Helical I Bevel Helical Gear Units Introduction. Design Features INTRODUCTION These Gear Units are available in parallel shaft helical units in single, double, triple and quadruple reduction gear stages having a maximum output torque rating uplO 950 kNm. And in right angled shaft bevel helical units in double, triple and quadruple reduction gear stages having a maximum output torque raling uplo 600 kNm. The modular design and construction of this series, offer many engineering and performance advantages induding high degree of interchangeability of parts and sub assemblies. Design of these Gear Units, made with gearing details following addendum modification based on the latest findings of gear design with the help of latest computer software programmes has been finalised keeping the most favourable ratio distribution and the no. of teeth, module, helix angle, face width combination in order to achieve the optimum evenly distributed power rating in various stages and to get the highest diameter for the shaft extension of the input shaft quite comparable to the shaft diameter of the prime mover. DESIGN FEATURES Gears Single helical gears, profile ground with the latest technique for tip relief and face crowning in the modem gear grinding machines are made out of NiCrMo case hardening alloy steel. This ensures high standards of accuracy to relevant ISO I DIN I AGMA standards to achieve quiet running characteristics. Spiral bevel gears are produced in the most modem Bevel generating machines and finished by lapping in dedicated machines, after case hardening. Gear casing Gear casings, created using the latest techniques of 30 modeling possess the most modern styling and the rigidity. For all Helical Gear units and For Bevel Helical Gear units sizes upto 320, are made of close grained Cast Iron to achieve favourable vibration dampening properties. Other features are: - Case design is made using the latest FEA techniques to get high strength to weight ratio. - Horizontal split case design for ease of maintenance • Inspection cover provided for viewing gear contacts during maintenance shut downs. - Provision of oil level dipstick, ventilator with dust proof filler and drain plugs. Optionally oil level sight glass can be provided in place of dipstick. - Gear casing in fabricated steel construction as alternative for all Helical Gear Units and for Bevel Helical Gear Units Sizes upto 320. For Bevel Helical Gear Units Sizes 360 and above, Casing is in fabricated steel construction only. Bearings Amply proportioned roller bearings are used to support all the shafts. For three and four stage design, the input shaft will have shorter span to avoid harmful deflection on load. Backstops (Holdback units) When required to operate on non-reversing drives, back stops can be fitted. The backstops are of centrifugal lift off type and are located on the pinion shafts. They have adequate capacities to with stand the full rated torque. Cooling Depending on the application and rating reqUirement, Gear Units are cooled : - Normal cooling by convection from the external surfaces of the gear case. • Mechanical fan fitted to high speed shaft which is effective for either direction of rotation. - Cooling water coil fitted in bottom half of gear case, dipped in the lubrication oil sump. - Fan and cooling coil. - Separate oil cooler, used in conjunction with forced lubrication system. Base plates Base plates can be supplied for assemblies comprising of Gear Units and foot mounted motors correctly aligned and connected by flexible couplings. Coupling guards can also be provided. Such requirements are supplied on specific request. Shaft mounted Gear Units I Hollow Output shaft Gear Units Shaft mounted Gear Units can be mounted on the driven machine shaft extension by using keys or with "Shrink Disc M device. Alternatively foot mounted Gear Units with hollow output shaft can be mounted on a common base plate with prime mover and coupling, the complete assembly being mounted on the driven machine shaft extension. In both the types, the connection to the foundation is to be made using Torque arm. Torque arm I Shrink Disc I Base plate are supplied as optional extra, on specific request. Motorised Gear Units Gear Units are available as assemblies comprising standard flange mounted (B5 type) motors directly mounted on input shaft line with the use of adaptor housings. Motor and Gear Unit shafts are connected by flexible couplings. Specify the scope relevant to the requirement. Lubrication lubrication in most instances is by the transfer of oil to the mesh points by gear dipping in the sump of Gear Unit bottom half. Wherever high pitch line speeds causing detrimental churning of lubricant are encountered, force lubrication system is provided for effective spraying of oil to the mesh points. Quantity of oil for normal dip I splash lubrication is given in the dimension tables. For grade of oil refer "Guidelines for Selection" sheet. Note: As improvements in design are continually being made, the specification given in this publication is not to be regarded as final and binding.Details pertaining to dimensions and rating capacities are subject to alteration without notice.Always insist for certified drawing,which will be sent on request. - 2-
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Helical I Bevel Helical Gear Units
Introduction. Design Features
INTRODUCTION
These Gear Units are available in parallel shaft helical units in single, double, triple and quadruple reduction gear stages having a maximum output torque rating uplO
950 kNm. And in right angled shaft bevel helical units in double, triple and quadruple reduction gear stages having a maximum output torque raling uplo 600 kNm.
