High-Performance Universal Joint Shafts Products Engineering Service

Transcription

1 High-Performance Universal Joint Shafts Products Engineering Service

2 Universal Joint Shafts and Hirth Couplings We are the experts for cardanic power transmission components and Hirth couplings within Voith Turbo. Voith Turbo, the specialist for hydrodynamic drive, coupling and braking systems for road, rail and industrial applications, as well as for ship propulsion systems, is a Group Division of Voith GmbH. Voith sets standards in the markets energy, oil & gas, paper, raw materials and transporta tion & automotive. Founded in 1867, Voith employs almost people, generates Euro 5.6 billion in sales, operates in about 50 countries around the world and is today one of the biggest family-owned companies in Europe. 2

3 Contents 1 Voith high-performance universal joint shafts What makes them unique? 4 8 Selection aids Definitions of operating variables 41 2 Range 6 3 Designs Center sections Flanges Type designations 9 4 Applications 10 5 Definitions and abbreviations Lengths Torque loads 15 6 Technical data S Series R Series CH Series E Series 26 7 Engineering basics Major components of a Voith universal joint shaft 7.2 Telescopic length compensation Kinematics of the universal joint Two universal joints Bearing forces on input and output shafts Balancing of universal joint shafts Size selection Operating speeds Masses Connection flanges and bolted connections 52 9 Service Installation and commissioning Training Genuine Voith spare parts Overhaul, maintenance Repair and maintenance Retrofit and modernizations Services and supplementary products Engineering Connecting components for universal joint shafts Quick-release coupling GT Voith Hirth serrations Universal joint shaft supports Universal joint shafts with carbon fiberreinforced polymer (CFRP) components 10.7 High-performance lubricant for universal joint shafts Safeset torque-limiting safety couplings ACIDA torque monitoring systems Integrated management system Quality Environment Occupational health and safety 77 3

4 1 2 1 Voith High-Performance Universal Joint Shafts What makes them unique? Features Closed bearing eye Drop-forged journal crosses FEM-optimized geometry High strength tempering and case-hardened steels Load-optimized welded joints Length compensation with SAE profile (straight flank profile) for larger series Patented balancing procedure Engineering and products from a single source Advantages Heavy-duty cross-sections without joints or bolts Minimal notch stresses Enclosed seal surfaces Maximum possible torque capacity Optimal design for torque transmission Minimal notch stresses Capability to withstand high static and dynamic loads Optimal design for torque transmission Lower normal forces and thus lower displacement forces Low surface pressure High wear resistance Dynamic balancing in two planes Balancing mass where unbalanced forces act Single contact person when designing the driveline Certifications and classifications for rail vehicles and marine vessels Made in Germany Voith Engineered Reliability Officially-approved product Seal of approval for quality, efficiency and precision Competent and trustworthy partner 4

5 3 4 1 Assembly building for Voith universal joint shafts 2 Welding robot 3 Balancing machine 4 Shipping Benefits + + Productivity increase + + Long service life + + Ease of movement + + Long service life + + Extremely smooth operation + + Time and cost savings + + Combined responsibility + + Time and cost savings + + Reliability + + Innovative product and system solutions 5

6 2 Range Voith high-performance universal joint shafts offer an ideal combination of torque capacity, torsional rigidity and deflection resistance. We supply stand ard universal joint shafts, customer-specific adaptations, as well as special designs. Technical consultation, simulation of torsional vibrations and measurement of operating parameters complete our range of services. Series Torque range M z [knm] Flange diameter a [mm] S 0.25 to to 225 R 32 to to 550 CH 260 to to E to to

7 Features Applications Standard design of Voith universal joint shafts Non-split bearing eyes thanks to single-piece forged flange yoke Length compensation with involute profile Paper machinery Pumps General industrial machinery Marine vessels Rail vehicles Test stands Construction machinery and cranes High torque capacity Optimized bearing life Flange in friction and positive locking design (see page 9) Length compensation with involute profile up to size 315; from size 350 with SAE profile (straight flank profile, see page 30); optional tripod Optimized torsional rigidity and deflection resistance in a low-weight design Particularly suitable for use with high-speed drives Optional: Low-maintenance length compensation through use of plasticcoated (Rilsan ) involute spline profile Rolling mill drives Heavy-duty industrial drives Paper machinery Pumps Marine vessels Rail vehicles Very high torque capacity Optimized bearing life Flange with Hirth connection for transmitting maximum torque Length compensation with SAE profile (straight flank profile, see page 30) Rolling mill drives Construction of heavy machinery Paper machinery Maximum torque capacity Optimized bearings for exceptionally demanding applications Patented 2-piece flange yoke Flange with Hirth connection for transmitting maximum torque Length compensation with SAE profile (straight flank profile, see page 30) Heavy-duty rolling mill drives 7

8 3 Designs 3.1 Center sections Type Description T Universal joint shaft with standard length compensation TL Universal joint shaft with longer length compensation TK Universal joint shaft with short length compensation TR Universal joint shaft with tripod length compensation 1 F Universal joint shaft without length compensation (fixed-length shaft) GK Joint coupling: short, separable joint shaft without length compensation FZ Intermediate shaft with a joint head and bearing Z Intermediate shaft with double bearing 1 Technical data: Please request separate catalog 8

9 3.2 Flanges Type Description Type Description S Friction flange, torque transmission by a non-positive connection K Flange with split sleeves for torque transmission (DIN ) Q Flange with face key for torque transmission H Flange with Hirth coupling for torque transmission 3.3 Type designations Example R T S 285 / 315 R Series S, R, CH, E Center-section design T, TL, TK, TR, F, GK, FZ, Z Size Flange design S, K, Q, H Flange size input end / output end, see section 7.1 (Page 28) Profile coating S: Steel (Standard) R: Rilsan Length l min or l z min in mm 9

10 1 2 10

11 3 1 Rolling mills (horizontal rolling stand) 2, 3 Rolling mills (edging mill stand) 4 Applications 11

12 1 2 12

13 Rail vehicle drives 2 Paper machines 3 Marine propulsion 4 Pumps 5 Test stands 6 Special drives (mine hoist) 13

14 5 Definitions and abbreviations 5.1 Lengths Universal joint shaft with length compensation Universal joint shaft without length compensation l B,max l z l v l B (=l) l B : Operating length (to be specified when ordering) l z : Shortest length of the universal joint shaft (fully collapsed) l B : Operating length, which corresponds to the universal joint shaft length l (to be specified when ordering) l v : Available length compensation The distance between the driving and the driven machines, together with any length changes during operation, deter mines the operating length: Optimal operating length: l B,opt l z + l v 3 Maximum permissible operating length: l B,max = l z + l v 14

