4 Project Planning for Drives

Transcription

1 Additional documentation Project Planning for Drives.1 Additional documentation In addition to the information in this catalog, SEWEURODRIVE offers extensive documentation covering the entire topic of electrical drive engineering. This is primarily documentation from the "Drive Engineering Practical Implementation" series. You can order the current documentation from SEWEURODRIVE. The documentation can also be downloaded in PDF format from the SEW homepage ( Drive Engineering Practical Implementation The publication "Drive Engineering Practical Implementation Drive Arrangements with SEW Gear Units" features extensive information on characteristics, different features and application areas of SEW drives. A comprehensive collection and assignment of the most important formulae for drive calculation as well as detailed examples for the most frequently used applications make this documentation an important tool for project planning and an essential addition to SEWEURODRIVE product catalogs. Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 33

2 .2 The following flow diagram illustrates the process for the project planning of a series X industrial gear unit. Query Step 1 Fill out the drive selection sheet Step 2 Calculate the basic data M, n, P, i, K2 2 K2 Step 3 Select the application factors F smin,, F F start Step Calculate the required gear unit nominal torque MN2min Step 5 Select the gear unit size M N2 Step 6 Calculate the required motor power P M Step 7 Check the peak load conditions M K2 max < M K2 per Step 8 Calculate the thermal rating P T = P x TH f 1 Step 9 Check the thermal rating P K1 < P T Step 10 Check the external additional forces F R2, F R1, F A1, FA2 Step 11 Select the optional equipment (if required), e.g. Oil drain valve Alternative sealing system Motor connection (e.g. motor adapter) Connection for auxiliary drive Status monitoring Drive package for conveyor belt drives (incl. swing base, drive coupling,...) Surface protection as well as final color Step 12 Summary of technical information 60605AEN 3 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

3 .2.1 Step 1: Drive selection data 1.0 Machine on LSS (Normally a driven machine) Key: [...] = Value to be filled in [X] = Mark your selection with 1.1 Field of application/industry 1.2 Application [...] 1.3 Ambient temperature [ C] [...] Normal Min. Max. 1. Installation altitude [m] [...] 1.5 Gear unit installation [X] Small space (va 0.5 m/s) Large spaces and halls (va 1. m/s) Installed outdoors with protection from sun (va 3 m/s) 2.7 Operating time/day [X] 3 hours hours > 10 hours 2.8 Backstop required [X] No Yes 2.9 Exact load cycle attached [X] No Yes 3.0 Machine on HSS (normally a drive machine) 3.1 Type: [X] AC motor AC motor/inverter DC motor Hydraulic motor Servomotor 3.2 Motor power P M [kw] [...] Normal Min. Max. 3.3 Motor speed n M [kw] [...] Normal Min. Max. 1.6 Ambient conditions [X] Normal Dusty Damp Corrosive Dry 2.0 Load characteristics 2.1 Required speed n 2 [1/min] [...] Normal Min. max. 2.2 Operating power on HSS P K1 [kw] [...] Normal Min. max. 3. Motor torque M M [knm] [...] 3.5 Drive speed n 1 [1/min] [...] Normal Min. Max. Normal Min. Max. 3.6 If electric motor: [X] [...] IEC NEMA Motor size (IEC or NEMA code): 3.7 Motor mounting position [X] [...] B3 B5 V1 Other: 2.3 Operating torque on LSS M K2 [knm] [...] Normal Min. max..0 Gear unit requirements.1 Gear unit type [X] Helical gear unit X.F.. Bevelhelical gear unit X.K.. 2. Frequency of peak loads (M K2 max. or P K1 max. ) [...] per hour 2.5 Number of startups per hour [...] startups.2 Mounting position [X] M1 M M2 M5 M3 M6.3 Mounting surface* [X] F1 F F2 F5 F3 F6 2.6 Direction of rotation under load (LSS) [X] Clockwise (CW) Counterclockwise (CCW) Both directions Reversible. Shaft position [X] AEN Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 35

