This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
The HANSA-TMP range of “GB” high torque Single or Multi-stages Reduction Planetary gear boxes
combined with Kawasaki / Staffa single, dual or variable displacement radial piston motors comprises 14
models offering ISO torque from 70.000 up to 1.200.000 Nm (from 52.000 up to 885.000 lbf.ft).
The “GB” range of gear boxes is available from 1 up to 5 stages with ratio from 3,43:1 up to 3794:1.
This versatile range of gear boxes accept standard Kawasaki / Staffa motors allowing the system designer
to select the right motor and gear box to optimise his circuit pressure and flow against the torque and speed
requirements of his transmission.
The output shaft of the “GB” planetary gear boxes include: splined male and female, parallel keyed and shrink disc.
Main features
- Flexibility in service: modular concept enables drive to be uprated in service with minimum inconvenience.
- Constant torques: throughout the infinitely variable speed range.
- Lower maintenance costs: modular system enables motors to be overhauled without disturbing the system.
- Uniform running at low speeds: speeds at fractions of one R.P.M. can be achieved smoothly.
- Excellent gear life: materials used are aimed at maximum running hours.
- Modular design: plug in concept enables standard motors to be fitted from existing stock.
- Complete transmission: full range gives a balanced transmission package for both automotive
and general industrial drives.
HT 05 / D / 117 / 0509 / E Pag. 5
High Torque Geared MotorsGB 130.000
GEARED MOTOR UNITS - General Information (continued)
Symbols and units of measurement
Symbol Unit Description
Fr2 N Output shaft radial load
Fa2 N Output shaft axial load
fs _ Service factor
ie _ Effective reduction ratio
in _ Nominal ratio
kf _ Output support life correction factor
Lmin mm. Torque arm lenghts
Mt max Nm Shrink disk torque
n1 n/min. Input speed
n1 x h n/min. x h Input duration index
n2 max n/min. Max output speed
n2 n/min. Rated output speed
h h Working Time in hours
hi _ Time percentage
p bar Pressure
P1 kW Input power
P2 kW Output power
Pd kW Dissipated power
Pt kW Thermal power
Q lt/min. Oil flow
Tf Nm Static braking torque
T1 Nm Input torque
T2 Nm Output torque
Teq Nm Equivalent torque
TISO Nm ISO limit torque
Tcont. Nm Continuous torque
Tmax. Nm Maximum torque
Timp. Nm Impulse torque
TM Nm Max. load torque
V cm3 Displacement
X mm. Reaction distance
m _ Mechanical efficiency
v _ Volumetric efficiency
t _ Total efficiency
SYMBOLS and UNIT of MEASURE
1 mm. = 0,03937 in.
CONVERSION TABLE
Length
1 mm. 0,03937 in.
1 in. = 25,4 mm.
1 mm. = 0,000328 ft
1 ft = 304,8 mm.
1 kp = 9,81 N
1 N = 0,102 kp
Force
p
1 kp = 2,2046 lbf
1 lbf = 0,4536 kp
1 Nm = 8,85 lbf. in
1 lbf.in = 0,1129 Nm
1 Nm = 0,737 lbf.ft
f f
Torque
1 lbf.ft = 1,355 Nm
1 n / min. = 0,1047 rad. /sec.
1 rad. / sec. = 9,549 n / min.
1 kW = 1,341 HP
1 HP = 0 7457 kW
Power
Angular speeed
1 HP = 0,7457 kW
1 kW = 1,3596 PS
1 PS = 0,7355 kW
1 kW = 101,972 kp.m / sec.