15 5.2 Torque loads Torque definitions Designation Explanation Components M (t) M DS M DW This is the reversing fatigue torque rating. The shaft will have an infinite fatigue life up to this torque level. M DW 0 t M DS M K This is the pulsating, one-way fatigue torque rating. The shaft will have infinite fatigue life up to this torque level. Here: M DS 1.5 M DW Maximum permissible torque. If this level is exceeded, plastic deformation may occur. Bearing Note M DW, M DS and M Z are load limits for the universal joint shaft. In the case of torque values that are close to the load limit, the transmission capability of the flange connection needs to be checked, especially when Hirth couplings are not being used. M Z Flanged connections The permissible torque for rarely occuring peak loads. At torque levels in excess of M Z, the bearing tracks might suffer plastic deformation. This can lead to a reduced bearing life. Individually designed 15

16 6 Technical data 6.1 S Series SF SGK l l fix General specifications ST 1 Size M z M DW CR ß max a k b ± 0.1 c H7 h C12 l m r t z g LA l v [knm] [knm] [knm] [ ] x A, B x A, B x A, B x A. B, C x A, B, C x A, B, C x A, B, C x C x C x C x C x C 140 Dimensions in mm 1 Longer l v on request 16

17 ST / STK l z l m øb øb øb t g l v øh øh øh SFZ SZ l l l d l d ød ød øc øk ør øa øb z = 4 z = 6 z = 8 t a g a t a g a LA: Length compensation A: without profile guard B: with profile guard C: Rilsan coating with profile guard STK 1 STK 2 STK 3 STK 4 2 SF SGK SFZ SZ SFZ, SZ I z min LA l v I z fix LA l v I z fix LA l v I z fix LA l v I z fix I min I fix I min I min I d d g a t a 240 B B B B B B B B B B B B B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C C C C C C C C C C C C C C C C C C C C C shorter l Z upon request 17

18 6.2 R Series RF RGK l l fix General specifications RT RTL 1 Size M z M DW CR ß max k l m r LA l v I z min LA l v I z min [knm] [knm] [knm] [ ] x 10 C x 12.5 B, C B, C x 12.5 B, C B, C x 12.5 B, C B, C x 16 B, C B, C x 22.2 B B x 25 B B x 28 B B x 32 B B x 32 B B Dimensions in mm 1 Longer l v on request 18

19 RT / RTL / RTK l z l m øk ør l v RFZ RZ l l l d l d ød ød t a g a t a g a LA: Length compensation B: with profile guard C: Rilsan coating with profile guard RTK 1 RTK 2 2 RF RGK RFZ RZ RFZ, RZ LA l v I z fix LA l v I z fix I min I fix I min I min l d d g a t a B, C B, C B, C B, C B, C B, C B, C B, C B B B B B B B B B B Shorter l z on request Flange dimensions: Pages 20 to 23 19

20 S flange: friction flange øb øb øa øb øc øk t g øh z = 8 z = 10 øh k 1 a b ± 0.2 c H7 g h C12 t z Note Standard Torque M DW = 18 knm Standard Torque M DW = 25 knm Standard Torque M DW = 36 knm Standard Torque M DW = 52 knm Standard Torque M DW = 75 knm Standard Torque M DW = 100 knm Standard Dimensions in mm. Additional flanges on request. 1 Rotation diameter of the universal joint shaft. 20

21 Q flange: flange with face key y øb øb øb øa øb øc x øk t g øh øh øh z = 8 z = 10 z = 16 k 1 a b ± 0.2 c H7 g h t x h9 y z Note Standard Standard Standard Standard Standard Standard Standard Standard Standard Dimensions in mm. Additional flanges on request. 1 Rotation diameter of the universal joint shaft. 21

22 K flange: flange with split sleeve øa øb øc øk øb øb ød ød øe øe t g øh z = z = øh k 1 a b ± 0.2 c H7 g h C12 t z d e h12 Note Standard Standard Standard Standard Standard Standard Standard Dimensions in mm. Additional flanges on request. 1 Rotation diameter of the universal joint shaft. 22

23 H flange: Flange with Hirth connections øb øb øb øa øb øc øk g øh øh øh z = 4 z = 6 z = 8 k 1 a b ± 0.2 c g h C12 u 2 z Note Standard Standard Standard Standard Standard Standard Standard Standard Standard Dimensions in mm. Bore on internal gear tooth. Additional flanges on request. 1 Rotation diameter of the universal joint shaft. 2 Number of teeth of Hirth coupling. 23

24 6.3 CH Series CHT l m l z øb øb øb øa øb øk ør g l v z = 12 øh øh z = 16 øh z = 24 CHF CHGK l l fix 24

25 LA: Length compensation A: without profile guard General specifications CHT 2 CHF 2 CHGK Size M z 1 [knm] M DW 1 [knm] CR [knm] ß max [ ] a k b ± 0.2 h l m r z g LA l v I z min I min I fix x B x B x B x B x B x B x B x B x B x B x B x B x B x x x x x x x x x x x x x x x x x x Dimensions in mm. From size to without internal bearing ring. 1 Values for forged components. 2 From size to customer specification. 25

26 6.4 E Series ET, EF and EGK designs Sizes up to Torque capacities upon request E Series high performance universal joint shaft Joints Features Flange geometry with optimal design for torque transmission Reinforced journal crosses Optimized cross-sections and transition radii on all torque-transmitting components Patented 2-piece flange yoke, with serrations alignment on the symmetry axis One-piece bearing eye Storage Maximum utilization of available space for installation with largest possible bearings and journal crosses Optimized incorporation of bearings Best leverage ratios at journal cross Roller bearings with outer and inner rings Optimized rolling element design Improved rolling element lubrication Connection technology Flange with Hirth coupling Full flange design E Series high-performance universal joint shafts with size comparison 26

27 Advantages Benefits Significantly higher torque capacity than with previous universal joint shaft designs Optimized to withstand torque peaks Heavy-duty cross-sections without joints or bolts + + Productivity increase + + Long service life + + Reduced maintenance costs + + Capability to roll higher strength steels Increased bearing life and capability to withstand high static and dynamic loads Long bearing life Uniformed load distribution throughout bearing Capability to withstand high static and dynamic loads Individually replaceable cartridge style roller bearings Optimized to withstand torque peaks Improved hydrodynamic lubrication Reliable transmission of the highest torques Optimal centering Easy to assemble No weakening of components as a result of necking or reduced cross-sections + + Low assembly and maintenance costs + + Productivity increase + + Capability to roll higher strength steels + + Able to withstand overloads Three-dimensional, sectioned model of an E Series joint 27

28 7 Engineering basics 7.1 Major components of a Voith universal joint shaft Design Hub yoke, output end Welded yoke Tube Splined hub Flange yoke Journal cross 28

29 Irrespective of their series, all versions and sizes of Voith univ er sal joint shafts share many of the same common at tri - butes that contribute to ensuring reliable operation: Yokes and flange yokes with optimized geometry Drop-forged journal crosses Low maintenance roller bearings with maximum load capacity Use of high-strength tempering and hardened steels Optimal welded joints Journal cross set Flange yoke Splined journal Welded yoke Dirt scraper Profile guard Shaft yoke, input end 29