4 .6 Required service factor F S min. [X] [...] based on Motor power P M / Motor torque M M Operating power P K1 / Operating torque M K1.7 Required bearing service life L h min [...] Hours.12 Machine shaft bearings 2 Bearings, gear unit transfers only torque 1 bearing opposite gear unit, the gear unit acts as a bearing point 1 bearing directly at the gear unit, the gear unit acts as a bearing point.13 Forces acting on the output shaft LSS [X] [...] FR FA + X 0.8 Housing fixation [X] Footmounted Flangemounted Torque Arm Axial force F A [kn] Radial force F R [kn] Distance from shaft shoulder X [mm] Shaft 3 Shaft Shaft 3 Shaft 3 Shaft Shaft 3.9 LSS connection to customer machine shaft [X] [...] Elastic coupling (claw coupling or pin coupling) Application angle of the radial force [ ] or variable Flexible coupling Rigid flange coupling Drum coupling Chain sprocket Pinion.1 Forces acting on drive shaft HSS [X] [...] Axial force F A [kn] Radial force F R [kn] Shaft 0 Shaft 1 Shaft 0 Shaft 1 Shaft 2 Shaft Hollow shaft torque arm Hollow shaft foot mounting Distance from shaft shoulder X [mm] Shaft 0 Shaft 1 Shaft 2 1 Hollow shaft flange mounting Other Application angle of the radial force [ ] or variable.10 LSS gear unit version [X] [...] LSS version (if solid shaft) Solid shaft with keyway Solid shaft without keyway Splined solid shaft DIN 580 Other.15 Electrical supply [X] [...] AC 3phase 1phase Mains supply V Mains AC 3phase 1phase Auxiliary voltage V Aux DC DC V V HZ HZ LSS version (if hollow shaft) Hollow shaft with keyway Hollow shaft for shrink disc connection, includes shrink disc Splined hollow shaft DIN 580 Other.11 HSS connection to motor [X] Customer installation (base frame) Motor adapter with elastic coupling Swing base/base frame Motor scoop with Vbelt drive Motor scoop Other, see diagram Enclosure Explosion protection required IP Yes No.16 Permitted cooling (if required) [X] Permitted Not permitted Fan Cooling cover/cartridge External oil/air cooler External oil/water cooler Cooling water available Yes No Cooling water temperature C 60606AEN 36 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

5 .2.2 Step 2: Calculate the basic data MK2, n2, i, η Constant torque P M = K1 x 9550 K2 n 2 M K2 = Required output torque [Nm] P K1 = Required operating power on the HSS [kw] n 2 = Output speed (LSS) 1/min x η [Nm] Comment: If P K1 unknown > P K1 = P [Nm] m Equivalent torque with load spectrum and constant speed n M = I K2equiv (M ) K2 I 100 MK2 = Required output torque [knm] t I = Duration of load [s] I, II,...n = Types of load t II 100 t (M ) K (M ) II 6.6 K2 n t n 100 Gear ratio i = n n 1 2 n 1 = Drive speed (HSS) 1/min n 2 = Output speed (LSS) 1/min Efficiency η η = f (i; Gear unit type) The efficiency of the gear unit is mainly determined by the gearing and bearing friction as well by churning losses. The following guide values apply to the calculation: X2F...: X3F...: 0.96 XF...: 0.9 X3K..: XK..: Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 37

6 .2.3 Step 3: Selection of the application factors Applicationspecific service factor F Smin Peak load factor F F Page 1 Startup factor F Start Page 1 F S Applicationspecific service factor The service factor F S takes into account the typical load condition in relationship to the machine that is driven. Recommended values with reference to Field of Application Type of driven machine Operating time/day are given in the following table. These tables apply only to gear units driven by electric motors. For other types of drive motors, the following correction values apply: Combustion engines with four or more cylinders: F s (selection table) Combustion engines with one or three cylinders: F s (selection table) Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

7 Field of Application Type of application (Driven machine) Service factor Operating period / day < 3 h 310 h > 10 h Impeller aerator Thickeners Waste water treatment Vacuum filters Collectors Screw pump Brush aerators 2.00 Crushers Mining Screens and shakers Slewing drives Bucket wheel excavators 1) Frequency converters Energy Water wheels (low speed) 1.70 Water turbines Bucket elevators Vertical conveyors other Belt conveyors 100 kw Belt conveyors > 100 kw Conveyors Apron feeders Screw feeders Shakers, screens Escalators Passenger elevators Extruders (plastic) Extruders (rubber) Rubber rollers (two in a row) Rubber rollers (three in a row) Warming rollers Rubber and plastic industry Calenders Mills Mixing rollers Slab roller Refiners Tire machines Timber industry Timber industry Crane systems Cranes and hoists 2) Food industry Metal production and processing Crushers and mills 1.75 Beet slicers Drying drums Winders Cutting rollers Table conveyors, individual drives Table conveyors, group drives Table conveyors, reciprocating Wire drawing machines Rollers Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 39

