Motion Control Drives FINE CYCLO D-Series Zero Backlash Speed Reducers

Transcription

1 Motion Control Drives FINE CYCLO D-Series Zero Backlash Speed Reducers Catalogue /EN-03/2014

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3 Page D Series 2 1 Principle Structure 3 2 Motor Mounting 3 3 Application Examples 3 4 Overview of Available Sizes 4 5 Speed Ratio & Rotation Direction 4 6 Nomenclature 4 7 Operating Principles 5 8 Ratings 6 9 Engineering Data Main Bearings Selection Details for Assembly and Assembly Tolerances Dimension Drawings 25 Copyright Sumitomo Drive Technologies (SDT) All rights reserved. Copying, including of extracts, is only permitted with our approval. The information in this catalogue has been checked for correctness with extreme care. However, no liability can be accepted for any incorrect or incomplete information. We reserve the right to make modifications.

4 D Series Main bearing (integrated angular ball bearing) Cycloid disc High speed shaft/eccentric Ring gear housing (housing shape F) Output flange Oil seal output side Excellent cost performance Improved design with less material and manufacturing expenditure than other single-stage gearboxes High torque, high bending moment, compact design Maximum permissible peak torque improved by up to 24 %, maximum permissible bending moment improved by up to 45 % (compared with the preceding model). Simple installation Sealed version available. Simple sealing of output possible. High speed shaft mounted in bearings means simplified motor mounting, even without input adapter Simple machine design as a result of the new flange design Design of the output flange with integrated slow speed shaft pin makes for simple fitting. The threaded holes can be varied in their position and number in accordance with the customer's wishes. Hollow shaft bore on the input side in clampring design as standard available In comparison with the preceding model, the overall length of the gearbox has been considerably reduced as a result of the integrated motor adapter, the possible hollow shaft bore has been increased by up to 33 %. Also available as a hollow shaft gearbox with extended high speed shaft. 4

5 1 F4CF-D Principle Structure 2 Motor Mounting Fig. D-1 Ring gear housing (housing shape F) Oil seal High speed shaft (eccentric) Integrated angular ball bearing Input carrier Slow speed shaft roller Ball bearing for high speed shaft Fine Cyclo (F4CF-D) Servo motor Eccentric bearing Output flange Cycloid disc Ring gear pin Motor adapter plate 3 Use and Application Examples Industrial robot Axis drive, robot travel axis Machine tool Pallet changer Tool positioning (Disc magazine and tool changer) Machine tool Automatic pallet changer Palletising robot Factory automation Traverse drive 5

6 4 Overview of Available Sizes Size Available ratios single stage D15 D25 D30 D35 D45 5 Speed Ratio & Rotation Direction Fig. D-2 1 Slow speed shaft Ring gear housing High speed shaft Gearbox Input: High speed shaft Output: Slow speed shaft Fixed: Ring gear housing i=-1/n 2 Gearbox Input: High speed shaft Output: Ring gear housing Fixed: Slow speed shaft i=1/(n+1) 3 Gearbox Input: Slow speed shaft Output: Ring gear housing Fixed: Slow speed shaft i=n/(n+1) Gearbox Input: Slow speed shaft Output: High speed shaft Fixed: Ring gear housing i=-n Speed increaser Input: Ring gear housing Output: High speed shaft Fixed: Slow speed shaft i=n+1 Speed increaser Input: Ring gear housing Output: Slow speed shaft Fixed: High speed shaft i=(n+1)/n 7 When all elements rotate at the same time, the speed ratio consists of a combination of the pictures to. i = Speed ratio = (output speed/input speed) ("-" indicates the possible opposite direction) n = Reduction ratio 6 Nomenclature F 4 C F S D15 59 Reduction ratio single stage Size Standard version: Special specification: S Shape of ring gear housing: Cylindrical (on request) - Flange (standard) F Symbol for Cyclo Integrated angular ball bearing Symbol for Fine 6

7 7 Operating Principles The gearbox of the Fine Cyclo series is fundamentally different in principle and mechanism from the involute gearing mechanism of competitive gear motors. The unique speed reducer portion is an ingenious combination of the following two mechanisms: A planet gear and a fixed internal sun gear (hollow gear). On the Fine Cyclo the planet gear has cycloidal cam motion (cycloid disc) and the fixed sun gear has a circular arrangement of ring gear pins. The fixed sun gear has one or two "teeth" more than the "planet gear" (cycloid disc). An involute gearing for constant speed. Direction of rotation of the planet gear Direction of rotation of the crankshaft Crankshaft axle (Eccentric shaft axle) Planet gear (P) (cycloid disc) Fixed sun gear (S) (hollow gear) Fig. D-3 Principle of the internal planetary gearbox In equation 1, below, P identifies the number of the planet gear teeth, S that of the sun gear, ω2 the angular velocity of the planet gear around its own axis (see Fig. D-3). The speed ratio of ω2 to ω1 is represented as follows: ω2 S Equation 1 = 1- = - ω1 P The highest velocity ratio is obtained with S greater than P by one or two in this equation. That is to say, if S-P=1 is applied to Equation 1, the velocity ratio may be calculated with the following equation: S-P P Angular speed of the planet gear ω2 ω2 Equation 2 = ω1 1 P Angular speed of the crankshaft ω1 Crankshaft (eccentric) Epitrochoidal planet gear (P) Curved spline Fig. D-4 Epitrochoidal planet gear, circular arrangement ring gear pins (PIN) combination Slow speed shaft pin Planet gear (cycloid disc) Eccentricity Double eccentricity Fig. D-5 Involute gearing for constant speed Ring gear pin (with roller) Cycloid disc Eccentricity Double eccentricity If, on the other hand, S-P=2 is applied to Equation 1, the velocity ratio may be calculated with the following equation: ω2 Equation 3 = ω1 2 P As the crankshaft rotates at the angular velocity ω1 around the axis of the sun gear, the planet gear also rotates at the angular velocity: 1ω1 - or - P 2ω1 P P indicates the number of the teeth of the planet gear and the symbol indicates that the planet gear rotates in a reverse direction to that of the crankshaft (eccentric). As shown in Fig. D-4, in the Fine Cyclo the circular teeth (pins) are adapted for the sun gear and the epitrochoid curved teeth for the planet gear, thereby avoiding interference of the splines. The rotation of the planet gear around its own axis is caused through a constant speed internal gearing mechanism (see Fig. D-5). In this mechanism shown in Fig. D-6, the pins of the slow speed shaft are evenly spaced on a circle that is concentric to the axis of the sun gear. The pins transmit the rotation of the planet gear by rolling internally on the circumference of the bores of each planet gear or cycloid disc. The diameter of the bores minus the diameter of the slow speed shaft pins is equal to twice the eccentricity value of the crank shaft (eccentric). This mechanism smoothly transmits only the rotation of the planet gear around its own axis to the slow speed shaft. 2e Slow speed shaft pin (with roller) Fig. D-6 Planet-sun gear combination and involute gearing for constant speed 7