1 kp.m / sec. = 0,0985 kW
1 bar = 0 981 kp / cm2
Pressure
1 bar = 0,981 kp / cm
1 kp / cm2 = 1,02 bar
1 bar = 14,5 PSI
1 PSI = 0,0689 bar
1 Mpa = 145 PSI
1 PSI = 0,00689 Mpa
Capacity / Flow rate
1 lt / min. = 0,22 Imp. GPM
1 Imp GPM = 4,546 lt / min.
1 lt / min. = 0,2642 US GPM
1 US GPM = 3,785 lt / min.
1 cm3 = 0,062 in3
Capacity / Flow rate
Volume / Displacement
1 cm ,
1 in3 = 16,387 cm3
1 °C = 5/9 (°F-32)
1 °F = 32+ 9/5 °C
Temperature
Pag. 6 HT 05 / D / 117 / 0509 / E
High Torque Geared MotorsGB 130.000
GEARED MOTOR UNITS - General Information (continued)
Service factor
fs = service factor: takes into account the duty of the application; it depends on the type and working condition, type of operation and start-up frequency.
fs x T2 < Tcont
Reduction ratio
ie = effective reduction ratio: ratio between the input and output speed of the gearboxin = nominal ratio: Renard R 20 numbers, near the value of ie.
Correction factor kf
kf = output support lifetime correction factor: used to obtain the theoretic duration of the support for values of n2 x h different from those found in the catalogue. For all gearboxes the external load curves are calculated for: n2 x h = 100.000 for the output supports n2 x h = 1.500.000 for the input supports
Torque arm lenght
Lmin.= minimum advised torque arm lenght for shaft mounted applications.
Shrink disk torque
Mt max.= maximum torque transmittable by the shrink disc when supplied by HANSA-TMP. Transmittable torque by the gearbox and the shrink disc must always be checked for compatibility.
Speed
n 1. = input speed: is the input speed of the gearbox.n 2 max.= maximum output speed: is the maximum output speed of the gearbox for continuous operation; values of speed near the maximum can be achieved in compatibility with the duty cycle. For further information please contact our Tech. Dpt.
Number of start-ups per hour < 5 5-50 > 50 < 5 5-50 > 50 < 5 5-50 > 50
Electric motor 1.1 1,2 1,4 1,2 1,4 1,6 1,4 1,6 1,8
SERVICE FACTOR
TYPE OF LOAD
fs
UNIFORM
U
MODERATE
M
HEAVY
H
HT 05 / D / 117 / 0509 / E Pag. 7
High Torque Geared MotorsGB 130.000
GEARED MOTOR UNITS - General Information (continued)
Lifetime
n2 x h = output duration index: product of the output speed and the duration in hours. It represents a number proportional to the stress applied to the element which limits the gearbox life. To correlate the speed and the life, the torque Tcont. is expressed as a function of the product n2 x h. With the speed n2 and the torque Tcont. required, the duration in hours can be calculated; or alternatively, if the speed and the duration in hours required are known then the Tcont. that the gearbox can transmit can be calculated: Example: duration necessary in hours h = 20.000 output speed of the gearbox n2 = 25 20.000 (h) x 25 (n2) = 500.000 (n2 x h) therefore a gearbox with a torque at 500.000 n2 x h corresponding to the torque required by the application will be selected. The same procedure is applied to diagrams of external loads, whilst knowing the application point of the load and its entity.n1 x h = input duration index: is the product of the input speed and the duration expressed in hours. It is used to calculate the duration of the bearings of the input support. If you know the speed n1, the loads applied and the application point, the life in hours can be obtained.
Power
Pt = thermal power: maximum mechanical power that the gearbox can transmit while operating continuously, with splash lubrication without exceeding the thermal limit (oil temperature not greater than 90°C). Greater powers can be transmitted by using an appropriate cooling system. The value refers to a continual operation with mechanical efficiency of 0,97 for each reduction stage, input speed of 1.500 n /min., ambient temperature 20°C, altitude 0 / 500 m., application to the cover. For different conditions, the thermal power value must be multiplied by the thermal factors shown in the following table. For limited operating periods followed by rests period that are sufficiently long to guarantee an adequate cooling of the gearbox, the thermal power loses its significance and can be disregarded.