8 Field of Application Mills and drums Pulp and paper industry Pump Agitators and mixers Cableways Fans Compressors Type of application (Driven machine) 1) Contact SEWEURODRIVE 2) Please contact SEWEURODRIVE; dimensioning according to FEM1001 Service factor Operating period / day < 3 h 310 h > 10 h Cooling and drying drums Rotary kilns 2.00 Ball mills 2.00 Coal mills Debarking drums and machines Rollers (pickup, wire drive, wire suction) Drying cylinders (antifriction bearings) Calenders (antifriction bearings) Filters (pressure and vacuum) Beaters and chippers Jordan mills Presses (bark, felt, glue, suction) 1.75 Reels 1.75 Pulpers Washer filters 1.50 Yankee cylinders (dryers) Centrifugal pumps Reciprocating pumps (singlecylinder) Reciprocating pumps (multicylinder) Screw pumps Rotary pumps (gear type, vane) 1.25 Agitators for liquids Agitators for liquids (variable density) Agitators for solids (nonuniform material) Agitators for solids (uniform material) Concrete mixers Material ropeways Aerial tramways Surface lifts Continuous aerial tramways Funicular railways Heat exchangers Dry cooling towers 2.00 Wet cooling towers Blowers (axial and radial) Reciprocating compressors Radial compressors Screwtype compressors Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

9 Peak load factor F F The peak load factor F F takes the overload capacity of gearing and rotating parts into account. Gear unit type X..S.: Output shaft as solid shaft X..A. / X..V.: Hollow shaft with formfit connection X..H.: Hollow shaft with shrink disc connection Peak load factor F F Frequency of peak per hour > Startup factor F start The startup factor F start takes the overload caused by the startup process into account. Startup mode Startup factor F start Direct 3.0 Soft startup 1.8 Frequency inverters ) Delta / star 1.3 Hydraulic coupling without delay chamber 2.0 Hydraulic coupling with delay chamber 1.6 1) Dependent on setting.2. Step : Calculation of the required gear unit nominal torque M N2. Constant load direction, constant torque: M N2 M K2 F S [Nm] M N2 M K2 F S = Nominal torque = Operating torque on the LSS = Service factor = M N2 / M K2 = P N1 / P K1 Reversing load direction constant torque: M N2 M K2 F S 1.3 [Nm] M N2 M K2 F S = Nominal torque = Operating torque on the LSS = Service factor = M N2 / M K2 = P N1 / P K1 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 1

10 .2.5 Step 5: Selecting the gear unit size M N2 The selection of the gear unit size is based on the gear unit nominal torque M N2 according to the speed/power overview tables beginning on page 89 and is divided into two ranges: Input speed n 1 = 1500 min 1 Input speed n 1 = 1800 min 1 The selection table guide on the foldout page of the catalog can be used to quickly locate the speed/power overview table and to make a preliminary selection of the gear unit size. If the input speed n 1 < 1500 min 1, the value for 1500 min 1 can be used for M N2. For input speeds n 1 > 1800 min 1, please contact SEWEURODRIVE. X.F190..,n 1 = /min knm [kw] H 2 O + H 2 O + H 2 O H 2 O oil H 2 O i N i ex n 2 M N2 P N [1/min] [knm] [kw] X2F.. X3F.. XF.. 20 C 0 C 20 C 0 C 20 C 0 C 20 C 0 C *) *) *) *) *) *) *) *) *) *) C C C E E E E E D D D D C C C C C C C C 61592AXX 2 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

11 .2.6 Step 6: Calculating the required motor power P M Calculating the required motor power P M Selecting the motor power P M P = M P k2 η P M P K2 = Nominal motor power = Output power [kw] Selecting the motor power.2.7 Step 7: Checking the peak load conditions M K2 per ; M K2max Permitted peak load torque M K2 per : Constant load direction, constant torque: M = K2 zul 2 x M N2 F F [Nm] M K2 zul M N2 F F = Permitted peak drive torque = Nominal torque = Peak load factor Reversing load direction constant torque M = K2 zul 2 x M N2 F F x 0.7 [Nm] M K2zul M N2 F F = Permitted peak output torque = Nominal torque = Peak load factor Calculating the peak load M K2 max : * Start M K2 max = M a x F [Nm] M K2 max M a F Start = Peak output torque = Output torque based on the motor power = Startup factor * If F start is not given, account for the startup factors according to page 1. Checking gear unit selection: M K2 max M K2 per Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 3