30 1 2 1 SAE profile (straight flank profile) 2 Involute profile 7.2 Telescopic length compensation For many applications, length compensation of the universal joint shaft is required. In comparison with other driveline products, in the case of universal joint shafts, length compensation is achieved by the center section and offset by the universal joints. For smaller universal joint shafts, which typically experience lower loads, the involute profile is a suitable solution with a good cost-benefit ratio. The SAE profile (straight flank profile) is a better solution for large, high-performance universal joint shafts. Two types of length compensation are used in Voith universal joint shafts: the SAE profile (straight flank profile) and the involute profile. The universal joint shaft series and size deter mine the type of length compensation. 30

31 Force introduced during torque transmission Torque transmission and centering Torque transmission Centering function F N > F U F N F U F U SAE profile (straight flank profile) Involute profile SAE profile (straight flank profile) Involute profile Length compensation with SAE profile (straight flank profile) Features Advantages Benefits Straight flank, diameter-centered profile Almost orthogonal introduction of force Separation of torque transmission and centering functions Lower normal forces and thus lower displacement forces + + Long service life + + Ease of movement Large contact surfaces Low surface pressure + + Long service life Favorable pairing of materials for hub and spline shaft Spline shaft nitrated as standard High wear resistance + + Long service life Patented lubrication mechanism in the grease distribution groove for uniform distribution of grease across the full diameter of the profile Tooth shape incorporates lubri cation reservoir for reliable supply of lubricant to sliding surfaces + + Extended maintenance intervals 31

32 7.3 Kinematics of the universal joint When the input shaft W 1 rotates at a constant angular velocity (v 1 = const.), the output shaft W 2 rotates at a varying angular velocity (v 2 const.). The angular velocity of the output shaft v 2 and the differential angle w = (a 1 a 2 ) vary in a sinusoidal manner, their values depending upon the deflection angle b. This characteristic of universal joints is called the gimbal error and must be taken into consideration when selecting a universal joint shaft. Universal joint a 1 G 1 Standard universal joint W 1 G 1 a 2 W 1 W 2 a 1, a 2 b M 1, M 2 v 1, v 2 Input shaft Output shaft Angle of rotation Deflection angle Torques Angular velocities M 1, v 1 b M 2, v 2 W 2 32

33 Movement relation b b b b b b = 12 w b = 6 l w maxl for b = b = b = cos a 1 With one rotation of the shaft W 1, the differential angle w changes four times, as does the angular velocity v 2. During the course of one rotation, the shaft W2 twice passes through the points of maximum acceleration and deceleration. At larger deflection angles b and higher velocities, considerable forces can be generated. The following equations apply: w = a 1 a 2 (1) tan a 1 = cos b tan a 2 (2) tan w = tan a 1 (cos b 1) 1 + cos b tan 2 a 1 (3) This gives the ratio of the angular velocities between the two shafts W 1 and W 2 : v 2 v = cos b (4) 1 1 sin 2 b sin 2 a 1 change to maximum: v 2 v = 1 1 max cos b at a 1 = 90 and a 1 = 270 change to minimum: v 2 (4a) v 1 = cos b at a min 1 = 0 and a 1 = 180 (4b) As regards the torque ratio, the following equation applies: M 2 M 1 v 1 = v (5) 2 change to maximum: M 2 M 1 max = 1 cos b at a 1 = 90 and a 1 = 270 (5a) change to minimum: M 2 M 1 min = cos b at a 1 = 0 and a 1 = 180 (5b) 33

34 Variation factor, differential angle Conclusions w max U A single universal joint should only be used if the following requirements are met: The variation in the rotational speed of the output shaft is of secondary importance The deflection angle is very small (b < 1 ) The forces transmitted are low w max U b One indicator of the variation is the variation factor U: U = v 2 v v 2 1 max v = 1 cos b = tan b sin b (6) 1 min cos b Finally, as regards to the maximum differential angle w max the following equation applies: 1 cos b tan w max = ± 2 cos b (7) All of the components of the universal joint shaft should lie in one plane G 1 A G 2 34

35 7.4 Double universal joints Section 7.3 shows that the output shaft W 2 always rotates at the varying angular velocity v 2 when connected via a single universal joint at a given deflection angle b. If, however, two universal joints G 1 and G 2 are connected together correctly in the form of a universal joint shaft in a Z- or W arrangement, the variations in the speeds of the input and output shaft fully cancel each other out. Universal joint shaft in Z arrangement, the input and output shafts lie parallel to each other in one plane Universal joint shaft in W arrangement, the input and output shafts lie parallel to each other in one plane b 1 b 1 b 2 b 2 Conditions for the synchronous rotation of the input and output shafts: The three conditions A, B and C ensure that joint G 2 operates with a phase shift of 90 and fully compensates for the gimbal error of joint G 1. This universal joint shaft arrangement is known as the ideal universal joint shaft arrangement with complete motion compensation. This is the arrangement to be aiming for. If just one of the three conditions is not satisfied, then the universal joint shaft no longer operates at constant input and output speeds, i.e. it no longer operates homo-kinetically. In such cases, please contact your Voith Turbo representative. Both yokes of the center section of the shaft lie in one plane The deflection angles b 1 and b 2 of the two joints are identical G 1 G 1 b 1 b 2 B C G 2 G 2 35

36 7.5 Bearing forces on input and output shafts Radial bearing forces Due to the deflection of the universal joint shaft, the connection bearings are also subjected to radial loads. The radial forces on the bearings vary from no forces to their maximum, twice per revolution. Maximum values for radial bearing forces on universal joint shafts in a Z-arrangement a b L M d b 1 A B G 1 b 2 e f G 2 E F b 1 b 2 b 1 = b 2 A 1 = M d b cos b 1 (tan b L a 1 tan b 2 ) A 1 = 0 a 1 = 0 B 1 F 1 A 1 E 1 B 1 = M d (a + b) cos b 1 (tan b L a 1 tan b 2 ) E 1 = M d (e + f) cos b 1 (tan b L f 1 tan b 2 ) B 1 = 0 E 1 = 0 F 1 = M d e cos b 1 (tan b L f 1 tan b 2 ) F 1 = 0 a 1 = 90 A 2 = M d tan b 1 a A 2 F 2 B 2 E 2 B 2 = M d tan b 1 a E 2 = M d F 2 = M d sin b 2 f cos b 1 sin b 2 f cos b 1 A 2 = M d tan b 1 a B 2 = M d tan b 1 a E 2 = M d tan b 1 f F 2 = M d tan b 1 f 36

