40 0.95 = 2.0

Therefore, the helical-worm gear unit must have an output torque rating,

Tamax > (4200 lb-in x 2.0)

Tamax > 8400 lb-in

From the S67 gear unit table on page 582, Tamax = 4240 lb-in, which is too low.

Thus, the solution requires an S77, 28.41:1, Tamax = 8750 lb-in, as shown on page 584.

4Axial forces and overhung loadsProject Planning


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4.6 Axial forces and overhung loads

Axial force If there is no overhung load, then an axial force. FA (tension or compression) equal to 50%of the overhung load given in the selection tables is permitted on the output shaft. The 50%rule applies to the following gear units:

• R-series helical gearmotors except R..137... to R..167...

• F-series parallel shaft with solid shaft except F97...

• K-series helical-bevel with solid shaft

• S-series helical-worm gear units with solid shaft

Overhung load (OHL)

The type of transmission component that is mounted to the output shaft has a direct impacton the overhung load. Some components impart higher forces than others, as shown by thetransmission factor, fZ in the following table.

The following formula determines the overhung load on the output shaft of a gear unit.

INFORMATION

Contact SEW-EURODRIVE for all other types of gear units, a greater axial load, or acombination of an overhung load and an axial load.

Component Transmission factor fZ Comments

Gears 1.15 < 17 teeth

Chain sprockets 1.40 < 13 teeth

Chain sprockets 1.25 < 20 teeth

Narrow V-belt pulleys 1.75 Due to pre-tension

Flat belt pulleys 2.50 Due to pre-tension

Timing or toothed belt pulleys 2.00 - 2.50 Due to pre-tension

Gear rack pinion, pre-tensioned 2.00 Due to pre-tension

FR = Overhung load (lbs)

T = Load torque (lb-in)

d0 = Diameter of the gear, sprocket, or pulley (in inches)

fZ = Transmission factor

FR2 T

do----------- fz=

4 Axial forces and overhung loadsProject Planning


Permissible OHL The basis for determining the permissible overhung loads is the calculation of the ratedbearing service life L10h of the rolling bearings (according to ISO 281).

The overhung load rating changes for every angle, and direction of rotation. Since therating listed in the catalog is based upon the most unfavorable angle and direction, a higheroverhung load rating is possible when considering your specific angle and rotation. Inaddition, even higher loads are permitted if heavy duty bearings are installed on the outputshaft of R, F, and K gear units. Contact SEW-EURODRIVE in such cases. Use the figurebelow to specify your angle of force.

The application force, is defined according to the following figure:

63214axx

= angle of force

FR = Permissible overhung load at distance, x [lbs]

FA = Permissible axial load [lbs]

0°0°

X

FR

FA

αα

INFORMATION

The overhung load values (FRa) shown in the rating tables of this catalog refer to a forceapplied at the center of a standard-length solid output shaft. These values are alsobased upon the most unfavorable application angle, and direction of rotation.

For OHL values of a hollow shaft gear unit, please consult SEW-EURODRIVE.

INFORMATIONReduction of overhung loads

• Only 50% of the FRa value specified in the selection tables is permitted in mountingposition M1 with wall attachment on the front face for K and S gear units.

• Helical-bevel gearmotors K167 and K187 in mounting positions M1 to M4: Amaximum of 50% of the overhung load FRa specified in the selection tables in thecase of gear unit mounting other than as shown in the mounting position sheets.

• Foot and flange-mounted helical gearmotors (R..F): A maximum of 50% of theoverhung load FRa specified in the selection tables in the case of torquetransmission via the flange mounting.

4Axial forces and overhung loadsProject Planning


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OHL conversion Please contact SEW-EURODRIVE to determine the permissible overhung load for an inputshaft assembly (ex: R67AD2) when the overhung load force is not located at the center ofthe input shaft.

When the overhung load force is not applied at the midpoint of the output shaft, the followingformulas should be used to determine two permissible overhung load values - FxL forbearing life, and FxW for shaft strength. The constants in the formulas are listed on the nextpage for each gear unit size.