8 8 Ratings 8.1 Selection list nominal torques at n 2 Output speed n Size Reduction ratio Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] D D D D D Table D-1 Rating table (reference value output speed n 2 ) Max. acceleration and Size deceleration torque T 2A Peak torque for Emergency Stop T 2max D D D D D Table D-2 Maximum acceleration and deceleration torque 8

9 Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Nominal output torque Input speed Max. permissible input power [kw] Max. permissible input speed n 1 max short time [min-1] Max. permissible input speed n 1 max 50% ED 100% ED Moment of inertia j related to the high speed shaft [ 10-4 kgm 2 ] Mass [kg] : 50%ED range : 100%ED range 1. Nominal output torque T 2N Nominal output torque corresponds to the max. permissible load torque at all output speeds. The nominal output torque for speeds less than 5 min -1 is equal to the value at 5 min -1. The value for the maximum permissible input power is calculated from the nominal output torque at 100%. This value takes the efficiency of Fine Cyclo into consideration. 2. n 1max = maximum permissible input speed Gearbox can be used within maximum input speed indicated in the table, however, the max. permissible mean input speed is limited by the load time ratio (%ED). 3. T 2A = max. acceleration and braking torque (for fatigue strength at 2x 10 7 load cycles) Permissible peak torque at normal start and stop procedures. 4. T 2max = max. permissible torque for EMERGENCY STOP situations or in the event of severe impacts (limited by the mechanical strength). (permissible 1000x over the entire lifetime) 5. The nominal torque T 2N is calculated using the following formula when the speed is not shown in the table above: T 2N = T 2N,15 ( ) n 2 T 2N : Rated torque at output speed n 2 T 2N,15 : Rated torque at output speed n 2 is 15 min -1 9

10 8.2 Selection list nominal torques at n 1 Input speed n Size Reduction ratio Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] D D D D D Table D-3 Rating table (reference value input speed n 1 ) Max. acceleration and Size deceleration torque T 2A Peak torque for Emergency Stop T 2max D D D D D Table D-2 Maximum acceleration and deceleration torque 10

11 Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Nominal output torque Output speed Max. permissible input power [kw] Max. permissible input speed n 1 max short time [min-1] Max. permissible input speed n 1 max 50% ED 100% ED Moment of inertia j related to the high speed shaft [ 10-4 kgm 2 ] Mass [kg] : 50%ED range : 100%ED range 1. Nominal output torque T 2N Nominal output torque corresponds to the max. permissible load torque at all input speeds. The nominal output torque for speeds less than 600 min -1 is equal to the value at 600 min -1. The value for the maximum permissible input power is calculated from the nominal output torque at 100%. This value takes the efficiency of Fine Cyclo into consideration. 2. n 1max = maximum permissible input speed Gearbox can be used within maximum input speed indicated in the table, however, the max. permissible mean input speed is limited by the load time ratio (%ED). 3. T 2A = max. acceleration and braking torque (for fatigue strength at 2x 10 7 load cycles) Permissible peak torque at normal start and stop procedures. 4. T 2max = max. permissible torque for EMERGENCY STOP situations or in the event of severe impacts (limited by the mechanical strength). (permissible 1000x over the entire lifetime) 5. The nominal torque T 2N is calculated using the following formula when the speed is not shown in the table above: T 2N = T 2N,1750 ( ) n 1 T 2N : Rated torque at input speed n 1 T 2N, 1750 : Rated torque at input speed n 1 is 1750 min -1 11

