PRECISION MOTION CONTROL

Transcription

1 PRECISION MOTION CONTROL Application & Selection Guide RPS System 5 Racks ROLLER PINION TECHNOLOGY 9 Gears 15 Pinions & Accessories 21 RPS System Life 31 Harmonic Gearhead 39 The most advanced technology in linear and rotary motion control. APPENDIX Definitions & Notes 51

2 A New Standard For Precision The Nexen Roller Pinion System (RPS) revolutionizes linear and rotary motion control possibilities. Giving a fresh face to traditional rack and pinion systems, the RPS overcomes the troublesome limitations of conventional drive systems and offers unmatched performance. Across industries as varied as laser cutting and mining, users will benefit from the accuracy and 99% efficiency of this new technology. The incredible performance of the RPS starts with a pinion consisting of bearing-supported rollers that engage a unique tooth profile. Two or more rollers engage the teeth in opposition at all times to eliminate backlash. The pinion rollers glide easily along a tangent path and roll smoothly down the tooth face for quiet, low-friction operation. Rollers in Opposition Constant Positional Accuracy Regardless of the Distance Traveled RPS Positional Accuracy Premium ±30 µm Universal ±50 µm Standard ±50 µm.003 in.004 in Endurance ±80 µm 75 µm 100 µm.006 in.01 in 150 µm 250 µm.02 in.03 in Versa ±500 µm 500 µm 750 µm.04 in.06 in 1000 µm 1500 µm Every aspect of the RPS system is designed for reliable, easy operation. With customizations available to meet the specific needs of any application and multiple material finishes, the RPS system can go anywhere. Even installation is worry-free with a simple alignment tool to ensure positional accuracy over multiple sections of rack. Dependable Performance. Every Time. The Nexen RPS System Always Delivers. Gantry Router Indexer Machine Tools Plasma & Laser Cutting 2 Woodworking Food Processing Multi-head On A Common Axis Gantries

3 THE NEXEN ADVANTAGE Overcoming Common Problems Found in Traditional Drive Systems INDUSTRY PROBLEMS Ball Screws Traditional Rack/Gear & Pinion Systems Belt Drives Chain Drives Linear Motors Direct Rotary Stages Direct Drive Motors ROLLER PINION SYSTEMS Low Accuracy x x High Positional Accuracy Backlash / Vibrations x x x x Near-Zero Backlash High Cost x x x Economical, Efficient Components Dirty Operation x x x x No Dust Emissions High Maintenance Low Load Capacity x x x x Little to No Maintenance x x High Load Capacity Noisy x x x x Low Speed x x Quiet: pinion rollers glide smoothly along teeth High Speeds (up to 11 m/sec) Magnetic Field x No magnetic field High Wear/ Low Life Limited System Length/Size x x x x x x x Long Life (up to 36 million meters) Custom Rack Sizes & Modular Components Rotopod Robot Transfer EVEN In The Most Challenging APPLICATIONS Medical Imaging Measurement Systems 3 Clean Rooms Material Handling Vacuum Environments Welding

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5 RPS System RPS System RPS SYSTEM Nexen offers both premium and value roller pinions with rack options to fit any application. The following tables show specifications for the various rack and pinion configurations. Rack & Pinion Model Comparisons... 6 Rack Thrust Capacity... 7 Pinion Torque... 7 Accuracy & Repeatability... 7 Rack Model Attributes

6 RPS System RPS System Configurations & Comparisons Nexen features six different rack models and two pinion types, ensuring the perfect solution for any application. First compare the rack attributes to determine which rack model best meets your needs. Then compare the specifications of both the premium and value pinions to select the ideal RPS system configuration. Rack Models Available As the name premium suggests, this is Nexen's top of the line model featuring market leading accuracy and a hard chrome coating for corrosion resistance. A perfect choice for any precision motion need. PREMIUM RACK Very High Precision/Accuracy Suitable for Dirty Environments Lubrication Free High Load Capacity High Corrosion Resistance STANDARD RACK Precision Assembly Equipment Machine Tool/CNC Mills High Precision Gantry Robotics The Standard Rack offers similar performance to the Premium model without the corrosion resistant coating. With slightly lower accuracy, the standard model still delivers dependable performance in many the same types of applications. A great, cost-saving choice when corrosion resistance is not required. High Precision/Accuracy High Load Capacity No Corrosion Resistance Lower Cost than Premium Rack Precision Assembly Equipment Machine Tool/CNC Mills High Precision Gantry Robotics This is the work horse of the product line, combining both high load capacity and good corrosion resistance. ENDURANCE RACK High Load Capacity Medium Corrosion Resistance Good Accuracy (not high precision) UNIVERSAL RACK UNIVERSAL STAINLESS RACK VERSA RACK General Assembly Equipment Machine Tool Gantry Systems With better accuracy than Endurance Racks, the Universal Rack is a great option for lower load applications when corrosion resistance is not required. High Accuracy Medium Load Capacity No Corrosion Resistance Material Handling Equipment Gantry Systems Packaging Equipment General Motion Control Get all the features of the Universal Rack with the added benefits of corrosion resistant stainless steel. High Accuracy Medium Load Capacity Wet or Dirty Environments Very High Corrosion Resistance Material Handling Equipment Gantry Systems Packaging Equipment General Motion Control Made from thermoplastic, this rack can go places no other racks can go. It s wide range of applications make it a great fit for general motion control applications looking for the advantages of the RPS in a conventional accuracy version. Extremely High Corrosion Resistance Light Load Motion Control High Durability Basic Actuator (similar to cylinder/belt) Equipment with Conventional Accuracy Requirements Packaging General Motion Control Pinion Models Available PREMIUM PINION This long time standard at Nexen offers the best precision on the market. Use with any RPS rack for unbeatable performance. Very High Precision/Accuracy High Torque Capacity Great Performance in Any Application VALUE PINION A great fit for unique applications, Nexen offers the Value pinion to fit applications looking for the general features of Nexen s RPS in a conventional accuracy version. Lighter Load, General Accuracy Applications Harsh Environments Available in Sizes 16, 20 & 25 6

7 RPS System Specifications Table 1 RPS Size Rack Thrust Capacity (N) Premium Rack Standard Rack Endurance Rack Universal & Universal Stainless Racks Versa Rack Accel. Avg. Static Accel. Avg. Static Accel. Avg. Static Accel. Avg. Static Accel. Avg. Static RPS System RPS System PREMIUM PINION VALUE PINION NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA Table 2 RPS Size Pinion Torque (Nm) Peak Torque Premium Pinion Max. Average Torque for Full Life Static Torque Peak Torque Value Pinion Max. Average Torque for Full Life Static Torque NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA Table 3 PINION TYPE Premium Pinion Value Pinion Accuracy & Repeatability RACK MODEL Premium Rack Standard Rack Endurance Rack Universal Rack & Universal Stainless Accuracy ± µm Repeatability ± µm Accuracy * ± µm Repeatability * ± µm Versa Rack Table 4 ATTRIBUTES Rack Model Attributes (not affected by pinion choice) RACK MODEL Premium Rack Standard Rack Endurance Rack Universal Rack Universal Stainless Backlash* µm 0 Corrosion Resistant Surface Treatment Hard Chrome None Nitrided None None Plastic Corrosion Resistance Rating High None Medium None Very High Extremely High Lubrication Free Operation Yes up to 30 m/min No Yes up to 30 m/min Noise Level db up to 75 (Speed Dependent) Temperature Range o C -5 to 40 No No Versa Rack Yes up to max speed * Specifications listed for the Value Pinion are "out-of-box" ratings. Over time, these specifications are affected by operating torque and speed. NOTE: Refer to the System Life section for Load Life Comparison. See the Definitions section at the end of this catalog for details on these attributes. 7