The final permissible value, FR, for the overhung load at point, x, is the smaller of the twovalues of FxL and FxW.

FxL, based on bearing life:

FxW, based upon shaft strength:

Figure 3 shows the overhung load FR not located at the shaft mid-point:

FRa = Permitted overhung load [lb] at the midpoint (x = I/2) of the output shaft for foot-mounted gear unit. See selection tables.

x = Distance from the shaft shoulder to the point of application [in]

a, b, f = Gear unit constants for overhung load conversion [in]

c = Gear unit constant for overhung load conversion [lb-in]

63215axxFigure 3: Overhung load, FR not located at shaft midpoint

FxL FRaa

b x+------------- [lb]=

FxWc 103

f x+---------------- [lb]=

x

x

FRa

FRaFR FR

d d

l

l/2

4 Axial forces and overhung loadsProject Planning


Constants for overhung load conversion

Values for gear unit types not listed are available on request.

Gear unit typea

[in]b

[in]c

[lb-in]f

[in]d

[in]l

[in]

RX/RXF57RX/RXF67RX/RXF77RX/RXF87RX/RXF97RX/RXF107

1.712.072.382.893.414.04

0.931.081.201.321.441.67

1.342.141.736.81

12.6621.86

1.351.56

01.932.122.45

0.7501.0001.2501.6252.1252.375

1.571.972.363.153.944.72

R/RF07R/RF17R/RF27R/RF37R/RF47R/RF57R/RF67R/RF77R/RF87R/RF97R/RF107R/RF137R/RF147R/RF167

2.833.484.194.655.395.816.636.848.53

10.0611.2413.5215.8317.72

2.052.703.213.664.214.435.265.266.567.708.48

10.1811.6913.58

0.410.581.381.102.163.342.353.517.50

10.5318.2354.3476.56111.52

0.430.670.46

00.590.71

00000

1.181.30

0

0.7500.7501.0001.0001.2501.3751.3751.6252.1252.3752.8753.6254.3754.750

1.571.571.971.972.362.762.763.153.944.725.516.698.278.27

F27F37F47F57F67F77F87F97F107F127F157

4.314.866.046.727.148.50

10.3513.7814.7017.4220.16

3.333.884.865.345.566.537.9911.0211.3613.2916.02

1.000.951.584.863.656.97

10.5318.5037.4483.6492.93

000

1.260000000

1.0001.0001.2501.3751.6252.0002.3752.8753.6254.3754.750

1.971.972.362.763.153.944.725.516.698.278.27

K37K47K57K67K77K87K97K107K127K157K167K187

4.866.046.687.148.509.92

12.5614.7017.4620.0424.4728.37

3.884.865.305.566.537.569.8011.3613.3315.9119.5522.07

1.251.586.023.656.81

14.5224.7848.9473.55

104.44166.39269.06

00

1.22000000000

1.0001.2501.3751.6252.0002.3752.8753.3254.3754.7506.2507.500

1.972.362.763.153.944.725.516.698.278.279.84

12.60

W10W20W30W37W47

3.343.884.314.775.73

2.553.093.523.984.55

0.320.390.530.613.74

0000

1.40

0.6250.7500.7500.7871.181

1.571.571.571.572.36

S37S47S57S67S77S87S97

4.675.125.917.248.8211.0812.85

3.884.134.725.877.058.72

10.09

0.531.181.892.694.66

14.8722.48

0000000

0.7501.0001.2501.3751.7502.3752.875

1.571.972.362.763.544.725.51

d = standard diameter of output shaft [in]

l = standard length of output shaft [in]

4AM adapter with IEC/NEMA motorProject Planning


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4.7 AM adapter with IEC/NEMA motor

Power ratings, mass moments of inertia

Selecting the gear unit

Input power (Pm) at alternate speed

The maximum input power (Pm) shown in this catalog corresponds to 1750 rpm. For inputspeeds other than 1750, use the formula below to calculate the maximum input power.