12 .2.8 Step 8: Calculating the thermal rating P T The thermal rating P T of a gear unit is the power that a gear unit can transmit without exceeding a certain oil temperature. The thermal rating depends on the following factors: Ambient temperature Air circulation and sunlight exposure at the installation site Installation altitude Heat conduction to the foundation at the installation site Mechanical utilization of the gear unit Type of gear unit, size and gear ratio Type of gear unit external cooling Type of gear unit lubrication Type of lubricant Cyclic duration factor For the following ambient conditions, the thermal rating can be directly read from the selection tables: Ambient temperature 20 C or 0 C (the thermal rating can be interpolated for ambient temperatures of 30 C). Installation in a large hall Natural cooling or cooling with Fan Integrated cooler (water cooling cover or water cooling cartridge) Combination of fan with integrated cooler Circulation cooling with oilwater cooler Foundation as steel support structure Installation altitude 1000 m above sea level Horizontal mounting position (M1) Splash lubrication Please contact SEWEURODRIVE in case of other ambient conditions. It is of fundamental importance that sufficient protection from direct sunlight be provided when installed outdoors. P T = f 1 = Nominal thermal rating of the gear unit. The values in the selection tables in sections depend on ambient temperature and the type of cooling. f 1 = Altitude factor Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

13 Altitude factor f 1 Altitude H [m above sea level] ) f ) Intermediate values must be interpolated Contact SEW in case of deviating conditions..2.9 Step 9: Checking the thermal rating: The gear unit's thermal rating must be at least as large as the operating power on the input shaft [HSS] P T P K1 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 5

14 .2.10 Step 10: Checking the external additional forces: Dependencies The permitted forces on the shaft depend on the following factors: Gear unit service factor Required bearing service life Direction of the axial force (from or towards gear unit) Application angle of the radial force (rotating or at a specific position) Application angle of the radial force in relation to the shaft shoulder Relation of axial to radial force and vice versa. Definition of force application X F R α F A 0 610AXX Determining overhung force An important factor for determining the resulting overhung force is the type of transmission element mounted to the shaft end. The following transmission element factors f Z must be considered for various transmission elements. Transmission element Transmission element factor f Z Comments Gears 1.15 < 17 teeth Chain sprockets 1.0 < 13 teeth Chain sprockets 1.25 < 20 teeth Narrow Vbelt pulleys 1.75 Influence of the pretensioning force Flatbelt pulleys 2.50 Influence of the pretensioning force Toothed belt pulleys 1.50 Influence of the pretensioning force The overhung force load exerted on the motor or gear unit shaft is then calculated as follows: X X F R M d d 0 f Z = Overhung force load [N] = Torque [Nm] = Average diameter of the mounted transmission element [mm] = Transmission element factor 6 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

15 Permitted overhung forces output shaft (LSS) The following table shows two values for the permitted radial force on standard solid shafts that apply under the following conditions: The application point of the radial force is on the midpoint of the shaft end No external axial force acts on the output shaft! The gear unit service factor is 1.3 or higher The application angle of the radial load is applied at the most unfavorable point For the force F Ra The shaft speed is less than or equal to the given value For the force F Ra max Applies only to footmounted gear units in mounting position M1 Max. possible peak value under more advantageous service conditions F Ra [kn] F R max [kn] X2FS.. X3FS.. X3KS.. XFS.. XKS.. X..S. Speed n /min 70 1/min 20 1/min Shaft position 1, 23 13, 2 1, 23 13, 2 03, 0 1, 23 13, 2 03, 0 All shaft Gear unit size positions Contact SEW in case of deviating conditions. Permitted axial forces output shaft [LSS] Please contact SEWEURODRIVE. Permitted overhung and axial forces input shaft (HSS) Please contact SEWEURODRIVE. Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 7