37 Designations and formulas G 1, G 2 Universal joints A, B, E, F Connection bearing M d Input torque A 1/2, B 1/2, E 1/2, F 1/2 Bearing forces a 1 Angle of rotation b 1, b 2 Deflection angle Maximum values for radial bearing forces on universal joint shafts in a W-arrangement L a b b 1 b 2 e f M d G 1 G 2 A B E F b 1 b 2 b 1 = b 2 A 1 = M d b cos b 1 (tan b L a 1 tan b 2 ) A 1 = 2 M d b sin b 1 L a a 1 = 0 B 1 F 1 A 1 E 1 B 1 = M d (a + b) cos b 1 (tan b L a 1 tan b 2 ) E 1 = M d (e + f) cos b 1 (tan b L f 1 tan b 2 ) B 1 = 2 M d (a + b) sin b 1 L a E 1 = 2 M d (e + f) sin b 1 L f F 1 = M d e cos b 1 (tan b L f 1 tan b 1 ) F 1 = 2 M d e sin b 1 L f a 1 = 90 A 2 = M d tan b 1 a A 2 E 2 B 2 F 2 B 2 = M d tan b 1 a E 2 = M d F 2 = M d sin b 2 f cos b 1 sin b 2 f cos b 1 A 2 = M d tan b 1 a B 2 = M d tan b 1 a E 2 = M d tan b 1 f F 2 = M d tan b 1 f 37

38 7.5.2 Axial bearing forces In principle, the kinematics of a universal joint shaft do not generate any axial forces. However, axial forces that need to be absorbed by adjacent bearings occur in universal joint shafts with length compensation for two reasons: 1. Force F ax, 1 as a result of friction in the length compensation assembly As the length changes during the transmission of torque, friction is generated between the flanks of the spline profiles in the length compensation assembly. The frictional force F ax,1, which acts in an axial direction, can be calculated using the following equation: 2. Force F ax, 2 as a result of the pressure build-up in the length compensation assembly during lubrication During the lubrication of the length compensation assembly, an axial force F ax, 2, occurs which depends on the force applied while lubricating. Please note that information on this subject is available in the installation and operating instructions. F ax,1 = m M d 2 cos b d m where: m Coefficient of friction; m 0.11 to 0.14 for steel against steel (lubricated) m 0.07 for Rilsan plastic coating against steel M d Input torque d m Pitch circle diameter of the spline profile b Deflection angle 1 Balancing machine 2 Balancing of universal joint shafts

39 7.6 Balancing of universal joint shafts As with any other torque transmitting shaft, a universal joint shaft also has a non-uniform distribution of mass around the axis of rotation. This leads to unbalanced forces during operation wich has to be compensated depending on the case of application. Depending on the operating speed and the speci fic applica tion, Voith universal joint shafts are dynamically balanced in two planes. The benefits of balancing: + + Prevention of vibrations and oscillations, resulting in smoother operation + + Longer service life of the universal joint shaft The balancing procedure employed by Voith for universal joint shafts is based on that prescribed in DIN ISO ("Mechanical vibration Balance quality requirements for rotors in a constant (rigid) state Part 1: Specification and verification of balance tolerances"). An extract from this Standard lists the following approximate values for balance quality levels: Type of machine general examples Balance quality level G Complete piston engines for cars, trucks and locomotives G 100 Cars: wheels, rims, wheel sets, universal joint shafts; crank drives with mass balancing on elastic mounts Agricultural machinery; crank drives with mass balancing on rigid mounts; size reduction machinery; input shafts (cardan shafts, propeller shafts) Jet engines; centrifuges; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed of up to 950 rpm; electric motors with a shaft height of less than 80 mm; fans; gearboxes; general industrial machinery; machine tools; paper machinery; process engineering equipment; pumps; turbochargers; hydro-power turbines Compressors; computer drives; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed of over 950 rpm; gas turbines, steam turbines; machine tool drives; textile machinery G 40 G 16 G 6.3 G 2.5 Depending on the application and maximum operating speed, the balance quality levels for universal joint shafts lie in the range between G 40 and G 6.3. The reproduction of the measurements can be subject to wider tolerances due to the influence of various physical factors. Such factors include: Design characteristics of the balancing machine Accuracy of the measuring method Tolerances in the connections to the universal joint shaft Radial and axial clearances in the universal joint bearings Deflection clearance in length compensation 39

40 8 Selection aids The design of a universal joint shaft depends on a number of factors. Reliable, verified calculations and tests prevent any danger to the surrounding area. Consideration of the costs that arise over the entire product lifecycle also comes into play. The design procedures described in this chapter are only intended to provide approximate guidelines. When making a final decision about a universal joint shaft, you can rely on our sales engineers for their technical knowledge and many years of experience. We will be happy to advise you. The following factors have a major influence upon any decision regarding universal joint shafts: Operating variables Main selection criteria: Bearing lifetime or durability Installation space Adjacent bearings Three-dimensional bending b v1 b v2 b h1 b h2 40

41 8.1 Definitions of operating variables Des ignation Usual unit Explanation P N [kw] Rated power of the drive motor n N [rpm] Rated speed of the drive motor M N [knm] Rated torque of the drive motor, where: M N = 60 P 2p n N 9.55 P N N n with M N in knm, n N in rpm and P N in kw N M E [knm] Equivalent torque This torque is an important operating variable if bearing lifetime is the main criterion in the selection of a universal joint shaft. It takes operating conditions into account and can be calculated for situations involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently known, the rated torque can be used as an initial estimate. n E [rpm] Equivalent speed This speed is an important operating variable if bearing lifetime is the main criteria in the selection of a universal joint shaft. It takes operating conditions into account and can be calculated for situations involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently known, the rated speed can be used as an initial estimate. M max [knm] Peak torque This is the maximum torque that occurs during normal operation. n max [rpm] Maximum speed This is the maximum speed that occurs during normal operation. n z1 [rpm] Maximum permissible speed as a function of the deflection angle during operation The center section of a universal joint shaft in a Z- or W arrangement (b 0 ) rotates at a varying speed. It experiences a mass acceleration torque that depends upon the speed and the deflection angle. To ensure smooth operation and prevent excessive wear, the mass acceleration torque is limited by avoiding the exceeding of the maximum speed of the universal joint shaft n z1. For additional information see section n z2 [rpm] Maximum permissible speed taking bending vibrations into account A universal joint shaft is an elastic body when bent. At a critical bending speed (whirling speed), the frequency of the bending vibrations equals the natural frequency of the universal joint shaft. The result is a high load on all of the universal joint shaft components. The maximum speed of the universal joint shaft must be significantly lower than this critical speed. For additional information, see section b [ ] Deflection angle during operation Deflection angle of the two joints in a Z or W arrangement, where: b = b 1 = b 2 If the situation involves three-dimensional deflection, the resulting deflection to angle b R can be determined thus: tan b R = tan 2 b h + tan 2 b V und es gilt: b = b R b max [ ] Maximum possible deflection angle This is the deflection angle that occurs during normal operation. 41