Type (IEC) Type (NEMA) Pm1) [HP]

1) Maximum rated power of the mounted electric motor at 1750 rpm

Japt [lb-ft²]

AM63 - 0.33 1.05 x 10-3

AM71 AM56 0.50 1.05 x 10-3

AM80 AM143 1.0 4.51 x 10-3

AM90 AM145 2.0 4.51 x 10-3

AM100 AM182 4.0 12.34 x 10-3

AM112 AM184 5.4 12.34 x 10-3

AM132S/M AM213/215 10 45.1 x 10-3

AM132ML - 12.5 45.1 x 10-3

AM160 AM254/256 20 216 x 10-3

AM180 AM284/286 30 214 x 10-3

AM200 AM324/326 40 413 x 10-3

AM225 AM364/365 60 413 x 10-3

AM250 - 75 411 x 10-3

AM280 - 125 1626 x 10-3

Determine the gear unit type

From the gear unit selection tables with AM adapter, determine the gear unit size based upon:• the maximum output torque (Tamax)• gear ratio (i)

Check the maximum permissible overhung load value on the output shaft (FRa)

Check the maximum permissible input power at the adapter (Pm) using the chart above and/or the equation below.

Is the required gear ratio available with the required adapter size?

Pnew Pm

RPMnew1750

--------------------------=

4 AM adapter with IEC/NEMA motorProject Planning


Backstop AM../RS

If the application requires only one direction of rotation, the AM adapter can be configuredwith a backstop. Backstops with centrifugal lift-off sprags are used. The advantage of thisdesign is that above a certain speed (lift-off speed), the sprags move around inside the back-stop without making contact. Therefore, the backstop is suited for high speeds and operatesmaintenance free, wear-free, and without losses.

Dimensions:

The backstop is completely integrated inside the adapter. Therefore, the dimensions are thesame with or without backstop.

Locking torques:

Type Maximum locking torque of the backstop

Minimum lift-off speed

[lb-in] [rpm]

AM80/90/RS,AM143/145/RS

575 820

AM100/112/RS,AM182/184/RS

3760 620

AM132/RS,AM213/215/RS

7525 530

AM160/180/RS,AM254/286/RS

12830 480

AM200/225/RS,AM324-365/RS

17260 450

AM250/280/RS 17260 450

4AR adapter with torque limiting couplingProject Planning


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4.8 AR adapter with torque limiting coupling

If torque limiting is desired for compound gear units (ex: R77R37..), the AR adaptercontaining a torque limiting coupling should preferably be placed between the two gear units(ex: R77AR95R37...) rather than placed at the motor. Please contact SEW-EURODRIVE ifyou intend to use a torque limiting coupling with a compound gear unit.


If torque limiting is required for a single gear unit (ex:R77), the AR adapter is placed betweenthe gear unit and motor. The sizes of the AR adapters correspond to those of the AMadapters for IEC motors.

This means you can select the gear unit using the selection tables for IEC AM adapters.Then, substitute the unit designation "AM" with "AR" and determine the required slip torque.

The slip torque should be about 1.5 times the rated torque of the drive. When determiningthe slip torque, bear in mind the maximum permissible output torque of the gear unit as wellas the variations in the slip torque of the coupling (+/-20%) which are a feature of the design.

When you order a gear unit with adapter and torque limiting coupling, please specify therequired slip torque of the coupling. If you do not specify, it will be set according to themaximum permissible output torque of the gear unit.

Slip torque values

Type Pm1) [HP]

1) Maximum rated power of the mounted electric motor at 1750 rpm

MR2) [lb-in]

2) Adjustable slip torque according to cup springs

Option 1 Option 2 Option 3

AR71 .50 9 - 53 54 - 142 -

AR80 1.0 9 - 53 54 - 142 -

AR90 2.0 9 - 53 54 - 142 150 - 285

AR100 4.0 44 - 115 124 - 708 -

AR112 5.4 44 - 115 124 - 708 -

AR132S/M 10 133 - 1150 - -

AR132ML 12.5 133 - 1150 - -

AR160 20 265 - 750 760 - 1770 -

AR180 30 265 - 750 760 - 2660 -

4 AR adapter with torque limiting couplingProject Planning


Speed monitor option /W

SEW-EURODRIVE recommends monitoring the speed of the coupling using a speed mon-itor to avoid uncontrolled slippage of the coupling and the associated wear on the frictionring pads.