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9 Racks RPS RACKS Nexen offers modular & custom rack sizes for unlimited system length. Choose from six rack models for a perfect fit in any application. PATENTED Rack Selection Process Application Data Calculations Specifications Dimensional Drawing Product Numbers

10 Linear Rack Selection Process Nexen offers a large range of rack sizes and materials, so you can find the perfect components for your application. Take advantage of the following guide designed to make selecting the right components for your system simple. If you don t find what you need, contact Nexen Group. Rack Selection Figure 1 Refer to this drawing when recording values for Force, Weight & Angle From Horizontal. F A F 1 F 2 etc. v F F w Including all drive & guide components F G Angle from Horizontal 0 H STEP 1: GATHER APPLICATION DATA Before you begin calculations, there are nine key measurements that you will need from your application. Collect the data and record it in the chart below. With this data available you can proceed on to the calculations on the following page. Measurements Required for RPS Selection Customer Data (record your values below) Sample Data Angle from Horizontal (q H) Refer to Figure Velocity This curve will select the smallest RPS Acceleration based on time is linear and may not reflect the actual curve. All calculations assume constant acceleration. Maximum Velocity (V max) m/s 0.5 m/s Travel Distance (L) (single direction move) m 5.4 m t Time Cycles Per Day (N day) (assumes single direction move) 1000 Acceleration Time (t A) or Known Acceleration seconds m/s s Weight to be Driven (W) kgf kgf Weight to be Driven should include all drive and guide components and structures being moved and should reflect the maximum weight each individual pinion must bear at any given time. Take into account any movable or asymmetric loads that may shift between multiple pinions during operation. Other Forces (F 1), (F 2) etc. Shock Factor (K) Circle the value that best reflects the smoothness of your application. Frictional Coefficient (µ) Circle the value that best reflects your application. Shockless Operation Normal Operation Operation with Impact Operation with High Impact Profile Guide Rail Ball Bearing Guide Rail Polymer Bushing Guide Bronze Bushing Guide N N Other Key Application Information Application Description: Environmental Conditions: c Typical Industrial c High Humidity c High Temperature c High Dust Positional Accuracy Requirements: 10

11 STEP 2: CALCULATING RPS REQUIREMENTS Rack selection is based on the load capacity required by your application. Using the information gathered on the preceding page, perform the following calculations to determine the Total Force of the Load. Use the space provided to record your calculations. (The sample calculations assume a single pinion driving an axis. Use the Sample Data from the chart on the preceding page.) Load Mass: M = W Use the total Weight to be Driven as your Load Mass value. Sample: M = kgf = 150 kg M = Load Mass Load Acceleration kg Rack Selection Load Acceleration: A = V max t A A known acceleration from a servo drive provider is preferred if available. A = m/s s A = m/s 2 Sample: A = 0.5 m/s 0.5 s = 1.0 m/s 2 Force Due to Load Acceleration Force Due to Load Acceleration: F A = M A F A = kg m/s 2 F A = N Sample: F A = 150 kg 1.0 m/s 2 = N Force Due to Gravity: F G = M g sin(q H ) Sample: F G = 150 kg 9.81 m/s 2 sin(60 ) = N F G = kg 9.81 m/s 2 sin ( ) F G = Force Due to Gravity N Force Due to Friction: F F = M µ g cos(q H ) F F = Sample: F F = 150 kg m/s 2 cos(60 ) = 7.4 N kg 9.81 m/s 2 cos ( ) F F = Force Due to Friction N Sum of Forces Sum of Forces: F S = F A + F G + F F + F 1 + F etc F S = N + N + N + N + N F S = N Sample: F S = N N N = N Total Force with Shock Factor Total Force with Shock Factor: F T = F S K Sample: F T = N 1.2 = N F T = N F T = N STEP 3: SELECTING A RACK MODEL Use Table 4 in the RPS System section to review the six different rack models and determine the model best suited for your application. STEP 4: SELECTING RACK SIZE Locate your chosen rack model in Table 1 in the RPS System section and determine the rack size with enough thrust capacity to handle the Total Force with Shock Factor calculated above for your application. STEP 5: EVALUATE LIFE AND VERIFY YOUR SYSTEM SPECIFICATIONS With the rack model and size selections, evaluate expected life in the System Life section and review the Common Rack Specifications (Table 5 in the Rack Section) to be sure that the rack you have selected will meet all of your application requirements. Rack Model Rack Size Rack Product Number 11

12 Rack Specifications Table 5 Attribute Common Rack Specifications Rack Size RPS10 RPS12 RPS16 RPS20 RPS25 RPS32 RPS40 RPS4014 Rack Specifications Max Pressure Angle o Avg Pressure Angle o Module mm Max Speed * All Metal Racks Versa Rack m/s m/s NA NA NA NA NA Rack Tooth Pitch mm Rack Height mm Rack Width mm Rack Section Size Half Half Half Full Half Full Half Full Half Full Half Full Half Full Rack Length mm Number of Rack Teeth Rack Weight All Metal Racks kg Versa Rack kg NA NA NA NA NA * The maximum rated speed of a RPS system is equal to the lowest rating of either the pinion or the rack. 12

13 Rack Dimensions All dimensions shown in mm. J C D E H F (Diameter & Number of Holes) A (Half Rack/ Full Rack) D G B Rack Thickness Reference Surface Rack Dimensions & Product Numbers RPS Size A B C D E F G H J Rack Length Rack Hole Hole From Hole Mounting Holes Half Full Thickness Height End Spacing Ø # Half Rack # Full Rack Rack Height RPS NA NA RPS NA NA RPS RPS RPS RPS RPS RPS See drawings or CAD models on Nexen s website for additional dimensions and tolerances. Tooth Pitch Axis to Base Rack Product Numbers RPS Size Rack Length Premium Standard Endurance Universal Universal Uncoated Stainless Universal Coated Stainless Half 480 mm NA NA NA Contact Nexen Contact Nexen NA Alignment Tool Half 480 mm NA NA NA Contact Nexen Contact Nexen NA Alignment Tool Half 512 mm Contact Nexen Contact Nexen Full 992 mm Alignment Tool Half 500 mm Contact Nexen Contact Nexen Contact Nexen Contact Nexen Full 1000 mm Alignment Tool Half 500 mm Contact Nexen Contact Nexen Contact Nexen Contact Nexen Full 1000 mm Alignment Tool Half 512 mm Contact Nexen Contact Nexen Contact Nexen NA Full 992 mm Contact Nexen NA Alignment Tool Half 520 mm Contact Nexen Contact Nexen Contact Nexen NA Full 1000 mm Contact Nexen NA Alignment Tool Half 520 mm Contact Nexen Contact Nexen Contact Nexen NA Full 1000 mm Contact Nexen NA Alignment Tool Rack Grease Versa

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15 Gears RPG GEARS Nexen offers the RPG Gears as solid rings up to 1.7 m in diameter. Segmented rings or arcs can also be combined to create your own custom rotary drive system. PATENTED Gear Selection Process Application Data Calculations Specifications Dimensional Drawings Product Numbers