42 8.2 Size selection There are essentially two selection criteria when choosing the size of a universal joint shaft: 1. The lifetime of the roller bearings in the joints 2. The fatigue-free operating range, and thus the torque capacity and / or load limits As a rule, the application determines the primary selection criteria. A selection based upon bearing lifetime is usually made if the drives need to have a long service life and pronounced torque spikes never occur or happen only briefly (for instance, during start-up). Typical examples include drives in paper machinery, pumps and fans. In all other applications, the selection is made on the basis of the fatigue-free operating range Selection based upon bearing lifetime The procedure used for calculating the bearing lifetime is based upon that prescribed in DIN ISO 281 ("Rolling bearings Dynamic load ratings and rating service life"). However, when applying this standard to universal joint shafts, several different factors are not taken into account; for instance, the support of the bearing, i.e. deformation of the bore under load. So far, these factors could only be assessed qualitatively. The theoretical lifetime of a bearing in a universal joint shaft can be calculated using the following equation: L h = n E b K B ( CR M E ) 10 3 where: L h is the theoretical lifetime of the bearing in hours [h] CR Load rating of the universal joint in knm (see the tables in Chapter 6) b Deflection angle in degrees [ ]; in the case of threedimensional bending, the resulting deflection angle b R is to be used; in any case, however, using a minimum angle of 2 K B Operational factor n E Equivalent speed in rpm M E Equivalent torque in knm Operational factor In drives with diesel engines, torque spikes occur that are taken into account by the operational factor K B : Prime mover (driving machine) Operational factor K B Electric motor 1 Diesel engine

43 Equivalent operating values The equation for the theoretical lifetime of the bearing assumes a constant load and speed. If the load changes in increments, the equivalent operating values can be determined that produce the same fatigue as the actual loads. The equivalent operating values are ultimately the equivalent speed n E and the equivalent torque M E. If a universal joint shaft transmits the torque M i for a time period T i at a speed of n i, a time segment q i that normalizes the time period T i with respect to the overall duration of operation T tot is first defined: Conclusions The bearing's calculated lifetime is a theoretical value that is usually significantly exceeded. The following additional factors affect the lifetime of the bearings, sometimes to a significant degree: Quality of the bearings Quality (hardness) of the journals Lubrication Plastic deformation as a result of overloading Quality of the seals u q i = T i with q T i = q 1 + q q u = 1 tot i = 1 In this way, the equivalent operating values can be determined: u n E = i = 1 ( M E = q i n i = q 1 n 1 + q 2 n q u n u u 10 3 q i n i M 3 10 i i = 1 n E ) = ( q 1 n 1 M q 1 2 n 2 M q u n u M u n E ) 3 10 Incremental variation of the load on a universal joint shaft M, n M 1 M u M 2 n 1 n 2 n u 0 q 1 q 2 q u 1 q 43

44 8.2.2 Selection on the basis of fatigue-free operating range Calculations regarding the fatigue-free operating range can be made using a load spectrum. In practice though, sufficiently accurate load spectra are seldom available. In this case, one needs to rely on the quasi-static dimensioning procedure. In this procedure, the expected peak torque M max is compared with the torques M DW, M DS and M Z (see section 5.2). The following estimate is made for the peak torque: M max K 3 M N K 3 is called the shock factor. These are empirical values based upon decades of experience in designing universal joint shafts. The peak torque determined in this manner must meet the following requirements: 1. M max M DW for alternating load 2. M max M DS for pulsating load 3. Individual and rarely occurring torque peaks must not exceed the value M Z. The permissible duration and fre quen cy of these torque spikes depends upon the appli ca tion; please contact Voith Turbo for more information. Shock load Shock factor K 3 Typical driven machinery Minimal Generators (under a uniform load) Centrifugal pumps Conveying equipment (under a uniform load) Machine tools Woodworking machinery Moderate Multi-cylinder compressors Multi-cylinder piston pumps Light-section rolling mills Continuous wire rolling mills Primary drives in locomotives and other rail vehicles Severe 2 3 Transport roller tables Continuous pipe mills Continuously operating main roller tables Medium-section rolling mills Single-cylinder compressors Single-cylinder piston pumps Fans Mixers Excavators Bending machines Presses Rotary drilling and boring equipment Secondary drives in locomotives and other rail vehicles Very severe Extremely severe 3 5 Reversing main roller tables Coiler drives Scale breakers Cogging/roughing stands 6 15 Roll stand drives Plate shears Coiler pressure rolls 44

45 8.3 Operating speeds Maximum permissible speed n z1 as a function of the deflection angle Section 7.3 shows that a universal joint exhibits a varying output motion. A universal joint shaft is a connection of two universal joints in series with one another. Under the conditions described in section 7.4, a universal joint shaft in a Z or W-arrangement exhibits homokinetic motion between the input and output. However, the center section of the uni versal joint shaft still rotates at the periodically varying angular vel ocity v 2. Since the center section of the universal joint shaft still exhibits a mass moment of inertia, it creates a moment of resistance to the angular acceleration dv 2 / dt. On universal joint shafts with length compensation, this alternating mass acceleration mo ment can cause clattering sounds in the profile. The consequences include less smooth operation and increased wear. In addition, the mass acceleration torque can affect the entire drive chain on universal joint shafts with length compensation, as well as universal joint shafts without length compensation. Torsional vibrations should be mentioned here by way of example. In order to prevent these adverse effects, please ensure the following conditions: n max n z1 Approximate values of n z1 as a function of b R R S S S S S S S S S S S S n z1 [rpm] R CH R CH R CH R CH R CH R R R b [ ] 45

46 8.3.2 Maximum permissible speed n z2 as a function of operating length Every universal joint shaft has a critical bending speed (whirling speed) at which the rotational bending speed (bending frequency) matches the natural frequency of the shaft. The result: high loads on all components of the universal joint shaft. Damage to or destruction of the universal joint shaft is possible in unfavorable situations. For normal connecting and operating conditions, it is possible to specify approximate values for the maximum permissible speeds n z2 as a function of the operating length l B : The calculation of this critical bending speed for a real universal joint shaft in a driveline is a complex task that Voith Turbo performs using numerical computing programs. The critical bending speed depends essentially upon three factors: Operating length l B Deflection resistance of the universal joint shaft Connecting conditions at the input and output ends The maximum permissible speed n z2 is determined in such a way that it provides a safety allowance with respect to the critical bending speed that is suitable for the particular application. For safety reasons and to prevent the failure of the universal joint shaft, please ensure the following conditions: n max n z2 46

47 Approximate values of n z2 as a function of l B for the S Series S S S n z2 [rpm] S S S S S S S S S I B [mm] Approximate values of n z2 as a function of l B for the R and CH Series R R R R R R CH R CH R CH R CH R CH n z2 [rpm] I B [mm] 47

48 8.4 Masses Size Values for the tube based on length Universal joint shafts with length compensation m' R [kg / m] m L min [kg] m L min [kg] m L min [kg] m L min [kg] m L min [kg] ST / STL / SF ST STL STK1 STK2 STK Values upon request RT / RTL / RF RT RTL RTK1 RTK Continued on pages 50 and 51 48