The speed of the output end coupling half is detected in a proximity-type method using atrigger cam and an inductive encoder. The speed monitor compares the pulses with adefined reference speed. The output relay (NC or NO contact) trips when the speed dropsbelow the specified speed (overload). The monitor is equipped with a start bypass tosuppress error messages during the startup phase. The start bypass can be set within a timewindow of 0.5 to 15 seconds.

Reference speed, start bypass and switching hysterisis can be set on the speed monitor.

The following figure shows the adapter with torque limiting coupling and speed monitor,

Connection The encoder is connected to the slip monitor using a two or three-core cable (depending onthe encoder type).

• Maximum cable length: 500 m with a line cross section of 1.5 mm2

• Standard supply cable: 3-core / 2 m

• Route the signal lines separately (not in multicore cables) and shield them, if necessary.

• Degree of protection: IP40 (terminals IP20)

• Operating voltage: AC 220 V or DC 24 V

• Maximum switching capability of the output relay: 6 A (AC 250 V)

65931AXX

[1] Trigger cam[2] Encoder (adapter)[3] Driving disk[4] Friction ring pads

[5] Cup spring[6] Slotted nut[7] Friction hub[8] Speed monitor

[1] [2] [3] [4] [5] [6] [7]

[8]

4AR adapter with torque limiting couplingProject Planning


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Terminal assignment

The following figure shows the terminal assignment for /W:

Dimensions The following figure shows the dimensions for /W:

53653AXX

[1] Relay output [6] Signal

[2] Connection voltage AC 230 V (47 to 63 Hz) [7] Encoder

[3] External slip reset [/W] Speed monitor

[4] DC 24 V supply voltage

[5] Jumper for synchronous operation monitoring

[4]

[6]

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/W

52250AXX

4 AD input shaftProject Planning


4.9 AD input shaft


Centering shoulder AD../ZR

The input shaft assembly can be configured with a machined centering shoulder as an option.This allows the customer to locate the exact center of the input shaft for proper alignment.

Backstop AD../RS The input shaft assembly can be supplied with a backstop if only one direction of rotation ispermissible. Backstops with centrifugal lift-off sprags are used. The advantage of this designis that above a certain speed (lift-off speed), the sprags move around inside the backstopwithout making contact. Therefore, the backstop is suited for high speeds and operatesmaintenance free, wear-free, and without losses.

Dimensions:

The backstop is completely integrated inside the cover. Therefore, there is no difference indimensions between an input shaft assembly with or without a backstop (see dimensionsheets in the "Input shaft assembly AD" chapter).

Locking torques:

Determine the gear unit type.

Determine the gear unit size based on the • maximum output torque (Ta max)• gear ratio (i)

Look in the gear unit selection tables with input shaft assembly AD.When selecting AD/P, please observe the weight limitation for additional components as shown on page 62.

Check the maximum overhung load permissible on the output shaft (FRa).

Check the maximum input power permissible on the input of the gear unit (Pe). Observe the thermal limit rating.

Check the overhung load at the input (FRe). The larger the AD size (ie: AD3 vs. AD2), the higher the price. So for maximum savings, select the smallest AD size that meets the overhung load rating.

If the case of higher requirements (e.g. larger overhung load on the input shaft), please contact SEW-EURODRIVE.