16 Rotary Gear Selection Process Nexen offers both gears and individual arc segments for unlimited possibilities in your machine design. Take advantage of the following guide designed to make selecting the right components for your system simple. If you don t find what you need, contact Nexen Group about a custom design. STEP 1: GATHER APPLICATION DATA Before you begin calculations, there are key measurements that you will need from your application. Collect the data and record it in the chart below. With this data available you can proceed on to the calculations on the following page. Measurements Required for RPG Selection Customer Data (record your values below) Sample Data Gear Selection Angle Gear Rotates Relative to Horizontal Plane (q H) 0 Rotational Moment of Inertia (I) kgm kgm 2 Indexes Per Revolution (N I ) IPR 8 IPR SAMPLE APPLICATION INFORMATION Electronics Assembly Indexing Table 1 meter in diameter 8 stations equally spaced 60 indexes per minute desired Dwell time 0.33 sec Indexes Per Day (N day) RPD Index Time (t I ) or Known Angular Acceleration (a) Weight to be Driven (W) Should include everything in motion. seconds rad/s 2 kg 0.66 sec 20.0 kg Dwell Time (t D) seconds 0.33 sec Maximum Allowable Ring Gear OD (D max) mm 400 mm Minimum Allowable Ring Gear ID (D min) mm 200 mm Ring Gear Tooth Orientation (Select one) Other Forces (T 1), (T 2) etc. May include gravitational forces due to imbalanced load, springs, wind, counterbalance, fluid dampening systems, etc. Shock Factor (K) Circle the value that best reflects the smoothness of your application. Frictional Coefficient (µ) Circle the value that best reflects your application. external/internal Shockless Operation Normal Operation Operation with Impact Operation with High Impact Rolling Bearing Sliding Bearing Nm ~ ~0.2 external 0 Nm Velocity This curve will select the smallest RPG t Time Acceleration based on time is linear and may not reflect the actual curve. All calculations assume constant acceleration. Diameter of Bearing Element (D B) mm 50 mm Other Key Application Information Application Description: Environmental Conditions: c Typical Industrial c High Humidity c High Temperature c High Dust Positional Accuracy Requirements: 16

17 STEP 2: CALCULATING RPG REQUIREMENTS FOR SIMPLE INDEXING APPLICATIONS Gear selection is based on the load capacity required by your application. Using the information gathered on the preceding page, perform the following calculations. If acceleration or deceleration times vary, or there are other changes in velocity, calculate the acceleration torque for each interval and use the highest value for RPG selection purposes. Acceleration Time Acceleration Time: t A = t I 2 Sample: t A = 0.66 seconds 2 = 0.33 seconds t A = sec 2 t A = sec Rotation Angle Per Index Rotation Angle Per Index: q = 2p N I Sample: q = 2p 8 IPR = rad q = 2p IPR q = rad Max Angular Speed: w = q t I 2 w = Sample: w = rad 0.66 seconds 2 = rad/sec rad sec 2 Max Angular Speed w = rad/sec Angular Acceleration Gear Selection Angular Acceleration: a = w t A a = rad/sec sec a = rad/s 2 Sample: a = rad/sec 0.33 sec = rad/s 2 Ring Gear Torque: T gear = (I a) + ((W g µ D B ) 2000) T gear = kgm 2 rad/s + ( 2 kg 9.81 m/s mm 2000) 2 T gear = Ring Gear Torque Nm Sample: T gear = (10 kgm rad/s 2 ) + ((20 kg 9.81 m/s mm) 2000) = Nm Ring Gear Torque with Shock Factor: T T = T gear K Sample: T T = Nm 1.2 = 86.6 Nm T T = Nm Ring Gear Torque w/ Shock Factor T T = Nm Pinion Thrust Required at Max OD: F 1 = (T T D max ) 2000 Sample: F 1 = (86.6 Nm 400 mm) 2000 = 433 N F 1 = Nm mm Pinion Thrust Required at Max OD 2000 F 1 = N Pinion Thrust Required at Min ID: F 2 = (T T D min ) 2000 Sample: F 2 = (86.6 Nm 200 mm) 2000 = 866 N F 2 = Nm mm 2000 Pinion Thrust Required at Min ID F 2 = N STEP 3: SELECTING A GEAR SIZE Using the table to the right, circle the RPG size needed to meet the Pinion Thrust requirements of your application (as calculated above). PREMIUM PINION Dynamic Thrust (N) VALUE PINION Dynamic Thrust (N) RPG Size Min Life Max Life NA NA STEP 4: VERIFY YOUR SYSTEM SPECIFICATIONS Using the selected RPG size and the Ring Gear Torque with Shock Factor requirement calculated above, use the tables on the next page to select a gear. Review Gear Specifications to ensure the selected gear meets all of your application requirements. 17 Gear Product Number

18 Gear Specifications RPG Size Gear Product Number Gear Ratio Pinion Type Maximum Dynamic Max Static Torque Accuracy Repeatability Minimum Life Maximum Life Max RPM Nm Nm Nm ArcSec ArcSec Gear Specifications : : : : : : : : : : : : :1 premium / /- 14 value / / premium / / value / / premium / /- 8.5 value / /- 8.5 premium / /- 7.1 value / /- 7.1 premium / /- 6.1 value / /- 6.1 premium / /- 2.8 value / /- 2.8 premium / /- 1.1 value / /- 1.1 premium / /- 2.4 value / /- 2.4 premium / /- 2.2 value / /- 2.2 premium / /- 1.9 value / /- 1.9 premium / /- 0.6 value / /- 0.6 premium / /- 0.5 value / /- 0.5 premium / /- 0.4 value / / : : : : : :1 premium / /- 8.9 value / /- 8.9 premium / /- 6.7 value / /- 6.7 premium / /- 5.4 value / /- 5.4 premium / /- 4.5 value / /- 4.5 premium / /- 3.6 value / /- 3.6 premium / /- 0.6 value / / :1 premium / / :1 premium / / :1 premium / / :1 premium / / :1 premium / / :1 premium / / :1 premium / / :1 premium / / :1 premium / /- 0.9 Common Attributes for All Gears Estimated Life See System Life section. Operating Temperature Range C -5 to 40 Tooth Grease Part Number

19 Gear Dimensions & Specifications by Product Number Figure A C Figure B Figure C E D F B A D B F A F B D A E Basic gear dimensions shown for selection purposes only and subject to change. Go to for detailed drawings and CAD models. If none of the products below meet your needs, contact Nexen and one can be designed to your specifications. Due to the variety of gears and gear segments, these products are made to order. Please contact Nexen for lead times. Gear Dimensions & Product Numbers RPG Size Dimensions shown in mm unless otherwise noted. Gear Product Number Alignment Tool Product Number Number of Teeth Teeth Orientation Moment of Inertia Weight Figure Coating A B C D E F Outer Inner segment/ring kgm² kg Diameter Max Width Bolt Circle Ø Arc Length/ Full Ring Distance from Center NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes external 30/ * 1.6* B Hard Chrome º/yes external 25/ * 1.8* B Hard Chrome º/yes external 28/ * 2.9* B Hard Chrome º/yes internal 25/ * 3.6* C Hard Chrome º/yes external 30/ * 2.7* B Hard Chrome º/yes external 30/ * 3.6* B Hard Chrome º/yes internal 19/ * 3.2* C Hard Chrome º/yes external 30/ * 4.9* B Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes external 27/ * 4.6* B Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes NA external NA/ A Black Oxide º/yes external 18/ * 7.7* B Hard Chrome º/yes external 19/ * 8.4* B Hard Chrome º/yes NA external NA/ A Hard Chrome º/yes external 11/ * 6.4* B Hard Chrome º/no NA external NA/ A Hard Chrome º/yes external 18/ * 17.3* B Hard Chrome º/yes external 12/ * 9.4* B Hard Chrome º/yes 1268 * Per Segment 19

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21 Roller Pinions RPS ROLLER PINION Once you have selected your rack/gear, finding the right pinion is easy. The following pages offer step-by-step selection instructions as well as pinion specifications and details on accessories. PATENTED Pinion Selection Process Specifications Dimensional Drawings Pinion Accessories Adapters Preloaders