Hours of life required
300 - 3.000
3.000 - 8.000
8.000 - 12.000
10.000 - 25.000
20.000 - 30.000
40.000 - 50.000
Application
Agricultural machines
Machines which operate intermittently or for brief periods (building machinery)
Machines which operate intermittently or for brief periods with a high operative reliability (hoists)
Machines which operate for 8 hours per day, but not fully utilised (various industrial machines, rotating crusher)
Machines which operate for 8 hours per day, fully utilised (various industrial machines, conveyor belts)
INDICATIVE VALUES OF THE DURATIONS REQUIRED FOR DIFFERENT APPLICATIONS
100% 80% 60% 40% 20%
10°C 1,2 1,3 1,4 1,6 1,8
20°C 1,0 1,1 1,3 1,4 1,6
30°C 0,8 1,0 1,1 1,3 . 1,4
40°C 0,7 0,8 1,0 1,1 1,3
50°C 0,5 0,7 0,8 1,0 1,1
400 800 1000 1500 2000
0 1,2 1,1 1,1 1,0 0,7
500 1,2 1,1 1,1 1,0 0,7
1.000 1,1 1,0 1,0 0,9 0,6
1.500 1,1 1,0 1,0 0,9 0,6
2.000 1,1 1,0 1,0 0,9 0,6
Room temperatureworking time
altitude
m
input speed
THERMAL FACTORS
Pag. 8 HT 05 / D / 117 / 0509 / E
High Torque Geared MotorsGB 130.000
GEARED MOTOR UNITS - General Information (continued)
Torque
TISO = limit torque: Transmittable torque of gearbox, with continuous operation, calculated in accordance to ISO DP 6336 for gears and safety factor 1. This torque corresponds to a life duration equal to 50x106 cycles of the most stressed element (theoretically considered unlimited by the ISO DP 6336; horizontal curve in the Wöhler fatigue diagram). This torque does not represent a duration but it is useful for a quick selection of a maximum size of the gearbox.
Tcont = continuous torque: Transmittable torque of gearbox with continuous operation, that guarantees a duration of "h" hours, with a gearbox output rotation speed of "n2". Tcont is expressed as a function of the product n2 x h.
Teq = equivalent torque: Teq represents the value of a constant torque which determines the same duration in hours of the torque induced by the work cycle. Known as T21 ...T2n the torque transmitted by the gearbox at the output speed n2ì for a time duration in hours of hì, the equivalent torque is:
where
Tmax = maximum torque: Value of maximum torque that the gearbox can transmit for short period of time.
Tmax = 1,25 x Tcont when n2 x h = 50.000
In application with high number of cycles and a torque near the maximum, one must take into account an opportune safety factor. In this case it is recommended that our Tech. Dpt. be contacted.
Timp = impulsive torque: Value of static torque or an istantaneous peak load that the gearbox can withstand:
Timp = ( from 1,25 to 1,9 ) x Tcont when n2 x h = 50.000
Each coefficient is given in the life time table.
Efficiency
nm = mechanical efficiency: ratio between the output power and input power. Normally it is considered to be equal to 0,97 - 0,98 per reduction stage that makes up the gearbox; it depends upon various factors, of which speed, torque, ratio, working position and lubrication.
HT 05 / D / 117 / 0509 / E Pag. 9
High Torque Geared MotorsGB 130.000
GEARBOX SELECTION METHOD
Selection
Once established the selection criteria, which can be defined using an ISO or AGMA safety factor, based upon theclass according to the F.E.M. standard or by expressing a minimum life duration, the equivalent output torque Teq
is determined as well as the required duration and the reduction ratio. Using these criteria the gearbox is selected.- safety factor ISO / AGMA: the gearbox must guarantee the requested theoretical lifetime.- F.E.M. class: the gearbox must guarantee that the requested theoretical lifetime correspond to that indicated by the F.E.M. class as a function of the max and Teq.- Life duration: the gearbox must have a life duration greater than that required as a function of Teq .