49 Universal joint shafts without length compensation Joint coupling m L min [kg] m L min [kg] m L fix [kg] STK4 SF SGK RWF RGK

50 Size Values for the tube based on length Universal joint shafts with length compensation m' R [kg / m] CHT / CHF m L min [kg] CHT Values for dimensions and series not listed are available on request Designation m' R Explanation Mass of the tube per 1 m of length Universal joint shafts with length compensation m L min Mass of the universal joint shaft for a length of l z min Calculations for the entire universal joint shaft: m tot Total mass m ges = m L min + (l z l z min ) m' R 50

51 Universal joint shafts without length compensation Joint coupling m L min [kg] CHF m L fix [kg] CHG Universal joint shafts without length compensation l min m ges = m L min + (l l min ) m' R 51

52 8.5 Connection flanges and bolted connections When installing the Voith universal joint shaft in a driveline, the connection flanges and bolted connections must satisfy a number of requirements: 1. Design When using a universal joint shaft without length compensa tion, a connection flange ("coupling") that is moveable in a longitudinal direction is required so that the universal joint shaft can slide over the spigot. The connection flange also absorbs additional length changes arising, for instance, from thermal expansion or changes in the deflection angle. 2. Material The material used for the connection flanges has been selected to permit the use of bolts of property class 10.9 (according to ISO / and/or DIN ). Special case for the S and R Series: If the material used for the connection flanges does not per mit the use of bolts of property class 10.9, the torques that can be transmitted by the flange connection are reduced. The specified tightening torques for the bolts must be redu ced accordingly. 3. Dimensions, bolted connections On universal joint shafts from the S and R Series, the dimen sions of the connection flanges match those of the universal joint shaft, apart from the locating diameter c. The locating diameter provides a clearance (fit H7 / h6). On universal joint shafts with an H flange, the dimensions of the connection flanges are identical to those of the unive rsal joint shaft. The Hirth couplings are self-centering. On universal joint shafts from the S and R Series, the relief diameter f g on the universal joint shaft flange is not suitable for locking hexagon head bolts or nuts. A relief diameter f a on the connection flange is suitable for this purpose. 52

53 Flange connection for universal joint shafts of the S and R Series A B A m min Z 1 m g g v n o p m min Z 1 m g g v Z 2 t y a x øa øf a øc øf g øb øa øf a øf g øb S flange / Q flange K flange H flange Fastener hole pattern for flange connections on the S and R Series of universal joint shafts A+B A A A A A A 8 x A 4 x B B A 8 x A A 12 x A A A 10 x A 4 x B A 10 x A A 16 x A A A A B A A A A A

54 Dimensions of the connection flanges Bolted connection (A) Comments Size a b ± 0.1 c H7 f a -0.3 f g g t v x P9 y a +0.5 Z 1, Z 2 z z z m Bolt S flange / K flange M5 x M6 x M6 x M8 x M8 x M10 x M10 x M12 x M12 x M12 x M14 x M16 x M16 x M18 x M20 x M22 x M22 x M24 x M27 x 120 Q flange M16 x M18 x M20 x M22 x M22 x M24 x M27 x M30 x M30 x 140 H flange M16 x M18 x M20 x M22 x M22 x M24 x M27 x M30 x M30 x 140 Dimensions in mm 54

55 Bolted connection with split sleeve (B) M A [Nm] 7 No 13 No 13 No 32 No 32 No 64 No 64 No 111 No 111 No 111 No 177 No EB z n Bolt o Sleeve p Washer M A [Nm] 270 No 4 M12 x x Yes 4 M12 x x No 4 M14 x x No 4 M16 x x Yes 4 M16 x x Yes 4 M18 x x No 4 M18 x x No 4 M20 x x No 372 No 526 No 710 No 710 No 906 No No No No 270 No 372 No 526 No 710 No 710 No 906 No No No Designation Explanation Comments a b c f a f g g t v Flange diameter Bolt circle diameter Locating diameter Flange diameter, bolt side Flange diameter, nut side Flange thickness Locating depth in connection flange Length from the contact surface of the nut to the end of the hexagon head bolt Additional information x Width of face key in universal joint shaft connection flanges with a face key y a Depth of face key in universal joint shaft connection flanges with a face key z 1 Axial run-out 1 Permissible values for deviation z 2 Concentricity in axial runout Z 1 and concentricity Z 2 at operating speeds below rpm. At operating speeds of rpm to rpm, the values should be halved! m m min Hexagon head bolt to ISO / or DIN with hexagon nuts to ISO or DIN Minimum length for the installation of bolts 2 z each per standard connection flange 3 z each per connection flange with face key 4 z each per connection flange with Hirth coupling 5 Dimension of hexagon head bolt with nut 6 Tightening torque for a coefficient of friction μ = 0.12 and 90 % utilization of the bolt yield point Length of the hexagon head bolt m including the height of the bolt head EB Insertion options 7 Insertion of bolts from the joint side n Hexagon head bolt to ISO / or DIN with hexagon nuts to ISO or DIN z each per connection flange 9 Dimension of hexagon head bolt with nut 12 Tightening torque for a coefficient of friction μ = 0.12 and 90 % utilization of the bolt yield point o Split sleeve 10 Outer diameter x length of the split sleeve [mm x mm] p Washer 11 Interior diameter of the washer [mm] No 55

56 Success needs reliable partners. That s what moves us. 56

57 9 Service For us, service means quality and dependability that exceeds the expectations of our customers. We will support you anywhere in the world throughout the entire lifetime of your Voith equipment. You can count on us from the planning and commissioning phase through to maintenance. With the Universal Joint Shaft capabilities from Voith Turbo, you will increase the reliability, availability and lifetime of your equipment. Voith Turbo Universal Joint Shaft Service Consulting and engineering Pre-sales After-sales Installation Commissioning Original spare parts' supply Overhaul Repairs Modernizations, retrofits Training Torque measurements (ACIDA) 57

58 9.1 Installation and commissioning The correct installation of a universal joint shaft provides the basis for trouble-free commissioning. A systematic com missioning procedure with extensive operational testing is an important factor in achieving the maximum reliability and long operational life of the universal joint shaft and the system as a whole. Our services Installation and commissioning by our service experts Training of operation and maintenance personnel Your benefits + + Immediate access to expert know-how throughout the start-up phase + + Assurance of problem-free and professional commissioning of your universal joint shaft 58

59 9.2 Training Efficiency, reliability and availability are essential factors in ensuring your system is successful. One requirement in this regard is having the best-trained employees in technology and servicing. Initial and ongoing training are worthwhile in vestments in ensuring the efficient operation of your universal joint shafts. Our training programs provide specific technical knowledge about your Voith equipment, as well as other potential products to enhance your system. We bring your personnel up to speed with the latest Voith technology in theory and in practice. Our services Product training at Voith or on-site at your premises Theoretical and practical maintenance and repair training Your benefits + + Safe handling of Voith products + + Avoidance of operating and maintenance errors + + Better understanding of Voith technology in the driveline 59