Type Maximum backstop locking torque [lb-in]

Minimum lift-off speed[rpm]

AD2/RS 575 820

AD3/RS 3760 620

AD4/RS 7525 530

AD5/RS 12830 480

AD6/RS 17260 450

AD7/RS 17260 450

AD8/RS 17260 450

4AD input shaftProject Planning


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Motor mounting platform AD.. /P

Available combinations

The following table shows the motors that are available for each mounting platform. Thehighlighted cells show the additional weight (lbs) that is permissible for installed components(pulley, sprockets, belts, etc).

Motor mounting platform

DRS Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P

DRS71S 12

DRS71M 12

DRS80S 12

DRS80M 12 25

DRS90M 12 25

DRS90L 25

DRS100M 25

DRS100L 25

DRS100LC 25

DRS112M 25

DRS132S 50

DRS132M 50

DRS132MC 50

DRS160S 50 90

DRS160M 90

DRS160MC 90

DRS180S 90

DRS180M 90

DRS180L 90

DRS180LC 90

DRS200L 135

DRS225S 135

DRS225M 135

DRS225MC 135

DV250 225

DV280 225

Combination is available / additional weight for installed components (lb)

4 AD input shaftProject Planning


PermissibleWeights

Permissible weights for installed components (pulley, sprockets, belts, etc).


DRE Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P

DRE80S 12

DRE80M 12

DRE90M 12 25

DRE90L 12 25

DRE100M 25

DRE100L 25

DRE100LC 25

DRE112M 25

DRE132S 25

DRE132M 50

DRE132MC 50

DRE160S 50 90

DRE160M 90

DRE160MC 90

DRE180S 90

DRE180M 90

DRE180L 90

DRE180LC 90

DRE200L 135

DRE225S 135

DRE225M 135

DVE250 225

DVE280 225


DRP Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P

DRP80M 12

DRP90M 12 25

DRP90L 12 25

DRP100M 25

DRP100L 25

DRP100LC 25

DRP112M 25

DRP132M 50

DRP132MC 50

DRP160S 50 90

DRP160M 50 90

DRP160MC 90

DRP180S 90

DRP180M 90

DRP180L 90

DRP180LC 90

DRP200L 135

DRP225S 135

DRP225M 135

DRP225MC 135

Combination is available / additional weight for installed components (lb)

4AD input shaftProject Planning


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Thermal limitations with AD input

The power values given in the selection tables for gear units with AD input shaft assemblyare based upon mechanical limitations. However, depending on the mounting position, gearunits may become thermally overloaded before they reach the mechanical limit. The columnin the selection tables (as circled below) lists mounting positions that may reduce the inputpower rating for each ratio.

Please contact SEW-EURODRIVE if the mounting position you require is shown in thiscolumn. By considering the actual operating conditions, SEW-EURODRIVE can calculatethe thermal limit rating based upon the specific application. Often, alternate measures areavailable (ex: using FKM seals and a synthetic lubricant with higher thermal stability) toincrease the thermal rating of the gear unit.

The following data is required for recalculation:

50494AUS

Gear unit type ... R, S, K, F, or W

Gear unit size ... 37, 47, etc.

Input speed ............... rpm

Gear ratio, i

Cyclic duration factor, CDF ................. %

Ambient temperature ............... °C

Load power ............... HP

Environment / convection ... in small, enclosed rooms... in large rooms, halls... outdoors

Installation / conduction ... base made of steel or concrete

R107 AD... , ne = 1700 rpm 38060 lb-in

i na[rpm]

Tamax[lb-in]

Pe[HP]

FRa[lb]

FRe[lb]

(/R) [ ' ]

StagesLg Sm[ratio]

INFORMATION

You may also visit our online selection program at www.ptpilot.com. PT Pilotautomatically calculates your oil sump temperature based upon your mounting positionand ambient temperature. When applicable, PT Pilot® adds synthetic oil and FKM sealsfor proper protection against heat.

4 RM - extended bearing housingProject Planning


4.10 RM - extended bearing housing

Project Planning You must take account of the higher overhung and axial loads when planning projects withRM helical gear units with extended bearing hub. Observe the following project planningprocedure. Note that all values are metric.