12 9 Engineering Data 9.1 Stiffness and Lost Motion Hysteresis curve: Lost Motion: Stiffness: If a torque is introduced in the slow speed shaft, with the high speed shaft at a standstill, the interaction between the distorsion angle and the torque can be read off on the following hysteresis curve (Fig. D-7). Distorsion angle at 3% of maximum permissible rated torque. Inclination of a straight line connecting two points on the hysteresis curve. The table value indicates the average torsional stiffness between 50 % and 100 % of the rated output torque. Note arcmin signifies one "minute arc". Table values of the stiffness are average values. Example: Calculation of the distorsion angle on size F4CF-D % Lost Motion -50% Distorsion angle φ [arcmin] a b 50% c d 100% 1) When torque is 15 Nm (less than the test torque of Lost Motion) φ = 15 1 = arcmin ) When torque is 600 Nm (greater than the test torque of Lost Motion) -3% +3% Torque T 2N,15 Torsional stiffness 3~50% : a/b 50~100% : c/d 3~100% : (a+c)/(b+d) φ = + = 3.12 arcmin Fig. D-7 Hysteresis curve Distorsion angle at ±3 % of T 2N.15 Size i T 2N.15 Test torque (±) Lost Motion Lost Motion [arcmin] D D D < D D Table D-4 Stiffness T 2N,15 : Rated output torque at an output speed n 2 = 15 min -1 Torsional stiffness [Nm/arcmin] 3% - 50% T 2N Torsional stiffness [Nm/arcmin] 3% - 100% T 2N Torsional stiffness [Nm/arcmin] 50% - 100% T 2N

13 9.2 No-Load Running Torque NLRT The no-load running torque indicates the torque on the high speed shaft without load torque. The quoted values apply to indicated standard designs in the clamping ring design from Item Note 1. Fig. D-8 shows the average no-load running torque after gearbox input. 2. Table D- 5 shows the measuring conditions Input torque Nm 2 Ring gear housing temperature Approx. 30 C Precision in assembly In accordance with 12.1 Lubrication Standard grease Table D-5 Measuring conditions 0,2 Fig. D-8 Input speed min Breakaway torque Indicates the necessary torque for breakaway of the gearbox on the input or output side, after stop without output side load. Breakaway torque on output side (BTO) Note 1. Table D-7 shows max. breakaway torque on the output side BTO. 2. Table D-6 shows the measuring conditions Precision in assembly In accordance with 12.1 Lubrication Standard grease Table D-6 Measuring conditions Size Breakaway torque BTO D15 70 D D D D Table D-7 Value of the breakaway torque on the output side (BTO) Breakaway torque on input side (BTI) Note 1. Table D-8 shows the max. breakaway torque BTI on the input side 2. Table D-6 shows the measuring conditions Size i Breakaway torque BTI D D D D D Table D-8 Value of breakaway torque on the input side (BTI) 13

14 9.4 Efficiency Efficiency varies by input speed, speed, load torque, grease temperature, gearbox size, reduction ratio, etc. Fig. D-9 indicates a comparison between efficiency and input speed at maximum permissible output torque with stable grease temperature. Variations in models and different reduction ratios are taken into account in the efficiency curve. Compensation efficiency = efficiency (Fig. D-9) x compensation factor for efficiency (Fig. D-10) Note 1. The efficiency changes if the load torque does not match the rated torque. Check the compensation factor in the diagram Fig. D-9 2. When the torque ratio is over 1.0, the compensation factor for efficiency is 1.0 (diagram Fig. D-10). 100 Efficiency % Compensation factor 1,0 0, ,8 0 0,5 1,0 Fig. D-9 Efficiency curve Input speed min -1 Torque ratio Fig. D-10 Compensation curve for efficiency Torque ratio (load torque/rated output torque) 9.5 Maximum permissible radial and axial load on the high speed shaft If the high speed shaft is fitted with a pinion or a disc, axial and radial forces act on the high speed shaft. The following formula is used to check whether the shaft load is permissible: F R1 = input side radial load 1. Input side radial load F R1 T 1V = equivalent torque on high speed shaft T F = 2 x 1V F d 0 = pitch circle diameter of sprocket, pinion 103 R1 x R1 max [N] d (Formula D-1) 0 L f1 x C f1 x B F R1 max = maximum permissible input side radial load f1 F A1 = input side axial load 2. Input side axial load F F A1 A1 max = maximum permissible input side axial load L f1 = load factor input (Table D-11) F A1 max F A1 = [N] C C (Formula D-2) f1 = correction factor input (Table D-12) f1 x B f1 B f1 = service factor input (Table D-13) L = distance of radial force from input side 3. When radial and axial load coexist carrier on gearboxes without motor adapter (Table D-11) F R1 x L f1 F A1 ( + ) x C f1 x B f1 1 (Formula D-3) F R1 max F A1 max 14

15 Size Input speed (input side radial load [N]) D D D D D Table D-9 Max. permissible input side radial load F R1 max Size Input speed (input side axial load [N]) D D D D D Table D-10 Max. permissible input side axial load F A1 max Calculation of the max. permissible radial load on the high speed shaft Calculation of the max. permissible radial load using the following formula when the speed is not shown in the table mentioned above F R1 max = F R1,1750 ( ) 1/3 Calculation of the max. permissible axial load on the high speed shaft Calculation of the max. permissible axial load using the following formula when the speed is not shown in the table mentioned above n 1 F A1 max = F A1,1750 ( ) 0.47 n 1 F R1 max F R1,1750 = maximum permissible input side radial load at input speed n 1 = Input side radial load at input speed n 1 = 1750 min -1 F A1 max F A1,1750 = maximum permissible input side axial load at input speed n 1 = input side axial load at input speed n 1 = 1750 min -1 L [mm] Load factor input L f1 Size D15 D25 D30 D35 D L f1 = 1 when L = L 1 =[mm] a Table D-11 L = distance from input side Carrier a = correction factor Correction factor input C f1 Chain 1 Pinion or gear 1.25 Timing belt 1.25 V-Belt 1.5 Table D-12 Load conditions input B f1 Practically no shock 1 Slight shocks Heavy shocks Table D-13 The following applies for intermediate values: L L 1 : L f1 = L /L 1 L < L 1 : L f1 = 1 - a / 5 (L 1 - L) Input side carrier Fig. D-11 15

