1104 Highway 27 W Alexandria, MN

Transcription

1 1104 Highway 27 W Alexandria, MN

2 APPLICATION GUIDE

3 A certified leader in precision engineered machines, parts, gears, and electro-mechanical products for over 30 years. Table of Contents HTSR High Torque to Space Ratio Spiroid and Helicon - Gear Form Spiroid vs Helicon... 3 Key Characteristics and Benefits - Instantaneous Line of Contact Simultaneous Tooth Contact Materials Selection and Versatility Strength and Durability Ratio Flexibility Quiet Operation Hi Side / Low Side... 7 Spiroid and Helicon Fill the Design Gap... 7 Application Data - Spiroid Data Factors Spiroid Charts Helicon Data Factors Helicon Charts Assembly and Installation - Housing Inspection Pinion Assembly Gear Assembly Backlash Check Backlash Chart Application Data Sheet Other ITW Products and Services

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5 HTSR (High Torque to Space Ratio) is an exclusive line of gearing and coupling products made possible by software, tooling, and manufacturing methods that are the intellectual property of Illinois Tool Works and ITW Heartland. As the acronym indicates, the real value of these products lay in their ability to transmit relatively large amounts of power in compact spaces and with minimal weight. Rather than modifying an application to the limited capability of a particular standard gearing method, HTSR Gearing is designed to meet some of the most difficult application requirements that exist in the Aerospace, Defense, Robotics, Medical, and General Industrial markets. In fact, HTSR products have been meeting these difficult application requirements for over 50 years. Simply put, there are times when traditional gearing methods simply will not provide the power and torque that are required within given space or weight limitations. It is in these times that HTSR products will rise to the occasion. The following represent the HTSR Gearing product profile: Spiroid right angle gearing Helicon right angle gearing Concurve spur-type gearing Endicon indexing and coupling rings This application guide will focus exclusively on Spiroid and Helicon right angle gearing. 2

6 Spiroid & Helicon Gear Form Spiroid and Helicon gears are members of the skew-axis gear family and are designed to broaden gearing design opportunities restricted by the physical limitations of conventional gearing. Spiroid and Helicon gear sets consist of two members; pinion and gear. By definition, the pinion has fewer teeth and is normally the driving member while the driven member is a face gear. Spiroid and Helicon pinions operate between the extreme operating positions of bevel gear pinions and worms. See Figure 1. The advantages of Spiroid gears stem from two facts. First, Spiroid/Helicon gears have more teeth in contact than a worm drive of equal gear diameter. See Figures 2 and 3. Secondly, in contrast to worm, hypoid, and spiral bevel gears, Spiroid/Helicon gears are insensitive to normal mounting variations. band of contact ROTATION OF PINION WORM Direction of sliding velocity Radius of curvature Spiroid vs. Helicon The difference between Spiroid and Helicon can be found in their respective pinions. Whereas Helicon pinions are cylindrical and typically engaging a flat-faced gear, Spiroid pinions are tapered and designed to engage a beveled gear face. See Figure 4. GEAR TOOTH PINION TOOTH SPIROID r R DIRECTION COMPONENT OF NORMAL FORCE NORMAL FORCE WORM NORMAL FORCE Friction FORCE Since tapered Spiroid pinions engage the hypotenuse of a beveled face gear and thus allow for more thread/tooth contact, Spiroid gear sets typically allow for greater torque output with slightly less efficiency than its Helicon equal. MOTION OF PINION TOOTH ROTATION OF GEAR Figure 3 COMPONENT OF FRICTION FORCE WORM GEAR ITW SPIROID GEAR SPIROID/HELICON GEAR ITW HELICON GEAR HYPOID GEAR SPIRAL BEVEL GEAR Spiroid 90 Shaft Angle Spiroid Acute Shaft Angle Helicon 90 Shaft Angle Helicon Acute Shaft Angle Figure 1 Figure 4 3

7 Key Characteristics and Benefits Instantaneous Line of Contact Before describing specific Spiroid and Helicon gear set characteristics, it should be pointed out that all gears can, at best, obtain only line contact under no load at any instantaneous position of mesh. Total length of line contact is one criterion of gear load carrying capabilities. Another is contact line movement during the engagement cycle. The contact line should not be stationary. It should sweep the entire available tooth surface. Movement or sweep of contact line brings freshly lubricated and cooler areas into mesh. This applies to all gears. Other factors, such as relative curvature of contacting surface and inclination of the contact lines relative to sliding velocity, must also be considered. Contact lines of spiroid pinion and gear Figure 5 In Spiroid and Helicon pinions, the line of instantaneous contact is an almost radial line on each convolution of the pinion thread. See Figure 5. It is almost perpendicular to the sliding velocity, and results in a full sweep of contact on the pinion and gear. By contrast, the instantaneous line of contact on worm gears is only slightly inclined to the direction of sliding velocity. This results in a narrow band of contact on the worm thread. See Figure 3 on page 3. 4