02457BUS

Axial loads during operation (N)

Overhung loads during operation (N)Permissible overhung load (at x=1000 mm) from data table (N)Permissible overhung load due to flange tensile strength (N)Permissible overhung load due to bearing life (N)

Output Torque (Nm)

Permissible axial load from table (N)

End ofProject Planning

Distance between force application

T

?

See next page for data tables

?F / T > 3a a(F X/F )<100AaR

and shaft shoulder (mm)X

Gear-unit constant from data table

all other bearing hours upon request

X < 500mm?

?

X

4RM - extended bearing housingProject Planning


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Permissible overhung loads and axial forces

The permissible overhung loads FRa and axial forces FAa are listed below for various servicefactors fB and nominal bearing service life L10h.

fBmin = 1.5; L10h = 10,000 h

fBmin = 2.0; L10h = 25,000 h

Output speed na [rpm]

< 16 16-25 26-40 41-60 61-100 101-160 161-250 251-400

RM57FRa [N] 400 400 400 400 400 405 410 415

FAa [N] 18800 15000 11500 9700 7100 5650 4450 3800

RM67FRa [N] 575 575 575 580 575 585 590 600

FAa [N] 19000 18900 15300 11900 9210 7470 5870 5050

RM77FRa [N] 1200 1200 1200 1200 1200 1210 1210 1220

FAa [N] 22000 22000 19400 15100 11400 9220 7200 6710

RM87FRa [N] 1970 1970 1970 1970 1980 1990 2000 2010

FAa [N] 30000 30000 23600 18000 14300 11000 8940 8030

RM97FRa [N] 2980 2980 2980 2990 3010 3050 3060 3080

FAa [N] 40000 36100 27300 20300 15900 12600 9640 7810

RM107FRa [N] 4230 4230 4230 4230 4230 4230 3580 3830

FAa [N] 48000 41000 30300 23000 18000 13100 9550 9030

RM137FRa [N] 8710 8710 8710 8710 7220 5060 3980 6750

FAa [N] 70000 70000 70000 57600 46900 44000 35600 32400

RM147FRa [N] 11100 11100 11100 11100 11100 10600 8640 10800

FAa [N] 70000 70000 69700 58400 45600 38000 32800 30800

RM167FRa [N] 14600 14600 14600 14600 14600 14700 - -

FAa [N] 70000 70000 70000 60300 45300 36900 - -

Output speed na [rpm]

< 16 16-25 26-40 41-60 61-100 101-160 161-250 251-400

RM57FRa [N] 410 410 410 410 410 415 415 420

FAa [N] 12100 9600 7350 6050 4300 3350 2600 2200

RM67FRa [N] 590 590 590 595 590 595 600 605

FAa [N] 15800 12000 9580 7330 5580 4460 3460 2930

RM77FRa [N] 1210 1210 1210 1210 1210 1220 1220 1220

FAa [N] 20000 15400 11900 9070 6670 5280 4010 3700

RM87FRa [N] 2000 2000 2000 2000 2000 1720 1690 1710

FAa [N] 24600 19200 14300 10600 8190 6100 5490 4860

RM97FRa [N] 3040 3040 3040 3050 3070 3080 2540 2430

FAa [N] 28400 22000 16200 11600 8850 6840 5830 4760

RM107FRa [N] 4330 4330 4330 4330 4330 3350 2810 2990

FAa [N] 32300 24800 17800 13000 9780 8170 5950 5620

RM137FRa [N] 8850 8850 8850 8830 5660 4020 3200 5240

FAa [N] 70000 59900 48000 37900 33800 31700 25600 23300

RM147FRa [N] 11400 11400 11400 11400 11400 8320 6850 8440

FAa [N] 70000 60600 45900 39900 33500 27900 24100 22600

RM167FRa [N] 15100 15100 15100 15100 15100 13100 - -

FAa [N] 70000 63500 51600 37800 26800 23600 - -

4 RM - extended bearing housingProject Planning


Conversion factors and gear unit constants

The following conversion factors and gear unit constants apply to calculating the permissibleoverhung load FxL at point x 1000 mm for RM gearmotors:

