SOFT-START DRIVES & COUPLINGS

Transcription

1 SOFT-START DRIVES & COUPLINGS

2 DODGE FLEXIDYNE SOFT-START DRIVES & COUPLINGS DODGE FLEXIDYNE is a dry fluid drive that provides smooth, controlled acceleration with a reduced current draw. Because of its unique concept in principle and design, it can handle difficult drive problems and is compatible with standard NEMA Design B motors commonly used in industry. It is not, however, recommended for use with variable-speed drives, internal combustion engines, or multiple-speed electric motors. HOUSING FLOW CHARGE HOUSING FLOW CHARGE MOTOR SHAFT MOTOR SHAFT OUTPUT SHAFT OUTPUT SHEAVE FLEXIBLE COUPLING ROTOR ROTOR FLEXIDYNE Drives FLEXIDYNE Couplings How FLEXIDYNE Works Housing is connected to motor shaft. Rotor within housing is connected to driven load. Fluid is heat-treated steel shot. Measured amount of flow charge is placed in housing. Circuit is energized, motor quickly accelerates to nearly full speed. Flow charge is thrown to perimeter of housing. Centrifugal force packs flow charge between housing and rotor. Driven load accelerates smoothly to motor speed. Housing and rotor lock together. FLEXIDYNE operates at 100% efficiency at full load speed without slip or wear. 2

3 DAILY NEWSPAPER USES FLEXIDYNE COUPLINGS TO PREVENT COSTLY MAINTENANCE A metropolitan daily newspaper uses a rail conveyor to haul large rolls of newsprint (weighing from 700 to 900 lbs.) to the pressroom. To prevent jolts that would frequently break the drag chain and reduce shock loads, crews installed a DODGE FLEXIDYNE coupling between the 7-1/2 HP, 1150 RPM electric motor and the floor-mounted speed reducer. HOW FLEXIDYNE CAN SOLVE YOUR COMMON DRIVE PROBLEMS COMMON DRIVE PROBLEMS High amperage drawn when starting electric motors SOLUTION: FLEXIDYNE Cuts duration of high amperage draw normally to less than one second Motor overheats at start Provides equivalent of no-load start Shock loads, bad power factor created by oversized motors Permits use of motor with capacity closer to running load Need for costly reduced-voltage starters Allows use of simple, across-the-line starters Frequent maintenance on moving parts, caused by starting shock Breakage of fragile materials (wire, thread, paper) caused by starting shock Damage to flywheel effect of motor rotor from sudden overloads Dangerous unattended overloads Hard-to-start heavy loads Ensures soft start, cuts maintenance, increases life of belt, gears, etc. Eliminates breakage with gentle, low-torque starting Slips when jam-up occurs, helps protect against damage Features speed drop cutout that automatically turns motor off if overload is prolonged Handles heavy loads easily when set for cushioned, high-torque starting Rough reversing and inching Smoothes out reversing and inching Motor burnout from overloads Can be set to slip before motor is damaged Overload damage from motor s high overload torque capacity Can be set to slip under overload at a torque level lower than motor capacity 3

4 TYPICAL APPLICATIONS FLEXIDYNE is available in three designs: drives, couplings, and C-face modules to meet most system needs. Trolley Motors Overhead Traveling Cranes Eliminates load swinging when starting and stopping lateral travel Eliminates need for expensive motor controls Punch Presses Materially assists motor in starting heavy flywheel Reduces motor current peaks required to bring flywheel back up to speed after each punch Conveyors Reduces need for shear pins Helps motor overcome initial starting inertia and shock loads from occasional overloads Reduces belt stretch Large Bakery Ovens Chain Conveyors Allows smoother starts Prevents spilling Paper Mills Stirring Tanks Helps power source overcome shock loads by dumping bales of scrap into tanks (while stirring paddle is revolving) Reciprocating Pumps Electric Motor-Driven, Oilfield Mud and Gathering, Pipeline, Chemical Plant Circulating, Paper Mill Circulating Absorbs shock loading caused by pistons and valves in pump Allows control of maximum pressures on pump Allows better manifolding of two or more pumps onto one line Crushers/Pulverizers Helps absorb initial starting inertia and shock loads Protects motors from overloads Reduces size of motor Increases motor efficiency and power factor Centrifuges Assists in overcoming high inertia of load on starting Reduces overall current consumption by allowing motor to operate in lower current range when picking up load Laundry Machines Reversing Action Greatly reduces shock stresses in drive chains and belts on starting or reversal Reduces overall current demand by greatly reducing time of peak motor current demands on each reversal Cooling Fans Reduces shock torque on fan blades caused by instantaneous high torque of motor when starting switch is closed Practically eliminates shearing off of large fan blades at hubs Hoisting Winches Power Shovels, Oilfield Drilling Rigs and Servicing Units, Steel Erecting Hoists, Drag Lines, Fishing Net, Logging Yarders and Loaders Allows smoother control of loads Eliminates possibility of killing motor by overloading Eliminates jerky lines, which can cause accidents Allows increased production by machine, giving better accelerating qualities from prime mover Reduces overall wear on bearings and gears by absorbing shocks Controls overloads on lines 4