8 Simultaneous Tooth Contact Furthermore, Spiroid and Helicon gears have many teeth in simultaneous contact. See figure 5 on page 4. The number of teeth in contact depends on the number of teeth in the gear member. Generally, 10% of the gear teeth are in simultaneous contact. However, even in the low ratio range, Spirod and Helicon have two to three times the number of teeth in contact than on worm gears. On higher ratios, there are many times more. Materials Selection and Versatility The more favorable contact conditions and lower sliding between Spiroid and Helicon gear members permit the use of hardenable grades of steel for both gears and pinions. This, plus the ideal lubricating film formation and the movement of contact lines, makes the use of hardened steelon-steel an ideal material for both Spiroid and Helicon gear sets. This is particularly advantageous in situations where high surface durability, high static loads, running loads, or shock loads are encountered. In worm gears, by contrast, the usual selection is hardened steel worm meshing with a bronze gear. Strength and Durability Givin all of the previously mentioned characteristics, it is clear that many factors combine to give Helicon or Spiroid gears their superior strength and high surface durability characteristics. These factors are: The number of teeth in simultaneous contact The individual contact lines in relation to the sliding velocity Large radii of curvature at the contact lines Greater latitude of material choices Ratio Flexibility For any gear of a given diameter, a higher ratio means more teeth which means a finer pitch. Since contact between the Helicon or Spiroid pinion and gear extends over the entire length of the pinion, a finer pitch or shorter lead gives a proportionately increased number of teeth in simultaneous contact, with very little sacrifice in capacity. With worm gears, for instance, the upper ratio limit is usually around 80:1. After selecting a pitch sufficient to carry the required load (bearing in mind that, at most, the worm set has two teeth in contact) the gear risks becoming too large. Therefore, in the case of worm gearing, higher ratios are usually handled by multiple reductions. Helicon or Spiroid gears, however, do not have an upper limitation. For a given gear diameter, a higher ratio means a shorter lead, finer pitch, and more teeth in contact. As a result, single reduction ratios above 300:1 are possible. 5

9 Key Characteristics and Benefits cont. Quiet Operation Gear accuracy is the most important factor in obtaining minimal vibration and maximum quietness. However, at high pitch line velocities even small inaccuracies can produce a pronounced noise, particularly if they occur at regular frequencies. Therefore, to achieve quiet gears, accuracy is combined with modifications in the profile and lead of the gear teeth, permitting them to engage gradually. It was previously pointed out that the contact lines on Spiroid and Helicon pinions are nearly radial, and sweep the entire length of the teeth. At such great tooth length, very effective modifications can be made at the entering and leaving sides, so that pinion teeth cam gently into and out of action. The commonly used term for these modifications is crowning. Incorporated in either the pinion or the gear, and in conjunction with the large number of teeth in simultaneous engagement, it accounts for the fact that Spiroid and Helicon gears are inherently quiet. The efficiency of a gear set is a measure of the power lost in the gear mesh which turns into heat that must be dissipated. Thus a gear set which is 70% efficient loses 30% of the power input and transmits 70%. The efficiency of Spiroid and Helicon gear sets, as well as all other gear types, is a function of the gear set geometry, i.e. the efficiency angles, and the coefficient of friction. Because of the previously stated geometry and ideal lubricating characteristics of Spiroid and Helicon gear sets, higher efficiencies are possible relative to worm gears. As with all other gear types, the higher the gear set ratio, the lower the efficiency. Sometimes, however, the low efficiency can be an asset, particularly when self-locking is desired. Self-locking is the ability of the gear to drive the pinion, or back drive, and is a characteristic common to higher ratio gear sets. Special design considerations can accommodate application requirements of higher dynamic efficiencies or self-locking efficiencies through the custom design versatility of Spiroid or Helicon gearing. Hi Side / Low Side Spiroid and Helicon tooth pressure angles are not symmetrical. See Figure 6. However, Spiroid and Helicon gearing operate at roughly the same efficiency and load rating in either direction of pinion rotation even though direction and magnitude of the forces on the teeth are different. While the resultant tooth forces are largely in the axial direction of the pinion (particularly in the higher ratio range) they also have components working in the radial direction of the pinion, which tend to separate the pinion and gear teeth. The radial component is greater when the high pressure angle of the tooth does the driving. See description of Tooth Load Components given in the Helicon & Spiroid gear set size selection sections. Modern engineering attempts to extract the most from any given opportunity. Therefore, it is preferable in the interest of maximum bearing life to let the low pressure angle side of the pinion threads do the driving on uni-directional drives. 6

10 Spiroid and Helicon Fill the Design Gap There are definite applications for both parallel axis and skew-axis gear systems. Selection depends on many factors including cost, space and power availability, ratio and torque requirements, as well as production or assembly limitations. Spiroid and Helicon gear systems offer increased design opportunities with these important obtainable features: Simple and positive control of backlash Ease of assembly / flexible mounting tolerances High level of accuracy Wide range of reduction ratios Superior shock strength Superior torque transmission Quiet operation Material versatility Compact, lightweight drives High stiffness Savings due to design flexibility 7