22 RPS Pinion Selection Process STEP 1: Determine your rack/gear size and find the same RPS pinion size. Always use the same size rack/gear and pinion. STEP 2: Select the material best suited for your application. (Other materials available upon request.) Hard Chrome: alloy steel with a thin, dense chrome coating Nickel: alloy steel with nickel plating Stainless: stainless steel with or without a hard chrome coating STEP 3: Select Mounting Style: For easy installation and maximum versatility, Nexen recommends using the flangemounted version when practical. Shaft Mount Shaft Coupling or Shaft & Keyway mounting option Coupling option uses a keyless mechanical compression coupling to secure to shaft Available in multiple bore diameters. Contact Nexen. Flange Mount Conforms to ISO 9409 specifications Nexen adapter preloader options available with this version Pinion Selection Pinion Type PREMIUM PINIONS RPS Size Number of Rollers Distance per Pitch Circle Bore Moment of Max Product Base Material/ Mass Revolution Diameter Mount Style Size Inertia RPM * Number Coating mm mm mm kg kgm 2 x Hard Chrome Shaft Coupling Hard Chrome Shaft Coupling Nickel Shaft Coupling Nickel Shaft Coupling Stainless Shaft Coupling Nickel Flange N/A Stainless Flange N/A Nickel Shaft Coupling Nickel Shaft Coupling Stainless Shaft Coupling Nickel Flange N/A Request Stainless Flange N/A Nickel Shaft Coupling Stainless Shaft Coupling Nickel Flange N/A Request Stainless Flange N/A Nickel Shaft Coupling Nickel Shaft Coupling Nickel Shaft Coupling Request Stainless Shaft Coupling Nickel Flange N/A Request Stainless Flange N/A Nickel Shaft Coupling Nickel Shaft Coupling Request Stainless Shaft Coupling Nickel Flange N/A Request Stainless Flange N/A Nickel Shaft Coupling Nickel Shaft Coupling Request Stainless Shaft Coupling Nickel Flange N/A Request Stainless Flange N/A VALUE PINIONS Aluminum Shaft & Keyway Aluminum Shaft & Keyway Aluminum Shaft & Keyway * The maximum rated speed of a RPS system is equal to the lowest rating of either the pinion or the rack. See the Definitions section for more information on these attributes. 22

23 Common Attributes for All Pinions Estimated Life See System Life section. Operating Temperature Range C -5 to 40 Lubrication/Tooth Grease Part Number Pinion Dimensions Additional Dimensions The Pinion dimensions listed here are for selection purposes only. For detailed drawings and CAD models, please visit Pinion Adapters Pinion adapters allow the pinion to mount to one frame-size larger of a reducer. Moving up a reducer size is sometimes needed due to reducer availability or motor sizing reasons. All Nexen pinion adapters are made from corrosion resistant materials or coatings. For your convenience, we have included pinion adapter dimensions next to each ISO9409 flange mounted pinion. See Table 6 for pinion adapter part numbers. RPS10 Premium Pinion Shaft Mounted Pinion Minimum Shaft Insertion RPS12 Premium Pinion Shaft Mounted Pinion Minimum Shaft Insertion Pinion Dimensions See Table See Table Reference B Surface 5.7 Reference Surface B

24 Pinion Dimensions RPS16 Premium Pinion Shaft Mounted Pinion ~52.5 ø67.0 2X ø Reference Surface -B Minimum Shaft Insertion 12.0 () See Table ISO 9409 Flange Mount Pinion ø9.0 Thru Pinion (8) M4 x 0.7 Screws (Shown) included for ISO Adapter (966688)* ø Pilot Length 3.5 ø67.0 2X Screw Length 6.5 (M4) Pilot ø Reference Surface -B- ø12.0 Thru Pilot ø Required For Some Gearhead Sizes 45 Typ M Screws Supplied *(4) M3 x 0.5 x 45 mm screws (Not Shown) included for use with APEX AD047 Adapter 22.5 ø ø48.0 Pilot Length Screw Length RPS16 Value Pinion Pinion Dimensions Note: See product drawing for keyway specifications Minimum Shaft Insertion ø67 See Table Shaft & Keyway Pinion 15.2 Reference Surface -B RPS20 Premium Pinion Shaft Mounted Pinion ~58.5 ø84.0 ø Reference Surface 32.0 Minimum Shaft Insertion 12.0 () See Table ISO 9409 Flange Mount Pinion M5-08 at 45 Nexen Supplied 1 ø31.50 ø16.0 Thru Pilot ø Pinion Pilot Length Screw Length 0.5 Bolt Head Protrusion 15.5 Reference Surface -B- -B- ø ø20.0 Thru ø50.0 Pilot ø Required For Some Gearhead Sizes M Screws Supplied Adapter Typ ø Screw Length 1 (8 Screws for Adapter Mount)(7 Screws for Direct Mount) Pilot Length

25 Pinion Dimensions RPS20 Value Pinion Note: See product drawing for keyway specifications Minimum Shaft Insertion ø84 See Table Shaft & Keyway Pinion Reference Surface -B RPS25 Premium Pinion Shaft Mounted Pinion Minimum Shaft 37.5 Insertion 14.0 () ø101.0 ø63.0 Reference Surface See Table ø23.5 Thru ISO 9409 Flange Mount Pinion M Custom 45 Supplied Pilot ø Pinion ø B ø B- Reference Surface 8.9 Screw Length Pilot Length ø31.5 Thru ø63.0 Required For Some Gearhead Sizes 45 Adapter Pilot ø Screw Length ø Pilot Length M Screws Supplied Pinion Dimensions RPS25 Value Pinion Note: See product drawing for keyway specifications Minimum Shaft Insertion ø101 See Table Shaft & Keyway Pinion 17.3 Reference Surface -B

26 Pinion Dimensions RPS32 Premium Pinion Shaft Mounted Pinion ø Reference -B- Surface Minimum Shaft Insertion 20.0 () See Table ISO 9409 Flange Mount Pinion ø M Screws Supplied x ø32.0 Thru Pilot ø Pinion Reference Surface 68.5 Screw ø80.0 Length 8.3 Pilot ø ø X 5.5 Pilot Length 22.0 Required For Some Gearhead Sizes M Screws Supplied Adapter 45 ø40.00 Thru 10.0 ø98.0 Pilot Length Screw Length RPS40 Premium Pinion Pinion Dimensions Shaft Mounted Pinion ø Minimum 30.0 Shaft Insertion See Table ISO 9409 Flange Mount Pinion ø40.0 Thru 30 Typ Pinion Screw Length ø X ø50.0 Thru Adapter Required For Some Gearhead Sizes 30 Typ ø Pilot Length 31.5 Reference Surface -B Pilot ø ø80.0 M Screws (Supplied) Reference Surface -B- 5.5Pilot Length 32.5 Pilot ø M Screws at 30 Supplied ø Screw Length RPS4014 Premium Pinion Shaft Mounted Pinion 33.0 ø Reference Surface -B Minimum Shaft Insertion 35.0 See Table ISO 9409 Flange Mount Pinion 12.5 ø125.0 ø60.0 Thru ø Typ 30 Typ Pinion 30 Typ Pilot ø M For ISO For Adapter 12 Screws Supplied Reference Surface B- -B Screw Length Pilot Length 7.5 Required For Some Gearhead Sizes X 24 M Screws Supplied Adapter Pilot Length 11.5 ø Pilot ø180.0 ø80.0 Thru ø Screw Length