For example, table on page 17 shows the continuous torques as a function of gearbox size and the reduction ratio. The start-up torque must not exceed the gearbox maximum torque. The number of start-up per hour and the hours of operation per day must be carefully considered. If the output speed is constantly less than 1 n/min., there may be problems with the lubrication of the output stage, which could reduce the calculated theoretical life. Contact our Tech.Dpt. for a proper selection.
We waives all responsability of improper use of the selection criteria mentioned above, in particular for all applicationssubject to special rules (for example when personnel safety is involved) and place this responsability on theapplication constructor. Contact our Tech. Dpt. for all technical support.
class
duration with
Teq <0,50 TM
(spectrum L1)
duration with
Teq <0,65 TM
(spectrum L2)
duration with
Teq <0,80 TM
(spectrum L3)
duration with
Teq < TM
(spectrum L4)
M1 400-800 h 200-400 h <200 h <200 h
M2 800-1.600 h 400-800 h 200-400 h <200 h
M3 1.600-3.200 h 1.600-3.200 h 400-800 h 200-400 h
M4 3.200-6.300 h 3.200-6.300 h 1.600-3.200 h 400-800 h
M5 6.300-12.500 h 6.300-12.500 h 3.200-6.300 h 800-1.600 h
M6 12.500-25.000 h 12.500-25.000 h 6.300-12.500 h 1.600-3.200 h
M7 25.000-50.000 h 25.000-50.000 h 12.500-25.000 h 3.200-6.300 h
M8 >50.000 h >50.000 h 25.000-50.000 h 6.300-12.500 h
DURATION REQUIRED BY THE FEM CLASSES
Type of appliance
hoisting slewing luffing traverse travel
Hand-operated appliance M1 - - M1 M1
Erection cranes M2-M3 M2-M3 M1-M2 M1-M2 M2-M3
Erection and dismantling cranes for power stations, machine shops... M2 - - M2 M2
Stocking and reclaiming transporters M5-M8 M4-M6 - M4-M7 M5-M8
Floating cranes and pontoon derricks for very heavy loads M3-M4 M3-M4 M3-M4 - -
Deck cranes M4-M6 M3-M4 M3-M4 M2-M5 M3-M4
Tower cranes for building M4 M5 M4 M3 M3
Derricks M2-M3 M1-M2 M1-M2 - -
Railway cranes allowed to run on train M3-M4 M2-M3 M2-M3 - -
MECHANISM SELECTION GUIDE ACCORDING TO FEM 1.001/3
Type of mechanism
Pag. 10 HT 05 / D / 117 / 0509 / E
High Torque Geared MotorsGB 130.000
GEARBOX SELECTION METHOD (continued)
Verifications
Gearbox output support:
For each gearbox the dynamic radial loads according to ISO 281 for a duration of L10 corresponding to n2 x h = 100.000are shown in the diagrams.For different durations, applicable radial loads can be obtained by multiplying the values in the diagrams by the correctionfactor kf.With regard to eventual axial loads, one must ensure that they do not exceed the maximum allowed values.Output torque: the output torque must never exceed Tmax.In the event that brakes are mounted on the gearbox or the motor, one must ensure that the braking torque does notexceed the maximum torque of the gearbox itself multiplied by 1,1; with regard to the real braking torque, it is alsonecessary to consider the efficiency of the gearbox.Input speed: must not exceed the maximum gearbox input speed.Thermal power: in the event that the installed power is greater than the thermal power of the gearbox,it is necessary to provide a cooling circuit or to select a larger gearbox.
The power to dissipate is: Pd = ( P2- Pt )x(1-çm )where P2 is the power transmitted by the gearbox.In the event that thermal power is not exceeded, but the application is particularly heavy, it may be necessary toinstall an oil circulation and filtering system.
MOTORS SELECTION METHOD
Hydraulic DrivesKnowing the hydraulic circuit pressure, from which the Dp of the motor can be obtained, the torque T1, the speed n1
required at the input of the gearbox, the hydraulic motor capacity must be greater or equal to:
where nm is the mechanical efficiency.
