ZF Friedrichshafen AG Special Driveline Technology. Planetary gearboxes for servomotors

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1 ZF Friedrichshafen G Special Driveline Techlogy Planetary gearboxes for servomotors

2 2 ZF-Servoplan CG Compact Gearbox ZF-Duoplan 2K Two-speed Gearboxes ZF-Ecolift Elevator Gearboxes ZF-Tiratron Hysteresis rakes Customer specific Gearboxes

3 3 Precision in movement The ZF Friedrichshafen division Special Driveline Techlogy is able to offer you a wide range of machine drives, brakes and clutches for applications in engineering as well as customer specific drive solutions. ZF-Servoplan Servogearboxes Our development and production activities are focused on servo-assisted drives for automation engineering, two-speed drive gearboxes for machine tools as well as customer-specific drives, such as for printing machines, robot applications and elevator gearboxes. Our invative standard products range from low backlash servogearboxes (ZF-Servoplan), and robust two-speed gearboxes (ZF- Duoplan) to hysteresis clutches and brakes for n-contact web control (ZF-Tiratron).

4 Servogearboxes 4 The ZF-Servoplan planetary gearbox series has been designed for direct mounting onto servomotors. The available wide range of sizes and the use of a modular system allows the application in almost any field of automation. The combination of servomotors with ZF-Servoplan planetary gearboxes constitutes a coaxial drive unit. The servomotor output shaft is connected to the sun gear of the gearbox by using a clamping coupling. The sun gear drives three planetary gears inside the planetary carrier, which rotate inside the internal ring gear. Since the power is distributed to three planetary gears, thereby distributing the forces evenly, this allows a very compact design with high power density. lso available from ZF: Compact gearboxes for automation and robot applications.

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6 Planetary Gearboxes 6 1. The robust output shaft shoulder allows the highest possible axial loads 2. High radial forces and an extreme tilt resistance through large-dimensioned taper roller bearings 3. high positional accuracy is achieved by using ground and highly accurate gears 4. High quality Viton shaft seals ensure a permanent and save sealing 5. High torsional rigidity thanks to an optimized sungear with a stable two-sided support for the planetary gears 6. Low running ise thanks to an optimized gear tooth shape 7. Compact design by using separated output bearings 8. special galvanic surface treatment makes the housing environmentally resistant, even under the most adverse conditions 9. Hermetically sealed housing by using robust sealed screws 10. Special surface treatment of the ring gear in order to optimize the lubrication supply of the teething 11. High acceleration torques permissible by using gearbox internal interlocking power transmission 12. Low gearbox temperatures and minimum power loss by using smallest possible seal diameters 13. acklash-free power transmission by using clamping coupling for motor shaft connection

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8 Planetary Gearbox, one-stage 8 T echnical Data: Nominal output torque lso applicable for S1 operation Emergency stop torque 1) Max. acceleration torque 2) Max. input speed 5) Nominal input speed acklash standard reduced 3) Reduction Ratio i: Size: 25/1 100/1 200/1 500/1 1200/1 T 2N [Nm] T 2Not [Nm] T 2 [Nm] n 1Max [rpm] n 1N [rpm] [arcmin] / ) Max times during gearbox lifetime. 2) t a maximum of 1000 cycles per hour, with the dynamic factor K1 page 16 to be taken into consideration in any other case. Torsional rigidity Moments of inertia Max. axial force Max. radial force 4) C t [Nm/ arcmin] I1 [kg cm 2 ] F [N] F R [N] Percentage of the overall running time less than 5 % and duration of the impulse under 0.3 sec. 3) Optional. Lifetime Efficiency Weight L h [h] > > > > > % 97 % 97 % 97 % 97 % m [kg] > % 62 4) Resultant force center of output shaft at output speed 300 rpm. 5) For cyclic duty only 6) t i=3: + 4 db() Operating ise at (n an = 3000 rpm) 6) Lubrication Surface protection Installation position Operating temperature Direction of rotation Degree of protection L p [d()] Lifetime lubrication, closed system luminium respectively steel, galvanically treated ny, variable - 10 o C to + 90 o C same as input IP 65 72