27 Pinion Preloader Pair Nexen s Flange-Mount Pinion with our RPS Pinion Preloader for easy integration into your machine design. Preloaders feature an adjuster that allows the pinion to be moved up or down into the rack while keeping the pinion properly oriented to the rack. The pilot in the adjuster plate accommodates common servo gearhead sizes from your favorite servo gearhead manufacturer. Preloader and Adapter components are either made from corrosion-resistant stainless steel, nickel, or zinc plating. FEATURES: High-Precision Ground Surfaces Allows Perpendicular Movement Corrosion Resistant Materials Preloader ISO 9409 Roller Pinion Gearhead with ISO 9409 Output Customer Machine Frame ISO 9409 Adapter (If Required) Pinion Adapter & Preloader SELECTING PINION ADAPTERS AND PRELOADERS If directly mounting the pinion to the reducer: Disregard the Pinion w/ Adapter column and select the preloader and gearhead for your RPS Pinion size. Table 6 Pinion Size Pinion w/ Adapter (not required in some applications) Pinion Preloader Customer Provided Gearhead Alpha/ Wittenstein APEX GAM Mijno Neugart Nidec- Shimpo SEW-Euro Stöber Sumitomo RPS16 N/A N/A N/A AD047 N/A N/A N/A VRT047 N/A N/A N/A RPS20 RPS16 & TP004 AD064 N/A BDB 085 PLFE/N 64 VRT064 PSBF221/2 PH/A/KX 321/2 RPS25 RPS32 Gearhead Compatibility Table RPS16 & RPS20 & RPS16 & RPS25 & If going up a reducer frame size: Start in the Pinion w/ Adapter column and select the compatible pinion, adapter, preloader and gearhead TP010 AD090 SPH-F75 BDB 120 PLFE/N 90 VRT090 PSBF321/2 PH/A/KX 421/ TP025 AD110 SPH-F100 BDB 145 PLFE/N 110 VRT110 PSBF521/2 PH/A/KX 521/2 RPS40 RPS32 & TP050 AD140 SPH-F140 BDB 180 PLFN 140 VRT140 PSBF621/2 PH/A/KX 721/2 RPS4014 RPS40 & TP110 AD200 N/A BDB 250 PLFN 200 VRT200 PSBF721/2 PH/A/KX 821/2 N/A RPS4014 & N/A N/A N/A N/A N/A N/A N/A N/A PH/A/KX 912/23 N/A RPS4014 & N/A N/A AD255 N/A N/A N/A VRT255 N/A N/A N/A N/A PNFX080 PNFX250 PNFX450 N/A N/A This is a partial list. Other gearheads may apply. 27

28 Preloader Dimensions RPS-PRE-ISO Product Number Preloader Details M4-0.7 X Screws Supplied ø79.0 R8.0 4x 35.0 Hex 3.0 mm Wrench 8.0 ø Min - Max Customer-Supplied Mounting Surface See View to Right Customer Mounting Surface Details Max M4-0.70, 9.0 mm 2 Holes Located as Shown 36.0 ø64.0 M4-0.7 x Screws Supplied Typ 47.5 M (4X) Shoulder Cap Screw (Supplied w/ Washers) Gearhead & Pinion Shown for Reference (Not Included) Mounting Surface ø M THRU ø8.013, 4.00 Deep 4 Holes Located as Shown Pinion Preloader RPS-PRE-ISO Product Number Preloader Details M6-1.0 X Screws Supplied ø ø109.0 M5-0.8 X Screws Supplied ø90.0 R8.0 4x Hex 8 mm Wrench [5/16] Min - Max M (4X) Shoulder Cap Screw Supplied w/ Washers Customer-Supplied Mounting Surface See View to Right Gearhead & Pinion Shown for Reference (Not Included) Customer Mounting Surface Details Max ø110.0 Mounting Surface M6-1.0, 8.0 Deep 2 Holes Located As Shown () 48.5 () M THRU ø10.013, 4.00 Deep 4 Holes Located as Shown RPS-PRE-ISO Product Number Preloader Details Hex 8 mm Wrench 50.0 M5-0.8 X Screws Supplied M6-1.0 X Screws Supplied Min - Max Customer-Supplied Mounting Surface See View to Right Customer Mounting Surface Details M6-1.0, 8.0 Deep 2 Holes Located As Shown M THRU 16.0 ø10.013, 4.00 Deep Max 6 Holes Located as Shown ø ø ø R8.0 4x Typ M (6X) Shoulder Cap Screw Supplied w/ Washers Gearhead & Pinion Shown for Reference (Not Included) Mounting Surface

29 Preloader Dimensions RPS-PRE-ISO Product Number Preloader Details M6-1.0 X Screws Supplied M6-1.0 X Screws Supplied ø168.0 ø Hex 8 mm Wrench Min - Max Customer Mounting Surface Details Customer-Supplied Mounting Surface See View to Right M6-1.0, 10.0 Deep 2 Holes Located As Shown 12.0 Max M THRU ø10.013, 4.00 Deep Holes Located as Shown R12.0 4x Typ M (8X) Shoulder Cap Screw Supplied With Washers Gearhead & Pinion Shown for Reference (Not Included) Mounting Surface ø193.0 RPS-PRE-ISO Product Number Preloader Details Hex 8 mm Wrench M Shoulder Cap Screws 8 Supplied w/ Washers ø M6-1.0 X Screws Supplied ø233.0 Min - Max Customer-Supplied Mounting Surface See View to Right Customer Mounting Surface Details M6-1.0, 10.0 Deep M THRU 2 Holes Located As Shown ø12.013, 4.13 Deep Holes Located as Shown Max ø Pinion Preloader R12.0 4x Typ M X Screws Supplied Gearhead & Pinion Shown for Reference (Not Included) Mounting Surface

30 30

31 RPS System Life RPS SYSTEM LIFE The RPS system offers an efficiency greater than 99% with a long life of up to 60,000,000 pinion revolutions (up to 36 million meters of travel). Typically the rack/gear lasts through several pinion changes. Pinion Life Data & Calculations Rack Life Data & Calculations System Life Graphs

32 Calculating RPS System Life The calculations in the following section will allow you to calculate the expected rack and pinion life. These calculations will result in the same values as the charts on the following pages. RPS Pinion Life Data & Calculations Table 7 RPS Pinion Life Values RPS10 RPS12 RPS16 RPS20 RPS25 premium value premium value premium value RPS32 RPS40 RPS4014 Max Torque (Tmax) Nm Torque at Max Life (Tfinal) Nm Distance Per Revolution (Lrev) meters Transition Point (ET) Max Life (Nmax contacts) million contacts million contacts Constant (C) NA NA NA NA NA NA NA STEP 1: GATHER APPLICATION DATA Before you begin calculations, there are three key measurements that you will need from your application. Collect the data and record it in space provided to the right. Measurements Required for Pinion Calculations Customer Data (record your values below) Sample Data Average Torque (T avg) Nm 85 Nm Distance Per Cycle (L) (single direction move) m 1.3 m Average Speed (V avg) m/s 2 m/s RPS Pinion Life STEP 2: CALCULATE THE TOTAL NUMBER OF PINION CONTACTS (N CONTACTS ) Perform the following calculations using the data collected from your application data in Step 1. PINION ROLLER CONTACTS (Ncontacts) The total number of roller contacts (Ncontacts) that an RPS Pinion can sustain before needing replacement is based on the average torque of your application. Determine which equivalency or inequality statement below is true for the average torque (T avg) of your application. Then complete the corresponding pinion roller contact equation and record your value below. IF T avg is: THEN N contacts : < T final = N max contacts Pinion Life in Roller Contacts > T final AND < Tmax = (C T avg ) = Nm N contacts = million contacts = T max = E T Sample: (Evaluating RPS20 size) Ncontacts = ( Nm) = 12 million contacts 32