5 Brick Plants Shale Digging Machines, Prime Movers for Brick Cards, Chain Conveyors through Baking Furnaces Controls overloading of chains and gears Absorbs shocks prevalent in digging operations Eliminates quick, jerky starts that spill loads and cause considerable loss Textile Mills Card, Spinning Frame, Bleacher, Dryer, Roving Frame, Spinning Mule Drives Allows smoother starting of all types of machines Assists in controlling tensions Allows better and less expensive compounding drives on various rollers handling continuous material through several processing tanks Refrigeration Pumps Large Refrigerator Storage Plants, Large Air Conditioning Units Reduces peak current demands on starting with electric motor Absorbs shocks caused by refrigerant pumps Allows use of internal combustion engines with automatic start and stop controls (where formerly only electric motors were used) Saw Mills Saw Mandrels, Feed Carriages, Planners Helps motors clear overloads by not pulling engine speeds down so radically Helps motors start high inertia loads Improves safety of overall machines Chip Conveyors Large Plants Provides overload protection in case of jamming or overloading and prevents damage to chains, belts, etc. Amusement Rides Merry-Go-Rounds, Ferris Wheels, Whirling Rides, Roller Coasters, Small Trains Assists in starting high inertia loads Gives smoother starts and stops for rider comfort Allows smaller prime mover (in most cases) Compressors Absorbs shocks in compressor drives Allows smaller prime mover (in many cases) Grain Elevators Helps prime mover compensate for instantaneous shock loads caused by varying loads on elevator Helps control overloading Acts as a safety against jamming Flour Mills Assists in starting heavy inertia of flour mills and blowers Helps motor overcome choke-up by allowing higher motor speeds when mill speed pulls down Printing Presses Assists in starting high inertia presses Allows use of smaller motors in many cases and eliminates low-voltage starting switches Absorbs shocks in drives caused by press 5

6 FLEXIDYNE COUPLINGS FILLER PLUG ALLOWS FLOW CHARGE TO BE POURED IN AND OUT OF UNIT, TAILORS TORQUE TO DRIVEN LOAD REQUIREMENTS. STEEL HOUSING (THROUGH SIZE 75) OFFERS SUPERIOR CORROSION RESIST- ANCE AND EXCELLENT BALANCE. LARGER SIZES (ABOVE 10 HP AT 1750 RPM) HAVE ALUMINUM HOUSINGS FOR IMPROVED THERMAL CHARACTERISTICS. DURABLE SYNTHETIC RUBBER SEALS KEEP FLOW CHARGE IN UNIT, PROTECT BEARINGS. TWO BEARINGS BALL AND BRONZE SLEEVE PROVIDE GENUINE STABILITY, ARE USED ONLY IN STARTING AND STOPPING. 6

7 PH Type FLEXIDYNE Coupling C Type FLEXIDYNE Coupling STOCK TAPER-LOCK BUSHINGS PERMIT QUICK AND EASY MOUNTING ON BOTH COUPLED SHAFTS. DODGE FLEXIDYNE couplings are a versatile solution when you want to transmit torque between in-line shafts. This low-cost, compact coupling provides smooth operating characteristics and a flexible connection. Its versatility also allows it to be adapted and directly connected to a wide variety of motors and driven machines. FLEXIDYNE couplings are available for applications from 1/2 HP 150 HP at 1800 RPM, 250 HP at 1200 RPM, and 125 HP at 900 RPM. Plus, installation is easy on a wide range of shaft diameters, because DODGE FLEXIDYNE couplings use DODGE TAPER-LOCK bushings for mounting. 7

8 FLEXIDYNE DRIVES FOR V-BELT DRIVE FROM MOTOR TO LOAD FILLER PLUG ALLOWS FLOW CHARGE TO BE POURED IN AND OUT OF UNIT, TAILORS TORQUE TO DRIVEN LOAD REQUIREMENTS. SHEAVES, AVAILABLE FROM STOCK, PROVIDE COUNTLESS RATIOS FOR PRECISE DRIVEN SPEEDS. TWO BEARINGS BALL AND NEEDLE ARE LUBRICATED FOR LIFE; PROVIDE THE STABILITY FOR A LONG, TROUBLE-FREE SERVICE LIFE. STOCK BORES FIT ANY STANDARD MOTOR SHAFT. 8