9 *Dimensions depending on motor. Please use page 19 for inquiries and orders. Dimensions [m m] : Size: 25/1 100/1 200/1 500/1 1200/1 DR M5 M8 M12 M16 M20 D 1 (g6) D D 3 ( k6 ) D D D 6 *(F7) min. max L 1* L 2 (+0.5) L L L 6 * min max L 7 * L L L13* min L L L L L22* /1 M D7/ D8/ D9 daptations available for all common servomotors, dimensions are variable. Please request specific installation drawing L7 D8 D9 L13 D1 D2 D3 max. D6 D7 45 Centering DIN 332 (G) Optional with key as per DIN 6885 sheet 1 90 DR DIN 332 L2 L12 L3 L4 L1 L22 L6 C-C L16 L15 L14 C D5 L11 L17 C D4

10 Planetary Gearbox, two-stage Size: T echnical Data: Reduction Ratio i: 25/2 100/2 200/2 500/2 1200/2 10 Nominal output torque lso applicable for S1 operation Emergency stop torque 1) Max. acceleration torque 2) Max. input speed 5) Nominal input speed acklash standard reduced 3) Torsional rigidity Moments of inertia max. Max. xialkraft axial force Max. radial force 4) Lifetime T 2N [Nm] 20, 35, 40, , T 2Not [Nm] 20, 35, 40, , T 2 [Nm] 20, 35, 40, , n 1Max [rpm] 20, 25, 35, , 50, 70, n 1N [rpm] 20, 25, 35, , 50, 70, [arcmin] C t [Nm/ arcmin] l 1 [kg cm 2 ] i = i = i = i = i = i = i = F [N] F R [N] L h [h] > > > > > Efficiency [%] 94 % 94 % 94 % 94 % 94 % Weight Operating ise at (n an = 3000 rpm) Lubrication Surface protection Installation position Operating temperature Direction of rotation Degree of protection m [kg] L P [d()] Lifetime lubrication, closed system luminium respectively steel, galvanically treated ny, variable - 10 o C to + 90 o C same as input IP 65 1) Max times during gearbox lifetime. 2) t a maximum of 1000 cycles per hour, with the dynamic factor K2 page 16 to be taken into consideration in any other case. Percentage of the overall running time less than 5 % and duration of the impulse under 0.3 sec. 3) Optional. 4) Resultant force. center of output shaft at output speed 300 rpm. 5) For cyclic duty only

11 *Dimensions depending on motor. Please use page 19 for inquiries and orders. Dimensions [m m] : Size: 25/2 100/2 200/2 500/2 1200/2 DR M5 M8 M12 M16 M20 D1(g6) D3(k6) D6*(F7)6 min. max L1* D2 D4 D5 L2 (+0.5) L3 L L6* min max L7* L L L13* min L L L L L22* D7/ D8/ D9 daptations available for all common servomotors, dimensions are variable. Please request specific installation drawing L7 D8 D9 L13 D1 D2 D3 max. D6 D7 45 Centering DIN 332 (G) Optional with key as per DIN 6885 sheet 1 90 DR DIN 332 L2 L12 L3 L4 L1 L22 L6 L16 L15 L14 C D5 L11 L17 C D4

12 Permitted shaft loads The permissible shaft loads in axial or radial direction (see table on page 8 and 10) correspond to a minal bearing lifetime of operating hours at a constant output shaft speed of 300 rpm. The load application point is located at the centre of the output shaft. The values for F R do t take any axial loads into account. For combined axial and radial forces the permissible force values are reduced. If the radial force F R acts on the output shaft outside its centre, the permissible force values are reduced L (x > 2 L ) or increased (x< 2 ), 2 2 respectively. F FR L2 x F orce (load) application points on gearbox output shaft F = permitted axial force F R = permitted radial force x = distance 12 Degree of protection The degree of protection is defined by the designation IP (International Protection corresponding EN 60529) and two digits. For our gearboxes the designation is IP 65. The first digit designates the degree of protection against contact (screen protection) and penetration of foreign bodies. In this instance, the first digit 6 means: - protection against dust infiltration (dust-tight) - complete screen protection. The second digit designates the degree of protection against water. In this instance, the digit 5 means: - protection against water jets which are emitted from a zzle and sprayed against the housing from all directions (jet water).