33 RPS Pinion Life Calculations STEP 3: CONVERT ROLLER CONTACTS TO HOURS, METERS OR REVOLUTIONS There are two options for converting contacts to other units: exact and estimated. Exact should be used whenever possible. The estimation is available for customers who do not have a well-defined distance per cycle. EXACT OPTION: PINION LIFE IN HOURS (N hours) Use Table 7 along with the data you collected above to calculate the total number of service hours your pinion can provide before needing replacement. First calculate E 1 to use in the N hours equation. E 1 = L L rev Must round E 1 up to the nearest whole integer. E 1 = round up Sample: E 1 = 1.3 m 0.2 m = 6.5 m Round up to 7. m Nm m = N hours = (N contacts 10 6 L) (3600 E 1 V avg) Pinion Life in Hours N = million 10 6 hours Nm m 3600 contacts m/s Nm N hours = hrs Sample: N hours = ( m) ( m/s) = hrs ESTIMATION OPTIONS: PINION LIFE IN METERS & LIFE IN REVOLUTIONS These calculations assume the pinion travels nonstop in one direction throughout its whole life. Pinion Life in Meters PINION LIFE IN METERS (N meters) N meters = N contacts L rev 10 6 N meters = m 10 6 N meters = m Sample: N meters = m 10 6 = 2,400,000 m PINION LIFE IN REVOLUTIONS (N rev) N rev = N contacts Sample: N rev = 12 million revolutions Pinion Life in Revolutions N rev = million revolutions RPS Pinion Life 33

34 RPS Rack Life Data Table 8 RPS Rack Life Values RPS Rack Size RPS10 RPS12 RPS16 RPS20 RPS25 RPS32 RPS40 RPS4014 Pitch (P) meters Distance Per Revolution (L rev) meters Max Dynamic Thrust (Fmax) N Premium & Standard Thrust at Max Life (Ffinal) Transition Point (ET) Max Life (Nmax contacts) N million contacts Million Contacts Slope (m) NA NA NA NA Intercept (b) N NA NA NA NA Max Dynamic Thrust (Fmax) N NA NA RPS Rack Life Universal & Versa Endurance Universal Stainless Thrust at Max Life (Tfinal) Transition Point (ET) N NA NA million contacts NA NA Max Life (Nmax contacts) NA NA 30 Million Contacts Slope (m) NA NA NA NA Intercept (b) N NA NA NA NA Max Dynamic Thrust (Fmax) Thrust at Max Life (Ffinal) N NA NA N NA NA Max Life (Nmax contacts) NA NA 5 Million Contacts 2 Million Contacts Max Dynamic Thrust (Fmax) Thrust at Max Life (Ffinal) N NA NA NA NA NA N NA NA NA NA NA Max Life (Nmax contacts) NA NA 2 Million Contacts NA 34

35 RPS Rack Life Calculations STEP 1: GATHER APPLICATION DATA Before you begin calculations, there are three key measurements that you will need from your application. Collect the data and record it in space provided below. Measurements Required for Rack Calculations Customer Data (record your values below) Sample Data Average Thrust Force (F avg) N 2500 N Distance Per Cycle (L) (single direction move) m 1.3 m Average Speed (V avg) m/s 2 m/s STEP 2: CALCULATE THE TOTAL NUMBER OF TOOTH CONTACTS Perform the following calculations using the data collected from your application and the values from Table 8. RACK TOOTH CONTACTS (N contacts) The total number of tooth contacts (N contacts ) that an RPS Rack can sustain before needing replacement is based on the average thrust force of your application. Use Table 5 to determine which equivalency or inequality statement below is true for the average thrust force (F avg) of your application. Then complete the corresponding rack tooth contact formula and record your value below. IF F avg is: THEN N contacts : < F final = N max contacts Rack Life in Tooth Contacts > F final AND < F max = (F avg b) m = N N = F max = E T Sample: (Evaluating RPS20 size) Ncontacts = (2500 N 3180) -56 = 12 million contacts N contacts = million contacts RPS Rack Life STEP 3: CONVERT RACK TOOTH CONTACTS TO HOURS OF LIFE Perform the following calculations using the data collected from your application and the values from Table 5. RACK LIFE IN HOURS (N hours) Use Table 5 along with the data you collected above to calculate the total number of service hours your rack can sustain before needing replacement. N hours = (N contacts 3600) (L V avg) 10 6 Rack Life in Hours N hours = 3600 m m/s 10 6 N hours = hours Sample: N hours = ( ) (1.3 m 2 m/s) 10 6 = 2166 hours 35

36 RPS System Life Graphs (RPS10, 12 & 16) The RPS system life ratings are based on the force of the load. Refer to the following graphs to determine the pinion and rack life based on your application load forces. Graphs show the thrust along side the corresponding torque to more easily calculate your complete system life. Typically the pinion can be replaced numerous times before replacing the rack. RPS10 System Life Graph RACK LIFE LOAD FORCES Thrust Torque (N) (Nm) PINION LIFE Premium Premium Tooth Contacts (Millions) Roller Contacts (Millions) RPS12 System Life Graph RACK LIFE LOAD FORCES Thrust (N) 800 Torque (Nm) 15.3 PINION LIFE Premium Premium RPS System Life Tooth Contacts (Millions) RPS16 System Life Graph RACK LIFE Premium & Standard Endurance Universal Versa 200 LOAD FORCES Thrust (N) Torque (Nm) Roller Contacts (Millions) PINION LIFE Premium Value Tooth Contacts (Millions) Roller Contacts (Millions) 36

37 RPS System Life Graphs (RPS20, 25 & 32) RPS20 System Life Graph LOAD FORCES RACK LIFE Premium & Standard Endurance Universal Versa Thrust (N) Torque (Nm) PINION LIFE Premium Value Tooth Contacts (Millions) Roller Contacts (Millions) RPS25 System Life Graph LOAD FORCES RACK LIFE Premium & Standard Endurance Universal Versa Thrust (N) Torque (Nm) PINION LIFE Premium Value Tooth Contacts (Millions) RPS32 System Life Graph RACK LIFE Premium & Standard Endurance Universal LOAD FORCES Thrust (N) Torque (Nm) Roller Contacts (Millions) PINION LIFE Premium RPS System Life Tooth Contacts (Millions) Roller Contacts (Millions) 37

38 RPS System Life Graphs (RPS40, 4014 & 50) RPS40 System Life Graph RACK LIFE LOAD FORCES Thrust (N) Torque (Nm) PINION LIFE Premium, Standard & Endurance Universal Premium Tooth Contacts (Millions) Roller Contacts (Millions) RPS4014 System Life Graph RACK LIFE LOAD FORCES Thrust (N) Torque (Nm) PINION LIFE Premium, Standard & Endurance Universal Premium RPS System Life Tooth Contacts (Millions) Roller Contacts (Millions) 38

39 HARMONIC GEARHEAD Nexen s revolutionary Harmonic Gearhead (HG) is the perfect combination of size and precision. Use the Harmonic Gearhead integrated with Nexen s RPS Pinion (HGP) to create a true backlash-free solution from the motor to the driven load. With up to a 70% reduction in length over standard gearheads, machine designers will appreciate the opportunities available with this space saving product. Features & Benefits Specifications PATENTED Selection Process Cycle Determination Stiffness Output Loading Efficiency Dimensional Drawings Life Graphs Input Motor HGP Preloader Harmonic Gearhead

40 The Nexen Harmonic Gearhead Advantage Nexen s patent pending Harmonic Gearhead (HG) offers a precision drive solution that overcomes the challenges of existing gearing methods. This new technology eliminates problems with backlash that have plagued the motion control industry, offering reliable precision even when intricate movements are required. In the tradition of Nexen's entire line of precision motion control products, the Harmonic Gearhead sets new standards with these great features: Zero Backlash High Positional Accuracy & Repeatability Quiet Operation Large, Rugged Cross-Roller Output Bearing Compact Save 70% or more in gearhead length. HGP Standard Two- Stage Planetary Harmonic Gearhead with Pinion Save space by taking advantage of Nexen s Harmonic Gearhead with Pinion (HGP). In this model, the RPS pinion comes fully integrated into the gearhead, creating the only drive solution that maintains zero backlash from the driving motor shaft through to the driven load for both linear and rotary motion. Harmonic Gearhead Features & Benefits DRIVING TECHNOLOGY IN ADVANCING MARKETS Nexen s HG(P) utilizes Harmonic Strain-Wave Technology made up of a circular spline, flex-spline and wave generator. As these components rotate, their unique shape and tooth profile allow 30% of the teeth to be engaged simultaneously for: Smooth Rotation High Torque Zero Backlash The effortless, low-stress meshing of the circular spline and flex-spline teeth results in a long gearhead life with reliable, quiet operation. Some operators call this peace of mind. Aerospace Robotics Semiconductor Factory Automation Medical / Surgical 40