60 9.3 Genuine Voith spare parts Avoid risk, use Voith orginal spares and wear parts. These are the only parts manufactured with Voith's know-how, and guarentee the reliable and safe operation of your Voith equipment. Ensuring the highest availa bility, in combination with efficient logistics, to ensure rapid deployment of parts globally. Our services Inventory of most original and wearing parts located at local service branches Same day shipment of in-stock parts (orders received by 11 a.m.) Consultation with your spare parts' management staff Preparation of spares kits for specific project maintenance Spares for older and obsolete series of Voith universal joint shafts still available Your benefits + + Safe and reliable operation of all components + + Parts of the highest quality that fit precisely first time + + Maximum lifetime of driveline components + + Manufacturer's warranty + + Maximum system availabilty + + Efficient and speedy delivery of spare parts Journal cross Flange yoke 60

61 9.4 Overhaul, maintenance Constant operation subjects universal joint shafts to natural wear, which is also influenced by the surroundings. Professional and regular overhauls of your universal joint shaft prevent damage and minimize the risk of expensive production downtimes. You gain operational reliability and save money in the long term. Our services Maintenance or complete overhaul by our service experts with all the necessary tools and special fixtures Use of original spare and wearing parts Consultation regarding your maintenance strategy Your benefits + + Safety due to professional maintenance + + Manufacturer's warranty + + Increased system availability 61

62 9.5 Repair and maintenance Even with the best preventive maintenance, unplanned downtime due to equipment failures cannot be ruled out. The priority then is to repair the components and equipment as quickly as possible. As the manufacturer we not only have the wealth of knowledge about universal joint shafts, but we also possess the necessary technical competence, experience and tools to ensure the most professional of rapid repairs. Our service techni cians can assess the damage in the minimum amount of time, in order to provide suggestions for the rapid rectification of the situation to enable operation of equipment as soon and as safely possible. Our services Rapid and professional repairs that comply with the latest safety standards on-site, or at one of our head officecertified Voith Service Centers located strategically around the globe Experience damage assessment, with analysis of the weaknesses Immediate delivery of replacement original spare parts Your benefits + + Maximum safety due to the best practice repairs + + Manufacturer's warranty + + Shortest possible outage and downtime of your equipment + + Avoidance of repeat outages, or malfunction 62

63 9.6 Retrofit and modernizations Technology is advancing all the time and sometimes the original require ments upon which the design of a system was based can change. Voith Turbo helps you achieve significant improvements in the efficiency and reliability of your equipment, through a modernization or retrofit program of old driveline equipment, e.g. slipper spindles. We will analyze, and provide advise as to the latest and most economical technology for your particular driveline application. Our services Modernization of existing, or new replacement designs for your universal joint shafts and connection components Even with the best preventative maintenance schedule, unplanned downtime due to equipment failure can never be ruled out Your benefits + + Improved reliability, availability and affordability of your driveline + + Reduction of operating costs + + Universal joint shafts that feature the latest technology 63

64 10 Services and Supplementary products 10.1 Engineering We not only supply products, but ideas too! You too can benefit from our many years of engineering expertise in allround project planning of complete drive systems: from design calculations, installation and commissioning, to questions about cost-optimized operating as well as main ten ance concepts. Engineering services Special universal joint shafts Specification preparation Preparation of project-specific drawings Torsional and bending vibration calculations Design and sizing of universal joint shafts and connecting components Clarification of special requirements from the operator and its employees Preparation of installation and maintenance instructions Documentation and certification Special acceptance tests conducted by classifying and certifying agencies Designing special universal joint shafts to match your drive system and your operating conditions is just one of the everyday engineering services we offer. These include: All necessary design work Integrity checks and optimization of design through the application of FEM analysis Reliability trials based on dynamic load testing Project planning of a driveline using CAD FEM analysis of a work roll, with a split connection coupling 64

65 10.2 Connecting components for universal joint shafts To ensure maximum reliability of the driveline, the input and output connecting parts of the universal joint shaft, should equally be analyzed for suitability, e.g.: All couplings All connecting flanges bolted or otherwise All Adapters Applications Features Rolling mills Paper machinery Pumps General industrial machinery Test stands Construction equipment and cranes Individual adaptation to all adjoining components Precision manufacturing through the use of state-of-the-art machining centers Maximum torque transmission capability through the use of the highest quality materials. Hardened contact surfaces to ensure maximim levels of wear resistance. Connection hubs (wobblers/couplings) to attach universal joint shafts to the work rolls 65

66 10.3 Quick-release GT coupling The quick-release GT coupling is designed to be an efficient and effective quick release connection device. The GT coupling allows you to assemble and disassemble a wide range of shaft connections, which in turn significantly reduces the amount of required downtime associated with maintenance and repair. which in turn significantly reduces downtimes for maintenance and repair. Applications Features Drivelines that require a quick release while retaining accurate radial alignment, e.g. universal joint shafts and disc couplings Roll connections, e.g. on paper machines Positive transmission of torque through radial drive dog design Quick and easy assembly / disassembly Compact design Only two major components Stainless steel versions available Schematic diagram of the quick-release GT coupling Universal joint shaft with a ring from a quick-release GT coupling 66

67 10.4 Voith Hirth couplings Voith Hirth couplings transmit maximum torque at the specified diameters. Applications Features High performance universal joint shafts, for high torque applications Connection flange for universal joint shafts (also when provided by the customer) Machine tools Turbo compressors Measuring equipment Robotic equipment Nuclear technology Medical equipment General industrial machinery Highest torque transmission capability, as the angular surfaces provide positive locking of most of the peripheral forces. The bolts only need to accomodate a small amount of axial force. Self-centering by means of optimized tooth geometry A high load bearing on the tooth profile, significantly inreases wear resistance of the hirth serration. Repeatability accuracy maximized as a result of the multiple tooth design. Positive locking Accurate indexing Self-centering F a Fu Universal joint shaft flanges with Hirth coupling Primary functions of the Hirth serration 67

68 10.5 Universal joint shaft supports To position and support a universal joint shaft and its connection coupling and flanges, a support mechanism is required. Applications Features Rolling mills Customer-specific drives Increased productivity and system availability as a result of shorter downtime for maintenance Reduction of energy and lubrication costs, together with higher transmission efficiency through the use of roller bearings Reduced wear as a result of uniform power transmission Universal joint shaft support (red) and coupling support (yellow) 68