13 Gearbox Output Shaft The gearbox output shaft is available in the following designs: Plain output shaft (standard) for shrunk, backlash-free shaft-hub connections. This allows lower levels of running (operating) ise. We recommend the use of output shafts with shrunk shaft-hub connections. lternatively available: Output shaft with key as per DIN 6885 sheet 1 (08.68 issue) for keyed shaft-hub connections. This type of connection is suitable for constant direction, where applications, requirements are t as stringent. This connection type requires additional axial fixing of the hub. centering bore with thread is provided on the face end of the gearbox output shaft for this purpose (as per DIN 332, sheet 2). Size: 13 25/1 25/2 100/1 100/2 200/1 200/2 500/1 500/2 1200/1 1200/2 3000/1 3000/2 Thread M5 M8 M12 M16 M20 T [Nm] 5, F V * [kn] 6, K min. [mm] 0,8 1,4 1,4 0,8 0,8 K max. [mm] 1,0 1,6 1,6 1,0 1,0 M ,4 1,6 *F V = Pretensioning Force X X F V K x 45 T The connecting part on the gearbox output shaft must have a chamfer "K" (high of chamfer see table) on the contact pattern to the gearbox.

14 Configuration and Selection Fast gearbox selection The quickest and most reliable method, to determine the appropriate gearbox size for a specific application, is a comparison of motor peak torque with gearbox datas. pplications are differentiated based on rm EN as to continuous duty (S1) or intermittent cyclic duty (S4/S5). For intermittent cyclic duties the maximum motor acceleration torque is relevant, whereas for continuous duties motor minal torque is used. In case the motor peak torque exceeds the permitted gearbox values, a calculation based on the actual application specific torques is required. Detailed configuration according to pages 15 to 17. Determination of switch-on time (ED) resp. load cycle duration (EZ) ED or EZ as per EN Continuous duty (S1) Cyclic duty (S4/S5) ED 60% or EZ 20 min. Motor minal torque T 1NMot Motor peak acceleration torque T 1Mot Determination of gearbox output minal torque T 2n = T 1NMot * i Select larger gearbox size or different ratio Determination of gearbox output peak acceleration torque T 2b = T 1Mot * i 14 T 2n T 2N Select larger gearbox size or different ratio T 2b T 2 Nominal motor speed n 1N n 1n n 1N Maximum motor speed n 1max n 1max n 1Max Motor shaft diameter D Mot Motor shaft diameter D Mot D 6min D mot D 6max D 6min D mot D 6max i from catalogue T 2N from catalogue T 2 from catalogue 1) T 1Mot motor data T 1NMot motor data Gearbox selection completed 1) For s. of cycles 1000 cycles per hour, and percentage of total running time 5% and duration of impulse less than 0.3 sec. n 1n minal motor speed n 1N gearbox minal input speed from catalogue n 1max maximum motor speed n 1Max gearbox max. minal input speed from catalogue

15 Configuration and Selection Detailed Gearbox Configuration In the detailed configuration the application specific loads are compared to the permitted gearbox datas. Further emergency-stop loads, as well as dynamic and occurrence factors are taken into consideration. pplication Loads Each application has specific and unique loads. Torque T 2 and speed n 2 refer to the gearbox output shaft, which, for acceleration movements, is defined by the principle of angular momentum. The required acceleration torque is calculated from the rotating mass J app which experiences a speed change in a given time period t. Torque at gearbox output T 2 [Nm]: T 2 = J app * n + T t Last J app [kgm 2 ]: T Last [Nm]: n t [1/s 2 ] : Mass moments of inertia of driven mass Load torque cceleration Typical load collective at gearbox output 15 T 2t T 2 T 2N T 2t T 2a T 2b T 2c n 2Max n 2N 1 n 2a = n 2c = 2 n 2b *n 2b t a t b t c t d EZ Cycle duration Start Stop T 2max = max. torque during load collective t max = duration of max. torque T 2max