16 10 Main Bearings Size Values of internal bearing distance l 1 [mm] a [mm] D D D D D Table D-14 Bearing distance dimensions (mm) Size Moment stiffness Θ 1 [Nm/arcmin] D D D D D Table D-15 Moment stiffness average values Fig. D-12 Distance between the individual load points l r = x - a + l 1 Correction factor output C f2 Chain 1 Pinion or gear 1.25 Timing belt 1.25 V-Belt 1.5 Table D-16 Note If: l r > 4 l 1 please contact Sumitomo Drive Technologies (SDT). Service factor output B f2 Uniform load (no shock) 1 Moderate shocks Heavy shocks Table D-17 Size Max. bending moment Tk max Max. permissible output side axial load F A2 max [N] D D D D D Table D-18 Maximum bending moment and max. permissible output side axial load Equivalent axial load F A2e (2670, 10791) D (2943, 8840) (1918, 7848) D35 D30 (1962, 7471) D15 D Equivalent bending moment T ke at output Fig. D-13 Diagram max. permissible bending moment and axial load 16

17 1. Moment stiffness The moment stiffness is the bending moment at which the output flange is tilted by the tilt angle. The tilt angle of the input flange is determined as follows: φ 1 = Θ 1 / T k (Formula D-4) 2. Max. permissible bending moment and max. permissible axial load Check the external bending moment and the external axial load using the Formulae D-5a, D-5b, D-6 and the Fig. D-13. External bending moment T k T k = F R2 x l r + F A2 x l a < T kmax Equivalent bending moment T ke at output (Formula D-5a) T ke = C f2 x B f2 x F R2 x l r +C f2 x B f2 x F A2 x l a < T kmax (Formula D-5b) F A2 = output side axial load F A2 max = maximum permissible output side axial load F A2e F R2 C f2 B f2 l 1 l r l a x a T k = equivalent output side axial load = output side radial load = correction factor output (Table D-16) = service factor output (Table D-17) = bearing distance dimension (Table D-14) = calculated dimension for bending moment = distance of axial load = distance of radial force to flange collar = correction dimension (Table D-14) = external bending moment T k max = maximum bending moment (Table D-18) T ke φ 1 Θ 1 = equivalent bending moment = bending angle = moment stiffness main bearing (Table D-15) Equivalent axial load F A2e at the slow speed shaft F A2e = F A2 x C f2 x B f2 < F A2 max (Formula D-6) 17

18 11 Selection Flow Chart and Formula of Selection Calculation of the load characteristic Output torque Input speed Calculation of the mean input speed (n 1m ) Calculation of the mean equivalent torque (T 2V ) Calculation of the permissible rated output torque at mean input speed (T 2n,n1m ) Selection table (Table D-1 or D-3) Fig. D-14 Working cycle n 1A : Mean input speed during acceleration n 1A = n 1R as per Fig. D-14 2 n 1R : Input speed during uniform movement T 2V T 2N Preliminary selection of size NO (Select larger size or reduce the calculated equivalent torque T 2V.) n 1B : Mean input speed during braking as per Fig. D-14 n 1m : Mean input speed t : Time [sec] n 1B = n 1R 2 Radial load at slow speed shaft Axial load at slow speed shaft Bending moment Check Input speed n 1 check t A : Acceleration time [sec] t R t B : Duration of uniform movement [sec] NO : Deceleration time [sec] t m : Duration of the movement phase of a working cycle [sec] NO Current radial load, Max. permissible t p : Duration of pauses [sec] axial load or bending radial load, axial load or moment bending moment t : Duration of a working cycle [sec] Maximum input speed (Table D-1 or D-3) Max. permissible input speed n 1max T 2A : Acceleration torque T 2R : Friction torque T 2B : Output side braking torque T 2V : Equivalent output torque (Table D-18, Formulae D-6, D-4, D-5a, D-5b) Calculation in % T 2N : Rated output torque T 2N max : Maximum permissible rated output torque NO Mean input speed Max. permissible input speed at ED % T 2N 600 : Rated output torque at n min -1 B f2 : Service factor output (Table D-1 or D-3) ED : Load time ratio % 18

19 Calculation in load condition in accordance with Fig. D-14 Mean input speed Equivalent output torque Max. permissible rated output torque at mean input speed ED % n 1m = ( t A x n 1A + t R x n 1R + t B x n 1B t m ) T 2V = ( t ) 1/3 A x n 1A x T 3 2A + t R x n 1R x T 3 3 2R + t B x n 1B x T 2B x B t f2 m x n 1m T 2N max = T 600 2N,600 ( ) 0.3 n 1m ED % = ( t m ) x100 [%] = t - t t ( p ) t x100 [%] (Formula D-8) (Formula D-9) (Formula D-10) (Formula D-11) T 2N,600 : Rated output torque at input speed 600 min -1 (Table D-3) If n 1m < 600 min -1 the value in the table at input speed of 600 min -1 applies for T 2N. When calculating the percentage load time ratio the max. duration of a working cycle is Σt = 10 minutes. If Σt exceeds 10 minutes please contact Sumitomo Drive Technologies (SDT). Service factor output B f2 Uniform load 1 Moderate shock Heavy shock Table D-19 Check peak torque T 2A and T 2B during acceleration and braking Check radial load F R1 on high speed shaft Peak torque Max. permissible peak during acceleration and torque at acceleration braking and braking (Table D-2) Emergency stop torque T 2max NO Input side radial load F R1 Max. permissible radial load F R1max (Table D-9, Formula D-1) NO Emergency stop torque Max. permissible peak torque for emergency stop NO (Table D-2) Size selection* End * When selecting the motor, the input side breakaway torque (BTI) or no-load running torque (NLRT) in accordance with 9.2 and 9.3 must be taken into account. 19