11 Application Data POSITION ONLY Spiroid Data Factors This section includes tables for gear set performance, pertinent dimensions and tooth loads. Standard design data for Spiroid gear sets is given in Tables represented on pages These gear sets are well-balanced designs suitable for the majority of general purpose applications. The tables are design tools to be used as a guide to allow the engineer to make preliminary size selection of a Helicon gear set. The gear sets listed in the table do not represent standard off-theshelf hardware. By varying both tooth and blank proportions, it is possible to place special emphasis on such specific performance characteristics as efficiency, self-locking, reversibility, high strength, exceptionally smooth angular velocity, etc. The design possibilities featuring and blending the various characteristics are, therefore, quite numerous. In making a size selection, apply the material and service factors from Tables A and B. Divide catalog ratings or multiply driven load by appropriate service and material factors. Then, select the gear set with the proper rating for the given input speed and ratio requirements. If a gear set is desired which falls in between two standard sizes, take the data from the closest set and scale all linear dimensions either up or down as needed. For special designs requiring particular performance characteristics or additional sizing options, please contact ITW Heartland representatives. Spiroid Gear Tooth Load Components When selecting bearings, it is necessary to know the direction and magnitude of the tooth forces so that bearing relations may be determined. The rating tables give the following unit tooth loads for all Helicon gear sets: Fx unit axial force acting on pinion Fy unit separating force acting on pinion Fz unit tangential force acting on pinion (Units for above forces are pounds/inch-pound output torque) 1. Hi-Lo side forces are shown acting on the gear. 2. Forces act on the gear tooth at mid-tooth depth and at mid-face on the center distance. 3. Forces on the pinion are in the reverse direction from those shown. Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters 8 Table 8 XX

12 Materials Helicon gear set size data tables are based on the following material combinations: 1. For gear O.D. less than 16 : Both pinion and gear are SAE 8620 Steel, carburize hardened to 60 R.C. Lubrication For steel-on-steel applications, full synthetic extreme pressure oil is recommended. For cases where normal shock-free service is expected, SAE grade 90 should be used. For cases where heavy duty or high shock loading is expected, SAE grade 140 should be used. For steel-on-bronze applications, full synthetic extreme pressure oil that is rated for usage with enclosed worm drives operating at medium to high speeds is recommended. Note: oil fill level should cover the gear set mesh Service Factor Horsepower and torque ratings are based on a unity service factor (1.0) as defined the table to the right. The ratings given in the tables are surface durability capacities and do not take into account any thermal limits. Rating adjustment factors for gear materials other than steel - mating with a hardened pinion. MATERIAL GEAR ONLY Powdered Iron Alloy Sintered and Hardened.65 Molded Plastics.25 Aluminum Bronze.80 Die Cast Aluminum.35 Shell Molded Ductile Iron.40 Prime Mover Duration of Service Uniform Moderate Shock Electric Motor Occasional 1/2 hr./day total (Normal service) Intermittent 2 hr./day total hours per day hours per day Electric Motor Occasional 1/2 hr./day total (More than 10 Intermittent 2 hr./day total starts per hour) 10 hours per day hours per day Multi-Cylinder Occasional 1/2 hr./day total Internal Combustion Intermittent 2 hr./day total Engine 10 hours per day hours per day Single Cylinder Occasional 1/2 hr./day total Internal Combustion Intermittent 2 hr./day total Engine 10 hours per day hours per day Temperature The maximum sustained operating oil sump temperature should not exceed 180 F. Oil level should cover gear set mesh. Driven Machine Load Classifications Heavy Shock 9

13 1.875" Outside Diameter Helicon Gear Ratio Details Diagram A POSITION ONLY POSITION ONLY The basic dimensional parameters of Spiroid and Helicon gear sets shown in Diagram A relate to gear and pinion interface. Center distance and pinion thread diameter specifications are intended to be guides, and can be found in the bottom sections of the charts located on pages Pinion and gear mounting distances are flexible, and can be specified depending on application requirements. Performance Ratings " O.D. Helicon RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 Diagram B Loading vectors are indicated in Diagram B by the directional arrows. Load multiplier factors can be found in the bottom sections of the charts located on pages Note that.001 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1 TQ Out TQ Out there are typically differences in load factors between low side and high side drive TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Fx Driving Side Hi Fy Fz Fx Driving Side Lo Fy Fz Note: Additional reduction ratios may be possible depending on application parameters Note: Data intended for general reference purposes only and may change as application parameters become further defined 10 Table 8 XX

14 C Dia a Pinion od F Dia max Diagram A F Z - LO F Z - LO Tooth lo p.a. hi side drive F Y - LO F X - HI F X - HI F Z - HI LO side drive F Z - HI hi side drive LO side drive Diagram B 11