Additional weight of RM gear units

Gear unit type a b cF (fB = 1.5) cF (fB = 2.0) FF

RM57 1047 47 1220600 1260400 277

RM67 1047 47 2047600 2100000 297.5

RM77 1050 50 2512800 2574700 340.5

RM87 1056.5 56.5 4917800 5029000 414

RM97 1061 61 10911600 11124100 481

RM107 1069 69 15367000 15652000 554.5

RM137 1088 88 25291700 25993600 650

RM147 1091 91 30038700 31173900 756

RM167 1089.5 89.5 42096100 43654300 869

Type Additional weight of RM compared to RF(compared to the smallest RF flange)

weight [lbs]

RM57 +26

RM67 +35

RM77 +55

RM87 +66

RM97 +113

RM107 +194

RM137 +245

RM147 +369

RM167 +431

4DUO - Oil aging monitorProject Planning


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4.11 DUO - Oil aging monitor

DUO10A diagnostic unit

Designations and part numbers

DUO10A Technical data

Preset oil grades

OIL1CLP mineral oil. Tmax = 100 °C

Bio oil Tmax = 100 °C

OIL2CLP HC synthetic oil: Tmax = 130 °C

CLP PAO oil Tmax = 130 °C

OIL3 CLP PG polyglycol Tmax = 130 °C

OIL4 Food grade oil Tmax = 100 °C

Switch outputs

1: Early warning (time to next oil change can be set to between 2 and 100 days)2: Main alarm (time to oil change 0 days)3: Exceeded temperature Tmax4: DUO10A is ready for operation

Permitted oil temperature -40 °C to +130 °C

Permitted temperature sensor PT1000

EMC IEC1000-4-2/3/4/6

Ambient temperature -25 °C to +70 °C

Operating voltage DC 18-28 V

Current consumption for DC 24 V

< 90 mA

Protection class III

Degree of protection IP67 (optionally IP69K)

Housing materialsEvaluation unit: V2A, EPDM/X, PBT, FPMTemperature sensor: V4A

Electrical connectionEvaluation unit: M12 plug connectorPT1000 temperature sensor: M12 plug connector

Designation Description Part number

DUO10A Evaluation unit (basic unit) 1 343 875 1

DUO10A-PUR-M12-5m 5 m PUR cable with 1 connector 1 343 877 8

DUO10A-PVC-M12-5m 5 m PVC cable with 1 connector 1 343 878 6

DUO10A Angle bracket 1 343 880 8

DUO10A D = 34 Mounting clamp 1 343 879 4

4 DUO - Oil aging monitorProject Planning


Mounting on standard gear units (R, F, K, S)

Adapter for mounting the PT1000 temperature sensor in screw plug holes:

Mounting base for installing the diagnostic unit at the gear unit with an angle bracket:

W4843 PT1000 PT1000 temperature sensor 1 343 881 6

W4843_4x0.34-2m-PUR 2 m PUR cable for PT10001) 1 343 882 4

W4843_4x0.34-2m-PVC 2 m PVC cable for PT10002) 1 343 883 2

DUO10A Protection cap (for aseptic design, IP69K)

1 343 902 2

1) PUR cables are particularly suited for use in oil-contaminated environments.

2) PVC cables are particularly suited for use in wet environments.

Designation Description Part number

Complete adapter for PT1000 sensor Part number

M10 1 1 343 903 0

M12 1.5 1 343 904 9

M22 1.5 1 343 905 7

M33 2 1 343 906 5

M42 2 1 343 907 3

Mounting base with sealing ring Part number

M10 1 1 343 441 1

M12 1.5 1 343 827 1

M22 1.5 1 343 829 8

M33 2 1 343 830 1

M42 2 1 343 832 8

4 project planning - sew eurodrive · 2016-07-07 · 4 project planning assistance project planning...

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