20 11.2 Selection example Calculation example for Type F4CF-D for following specification: T 2A = output side acceleration torque 600 Nm T 2R = friction torque 250 Nm T 2B = output side braking torque 400 Nm T 2 max = EMERGENCY STOP torque 700 Nm (1000x over the entire lifetime) n 1A = mean input speed during acceleration 1250 min -1 n 1R = input speed during uniform movement 2500 min -1 n 1B = mean input speed during deceleration or braking 1250 min -1 t A = acceleration time 0.3 sec t R = duration of the same shape movement 3.0 sec t B = deceleration time 0.3 sec t m = duration of the movement phase of a working cycle 3.6 sec t p = duration of pauses 3.6 sec t = duration of working cycle 7.2 sec F R1 = radial load on high speed shaft Driven by toothed belt, slight shocks, F R1 = 196 N, with force application point 25 mm F R2 = radial load on the slow speed shaft Connection with pinion, moderate shocks, F R2 = 4116 N, 55 mm from the side of the flange It was considered that the gearbox for operating a robot linkage is employed with moderate shocks (B f2 = 1). Mean input speed n 1m = ( 0.3 x x x 1250 ) Calculation of ED % ED % = ( ) 3.6 x 100 = 50% = 2292 min-1 Equivalent output torque T 2V = ( 0.3 x 1250 x x 2500 x x 1250 x ) 1/3 x 1 = 300 Nm 3.6 x 2292 Max. permissible output torque at mean input speed T 2N = ( ) 0.3 x 487 = 326 Nm 300 Nm Type F4CF-D

21 Testing the maximum input speed n 1 = 2500 min -1 < n 1 max = 5050 min -1 (Table D-1 or D-3) Checking the mean input speed n 1m = 2292 min -1 at 50% ED < n 1m max = 4200 min -1 at 50% ED (Table D-1 or D-3) Checking the peak torque during acceleration and braking T 2A = 600 Nm < 883 Nm (Table D-2) Checking the emergency stop torque T 2 max = 1700 Nm < 1766 Nm (Table D-2) Max. permissible radial load on high speed shaft when considering the correction factors F R1 max 1750 = F R1,1750 ( ) 1/3 = 441 ( ) 1/3 = 403 N n F R1 max 403 F R1 = = = 215 N > 196 N L f1 x C f1 x B f x 1.25 x 1.2 Checking the max. perm. bending moment T k l r = x - a + l 1 = = mm Calculated dimension for bending moment l r External bending moment calculated with correction factors C f2 = 1.25, B f2 = 1.2, T k = C f2 B f2 F R2 l r < T k max T k = x 10-3 T k = 1084 Nm < 1177 Nm Selection/result Type F4CF-D was selected by using the above evaluation. 21

22 12 Details for Assembly and Assembly Tolerances 12.1 Mounting Fittings for mounting input parts (motor adapter plate or machine housing) are shown as C in the following figure. Use fitting A for the output side machine housing assembly, fitting B for the slow speed shaft on the machine. Example for Assembly 1 Example for Assembly 2 Slow speed shaft on machine Casing of machine Slow speed shaft on Motor machine Casing of machine Motor Motor adapter plate Fig. D-15 Method of assembly A Øe Øf Centre of rotation Ød Fig. D-16 Precision in assembly dimensions Øg A Centreline of motor shaft Size Ø d Ø e Ø f Ø g D H7/h7 47 H7/h7 123 H7/h D H7/h7 80 H7/h7 145 H7/h D H7/h7 100 H7/h7 160 H7/h D H7/h7 75 H7/h7 174 H7/h D H7/h7 100 H7/h7 220 H7/h Table D-20 The recommended concentricity g for fastening parts should correspond to the details in Table D-20 or be less. Spigots are "d," "e," and "f" in Table D-20 22

23 12.2 Tightening Torque and Allowable Transmitted Torque for Bolts The permissible transmitted torque for bolts, the number, size and tightening torque for fixing the output side flange and the ring gear housing and the maximum permissible emergency stop torque are listed in Table D-21. Output flange bolts Ring gear housing Max. permissible transmitted Size Number and Tightening torque Number and Tightening torque torque for bolts* size of bolts Nm size of bolts Nm Nm D15 12 x M x M D25 12 x M x M D30 16 x M x M D35 12 x M x M D45 16 x M x M Table D-21 *Friction factor 0.15 Bolt: Use metric hexagon socket head cap screws (DIN 4762, strength grade 12.9). Countermeasure for bolts loosening: Use adhesives (Loctite 262, etc.) or spring washer (DIN 127A). Use springwashers (DIN 6796) when connecting the gearbox to the flange side, so that the bolt contact faces do not get damaged. 23