15 1.875" Outside Diameter Helicon 1.500" O.D. Spiroid 12 Performance Ratings - RPM Output POSITION 10:1 ONLY 12:1 14:1 17:1 21:1 25:1 POSITION 31:1 38:1 ONLY 47:1 1 TQ Out TQ Out N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Performance Ratings ".021 O.D..025 Helicon RPM Output 200 TQ 4:1 Out 6:176 8: :1 9812: : :1 21: :110931: : : :1 HP.001Out N/A.034 N/A.028 N/A.030 N/A.045 N/A.022 N/A N/A.018 N/A.016 N/A.013 N/A.011 N/A N/A 1 TQ Out TQ Out TQ Out HP 115Out TQ.914 Out TQ Out HP 108Out TQ.921 Out TQ Out HP.926 Out TQ.219 Out TQ Out HP.934 Out TQ.306 Out TQ Out HP.386 Out TQ Out TQ 83Out HP.517 Out TQ Out TQ 76Out TQ Out HP 70 Out TQ.952 Out TQ Out HP 63Out N/A TQ.957 Out TQ Out TQ Out Dimension Data Center Distance TQ equals output torque in inch-lbs Pinion Diameter Dimension Pressure Data Angle - Lo Center Pressure Distance Angle Hi Pinion Diameter Pressure Angle Tooth - LoLoad 20 Data Pressure Angle - Hi Fx Driving Side Hi Fy Tooth Load Data Fz Fx Fx Driving Side Driving Hi Side Lo Fy Fy Fz Fz Fx Driving Side Lo Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. Table 8 XX

16 1.875" O.D. Spiroid Performance Ratings RPM Output 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 13

17 1.875" Outside Diameter Helicon 2.250" O.D. Spiroid 14 Performance Ratings RPM Output POSITION 10:1 ONLY 12:1 14:1 17:1 21:1 25:1 31:1 POSITION 38:1 ONLY 47:1 58:1 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1 TQ Out TQ Out Performance Ratings ".056 O.D..056 Helicon RPM 200 Output TQ 4:1 Out 6: : : : : : :1 25: : : :135158: HP.001 Out N/A.104 N/A.089 N/A.080 N/A.079 N/A.068 N/A.057 N/A.050 N/A N/A.040 N/A.034 N/A.027N/A 1 TQ Out TQ Out TQ Out HP 115 Out TQ.914 Out TQ Out HP 108 Out TQ.921 Out TQ Out HP.926 Out TQ.219 Out TQ Out HP.934 Out TQ.306 Out TQ Out HP.386 Out TQ Out TQ 83 Out HP.517 Out TQ Out TQ 76 Out TQ Out TQ.952 Out TQ Out HP 63 Out TQ.957 Out TQ Out TQ equals output.962 torque.943 in inch-lbs TQ Out Dimension Data Center Distance TQ equals output torque in inch-lbs Pinion Diameter Dimension Pressure Data Angle - Lo Center Pressure Distance Angle Hi Pinion Diameter Pressure Tooth Angle - Lo Load 20Data Pressure Angle - Hi 35Fx Driving Side Hi Fy Tooth Load Data Fz Fx Fx Driving Driving Side HiSide Lo Fy Fy Fz Fz Fx Driving Tooth Side load Lo Fycomponents equals lbs./inch-lb output 0.441torque Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. Table 8 XX

18 3.000" O.D. Spiroid Performance Ratings RPM Output 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out N/A N/A N/A TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 15

19 1.875" Outside Diameter Helicon 3.750" O.D. Spiroid 16 Performance Ratings RPM Output POSITION 10:1 ONLY12:1 14:1 17:1 21:1 25:1 31:1 POSITION 38:1 ONLY 47:1 58: TQ Out TQ Out Performance Ratings ".237 O.D..251 Helicon RPM 200 Output TQ 4:1 Out 6: : : : : : :1 25: : : : : HP.001 Out N/A.428 N/A.388 N/A.332 N/A.349 N/A.285 N/A.255 N/A N/A.210 N/A.179 N/A.141 N/A.120N/A TQ Out TQ 129 Out TQ Out HP 115 Out TQ.914 Out TQ Out HP 108 Out TQ.921 Out TQ Out HP.926 Out TQ.219 Out TQ Out HP.934 Out TQ.306 Out TQ Out HP.386 Out TQ Out TQ 83Out HP.517 Out TQ Out TQ 76Out TQ Out TQ.952 Out TQ Out HP 63Out TQ.957 Out TQ Out TQ equals output.962 torque.943 in inch-lbs Dimension TQ Out 44Data Center Distance TQ equals output torque in inch-lbs Pinion Diameter Dimension Pressure Data Angle - Lo Center Pressure DistanceAngle Hi Pinion Diameter Pressure Angle Tooth - LoLoad 20 Data Pressure Angle - Hi 35 Fx Driving Side Hi Fy Tooth Load Data Fz Fx 1.065Fx Driving Driving Side Hi Side Lo Fy 1.240Fy Fz 0.890Fz Fx Driving Tooth Side load Lo components equals lbs./inch-lb. output torque Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. Table 8 XX

20 4.500" O.D. Spiroid Performance Ratings RPM Output 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and Tooth reduction load data components provided equals for reference lbs./inch-lb. purposes output only; torque ITW Spiroid can provide recommendations for specific application needs. 17