16 Sample for project planning: Conveyor drive.3 Sample for project planning: Conveyor drive The following project planning example shows the planning of a conveyor drive. 615AXX Technical data and application conditions Footmounted gear unit with hollow shaft Output speed n 2 = 35 1/min Input speed motor n 1 = 170 1/min Operating power on the output shaft LSS P K2 = 135 kw Peak operating torque on the output shaft LSS M K2 max = 55 knm Operating time: 16 hours a day The gear unit is started up once per hour (frequency of maximum output torque). The gear unit is to be operated in a large hall under very dusty conditions and an ambient temperature range of 0 C 0 C. Installation altitude H = 1200 m Customer request: Min. Service factor F S 1. 8 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

17 Sample for project planning: Conveyor drive Step 1: Filling out the drive selection sheet Step 2: Calculating the basic data Constant operating torque M K2 : P M = K2 x kw x 9550 K2 = n /min = 36.8 knm M K2 P K2 n 2 = Operating torque on the LSS [Nm] = Output power [kw] = Output speed LSS [1/min] Calculate the gear unit reduction ratio using the following formula: i = n 1 n 2 = = 2 i n 1 n 2 = Gear ratio = Input speed (HSS) [1/min] = Output speed (LSS) [1/min] This value is used to specify the nominal gear ratio i nominal = 5. Step 3: Selection of the application factors Applicationspecific service factor (Belt conveyor P > 100 kw, t > 10 h/day) Peak load factor (1...5 peak loads per hour) Startup factor (Hydraulic coupling with delay chamber) F S min = 1.5 F F = 1.0 F Start = 1.6 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 9

18 Sample for project planning: Conveyor drive Step : Calculation of the required gear unit nominal torque The required gear unit nominal torque M N2 : M N2 M K2 F S [Nm] = 36.8 knm x 1.5 = 55.2 knm M N2 M K2 F S = Nominal torque [knm] = Operating torque on the LSS [knm] = Service factor Step 5: Selecting the gear unit size Select a gear unit of the nextlarger torque class using the foldout page See selection table page 18. Gear unit type X3KA180 /B Nominal gear ratio i nominal = 5 exact gear ratio i ex = 3.6 Nominal gear unit torque M N2 = 58 knm Step 6: Calculating the required motor power Required motor power: P M = P K2 η = 135 kw = 11. kw P M P K2 η = Motor power [kw] = Output power [kw] = Efficiency from section.2.2 Select a motor of the nextlarger power class: P M = 160 kw 50 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal

19 Sample for project planning: Conveyor drive Step 7: Checking the peak load conditions Permitted peak load torque M K2 per : M = K2 zul 2 x M N2 F F 2 x 58 knm = = 116 knm 1 M K2zul M N2 F F = Permitted peak output torque [knm] = Nominal torque [knm] = Peak load factor Calculating the output torque based on the motor power P M = M x 9.55 x η 160 kw x 9.55 x a = n /min = 1.7 knm Calculating the peak load M k2 max : M K2 max = M a x F start = 1.7 knm x 1.6 = 66.7 knm The peak operating torque M K2 max must not exceed the permitted peak output torque M K2 zul M K2 max M K2 zul 66.7 knm 116 knm This means you may use the selected gear unit size. Step 8: Calculating the thermal rating P T = x f 1 = 80 kw x 0.95 = 76 kw f 1 = 0.95 H = 1200 m P T f 1 = Thermal rating [kw] = Nominal thermal rating [kw] = Altitude factor Catalog Helical and BevelHelical Gear Units Series X.. Horizontal 51

20 Sample for project planning: Conveyor drive Step 9: Checking the thermal rating and selecting the gear unit cooling The operating power P K1 may never exceed the thermal rating P T (P K1 P T ). Additional cooling is required if P K1 > P T 11. kw > 76 kw Thermal rating at 0 C is not sufficient without additional cooling With one fan: P T = x f 1 = 171 kw x 0.95 = kw 11. kw < kw Thermal rating at 0 C with one fan sufficient Step 10: Checking the external additional forces There are no external additional forces Schritt 11: Selecting the optional equipment Dusty environment Taconite seals on the drive and output shafts (see section "Sealing systems" 2.9). Step 12: Summary of all the technical information Gear unit type: X3KA180 /B Gear ratio i ex = 3.6 Nominal gear unit torque M N2 = 58 knm Motor: P M = 160 kw Taconite seals on the drive and output shafts Fan on the input shaft 52 Catalog Helical and BevelHelical Gear Units Series X.. Horizontal