9 FLEXIDYNE drives mount directly on the motor shaft to provide an extremely compact unit for belted service. They actually take little more space than a sheave. They are available from stock for motors from 1/2 HP 100 HP at 1800 RPM, 150 HP at 1200 RPM, and 60 HP at 900 RPM. STEEL HOUSING (THROUGH SIZE 75) OFFERS CORROSION RESISTANCE AND EXCELLENT BALANCE. LARGER SIZES (ABOVE 10 HP AT 1750 RPM) HAVE ALU- MINUM HOUSINGS FOR IMPROVED THERMAL CHARACTERISTICS. Bolt-on V-belt sheaves are standard. Pulleys for flat belt or synchronous belts can be provided. FLEXIDYNE PROTECTIVE DEVICE DURABLE SYNTHETIC RUBBER SEALS KEEP FLOW CHARGE IN UNIT, PROTECT BEARINGS. FLEXIDYNE Speed Drop Cutouts The speed drop cutout senses a reduction in the output speed of the FLEXIDYNE and stops the motor before damage occurs. Both units are available in standard and explosion-proof construction. See current catalog for specifications. Both switches are intended for use only in control circuits and not in the line for starting the motor. FLEXIDYNE ACCESSORIES Stainless-Steel Flow Change Ideal for applications where excessive moisture, humidity, or wide temperature variations can cause internal condensation. 9

10 FLEXIDYNE SELECTION HP/RPM D, 5C 5D, 5C D, 5C 55D, 55C 70D, 70C D, 5C 55D, 55C 70D, 70C 1 55D, 55C 70D, 70C 75D, 75C D, 55C 70D, 70C 75D, 75C 2 55D, 55C 75D, 75C 9D, 9C 3 70D, 70C 75D, 75C 9D, 9C 5 70D, 70C 9D, 9C 11D, 11C D, 75C 9D, 9C 11D, 11C 10 75D, 75C 11D, 11C 15D, D, 9C 11D, 11C 15D, D, 9C 11D, 11C 15D, D, 11C 15D, D D, 11C 15D, D D, 11C 15D, D, D, 11C 15D, D15116, 18D* 18D, D, D, D15116, 18D* 18D, D, D, D15116, 18D* D D, D, D D D, D D D, D D * Drive selection based on starting torque. Consult catalog for ratings. 55D 18D FLEXIDYNE DRIVE DRIVE MAX. NOM. STOCK PART SIZE RPM BORES NO. 55D / /8 (Max.) D / /8 (Max.) D / /8 (Max.) D / / / /8 (Max.) D / / /8 (Max.) DL /8 (Max.) D / / /8 (Max.) D / /8 (Max.) See DODGE PT Components Engineering Catalog for dimensional information and selection. ITEMS REQUIRED FOR COMPLETE COUPLING COUPLING MECHANISM TAPER-LOCK FLANGE ASSEMBLY RESPECTIVE TYPES STD. (REV.) TYPE H TYPE F SIZE PART NO. SIZE PART NO. PART NO. PART NO PX PX PX D PX D PX PX D PX

11 55C 11C FLEXIDYNE COUPLINGS COUPLING SIZE BORE RANGE OF BUSHING MAX. RPM MECHANISM (INCLUDES DISC) ITEMS REQUIRED FOR COMPLETE COUPLING POLY-DISC FLANGE WITHOUT BUSHINGS BUSHINGS MOTOR END BUSHINGS DRIVEN END TYPE H TYPE F BUSH AVG. BUSH MIN. MAX. PART NO. SIZE PART NO. PART NO. NO. WT. LBS. NO. 55C 1/ / C 1/2 * C 1/2 1-11/ / C 1/2 2-11/ C 1/2 2-11/ * Motor end = 1-1/4", Driven end = 1-5/8". TYPE PH FLEXIDYNE COUPLINGS WITH TAPER-LOCK FLANGES ELEMENT BS TAPER-LOCK BUSHINGS RIGHT BORED MECHANISM FLANGE ASSEMBLY AVG. AVG. SIZE PART NO. SIZE BORE PART NO. SIZE PART NO. WT. LBS. PART NO. WT. LBS. PH PX70BS PH PX80BS PH PX100BS PH PX100BS D PH PX110BS D PH PX140BS 2-1/ PH PX140BS 2-1/ D