21 1.875" Outside Diameter Helicon 5.250" O.D. Spiroid Performance Ratings RPM Output POSITION 10:1 ONLY12:1 14:1 17:1 21:1 31:1 38:1 POSITION 21:1 ONLY 47:1 58: TQ Out TQ Out Performance Ratings ".606 O.D..641 Helicon RPM 200 Output TQ 4:1 Out 6: : : : : : :1 25: : : : : HP.001 Out N/A N/A.978 N/A.839 N/A.885 N/A.771 N/A.649 N/A N/A.522 N/A.493 N/A.390 N/A.329N/A TQ Out TQ 129 Out TQ Out HP 115 Out TQ.914 Out TQ Out HP 108 Out TQ.921 Out TQ Out HP.926 Out TQ.219 Out TQ Out HP.934 Out TQ.306 Out TQ Out TQ Out TQ 83 Out HP.517 Out TQ Out TQ 76 Out TQ equals TQ Outoutput 70 torque 67in inch-lbs Dimension.878 Data TQ Out Center Distance Pinion Diameter Pressure TQ OutAngle 54- Lo Pressure Angle Hi Tooth TQ OutLoad 44 Data Fx Driving Side Hi TQ equals output torque Fy in inch-lbs Dimension Data Fz Center Distance 0.305Fx Driving Side Lo Pinion Diameter 0.589Fy Pressure Angle - Lo 20 Fz Pressure Angle - Hi Tooth load components equals lbs./inch-lb. output torque Tooth Load Data Fx Driving Side Hi Fy Fz Fx Driving Side Lo Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. 18 Table 8 XX

22 6.000" O.D. Spiroid Performance Ratings RPM Output 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 19

23 Application Data POSITION ONLY Helicon Data Factors This section includes tables for gear set performance, pertinent dimensions and tooth loads. Standard design data for Helicon gear sets is given in Tables represented on pages These gear sets are well-balanced designs suitable for the majority of general purpose applications. The tables are design tools to be used as a guide to allow the engineer to make preliminary size selection of a Helicon gear set. The gear sets listed in the table do not represent standard off-theshelf hardware. By varying both tooth and blank proportions, it is possible to place special emphasis on such specific performance characteristics as efficiency, self-locking, reversibility, high strength, exceptionally smooth angular velocity, etc. The design possibilities featuring and blending the various characteristics are, therefore, quite numerous. In making a size selection, apply the material and service factors from Tables A and B. Divide catalog ratings or multiply driven load by appropriate service and material factors. Then, select the gear set with the proper rating for the given input speed and ratio requirements. If a gear set is desired which falls in between two standard sizes, take the data from the closest set and scale all linear dimensions either up or down as needed. For special designs requiring particular performance characteristics, please contac titw Heartland representatives. Helicon Gear Tooth Load Components When selecting bearings, it is necessary to know the direction and magnitude of the tooth forces so that bearing relations may be determined. The rating tables give the following unit tooth loads for all Helicon gear sets: Fx unit axial force acting on pinion Fy unit separating force acting on pinion Fz unit tangential force acting on pinion (Units for above forces are pounds/inch-pound output torque) 1. Hi-Lo side forces are shown acting on the gear. 2. Forces act on the gear tooth at mid-tooth depth and at mid-face on the center distance. 3. Forces on the pinion are in the reverse direction from those shown. Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters 20 Table 8 XX

24 Materials Helicon gear set size data tables are based on the following material combinations: 1. For gear O.D. less than 16 : Both pinion and gear are SAE 8620 Steel, carburize hardened to 60 R.C. Lubrication For steel-on-steel applications, full synthetic extreme pressure oil is recommended. For cases where normal shock-free service is expected, SAE grade 90 should be used. For cases where heavy duty or high shock loading is expected, SAE grade 140 should be used. For steel-on-bronze applications, full synthetic extreme pressure oil that is rated for usage with enclosed worm drives operating at medium to high speeds is recommended. Note: oil fill level should cover the gear set mesh Service Factor Horsepower and torque ratings are based on a unity service factor (1.0) as defined in the table on the right. The ratings given in the tables are surface durability capacities and do not take into account any thermal limits. Rating adjustment factors for gear materials other than steel - mating with a hardened pinion. MATERIAL GEAR ONLY Powdered Iron Alloy Sintered and Hardened.65 Molded Plastics.25 Aluminum Bronze.80 Die Cast Aluminum.35 Shell Molded Ductile Iron.40 Prime Mover Duration of Service Uniform Moderate Shock Electric Motor Occasional 1/2 hr./day total (Normal service) Intermittent 2 hr./day total hours per day hours per day Electric Motor Occasional 1/2 hr./day total (More than 10 Intermittent 2 hr./day total starts per hour) 10 hours per day hours per day Multi-Cylinder Occasional 1/2 hr./day total Internal Combustion Intermittent 2 hr./day total Engine 10 hours per day hours per day Single Cylinder Occasional 1/2 hr./day total Internal Combustion Intermittent 2 hr./day total Engine 10 hours per day hours per day Temperature The maximum sustained operating oil sump temperature should not exceed 180 F. Oil level should cover gear set mesh. Driven Machine Load Classifications Heavy Shock 21