41 Harmonic Gearhead Specifications HARMONIC GEARHEAD (HG) Specifications HG17 HG25 HG32 HG50 Gear Ratio 50:1 80:1 100:1 120:1 50:1 80:1 100:1 120:1 50:1 80:1 100:1 120:1 80:1 100:1 120:1 Max Acceleration Torque 1 Nm Max Average Torque 1 Nm Inertia at Input kg-cm Backlash ArcSec One Way Accuracy ±ArcSec One Way Repeatability ±ArcSec Weight kg Product Number HARMONIC GEARHEAD WITH PINION (HGP) Specifications HGP17 HGP25 HGP32 HGP50 Integrated Pinion Size RPS16 RPS20 RPS25 RPS40 Gear Ratio 50:1 80:1 100:1 120:1 50:1 80:1 100:1 120:1 50:1 80:1 100:1 120:1 80:1 100:1 120:1 Max Torque (Nm) Acceleration 1 Thrust (N) Max Average 1 Torque (Nm) Thrust (N) Inertia at Input kg-cm Backlash μm One Way Accuracy ± μm One Way Repeatability ± μm Weight kg Product Number GENERAL SPECIFICATIONS FOR BOTH HG & HGP UNITS Specifications Size 17 Size 25 Size 32 Size 50 Max Input Speed 1 cyclic RPM continuous RPM Max Average Input Speed 1 RPM Max Input Acceleration Rate rad/sec Max Average Torque (E T_max ) Stiffness, Hysteresis Output Loading Temperature Limits Mounting Position Direction of Rotation Lubrication Life 80% ±5% See Stiffness Section See Output Loading Section Ambient Temperature: 0ºC to +40ºC Maximum Unit Temperature: < 90ºC No Restriction Motor Opposite Gearhead Lubricated for Life See HG & HGP Life Section Harmonic Gearhead Specifications 1 Refer to the Harmonic Gearhead Selection Process section for product sizing procedures. Note: All accuracy data taken at 2% of maximum load. 41

42 Harmonic Gearhead Selection Process When selecting the proper Harmonic Gearhead, use the Specifications table to determine the HG/HGP size that best fits the application s torque, speed and physical size requirements. Then, use the following calculation sections to evaluate whether the cycle type, stiffness, efficiency and bearing load capacity of the selected HG/HGP size meets all the application requirements. HG/HGP Cycle Determination Correct sizing of the Harmonic Gearhead is critical to the proper function and life expectancy of your unit. The following section provides information regarding cycle type to be used in the gearhead sizing process. The two Cycle Types are: Continuous Motion & Cyclic Motion STEP 1: Determine which Cycle Type applies to your application. STEP 2: Use the Cycle Limitations information to correctly size the Gearhead. CONTINUOUS MOTION: single direction motion lasting longer than one hour Cycle Limitations Example Cycle Input Speed Max average input speed Output Torque Max average torque INPUT SPEED V MAX Time (hr) LOAD TORQUE T MAX Time (hr) CYCLIC MOTION: reversing direction motion Cycle Limitations Example Cycle Harmonic Gearhead Cycle Types Input Speed Output Torque Time at Max Input Speed <10 seconds (t 2 ) Time above Max Average Input Speed <30 seconds (t 1 ) Average over any 2 minutes < Max Average Input Speed Time at Max Acceleration Torque <10 seconds (t 3 ) Time above Max Average Torque <10 seconds Average over any 2 minutes < Max Average Torque LOAD TORQUE INPUT SPEED V MAX V AVG 0 V AVG V MAX T MAX t3 T AVG 0 T AVG T MAX Accel t1 t2 Operating Decel Time (min) Time (min) 42

43 HG/HGP Torsional Stiffness Unlike many other gearing types, Harmonic Gearhead stiffness is non-linear. As torque increases, stiffness also increases, as shown in the graph below. NOTE: If you wish to calculate "windup" at torque greater than T1, remember to include the displacement caused by lower stiffness regions. HG STIFFNESS HYSTERESIS Hysteresis HYSTERESIS K3 D 3 D 2 K 2 -T +T D 1 K 1 T 1 T2 T 3 HG AND HGP STIFFNESS DATA Torsional stiffness is determined by applying a torque to the output of the gearhead while the input is held from rotation. For ease of calculation, the slope of the curve is approximated using three straight lines representing stiffness values K 1, K 2, & K 3. Refer to the tables below for the typical stiffness values for each size HG and HGP. Reference Torque (Nm) Ref. Disp. (ArcMin) Stiffness (Nm/ArcMin) 50:1 80:1 + 50:1 80:1 + Reference Torque (Nm) Ref. Disp. (ArcMin) Stiffness (Nm/ArcMin) 50:1 80:1 + 50:1 80:1 + Size 17 T D K T D K T D K Size 32 T D K T D K T D K Size 25 T D K T D K T 3 90 D K Size 50 T D K T D 2 NA 5.81 K 2 NA T D K HYSTERESIS Hysteresis is measured by applying maximum average torque in both directions on the output with the input locked. Typical values are provided in the table to the right. Hysteresis (ArcSec) Size 17 Size 25 Size 32 Size Harmonic Gearhead Stiffness 43

44 HG Output Loading Harmonic Gearheads come equipped with a cross roller bearing on the output, offering high precision and large, load-carrying capabilities. Use the following information to verify that the selected gearhead meets all application load requirements. F R Table 9 Harmonic Gearhead Output Load Ratings Table HG(P)17 HG(P)25 HG(P)32 HG(P)50 Bearing Constant (C B) m F A_sup Bearing Center Distance to Flange (L) m F A_sus T M Max Axial Suspended Load (F A_sus_max) N Max Axial Supported Load (F A_sup_max) N Max Radial Load (F R_max) N Max Moment Load (T M_max) Nm L Max Combined Load (P C_max) N Single vs. Multiple Load Direction Single Loading Direction If only one loading direction applies to your application, simply compare the maximum application load with the HG ratings above to ensure that the gearhead is capable of withstanding the application load. Multiple Loading directions When two or more loading directions apply, calculate the combined load using radial, axial and moment load values. Record your application data and perform the calculations on the following page to determine the Combined Load (P C ) of your application. Then compare this value with the Max Combined Load in Table 9 above. NOTE: Although Combined Load is calculated using average loads, no load should exceed the maximum rated load for that loading direction. Harmonic Gearhead Output Loading 44