12 DODGE FLUID COUPLINGS FOR SPECIAL DRIVE APPLICATIONS OVERLOAD FUSE PLUG FOR PROTECTION (290 F STANDARD, 140 C). SHEAVE MOUNTS ON MOTOR SIDE. SPLINED HUB PROVIDES EVEN LOAD DISTRIBUTION. CAST ALUMINUM WING CONSTRUCTION HOUSING FOR REDUCED WEIGHT, GREATER STRENGTH. 12

13 NOMENCLATURE 17 C KC P x 2-7/8" Fluid Coupling Size 17" Approximate Rotor Diameter Delay Fill (Optional) KC = Coupling Style KS = Sheave/Drive Style P = PARA-FLEX PH Element D = Drive Style Fluid Coupling Bore SELECTION Fluid Coupling Selection RPM HP PX Spacing Flange with PH Element & Bolt Ring PARA-FLEX high-speed coupling assembly drops out for easy access to motor and driven equipment. PARA-FLEX high-speed element dampens vibration and shock loads, accommodates combination of angular and parallel misalignment. Fluid Coupling Circuit with Delay-Fill Chamber & Adapter Plate Delay-fill style available on sizes for softer starts (limits starting torque to 140%). Recommended in applications > 100 HP. Adapter plate ties whole system together. Cast aluminum wing construction housing reduces weight, and offers greater strength. Overload fuse plug provides protection. Shaft Hub with TAPER-LOCK Bushing Incorporates TAPER-LOCK bushing to accommodate wide range of bore sizes. Also available in finished bore. Provides true, tight grip. Easy on, easy off. Collet Mounting Sizes 7 19 are available in a wide range of bores. Sizes 15 and up are available in finished bore. KSD/CKSD Fluid Coupling (Sheave Drive) Sheave styles available in: Sizes 7 24 standard QD Sizes bolt-on style (Priced on request) Delay fill available in: Sizes

14 KSD FOR USE WITH QD SHEAVE MOTOR QD 7 1-1/8" C SDS /8" C SDS /8" C SK /8" C SF /8" C E /8" C E /8" C E /8" C F /8" C F /8" C J /8" C J /8" FB M /8" FB M CKSD FOR USE WITH QD SHEAVE MOTOR QD /8" C SF /8" C E /8" C E /8" C E /8" C F /8" C F /8" C J /8" C J /8" FB M /8" FB M KSD FOR USE WITH BOLT-ON SHEAVE MOTOR /8" FB /8" C /8" FB /8" C /8" C /8" FB /8" C /8" FB /8" C /8" FB /8" FB C = Collet Mount FB = Finish Bore

15 KCM FLUID COUPLING MAX. BORE 7 1-3/4" /4" /4" /4" /4" /4" /8" /8" /8" /8" /8" /8" /8" CKCM FLUID COUPLING MAX. BORE /4" /4" /4" /8" /8" /8" /8" /8" /8" /8" KCP FLUID COUPLING /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" CKCP FLUID COUPLING /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8" /8"

16 C C A B D D B E H THREAD E (1) Shrouded bolt design for sizes Exposed bolt design for sizes (2) Gear couplings not shown. SIZE A B C C D E E WT. LESS OIL OIL MAX. H GEAR (LBS.) (U.S. GAL.) COUPLING KCM CKCM NO. DIA. KCM CKCM KCM CKCM SIZE (1) (2) /4-28 UNF /4-28 UNF /8-24 UNF 1-1/ /8-24 UNF 1-1/ /8-24 UNF 1-1/ /8-24 UNF 1-1/ /2-20 UNF 2-1/ /2-20 UNF 2-1/ /2-20 UNF 2-1/ /2-20 UNF 2-1/ /2-20 UNF 2-1/ , /4-16 UNF 3-1/ /4-16 UNF 3-1/ /4-16 UNF Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI USA, Tel: (1) , Fax: (1) Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC USA, Tel: (1) , Fax: (1) Canada: Rockwell Automation Canada, 296 Walker Drive, Bramalea, Ontario, Canada L6T 4B3, Tel: (1) Europe: Rockwell Automation, Brühlstraße 22, D Elztal-Dallau, Germany, Tel: (49) , Fax: (49) Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore , Tel: (65) , Fax: (65) Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI USA, Tel: (1) , Fax: (1) DMR /02-5M-K This material is not intended to provide operational instructions. Appropriate Rockwell Automation instruction manuals and precautions should be studied prior to installation, operation, or maintenance of equipment. Copyright 2002 Rockwell Automation. All rights reserved. Printed in USA. DODGE and RELIANCE ELECTRIC are trademarks of Rockwell Automation.