25 1.875" Outside Diameter Helicon POSITION ONLY Gear Ratio Details POSITION ONLY Diagram A The basic dimensional parameters of Spiroid and Helicon gear sets shown in Diagram A relate to gear and pinion interface. Center distance and pinion thread diameter specifications are intended to be guides, and can be found in the bottom sections of the charts located on pages Pinion and gear mounting distances are flexible, and can be specified depending on application requirements. Performance Ratings " O.D. Helicon RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 Diagram B Loading vectors are indicated in Diagram B by the directional arrows. Load multiplier factors can be found in the bottom sections of the charts located on pages Note that.001 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1 TQ Out TQ Out there are typically.914 differences in.788 load.741 factors.702 between.643 low.594 side.549 and.475 high.429 side drive TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Fx Driving Side Hi Fy Fz Fx Driving Side Lo Fy Fz Note: Additional reduction ratios may be possible depending on application parameters Note: Data intended for general reference purposes only and may change as application parameters become further defined 22 Table 8 XX

26 C Dia a Pinion od F Dia max Diagram A F Z - LO F Z - LO Tooth lo p.a. hi side drive F Y - LO F X - HI F X - HI F Z - HI LO side drive F Z - HI hi side drive LO side drive Diagram B 23

27 1.875" Outside Diameter Helicon 1.500" O.D. Helicon Performance Ratings POSITION ONLY POSITION ONLY RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A TQ equals output torque in inch-lbs Dimension Data Center TQ equals Distance output torque in inch-lbs Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. 24 Table 8 XX

28 1.875" O.D. Helicon Performance Ratings RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out.001 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 25

29 1.875" Outside Diameter Helicon 2.250" O.D. Helicon 26 Performance Ratings RPM Output 4:1 POSITION 6:1 ONLY 8:1 10:1 12:1 14:1 17:1 21:1 POSITION 25:1 31:1 ONLY 38:1 47:1 58: N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1 TQ Out TQ Out Performance Ratings ".071 O.D..062 Helicon RPM TQ Out Output 184 4:1 1796:1 1858: :1 12: : : :130425: : : :1 58: N/A.102 N/A.101 N/A.088 N/A N/A.073 N/A.079 N/A.063 N/A.057 N/A.042 N/A.037 N/A.029 N/A TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ OutTQ Out TQ OutTQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ equals output torque in inch-lbs TQ Out Dimension Data Center Distance TQ equals output torque in inch-lbs Pinion Diameter Pressure Angle Dimension - Lo Data Pressure Angle Center - Hi Distance Pinion Diameter Tooth Pressure Load Angle Data- Lo Pressure Angle - Hi Fx Driving Side Hi Fy Tooth Load Fz Data Fx Fx Driving Side Driving Lo Side Hi Fy Fy Fz Fz Fx Driving Side Lo Tooth load components Fy equals lbs./inch-lb output torque Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. Table 8 XX

30 3.000" O.D. Helicon Performance Ratings RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz N/A N/A N/A N/A Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 27

31 1.875" Outside Diameter Helicon 3.750" O.D. Helicon 28 Performance Ratings RPM Output 4:1 POSITION 6:1 ONLY 8:1 10:1 12:1 14:1 17:1 21:1 POSITION 25:1 31:1 ONLY 38:1 47:1 58:1 1 TQ Out 100 TQ Out HP Performance Out Ratings ".296 O.D..261 Helicon RPM TQ Out Output 847 4: : : : :1 14: : : : : : :1 58: N/A.420 N/A.417 N/A.366 N/A N/A.306 N/A.330 N/A.287 N/A.239 N/A.177 N/A.154 N/A.122 N/A TQ OutTQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ OutTQ Out TQ OutTQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ equals output torque in inch-lbs Dimension Data TQ Out Center Distance TQ equals output torque in inch-lbs Pinion Diameter Pressure Angle Dimension - Lo Data Pressure Angle Center - Hi Distance Pinion Diameter Tooth Pressure Load Data Angle - Lo Pressure Fx Angle Hi Driving Side Hi Fy Tooth Fz Load Data Fx Driving Side Fx Driving Lo Side Fy Hi Fy Fz Fz Fx Tooth load Driving components Side Lo equals lbs./inch-lb. output torque Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. Table 8 XX

32 4.500" O.D. Helicon Performance Ratings RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out 6000 TQ Out TQ Out TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 29

33 1.875" Outside Diameter Helicon 5.250" O.D. Helicon Performance Ratings RPM Output 4:1 POSITION 6:1 ONLY 8:1 10:1 12:1 14:1 17:1 21:1 POSITION 25:1 31:1 ONLY 38:1 47:1 58: TQ Out TQ Out Performance Ratings ".797 O.D..663 Helicon RPM TQ Out Output : : : : : :1 17: : : : : :1 58: N/A N/A N/A.924 N/A N/A.777 N/A.837 N/A.729 N/A.608 N/A.523 N/A.390 N/A N/A TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ Out TQ OutTQ Out TQ OutTQ Out TQ equals output 2500 torque TQ Out in inch-lbs Dimension Data 3600 TQ Out Center Distance Pinion Diameter Pressure 6000 Angle - LoTQ Out Pressure Angle - Hi Tooth Load Data TQ Out Fx Driving Side TQ Hi equals Fy output 0.438torque in inch-lbs Dimension Fz Data Center Fx Distance Driving Side Pinion Lo Diameter Fy Pressure Angle - Lo Fz Pressure Angle - Hi Tooth load components equals lbs./inch-lb. output torque Tooth Load Data Fx Driving Side Hi Fy Fz Fx Driving Side Lo Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters Note: Rating Note: and reduction Data intended data provided for general for reference purposes only; and ITW may Spiroid change can as provide application recommendations parameters become for specific further application defined needs. 30 Table 8 XX