The modular design and construction of this series, offer many engineering and performance advantages induding high degree of interchangeability of parts
and sub assemblies.
Design of these Gear Units, made with gearing details following addendum modification based on the latest findings of gear design with the help of latest computer
software programmes has been finalised keeping the most favourable ratio distribution and the no. of teeth, module, helix angle, face width combination in order to
achieve the optimum evenly distributed power rating in various stages and to get the highest diameter for the shaft extension of the input shaft quite comparable to
the shaft diameter of the prime mover.
DESIGN FEATURES
Gears
Single helical gears, profile ground with the latest technique for tip relief and face crowning in the modem gear grinding machines are made out of NiCrMo case
hardening alloy steel. This ensures high standards of accuracy to relevant ISO I DIN I AGMA standards to achieve quiet running characteristics. Spiral bevel
gears are produced in the most modem Bevel generating machines and finished by lapping in dedicated machines, after case hardening.
Gear casing
Gear casings, created using the latest techniques of 30 modeling possess the most modern styling and the rigidity. For all Helical Gear units and For Bevel Helical
Gear units sizes upto 320, are made of close grained Cast Iron to achieve favourable vibration dampening properties.
Other features are:
- Case design is made using the latest FEA techniques to get high strength to weight ratio.
- Horizontal split case design for ease of maintenance
• Inspection cover provided for viewing gear contacts during maintenance shut downs.
- Provision of oil level dipstick, ventilator with dust proof filler and drain plugs. Optionally oil level sight glass can be provided in place of dipstick.
- Gear casing in fabricated steel construction as alternative for all Helical Gear Units and for Bevel Helical Gear Units Sizes upto 320. For Bevel Helical Gear Units
Sizes 360 and above, Casing is in fabricated steel construction only.
Bearings
Amply proportioned roller bearings are used to support all the shafts. For three and four stage design, the input shaft will have shorter span to avoid harmful
deflection on load.
Backstops (Holdback units)
When required to operate on non-reversing drives, back stops can be fitted. The backstops are of centrifugal lift off type and are located on the pinion shafts.
They have adequate capacities to with stand the full rated torque.
Cooling
Depending on the application and rating reqUirement, Gear Units are cooled b~' :
- Normal cooling by convection from the external surfaces of the gear case.
• Mechanical fan fitted to high speed shaft which is effective for either direction of rotation.
- Cooling water coil fitted in bottom half of gear case, dipped in the lubrication oil sump.
- Fan and cooling coil.
- Separate oil cooler, used in conjunction with forced lubrication system.
Base plates
Base plates can be supplied for assemblies comprising of Gear Units and foot mounted motors correctly aligned and connected by flexible couplings. Coupling guards
can also be provided. Such requirements are supplied on specific request.
Shaft mounted Gear Units I Hollow Output shaft Gear Units
Shaft mounted Gear Units can be mounted on the driven machine shaft extension by using keys or with "Shrink DiscM device. Alternatively foot mounted Gear Units
with hollow output shaft can be mounted on a common base plate with prime mover and coupling, the complete assembly being mounted on the driven machine shaft
extension. In both the types, the connection to the foundation is to be made using Torque arm. Torque arm I Shrink Disc I Base plate are supplied as optional extra,
on specific request.
Motorised Gear Units
Gear Units are available as assemblies comprising standard flange mounted (B5 type) motors directly mounted on input shaft line with the use of adaptor housings.
Motor and Gear Unit shafts are connected by flexible couplings. Specify the scope relevant to the requirement.
Lubrication
lubrication in most instances is by the transfer of oil to the mesh points by gear dipping in the sump of Gear Unit bottom half. Wherever high pitch line speeds causing
detrimental churning of lubricant are encountered, force lubrication system is provided for effective spraying of oil to the mesh points. Quantity of oil for normal
dip I splash lubrication is given in the dimension tables. For grade of oil refer "Guidelines for Selection" sheet.
Note: As improvements in design are continually being made, the specification given in this publication is not to be regarded as final
and binding.Details pertaining to dimensions and rating capacities are subject to alteration without notice.Always insist for certified
drawing,which will be sent on request.