The necessary supply flow rate is:
where nv is the volumetric efficiency of the motor.
Please use the following table as a guide for hydraulic motor selection.
Use medium - heavy
Pressure - bar 175 - 250
Type of motor radial piston
Speed - n/min. < 500
m 0,90
v 0,96
HYDRAULIC MOTORS
HT 05 / D / 117 / 0509 / E Pag. 11
High Torque Geared MotorsGB 130.000
MOTOR MOUNTING INSTRUCTION
Circuit and Application Notes
Mineral Oil recommendationsThe fluid should be a good hydraulic grade, non-detergent Mineral Oil.It should contain anti-oxidant, antifoam and demulsifying additives. It should contain antiwear or EP additives.WARNING: Automatic transmission fluids and motor oils are not recommended.
Temperature limitsAmbient min. -30°C (-22°F)Ambient max. + 70°C (158°F)Max. operating temperature range.Min -20°C (-4°F) +10°C (50°F)Max. + 80°C (175°F) +54°C (130°F)Note: To obtain optimum service life from both fluid and hydraulic systems components, a fluid operating temperature of 40°C is recommended.
FiltrationFull flow filtration (open circuit), or full boost flow filtration (closed circuit) to ensure system cleanliness toISO 4406/1986 code 18/15/12 (Class 7 NAS 1638) or cleaner.
Start - upFill the motor crankcase with clean system fluid.
Noise levelThe airborne noise level is less than 66.7 dB(A) DIN (dB (A) NFPA) through the “continuous” operating envelope.Where noise is a critical factor, installation resonances can be reduced by isolating the motor by elastomeric meansfrom the structure and the return line installation.Potential return line resonances originating from liquid borne noise can be further attenuated by providing a return lineback pressure of 2 to 5 bar.
Pag. 12 HT 05 / D / 117 / 0509 / E
High Torque Geared MotorsGB 130.000
MOTOR MOUNTING INSTRUCTION (continued)
Assembly Positions - Crankcase Drain
Motor Axis Horizontal.
The recommended minimum pipe size for drain linelengths up to approx. 5m is 12.0mm 1/2” bore.Longer drain lines should have their bore sizeincreased to keep the crankcase pressurewithin limits.The crankcase drain must be taken from a positionabove the horizontal centre line of the motor to ensurelubrication of the shaft bearings.
Motor Axis Vertical, shaft down.The piping, from any drain port, must be takenabove the level of the motorcase to ensure goodbearing lubrication.The drain line should be run above the level of theuppermost bearing.If there is a risk of syphoning then a syphon breakershould be fitted.
Motor Axis Vertical, shaft up.
Specify “V” within the model code for extra drainport, G1/4” (BSPF). Connect this port into themain drain line downstream of a 0.35 bar checkvalve to ensure good bearing lubrication.The piping arrangement must not allow syphoningfrom the motorcase.
An additional G 1/4" (BSPF) drain port is providedwhen “V” (shaft vertically upwards) designator is givenafter the shaft type (see Ordering Code).This additional drain should be connected into the mainmotor casing drain line downstream of a 0.35 barcheck valve to ensure lubrication of the upper bearing(see installation diagram).
Connect to a drain port above motor
centre line
Additional drain port G1/4" (BSPF)
Standard drain port 3/4" - 16 UNF
0.35 bar
HT 05 / D / 117 / 0509 / E Pag. 13
High Torque Geared MotorsGB 130.000
GEARBOX MOUNTING INSTRUCTION
Assembly Positions
In order to provide a complete definition of the constructive form of the gearbox, the assembly position must bedefined.Based upon the position it is also possible to identify the oil filling, level and drain plugs.
InstallationGearbox with flange and male shaft:
The connecting surface should be flat, unpainted, machined and perpendicular to the rotation axis.The following table shows the required spigot with their representative tolerances.