34 6.000" O.D. Helicon Performance Ratings RPM Output 4:1 6:1 8:1 10:1 12:1 14:1 17:1 21:1 25:1 31:1 38:1 47:1 58:1 1 TQ Out 100 TQ Out 200 TQ Out 300 TQ Out 600 TQ Out 900 TQ Out 1200 TQ Out 1750 TQ Out 2500 TQ Out 3600 TQ Out TQ equals output torque in inch-lbs Dimension Data Center Distance Pinion Diameter Pressure Angle - Lo Pressure Angle - Hi Tooth Load Data Driving Side Hi Driving Side Lo Fx Fy Fz Fx Fy Fz Tooth load components equals lbs./inch-lb. output torque Note: Rating and reduction data provided for reference purposes only; ITW Spiroid can provide recommendations for specific application needs. 31

35 Assembly and Installation How to assemble SPIROID and HELICON gearing Following the steps outlined in this guide will allow you to properly assemble your gear sets. Proper assembly ensures optimal operation of the many features offered by Spiroid and Helicon gearing. Applications can be designed to minimize the assembly effort. Many details affecting the mounting of the gear set can be designed and toleranced to allow simple assembly and assure adequate backlash and running clearances. The basic steps described here will permit maximum utilization of the simple and positive backlash control features of Spiroid and Helicon gearing. This procedure suggests the main steps to be followed to set and check the backlash and adjust for a precise amount of backlash. Both Spiroid and Helicon gearing can be adjusted for backlash by axial movement of the gear member. Spiroid gearing can be adjusted to a finer degree by axial movement of the pinion. Housing Inspection Proper alignment is critical for maximized gear set performance. In preparation for assembly of the gear set, the housing should be inspected. The center distance or A dimension should be established (Figure 1). This dimension is important and should be within ±. 001 in./in. (For example, a inch center distance would have a tolerance of ±0.003 inch). The alignment of the bores, which will locate the pinion and gear, should also be checked. The shaft angle (usually 90 ) should be within ±5. Deviation from the nominal shaft angle will cause a contact pattern shift between the assembled pinion and gear. Heavy localized contact toward the inner or outer band of gear teeth is not desirable. AXIAL TRAVEL OF GEAR DECREASE BACKLASH GEAR MOUNTING DISTANCE SECTION A-A TYPICAL SHIM LOCATION A (CENTER DISTANCE) PINION MOUNTING DISTANCE A A Pinion Assembly Proper position of the pinion is important. SHAFT ANGLE Assembly Figure 1 The pinion is normally the first gearing member to be assembled. The nominal pinion mounting distance should have been determined during the design and detail stage of the project. The pinion mounting distance is usually the dimension from the centerline of gear to the bearing shoulder (Figure 1). Both Spiroid and Helicon pinions have threads of constant lead and pressure angle; and are proportioned to be wider than the band of gear teeth that they mesh with. A Helicon pinion is insensitive to its axial position, but should be located within ±.030 inches of the nominal mounting distance. The Spiroid pinion, with the 5 angle, should be located within ±.010 inches of the nominal mounting distance. Axial Movement of the pinion must be avoided. It is important to check the pinion for axial play due to lack of preload in the bearings. Any axial movement will affect the backlash readings and give erroneous results. Axial movement in the pinion should be avoided in close backlash applications, as well as high precision, reverse loading, and Tooth reverse load components driving applications. equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters 32 Table 8 XX

36 Gear Assembly (Either Spiroid or Helicon) The gear shaft bearings should be assembled and adjusted for proper fit. Assemble gear into mesh with pinion; position by spacer or shims to provide correct nominal mounting distance as specified by ITW Spiroid. Turn pinion by hand until gear rotates thru 360 and check for binding or tight spots; if this occurs, increase backlash. Check backlash Either clamp an indicator directly to the housing or clamp both the housing and indicator to a rigid plate. The accuracy of the indicator readings will depend on the rigidity of the mounting of the indicator in relation to the gear. The indicator finger should contact a gear tooth working face such that its travel is normal to this face. Prevent any axial or rotational movement of the pinion when checking backlash on the gear. Not all gear set assemblies lend themselves to having the gear teeth accessible for mounting an indicator typical of Figure 2. In such cases, it may be necessary to improvise an alternate surface for checking backlash. (See Figure 3) The output shaft or equivalent driven member can be utilized directly or as a mounting for a lever arm. Whatever is used must be rigidly mounted so the surface being checked indicates actual gear movement. The surface being checked with the indicator must be normal to the arc of rotation. (See Figure 2) The indicator need not be located exactly at a radius equivalent to the gear set center distance. Checking backlash at a larger or smaller radius must be adjusted linearly to the equivalent backlash at the radius of the center distance. (For example, if a inch center distance gear set has.001 inch backlash, this would be equivalent to.0005 inch backlash if measured at a inch radius or.002 inch backlash if measured at a inch radius.) A (C.D.) OUTPUT SHAFT SECURE PINION SHAFT EQUIV. A (C.D.) DIAL INDICATOR GEAR PINION IMPROVED CLAMP tangent to tooth surface Assembly Figure 2 travel of indicator finger normal to tooth surface line of travel of finger will automatically be tangent to a circle approximately equal to the center distance In some cases, a reliable backlash check cannot be made on the output or driven side of the gear. As an alternate, backlash checks might have to be made by checking the rotational lash of the pinion. The Spiroid Engineering Department would have to determine the equivalent circular movement of the pinion that would be equivalent to some increment of backlash. If the pinion is going to be used to determine the backlash, the gear must be secured so a true backlash reading can be established. After securing the gear, place a clamp on the pinion. Assembly Figure 3 33