45 HG Output Loading (continued) CALCULATING COMBINED LOAD REQUIREMENTS Refer to the explainations and data on the preceding page to complete the following calculations to determine the combined load requirements of your application. STEP 1: GATHER APPLICATION DATA Axial (F A ), Radial (F R ), and Moment (T M ) Loads are application specific. Use the table below to record the average loads that the gearhead will be subjected to during operation. Application Loads Required for Gearhead Selection Average Axial Load (F A) [Either suspended (FA_sus) or supported (FA_sup), whichever is present in your application] Customer Application Data (record your values below) N Sample Data (HG25) 1000 N (F A_sup) Average Radial Load (F R) N 500 N Sample Application FR = 500 N FA = 1000 N 0.5 m Average Moment Load (T M) Nm 250 Nm STEP 2: CALCULATE COMBINED LOAD ON BEARING Calculating a Combined Load simplifies a complex load scenario into a single value that characterizes the application and can be compared to the Maximum Combined Load (P C_max ) in the ratings table. Follow the steps below to find the Combined Load that characterizes your application. Radial/Moment Load (F RM ): F RM = F R + (C B T M ) F RM = Sample: F RM = 500 N + (23.81 m Nm) = N N + m -1 Nm Radial/Moment Load (F RM) F RM = N Use this table to determine the correct value for X & Y to be used in the Combined Load equation below. F A F RM = N = N IF: X THEN: F A F RM < F A F RM > Y Sample: 1000 N N = So, X = 1 & Y = 0.45 Combined Load (P C ): P C = (X F RM ) + (Y F A ) P C = Sample: P C = ( N) + ( N) = N N STEP 3: VERIFY APPROPRIATE HG SIZE Compare the calculated Combined Load (P C ) value with the Max Combined Load (P C_max ) found in Table 9 to verify whether the selected HG size meets your application load requirements. NOTE: Consult Nexen if application subjects the HG output to significant vibrations or impact loading. + N P C = Combined Load (P C) N Harmonic Gearhead Output Loading 45

46 HG / HGP Efficiency Gearhead efficiency is dependent on many factors, including temperature, speed, torque, and lubrication type. However, the biggest contributor to efficiency loss is running torque, therefore the following calculations focus on your application torque. As is true with any system, efficiency calculations are merely estimations and should be treated as such. STEP 1: CALCULATE THE TORQUE RATIO To find the Torque Ratio, divide your application torque by the maximum average torque. a. Refer to the HG Specifications Table to find max average torque values. b. Determine the torque on which you want to base your efficiency ratings. Application Torque (Tap) Max Torque (Tmax) Sample: 12 Nm Sample: 25 Nm Torque Ratio Torque Ratio: R = Sample: R = = 0.48 T AP R = R = T max STEP 2: FIND THE EFFICIENCY COMPENSATION COEFFICIENT (C E ) Use the graph below to determine the Compensation Coefficient (C E ). a. Mark on the x-axis the Torque Ratio (R) value calculated in Step One. b. Draw a vertical line from this point until it intersects the curve. c. From the intersection point marked on the curve, draw a horizontal line to the y-axis. d. Record the value at this y-axis intersection point as the Compensation Coefficient (C E ). EFFICIENCY COMPENSATION COEFFICIENT GRAPH Harmonic Gearhead Efficiency COMPENSATION COEFFICIENT (CE) TORQUE RATIO (R) Sample Compensation Coefficient STEP 3: CALCULATE EXPECTED APPLICATION EFFICIENCY To find the expected efficiency at your application torque, simply multiply the Efficiency Compensation Coefficient (C E ) by the Efficiency at Max Torque (E T_max ). a. Refer to the HG Specifications table to find the E T_max value and record it in the equation below. C E = Sample: C E = 0.88 Expected Application Efficiency Expected Application Efficiency: E A = C E E T_max E A = % E A = % Sample: E A = % = 70.4% 46

47 Harmonic Gearhead Dimensional Drawings SAMPLE INPUT CONFIGURATION Input can be configured for user servomotor. Contact Nexen. All dimensions shown in mm. Motor Dimensions HG & HGP Input G E K H F A D I J B C Max Shaft Length HG/HGP A B C (max) D E F G H I (h7) J (h7) K Size 17 Ø Ø9.0 M4 x 0.7 (12 holes) Ø86.0 M4 x 0.7 (4 holes) Ø63.0 Ø92.0 Ø Size 25 Ø Ø14.0 M4 x 0.7 (12 holes) Ø107.0 M5 x 0.8 (4 holes) Ø75.0 Ø115.0 Ø Size 32 Ø Ø19.0 M5 x 0.8 (12 holes) Ø138.0 M6 x 1.0 (4 holes) Ø100.0 Ø148.0 Ø Size 50 Ø Ø32.0 M8 x 1.25 (12 holes) Ø212.0 M10 x 1.5 (4 holes) Ø165.0 Ø225.0 Ø OUTPUT CONFIGURATION All dimensions shown in mm. HGP Output HG Output L M R S U Pilot Depth P Q N V W SIZE L M N HGP Ø67.0 HGP Ø84.0 HGP Ø101.0 HGP Ø190.0 HG17 Ø HG25 Ø HG32 Ø HG50 Ø T O (H7) P Q R S T U V (H7) W (h8) M5 x.08 Ø Ø20.0 Ø Holes M6 x 1.0 Ø Ø31.5 Ø Holes M6 x 1.0 Ø Ø40.0 Ø Holes M10 x 1.5 Ø Ø80.0 Ø Holes O Harmonic Gearhead Dimensions 47

48 HG & HGP Life Harmonic Gearhead life is based on average output torque and ratio. Output Torque (Nm) HG/HGP 17 Life Output Revolutions (Million) RATIO 50:1 80:1 100:1 120:1 Output Torque (Nm) HG/HGP 25 Life Output Revolutions (Million) RATIO 50:1 80:1 100:1 120:1 Output Torque (Nm) HG/HGP 32 Life Output Revolutions (Million) RATIO 50:1 80:1 100:1 120:1 Output Torque (Nm) HG/HGP 50 Life Output Revolutions (Million) RATIO 80:1 100:1 120:1 Input Motor Recommendations Allowable Motor Tilting Torque Allowable motor tilting torque is defined as the combination of static and dynamic force acting through the motor's center of gravity, multiplied by the distance (d CG) to the HG motor adaptor mounting face. NOTE: DO NOT subject the input coupling to an overhung load (example: pulley, sheave, etc.). HG(P) Size Torque (Nm) d CG F Harmonic Gearhead Life & Input Motor Input Sealing A gasket seal is positioned between the motor adaptor and the motor pilot to help seal the HG product from external dust and debris. Be sure to use a properly sized servo motor input flange. A servo motor with an oil seal on the output shaft is recommended. NOTE: Consult Nexen in the following situations: a) before using a motor with an interrupted pilot; b) applications in which liquids or excessive dust are present and may ingress into the product. Heat Dissipation To dissipate heat generated by the motor, Nexen recommends mounting the gearhead to a machine frame or heat sink. Refer to the table at the right for aluminum heat sink plate sizes used in testing by Nexen. 48 Heat Sink Surface Area (m 2 ) HG(P)17 HG(P)25 HG(P)32 HG(P)

49 HGP Preloader Pair Nexen s Harmonic Gearhead with our HG Preloader for easy integration into your machine design. Preloaders feature an adjuster that allows the HGP to be moved up or down into the rack while keeping the pinion properly oriented to the rack. Preloader components are made of an alloy steel with a corrosion-resistant nickel finish. High-Precision Ground Surfaces Allows Perpendicular Movement Corrosion Resistant Materials HGP Preloader Customer Machine Frame HGP Preloader Dimensional Drawings HGP17 Product Number Preloader Details M4 X Screws Supplied M4 X Screws Supplied (ø113.70) ø86.00 ø º TYP R8.0 4X Hex 3 mm Wrench Max ( Min) M6 X 1.0 (4X) Shoulder Cap Screws Supplied with Washers Customer-Supplied Mounting Surface see View to Right X 4.3 Gearhead & Pinion Shown for Reference Not Included ø100.0 M6 X 1.0, 13.5 MIN ø8.013 ±.013, Holes Located as Shown ± All dimensions shown in mm. Customer Mounting Surface Details M4 X MIN 2 Holes Located as Shown (2X) (2X) Mounting Surface Harmonic Gearhead Preloader 49