- 2 -
Helical I Bevel Helical Gear Units
Guidelines for Selection
;, P d ~ P G1 x 't
;, P d ~ P G2 x 't;, P d ~ P G3 X't;, P d ~ P G4 x 't;, P d > P G4 X't
GUIDELINES FOR SELECTION
Select Gear Unit Design
Parallel shaft (Helical) or Right angled shaft (Beve! Helical)
Foot mounted (Solid Output shaft) or Shaft mounted (Hollow Output shaft) with I without Foot
If Hollow Output shaft· Key connection or Shrink Disc connection
Output shaft configuration - Horizontal or Vertical
Determine required transmission ratio
. "1I req =-
n2
Select appropriate nearest nominal ratio
'N
Determine required Mechanical Power CapacityP req = P d xf 1 xf 2
Select Gear Unit Type and Size
Type based on Gear Unit design with appropriate nearest nominal ratio and
Size using PN ~ P req
Select Type of cooling
natural Air cooling(without additional cooling)
with Fan cooling
with Cooling coil
with Fan and Cooling coil
with external Cooler(please refer to us)
EXAMPLE
i req
'N
" 1[rpm)
"2 [rpm)
P req [kWj
PN [kW]
Pd [kWj
, 1
'2, t
P G1 [kW]
P G2 [kW]
P G3 [kW]
P G4 [kWj
required transmission ratio
nominal ratio
input speed
output speed
required Mechanical Power Capacity
nominal Mechanical Power Capacity
absorbed power of connected driven machine,if not knowntake consumed power of prime mover
mechanical service factor, refer Table 2
frequency starts factor, refer Table 3
thermal service factor, refer Table 4
Thermal Power Capacities of Gear Unitswithout additional cooling
Thermal Power Capacities of Gear Unitswith Fan cooling
Thermal Power Capacities of Gear Unitswith Cooling coil
Thermal Power Capacities of Gear Unitswith Fan and Cooling coil
Given Data
Prime mover: Electric motor
Power
Speed
90 kW
n 1 : 1500 rpm
Driven machine: Belt Conveyor (Uniform loading)
Power Pd 80 kW
Speed n 2 52 rpm
Duty 24 hr I day
Starts per hour 9
Running time per hour ED 100%
Ambient temperature 50 Q C
Gear Unit Design
Parallel shaft
Hollow Output shaft with Foot
With Shrink Disc connection
Horizontal Output shaft
Gear Unit Design
Required transmission ratio
Nominal ratio
Required Mechanical Power Capacity
Gear Unit Type and Size
Foot mounted, Helical, Horizontal Hollow Output with Shrink Disc connection
. n1 1500, = - = -- = 28.8
req n2 52
iN = 28
P req = Pd xf 1 xf 2 = 80 x1.25x1.08 = 108 kW
According to Gear Unit design and Nominal ratio, Gear Unit Type is selected as HTAD
According to required Mechanical Power Capacity Gear Unit Size 250 with P N = 115 kW is selected
Type of Cooling
CONCLUSION
Pd =80kW
P G1 xf t = 110xO.63 = 69.3 kW
PG2 xf t = 170xO.7 = 119 kW
P d > PG1 xf t
Pd < PG2 xf t
Additional cooling required.
Fan cooling sufficient
Helical Gear Unit, Triple Stage, Horizontal, Foot mounted, Hollow Ouput shaft Type HTAD, Size 250, 28:1 nominal ratio with Fan cooling is selected.
The Mechanical Power Capacities (P N ) in kW, given in Rating sheets are applicable for Uniform load (i.e. shock free operation) for a period of 10 hours per day and
can accomodate the following peak load conditions.
- not more than four peaks per eight hours period,
- the time duration of each peak shall not exceed five(5) seconds,
- each peak shall not exceed 200 percent of the Mechanical Power Capacity.
The Rating sheets also show the Thermal Power Capacities under various conditions. These Power Capacities are given with a Thermal Service Factor of 1 for 20 Q C
ambient temperature and 100% running time per hour. For other ambient temperatures and running time per hour take appropriate Thermal Service Factor, f t from
Table 4.