37 Backlash Chart Spiroid and Helicon gearing can be used in zero backlash applications. However, the desire and need for zero backlash must be communicated early in the design process as many factors must be considered for a successful design. The following chart illustrates the backlash capabilities of Spiroid and Helicon gearing relative to the manufacturing processes that are used to produce them. As you can see, ITW Heartland s standard manufacturing methods will yield a backlash between and ArcMinutes. With enhanced manufacturing processes, near-zero backlash is achievable depending on the gear radius, tolerances, and thread grinding and lapping procedures that are used. It is important to note, however, that these processes will also add cost to a given project. ArcMinutes Per Gear Radius Radians (in.) ArcMin Block tolerances, standard thread 9.1 to 19 Good tolerances, finish ground thread, standard process controls 4.1 to 9 Above + light lapping, non-matched 0 to 4 Above + restrictive tolerances, heavier lapping, matched sets 34

38 APPLICATION DATA SHEET Contact Information Contact Title Company Address City State Zip Code Phone General Information TIMING Date Initiated Desired Quote Date Desired Design Confirmation Date APPLICATION STAGE Prototype 1st Article Production Other APPLICATION MARKET - check all that apply Commercial Military Aerospace / Aviation Robotics Medical Other APPLICATION PROJECTIONS Annual Usage Target price Quote Quantities Input Parameters Power Source AC DC Servo Other Pinion Speed (RPM) Dynamic Motor Torque (in. lbs) Max Motor Stall Torque (in. lbs) Max Normal Max Normal Output Parameters Sustained Torque (in. lbs) Max Stall Torque (in. lbs) Max Normal Max Normal Output Load Classification Shock Gradually Applied Constant Cyclic Intermittent Life Cycle / Environmental Design Life Hours Cycles Duty Cycle Definition (Frequency of Starts & Stops Duration of Operation Etc.) Duration of Service.5 hrs / day 2 hrs / day 10 hrs / day 24 hrs / day Other Rotation Single Direction Bi-directional Ambient Temperature ( F to F) Special Requirements Material Ratio to 1 Exact Approximate Backdrive Preference Desired Backlash Desired Space Claim Self Locking Backdriveable Stick-Slip Does Not Matter Degrees ArcMinutes ArcSeconds Radians In. Mm. Notes Please attach relevant sketch, prints, or model of the concept under consideration th Avenue Alexandria, MN Toll:

39 Other ITW Heartland Products and Services Strategic Assembly Solutions Experts in Automation, Innovation, and Motion Control The Strategic Assembly Solutions team provides a variety of manufacturing services that range from building custom automated industrial machines to sub-assemblies for other manufacturing companies. To deliver the world-class service and support that has come to be expected of this team, Strategic Assembly Solutions offers extensive product and process testing, as well as 24/7 spare parts service to cover global locations. Strategic Assembly Solutions serves many industries with an array of automated equipment and assembly capabilities including mechanical assembly, electrical controls, robotics, pneumatics and hydraulics and material handling. /StrategicAssembly Manufactured Products Custom Precision Machining With a focus on close-tolerance, complex, value added machined components, Manufactured Products offers a single-source machining capability for manufacturing companies across the globe. It also utilizes robust engineering resources and a strong investment in employees, machines, and processes to ensure that each customer gets good parts, on-time, headache-free. In particular, over the years Manufactured Products has developed a distinct expertise in complex, value-add Horizontal CNC machining for companies operating in a variety of markets. Its ability to remove more metal with less operations and part handling has won Manufactured Products the decades-long loyalty of more than a handful of successful customers. /ManufacturedProducts Tooth load components equals lbs./inch-lb. output torque Note: Additional reduction ratios may be possible depending on application parameters 36 Table 8 XX

40 ITW Gear Machines Your Experts in Automated Gear Inspection and Burnishing Designed to maximize accuracy, increase uptime, and maximize productivity, ITW Heartland s patented gear systems are the easiest to use and most reliable gear inspection machines in the industry. With two gear equipment patents, ITW Gear Machines high speed, automatic gear burnishing and inspection processes offer fast and easy changeover. In addition, it employs proprietary, easy-to-use gear inspection software to facilitate its gear measurement, data acquisition, SPC, count summaries, auto calibration, and error compensation processes. /GearMachines Contact us today for your manufacturing needs 37