24 12.3 Assembly notes 1 High speed shaft Oil seal Casing of machine Example for assembly 1 The D Series gearbox must be fixed to the machine casing with bolts according to Table D-21 (spigot C). Motor adaptor is a part of the machine casing in this example. Please bear this in mind! The gearbox is sealed with an oil seal and O-ring on spigot C between the machine casing and the high speed shaft. The oil seal is not part of our standard supply if the delivery does not include the motor adapter (assembly example 2). 2 Casing of machine Motor The alignment of the central axis of the motor (motor shaft) and the gearbox drive shaft (gearbox axis) must coincide (see Table D-20 for tolerances). Attach motor to machine casing with bolts. Apply anti-corrosive to motor shaft before assembly in order to avoid fretting corrosion! Motor shaft 3 Slow speed shaft on machine Output flange Fix the output flange of the FINE CYCLO gearbox to the machine slow speed shaft with bolts (spigot B). Please note! If the FINE CYCLO gearbox is not sealed on the output side as standard, use liquid seals on the flat face of the output flange. Liquid sealing material, washers for the bolts and the fastening bolts are to be provided and fitted by the customer. Flat surface output flange Machine casing Note! 1. Make sure to apply specified tightening torque (refer to Table D-21) to bolts when attaching the gearbox. 2. Use bolts that are shorter than the threaded holes in the dimension drawing for the output flange. 3. Recommended liquid gasket: Three Bond 1215 by Three Bond Co., Ltd. 24

25 1 O-ring recess Oil seal Example for assembly 2 The D Series gearbox must be fixed to the machine casing with bolts according to Table D-21 (spigot A). If attaching motor adapter plate, bolt together with gearbox. The gearbox must be sealed with an oil seal and O-ring on spigot C between the motor adapter plate and the high speed shaft. The oil seal is not part of our standard supply if the delivery does not include the motor adapter (assembly example 2). Motor adapter plate Casing of machine 2 Motor The alignment of the central axis of the motor (motor shaft) and the gearbox drive shaft (gearbox axis) must coincide (see Table D-20 for tolerances). Attach motor to motor adapter plate with bolts. Apply anti-corrosive to motor shaft before assembly in order to avoid fretting corrosion! 3 Output flange Slow speed shaft on machine Fix the output flange of the FINE CYCLO gearbox to the machine slow speed shaft with bolts (spigot B). Please note! If the FINE CYCLO gearbox is not sealed on the output side as standard, use liquid seals on the flat face of the output flange. Liquid sealing material, washers for the bolts and the fastening bolts are to be provided and fitted by the customer. Flat surface output flange Note! 1. Make sure to apply specified tightening torque (refer to Table D-21) to bolts when attaching the gearbox. 2. Use bolts that are shorter than the threaded holes in the dimension drawing for the output flange. 3. Recommended liquid gasket: Three Bond 1215 by Three Bond Co., Ltd. 25

26 12.4 Lubrication Vertical 1 High speed shaft Grease level Lubrication port On gearboxes that are not sealed the delivery does not include lubricant (grease filling). Customer therefore must prepare and fill appropriate amount (Table D-23) of recommended grease (Table D-22). Use the number quoted in Table D-23 as an approximate value, check the grease level. Align the grease filler holes and the grease drain on the output side. (See "A" in Fig. D-17 and Table D-23) When filling grease for the first time use the bottom hole in order to ensure grease circulation. The grease must be replaced after 20,000 operating hours or every 3-5 years. Regreasing the D gearbox can extend the lifetime of the gearbox. Lubrication port Vertical 2 Lubrication port Recommendation Multemp FZ No. 00 Supplier Kyodo Yushi Co., Ltd. Table D-22 Recommended grease for D Series Ambient temperature: C Horizontal Lubrication port Size Vertical Quantity of grease [g] Vertical Horizontal Distance grease filler hole A [mm] D D D D D Table D-23 (if delivery does not include grease filling) Lubrication port A Grease level Grease level Lubrication port Fig. D-17 26

27 13. Dimension drawings 13.1 Input schematic Evolvent spline Solid shaft Hollow shaft Keyway connection Clamp connection Specification of the high speed shaft geometry The D Series gearboxes are defined as clamp connection in the standard version. Standardised motor dimensions can be found on the dimension sheets of the gearbox with defined input design. As an option, it is possible to supply the type of connection as a hollow shaft with a keyway, evolvent internal spline, solid shaft or as a hollow shaft. For connection methods that differ from standard please consult Sumitomo Drive Technologies (SDT). 27

28 Ø157 Fine Cyclo D Series 13.2 Gearbox without defined input design F4CF-D for O-Ring AS x Ø6.6 M Locking screw R1/8" 2x Ø135 Ø124 h7 90Ø Ø47 h7 Ø max. Ø15 Ø89 Ø ,05 +0,00 Ø Ø123 h7 Ø130 1x Ø 8 Ø145 Design (71.5) 9 1 Maximum diameter of high speed hollow shaft Keyway Ø14 (keyway acc. to DIN 6885 page 1) Clamp ring Ø19 or full-length hollow shaft 15 mm Type with keyway, clamp ring or splined shaft Note 30 16x M8 M Ø68 2x M6 for dismantling Weight: 5kg - without high speed shaft For specifications of the high speed shaft please refer to Sumitomo Drive Technologies (SDT). F4CF-D for O-Ring AS x Ø6,6 M Locking screw R1/8" 2x 180 2x M6 for dismantling Ø169 Ø145 h7 Ø114 Ø113 h7 Ø80 Ø max. Ø22 Ø110 Ø125 Ø142 Ø Ø x30 Design (81.5) Maximum diameter of high speed hollow shaft Keyway Ø19 (keyway acc. to DIN 6885 page 1) Clamp ring Ø24 or full-length hollow shaft 22 mm Type with keyway, clamp ring or splined shaft Note 30 16x M8 M Ø95 Weight: 8kg - without high speed shaft For specifications of the high speed shaft please refer to Sumitomo Drive Technologies (SDT). 28