- 3 -
Helical I Bevel Helical Gear Units
Guidelines for Selection
Driven Machine
TABLE 1 - LOAD CLASSIFICATION
Type ofLoad
Driven MachineType of
Load Driven MachineType of
Load Driven MachineType of
Load
•
•
•
•
•
•
•
•
•
•
•
••
u
U
MUM
uuUM
MMMM
M
MM
MM
M
M
MM
M
MMMMM
MM
M
M
MMM
H
HM
HMM
MUM
uu
MMM
UM
suction rotl
washers and thickners
windersPrinting pressesPullers
barge haul
PumpscentrifugalproportiOfling
reciprocating
single acting,3 or more cylinders Mdouble acting,2 or more cylinders Msingle acting,1 or two cylinders
double acting, single cylinder
cola.,.gear typelobe, vane
Rubber and Plastic industriescrackerslaboratory equipment
For ratings above 1500rpm and below 750rpm input speed, refer to usIntermediate ratios are also possible, for details refer to usGear units with ratings in bold figures ( and marked· ) require force lubrication.1) Thermal ratings on request.
- 14 -
Helical Gear Units, Triple Stage,
Horizontal, Foot mounted,
Solid Output
Type HTN
PRINCIPAL DIMENSIONS (mm)
:-..
HD -131
~
~-=--"+~ d--.jlf'
•'-r-.2 /2
1-.,,--1
11
/,
-50l--- n2--j
Pk .
\12 1211 ~)fJ IJ IJ
- b' 0, " -b
50- r-n,-
Handing f Direction of rotation
i3~ ~ i3~ur+- h ~u,,,
~,~
~i3~
. 9Uu i3 "L u uu'
,~
~98RD u LD DDDR
~
~. · ,,~
~. · 9
~·-8
~uRR
i3~ J i3~ i3~ ~u, u, u, u,
;;t, ,
~,~
." L i3~ 98u ~ u u ~u u u u',~
~',~
~+RL 98 u9 LL DL 98 LR
Input shaft Output shaft Housing
Size d, / , d, / , d, J , d, J , • J d" ." d2 /2 ·2 0 b b, h, hJ n, n2 OJ r J s
- Shaft extension, with parallel key to IS:2048 I DIN 6885 part 1 and threaded360 520 250 360 35 M30 8 1430 137 centre hole. For details refer to sheet ST-001.400 590 275 400 42 M36 8 1980 182
• Gear units are shown with Cast Iron casing, alternatively fabricated steel450 650 310 450 42 M36 8 2680 255
casing, can also be given. Specify while ordering.
500 710 335 500 48 M42 8 3870 355 - Special input and output extensions, on request.
560 790 370 560 48 M42 8 5170 520
630 890 420 630 56 M48 8 7270 560
710 1000 470 710 56 M48 8 11000 890
800 1140 530 800 66 M56 8 14100 1190
- 21 -
Helical Gear Units, Quadruple Stage,
Horizontal, Foot mounted,
Hollow Output Key connection
Type HQAH
PRINCIPAL DIMENSIONS (mm) HD -142
'".. a-ii-l
••..~
..,•..
kS~kSt- k'
k2 k2
-- -.c "L~--.L~
I+--+-r,e~'---0
11
I
-.c1
",
b!+-fJ--fJ--l--+ fJ-I,-J----- 0' ---_I- f' -I
------b---------"
Handing I Direction of rotation
~1 ~1 ~1 ~
. ~~~
u u u u u, :: :-~lr ~1·
,,:: "~
t~~
~6~ 6~
~ 6~u u 8 u u ~ uu uu u u
~ "~ ~6 ~6uu u
RL LL DL LR RR DR
Input shaft Output shaft Housing
Size d, J , d, J , d, J , d, f , k, °2 k 2 ks 0 b b, h , h" hJ ", "2 0, r , s
• Dimensions are SUbject to modification. Get certified Principal Dimensional
drawing while ordering.360 520 250 360 35 M30 8 1430 137 - Shaft extension, with parallel key to 15:2048 I DIN 6885 part 1 and threaded400 590 275 400 42 M36 8 1980 182
centre hole. For details refer to sheet ST-001.450 650 310 450 42 M36 8 2680 255 - Gear units are shown with Cast Iron casing, alternatively fabricated steel
SOD 710 335 500 48 M42 8 3870 355 casing, can also be given. Specify while ordering.
560 790 370 560 48 M42 8 5170 520 - Special input extension, on request.
630 890 20 630 56 M48 8 7270 560 - For more details of hollow output shaft refer to sheet ST-003.