Gearbox with female splined shaft:
The female version gearboxes are not suitable for supporting output radial loads, it is therefore extremely important toproperly align between the gearbox and the driven shaft.It is also necessary to check that driven shaft does not undergo bending during the working phases.
Torque arm mounted gearbox:
It is necessary to carry out an anchorage of the torque arm that is not constrained to the axis of the gearbox.The anchorage must also be suitable shock proof.
In the dimension tables of each gearbox one can find the minimum torque arm lenght needed to carry out theapplication correctly.
WARNING: The gearbox is supplied without lubrication oil.
Before use, the gearbox must be filled with oil up to the level indicated using one of the lubricating oils recommended.The choice and the quantity of oil will be referred to the installer / user based upon the type of application.
PaintThe supplied gearboxes are not painted. A few parts are treated with a base layer of water soluble epoxy ester red oxide.The customer must take care to carry out the surface treatment using a paint that is compatible with the base layer.O-Rings must be protected during the painting.
Installation of flange motorThe installation of the motor to the coupling flange supplied is a particularly simple operation, but it must be carried outfollowing some important suggestions:- Lubricate the motor shaft and the coupling with a light film of grease or anti-seizure lubricant.- Ensure that the motor rests freely on the gearbox fixing flange without forcing on either the shaft or the spigot.- Tighten the fixing screws as indicated to the table on the previous page.
STORAGEThe gearboxes must not be stored in the open or in direct contact with the ground. For long time periods they must bestored full of oil, with external worked parts covered with grease and the coupling surfaces protected with anti-oxidantagents.We recommend to operate the gearboxes (a complete rotation of the output shaft is sufficient) without load at least onceevery two months. For further information regarding storage, please refer to the maintenance and operating manual.
HT 05 / D / 117 / 0509 / E Pag. 15
High Torque Geared MotorsGB 130.000
GEARBOX LUBRICATION
Type of lubricantThe gearboxes lubrication is carried out by an oil bath; before the first start-up it is necessary to fill it with oil, whilstensuring visually using the level plug that the correct level is reached. This operation requires particular attention and thelevel must be re-checked after a few minutes of operation to ensure it has been carried out correctly. The quantities of oilshown in the catalogue are purely indicative and can vary in function of the reduction ratio and the type of gearbox input.
Choice of oilAny type of oil for mechanical transmission can be used with EP additives with viscosity classes from VG 68to VG 220 according ISO 3448 or SAE 80-90 W according SAE J 306-81.In particular cases we can use oils with different viscosities, in this event please contact our Tech. Dpt.The oil viscosity must be chosen as a function of the ambient temperature of the gearbox.For gearboxes that have to operate at high ambient temperatures or where there are strong thermal excursions, the useof synthetic based oils is recommended.In gearboxes with vertical installation and continuous operation, the oil can undergo excessive overheating ; in this casean external expansion tank is necessary to enable the oil to expand due to the thermal action.
Oil changeThe oil change must be carried out after the first 150 hours of effective work, and then after the following 2000 to 4000hours of operation, depending on the working condition and at least once a year. To facilitate the emptying of the gearbox,we advise that the oil change is carried out while the gearbox is warm. The internal parts must be washed with suitableliquid before the new oil introduction. Different oils must not be mixed together: this is particularly true for mineral andsynthetic oils.After the gearbox has been operated, the oil level must be checked periodically and re-filling carried out if necessary.
Oil quantityThe oil quantities required for proper lubrication can be found in page 23.
As HANSA-TMP has a very extensive range of products and some productshave a variety of applications, the information supplied may often only applyto specific situations.
If the catalogue does not supply all the information required, please contactHANSA-TMP.In order to provide a comprehensive reply to queries we may require specificdata regarding the proposed application.
Whilst every reasonable endeavour has been made to ensure accuracy, thispublication cannot be considered to represent part of any contract, whetherexpressed or implied.
HANSA-TMP reserves the right to amend specifications at their discretion.