29 Ø175 Fine Cyclo D Series F4CF-D for O-Ring AS x Ø6,6 M Locking screw R1/8" 2x 180 2x M6 for dismantling Ø187 Ø163 h7 Ø139 Ø100 h7 Ø92 max. Ø30 Ø128 Ø Ø160 Ø 1x Ø Design (94.5) Maximum diameter of high speed hollow shaft Keyway Ø24 (keyway acc. to DIN 6885 page 1) Clamp ring Ø32 or full-length hollow shaft Ø 30 mm Type with keyway, clamp ring or splined shaft Note x M8 M Ø125 Weight: 11kg - without high speed shaft For specifications of the high speed shaft please refer to Sumitomo Drive Technologies (SDT). F4CF-D , for O-Ring AS x Ø9 M Locking screw R1/8" 2x 180 2x M8 for dismantling Ø190 Ø204 Ø174 h7 Ø140 Ø75 h7 Ø max.ø32 Ø137 Ø Ø174 h7 Ø 1x30 5 Ø Design 7 62 (90) Maximum diameter of high speed hollow shaft 21 Type with keyway, clamp ring or splined shaft Keyway Ø32 (keyway acc. to DIN 6885 page 1) Clamp ring Ø35 or full-length hollow shaft Ø 32 mm Note 30 12x M10 M Ø115 Weight: 15kg - without high speed shaft For specifications of the high speed shaft please refer to Sumitomo Drive Technologies (SDT). 29

30 F4CF-D for O-Ring AS x Ø11 M Locking screw R1/8" 2x 180 2x M10 for dismantling Ø238 Ø256 Ø220 h7 Ø174 Ø100 h7 Ø max. Ø45 Ø169 Ø Ø220 h7 Ø 1x30 5 Ø Design (102) Maximum diameter of high speed hollow shaft Keyway Ø38 (keyway acc. to DIN 6885 page 1) Clamp ring Ø38 or full-length hollow shaft Ø 45 mm 22 Type with keyway, clamp ring or splined shaft Note x M12 M Ø140 Weight: 24kg - without high speed shaft For specifications of the high speed shaft please refer to Sumitomo Drive Technologies (SDT). 30

31 13.3 Gearbox with defined input design F4CF-D15 Clamp ring design Locking cap x s1 x1 deep (90 + k1) k x Ø6.6 M Locking screw R1/8" 2x 180 Ø135 Øe1 q1 i1 Ø124 h7 Ø90 Ø47 h7 4 Ø123 Ø147 h7 Ø120 Ød1 F7 Øb1 F7 Øa1 f1 A A Ø68 14* Sketched clamp connection DIN M 5* Tightening torque 5.5Nm* (M 8 ) 15 A-A (s1) Ø x M8 M (x1) Observe mounting position of clamp ring. (Grooves one above the other) The high speed hollow shaft and motor shaft must be free from grease. T1max. clamp ring = q2 Nm T2max. Gearbox = 834 Nm * With clamp diameter Ø19 - Bolt M6-8.8 Distance clamp ring 17 Tightening torque 9.5 Nm Motor mounting dimensions F4CF-D15 Hole for shaft Reducing bush Spigot F7 Ø Spigot seat depth Pitch circle Ø Thread in gearbox flange Thread depth Motor flange Diameter Width Shaft recess Position dimension Clamp ring Transmitted torque clamp ring Ød1 b1 f1 e1 4x s1 x1 Øa1 k1 i1 q1 q2 mm mm mm Nm kg Weight Flange code Ø11 Ø14 o M E11G M E30G M H10G M H11G M H12G M H18G M H24G M H25G M H30G M / H50G Ø M M17G M M30G Note Other mounting dimensions available on request. Please consult Sumitomo Drive Technologies (SDT). 31

32 F4CF-D25 Clamp ring design Locking cap x s1 x1 deep 8 ( k1) k1 Ø157 16x Ø6.6 M Locking screw R1/8" 2x 180 Øe1 q1 B Ø145 h7 Ø114 Ø113 h7 Ø Ø144.5 Ø169 Ø169 h7 Ø145 i1 Ød1 F7 Øb1 F7 Øa1 A A B Ø95 17 Sketched clamp connection DIN M Tightening torque 9.5Nm (M 8 ) 13 (Ø 6.6 ) B-B (36) A-A f1 (s1) 30 16x M8 M (x1) Observe mounting position of clamp ring. (Grooves one above the other) The high speed hollow shaft and motor shaft must be free from grease. T1max. clamp ring = q2 Nm T2max. Gearbox = 1766 Nm Motor connection dimensions* F4CF-D25 Hole for shaft Reducing bush Spigot F7 Ø Spigot seat depth Pitch circle Ø Thread in gearbox flange Thread depth Motor flange Diameter Width Shaft recess Position dimension Clamp ring Transmitted torque clamp ring Ød1 b1 f1 e1 4x s1 x1 Øa1 k1 i1 q1 q2 mm mm mm Nm kg Weight Flange code Ø10 o M D30G Ø M H10G M H11G M H25G M H30L Ø16 o M J30G Ø19 o M M17G M M18G M M30G M M35G M / M60L Ø Z--- Note Other mounting dimensions available on request. Please consult Sumitomo Drive Technologies (SDT). 32