69 10.6 Universal joint shafts with carbon fiber-reinforced polymer (CFRP) components Universal joint shafts with CFRP components increase the efficiency and performance of machines and plants. CFRP use in universal joint shaft construction, reduces masses, vibrations, deformations and power consuption of the machines. We offer not only the characteristic know-how, but also the production know-how of CFRP components all from a single source. Applications Features Long drivelines without the need for intermediate bearing supports Drivelines with low masses Drivelines that require optimized vibration behaviour Pumps Marine vessels Rail vehicles General industrial machinery Depending on the requirements of the specific application, universal joint shafts can incorporate CFRP tube, or solid shafts Reduced dynamic loads, due to lower masses Extremely smooth operation and low vibration induced wear, as a result of the higher rigidity of CFRP Lower acceleration / deceleration torques as a result of the lower mass of intertia of CFRP Universal joint shaft with CFRP tube 69

70 1 1 Voith WearCare 500 in 45 kg and 180 kg drums 10.7 High-performance lubricant for universal joint shafts Voith development engineers have combined their universal joint shaft know-how with the tribological knowledge and experience of renowned bearing and lubricant manufacturers. The result of this cooperation is an innovative and exclusive lubricant with properties that far exceed those of conventional lubricants. This lubricant gives bearings in universal joint shafts operating at low speeds and under high loads an even longer life. In addition, lubrication intervals can be extended and emergency dry-running characteristics are improved sig nificantly. 70

71 Characteristics of the Voith WearCare 500 high-performance lubricant Advantages Optimum adhesion and surface wetting + + Lubricating film even in the event of poor lubrication + + Formulated for oscillating bearing motion Exceptional corrosion protection + + Ideal for rolling mills Maximum ability to withstand pressure + + Hydrodynamic lubricating film even under maximum torque conditions Optimal and long-lasting lubricating action + + Minimal abrasive wear in the bearing + + Extended lubrication intervals + + Reduced maintenance costs Can be mixed with lithium-based greases + + Simple changeover to Voith's high-performance lubricant High resistance to aging + + Long shelf life Excellent compatibility with all bearing components + + No softening of bearing seals + + Does not corrode non-ferrous metals Free of silicone and copper-based ingredients + + Suitable for aluminum rolling mills Field trial Metal particles in the bearing lubricant of a high-performance universal joint shaft used in a rolling mill drive FE8 test stand trial Bearing wear in an axial cylindrical roller bearing Relative metal particles in the lubricant Reference wear condition Standard lubricant Voith WearCare 500 Extended operating time Relative bearing wear Standard lubricant Voith WearCare Operating time in months 71

72 10.8 Safeset torque-limiting safety couplings The Safeset coupling is a torque-limiting safety coupling that instantaneously disengages the power transmission of the driveline in the event of a potentially catastrophic torque overload event. Thus it protects all of the drive components in the driveline such as motors, gearboxes, universal joint shafts etc. against costly and time consuming damage. By integrating the Safeset safety coupling into the universal joint shaft, which is known as the Voith 'integral design', reduces the deflection angle of the universal joints, and thus increases the lifetime of driveline components. Applications Features Protects drivelines from potentially catastrophic overload damage Rolling mills Shredders Cement mills Sugar mills Rail vehicle drives Adjustable release torque The Safeset coupling reacts instantaneously to a torque overload event Backlash-free power transmission Compact, lightweight design Low mass moment of inertia Minimal maintenance required 3D cut away section through a Safeset safety coupling (type SR-C) Safeset torque limiting safety couplings (blue) 'integral design' in a Voith high performance universal joint shaft 72

73 10.9 ACIDA torque monitoring systems ACIDA torque monitoring systems have proven their worth in accurately measuring dynamics in universal joint shafts. The direct measuring of the actual, mechanical drive load provides important information for process observation and plant optimization. Analysis modules, for instance load spectra or lifetime observation, have been developed especially for extremely heavy-duty drives and unusually severe load conditions. Additional options include online vibration diagnosis for gearboxes and roller bearings. Applications Features Torque monitoring Vibration monitoring Process optimization Condition-based maintenance Reference systems: Rolling mills, cement mills, briquetting plants, agitators, conveying equipment, marine propulsion systems, locomotives, paper machines, mining, etc. Permanent or temporary torque sensors Complete monitoring systems, incl. hardware and software Report generator with automatic analysis, alarm signaling and reporting Tele-service with expert support Non-contact torque monitoring system The ACIDA monitoring system in comparison Torque [Nm] Time [s] 1 Rotor: Strain gauges and telemetry (requires no drive modifications) 2 Air gap: No contact between rotor and stator 3 Stator: Signal reception and inductive power supply Light blue: ACIDA monitoring systems measure torques and dynamics with extreme accuracy. Dark blue: Conventional systems measure, for example, the motor current or hydraulic pressure with insufficient signal dynamics. 73

74 1 11 Integrated management system At Voith, our top priority is to ensure the affordability, reliability, environmental compatibility and safety of our products and services. In order to maintain these principles in the future just as we do today, Voith Turbo has a firmly established integrated management system focused on quality, the environment, and health and safety at work. For our customers, this means that they are purchasing high-quality capital goods that are manufactured and can be used in safe surroundings and with minimal environmental impact. 74

75 2 1 Certificates for management systems according to ISO 9 001: (Quality), ISO : (Environment) and OHSAS : (Occupational Health and Safety) 2 Flange for a high-performance universal joint shaft on a 3-D coordinate measuring machine 11.1 Quality We employ state-of-the-art 3-D coordinate measuring machines for quality assurance. To ensure perfectly welded joints, we conduct X-ray inspections in-house. We offer our customers a variety of product and application-specific certifications and classifications. Production and assembly fixtures are inspected on a regular basis. Quality-relevant measuring and testing instruments are subject to systematic monitoring. In the case of the welding methods employed, process controls according to ISO are used. Welding technicians are qualified to EN287 and our welding equipment is constantly monitored. Employees performing non-destructive testing are qualified to ASNT C 1A and / or EN

76 Environment Voith universal joint shafts are fitted with sealed roller bea rings. These offer two major advantages over slipper and gear type spindles: 1. Lubricant consumption is considerably lower because of the seals. 2. Efficiency is enhanced, as rolling friction is significantly less than sliding friction. This translates into reduced CO 2 emissions and helps to protect the environment. Comparison of efficiency and power loss in the main drive of a rolling mill % 71.1 kw Input power kw, deflection angle % 41.1 kw Efficiency Power loss 0.32 kw Voith universal joint shaft Gear spindle % Slipper spindle 76

77 2 1 An employee coats the roller bearing of a universal joint shaft with Voith WearCare 500 high-performance lubricant 2 Voith universal joint shafts receive their final finish in a modern paint booth 11.3 Occupational health and safety When painting a Voith universal joint shaft, Voith paint tech nicians use a modern paint system that meets all of the requirements for health and safety at work, and environmetal protection. The paint is electrostatically applied to reduce overspray and waste. An exhaust system extracts any residual mist that is created as part of the paint process. An exhaust air treatment system with combined heat recovery reduces the impact on our employees, as well as the environment. 77