33 F4CF-D30 Clamp ring design Locking cap x s1 x1 deep ( k1) k1 10 Ø175 16x Ø6,6 M Locking screw R1/8" 2x 180 Øe1 q1 i1 Ø163 h7 Ø139 Ø100 h7 Ø Ø162.5 Ø187 Ø187 h7 Ø160 Ød1 F7 Øb1 F7 Øa1 A A 21 f Ø125 Sketched clamp connection DIN M Tightening torque 23Nm 15 A-A (s1) 16x M8 M (M 8 ) 10.5 Observe mounting position of clamp ring. (Grooves one above the other) The high speed hollow shaft and motor shaft must be free from grease. T1max. clamp ring = q2 Nm T2max. Gearbox = 2453 Nm (Ø6.6) (x1) Motor connection dimensions* F4CF-D30 Hole for shaft Reducing bush Spigot F7 Ø Spigot seat depth Pitch circle Ø Thread in gearbox flange Thread depth Motor flange Diameter Width Shaft recess Position dimension Clamp ring Transmitted torque clamp ring Ød1 b1 f1 e1 4x s1 x1 Øa1 k1 i1 q1 q2 mm mm mm Nm kg Weight Flange code Ø19 Ø22 o M M35G M M50G M M60G M N60G M N60L Ø M Z45L M Z50G M Z64G Note Other mounting dimensions available on request. Please consult Sumitomo Drive Technologies (SDT). 33

34 F4CF-D35 Clamp ring design Locking cap x s1 x1 deep 7 (109 + k1) k x Ø9 M Locking screw R1/8" 2x 180 Øe1 Ø174 h7 Ø140 Ø75 h7 5 Ø173.5 Ø204 Ø209 h7 Ø174 q1 i1 Ød1 F7 Øb1 F7 Øa1 Ø190 A A B B f1 Ø B-B 30 Sketched clamp connection DIN M Tightening torque 46Nm (M 10 ) 17 (Ø9) (40) A-A (s1) 12x M10 M (x1) Observe mounting position of clamp ring. (Grooves one above the other) The high speed hollow shaft and motor shaft must be free from grease. 20 T1max. clamp ring = q2 Nm T2max. Gearbox = 3581 Nm Motor connection dimensions* F4CF-D35 Hole for shaft Reducing bush Spigot F7 Ø Spigot seat depth Pitch circle Ø Thread in gearbox flange Thread depth Motor flange Diameter Width Shaft recess Position dimension Clamp ring Transmitted torque clamp ring Ød1 b1 f1 e1 4x s1 x1 Øa1 k1 i1 q1 q2 mm mm mm Nm kg Weight Flange code Ø M M30G M M35G M M60G M M60L Ø22 o M N60G Ø M Z50G M Z60G M Z70G Ø M S70G Note Other mounting dimensions available on request. Please consult Sumitomo Drive Technologies (SDT). 34

35 F4CF-D45 Clamp ring design Locking cap 90 4x s1 x1 deep 45 (122 + K1) k1 16x Ø11 M Locking screw R1/8" 2x 180 Ø238 Øe1 q1 i1 Ø220 h7 Ø174 Ø100 h7 5 Ø219 Ø256 Ø259 h7 Ø220 Ød1 F7 f1 Øb1 F7 Øa1 A A Ø Sketched clamp connection DIN M Tightening torque 117Nm M12 18 A-A (s1) 16x M12 M (x1) Observe mounting position of clamp ring. (Grooves one above the other) The high speed hollow shaft and motor shaft must be free from grease. T1max. clamp ring = q2 Nm T2max. Gearbox = 6377 Nm (Ø11) Motor connection dimensions* F4CF-D45 Hole for shaft Reducing bush Spigot F7 Ø Spigot seat depth Pitch circle Ø Thread in gearbox flange Thread depth Motor flange Diameter Width Shaft recess Position dimension Clamp ring Transmitted torque clamp ring Ød1 b1 f1 e1 4x s1 x1 Øa1 k1 i1 q1 q2 mm mm mm Nm kg Weight Flange code Ø19 Ø M M35G M M45G M M60L M Z50G M Z70G Ø28 o M Q60G M Q76L Ø M S70G M S88G Ø35 o M T76G Ø M U60G M U80G Note Other mounting dimensions available on request. Please consult Sumitomo Drive Technologies (SDT). 35

36 Worldwide locations World Headquarters JAPAN Sumitomo Heavy Industries Ltd. PTC Group Think Park Tower, 1-1, Osaki 2-chome, Shinagawa-ku, Tokyo Headquarters & Manufacturing USA Sumitomo Drive Technologies Sumitomo Machinery Corp. of America 4200 Holland Boulevard Chesapeake, VA Headquarters & Manufacturing EUROPE Germany Sumitomo (SHI) Cyclo Drive Germany GmbH European Headquarters Cyclostraße Markt Indersdorf Germany Tel Fax Subsidiaries & Sales Offices in Europe Austria Sales Office Austria Gruentalerstraße 30 A 4020 Linz Austria Tel Fax Benelux Sales Office Benelux Fazantenlaan Kessel-Lo/ Leuven Belgium Tel Fax Spain SM-Cyclo Iberia, S.L.U. Edificio Gobelas C/Landabarri Nº 3, 6º B Leioa-Vizcaya Spain Tel Fax Sweden SM-Cyclo Scandinavia AB Industrigatan 21B Lomma Sweden Tel France SM-Cyclo France S.A.S. 8 Avenue Christian Doppler Serris France Tél Fax Italy SM-Cyclo Italy S.R.L Via dell Artigianato Cornaredo (MI) Italy Tel Fax Sumitomo (SHI) Cyclo Drive Germany GmbH Turkey SM-Cyclo Turkey Güç Aktarim Sis. Tic. Ltd. Büyükdere Çayırbası Cd. Dede Yusuf Sk. No: Sarıyer Istanbul Istanbul Turkey Tel/Fax United Kingdom SM-Cyclo UK, Ltd. Unit 29, Bergen Way, Sutton Fields Industrial Estate Kingston upon Hull HU7 0YQ, East Yorkshire United Kingdom Tel Fax