16 Configuration and Selection For gearbox selection following performance datas are required: Duration of single cycle [sec]: Nos. of single cycles per hour [1/h]: Maximum input speed n 1max [rpm]: Maximum gearbox output torque T 2max [Nm]: Switch-on time ED [%]: Load cycle duration EZ [min]: Duration of max. torque T 2max during the cycle [sec.]: Duration percentage of max. acceleration torque during total cycle [%]: Cycle duration = ta + tb + tc +td s.of cycles = 3600 cycle duration n 1max = i * maximum (n2a, n2b,..., n2n) T 2max = maximum (T2a, T2b,..., T2n) ED = (ta + tb + tc) * 100 (ta + tb + tc + td) EZ = ta + tb + tc determination from application E max = t max * 100 cycle duration Mean output speed n 2m [rpm]: n2m = 3 n2a 3 *ta + n2b 3 *tb + n2n 3 *tn ta + tb tn Mean input speed n 1m [rpm]: Mean output torque T 2m [Nm]: Emergency-stop output torque T 2t [Nm]: n 1m = i* n 2m T2m = 3 ta * T2a 3 + tb * T2b tn * T2n 3 Zykluszeit determination from application 16 Diagram 1: Dynamic factor k1 For the peak torques caused by short acceleration times with high s. of cycles, the dynamic factor needs to be considered. For s. of cycles < 1000 cycles per hour and for continuous duties the dynamic factor k1 = 1.0. Dynamic faktor k1 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0, Nos. of cycles (1/h) Diagram 2: Frequency factor k2 There is a substantial influence of high output torques on the gearbox lifetime. The frequency factor takes into account the duration percentage of maximum acceleration torque of total cycle. For continuous duties, the frequency factor k2 = 1.0. Frequency factor k2 2,5 2,0 1,5 1,0 0, E max (%)

17 Configuration and Selection Detailed gearbox selection Determination of cycle duration Determination of switch-on time Determination s. of cycles Determination of dynamic factor k1 EZ = ta + tb + tc [min] ED = (ta + tb + tc) * 100 [%] (ta + tb + tc + td) Cycle duration = ta + tb + tc + td [s] Nos. of cycles = 3600 [1/h] cycle duration k1 from diagramm 1 Select larger gearbox size or different ratio Select higher ratio or lower input speed. Selection of suitable ratio n 1max n 1Max. Determination of peak output acceleration torque T 2max Duration percentage of peak torque E max [%] Determination of frequency factor k2 Determination of permissible peak output acceleration torque T 2zul i = possible input speed max. output speed i from catalogue n 1Max from catalogue n 1max = i * maximum (n2a, n2b,..., n2n) [rpm] T 2max = maximum (T2a, T2b,..., T2n) [Nm] E max = t max * 100 [%] cycle duration k2 from diagram 2 T 2N from catalogue T 2zul. =T 2N * k1* k2 [Nm] T 2max T 2zul Continuous duty T 2t T 2Not ED 60% EZ 20 min T 2t depending on application T 2Not from catalogue 17 Determination of mean output speed n 1m n 1m n 1N Cyclic duty n2a n2m = 3 3 *ta + n2b 3 *tb + n2n 3 *tn ta + tb tn n 1m = i* n 2m [rpm] [rpm] Determination of mean output acceleration torque T 2m T2m = 3 ta * T2a 3 + tb * T2b tn * T2n 3 Zykluszeit [Nm] T 2m T 2N Determination of bearing load at output F r F R F a F Selection completed

18 Ordering Number P G Size 25/1, 25/2 100/1, 100/2 200/1, 200/2 500/1, 500/2 1200/1, 1200/2 3000/1, 3000/2 Size 25/1 25/2 100/1 100/2 200/1 200/2 500/1 500/2 1200/1 1200/2 3000/1 D6 [mm] Size Code Motor Shaft Code C D E F G H I C D E F G C D E F C D E F G C D E F G H IJ K L C D Size 25/1 25/2 100/1 100/2 200/1 200/2 500/1 500/2 1200/1 1200/2 3000/1 D7 D8 D9 L6 L6 L7 L22 min max [mm] [mm] [mm] [mm] [mm] [mm] M M M M M M M D M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M Flange Code C D E F G H I J K L M N O P Q R S T C D E F G H I J K L M N O P Q R C D E G H I J C D E F G H I J C D E F G H I J K L M N O P Q R S C D E Output Flange Standard Substitute acklash Standard Reduced Output shaft Plain Keyed i Version 0 Type Code Ratio Code 003* acklash Code Form Code 0 1 *vailable for gearbox size 200/1; 500/1; 1200/1; 3000/1 For additional ordering numbers please refer also to our homepage:

19 Quotation Request: Kindly fill out below questionnaire for speedy processing and send to: Fax: ++49/(0)7541/ or 19 c1 s1 e1 f d1 b2 Motor data: Motor manufacturer: Type: Motor shaft diameter d1 [mm]: Flange face distance b1 [mm]: Motor shaft length b2 [mm]: Centering diameter z1 [mm]: b1 z1 Fixing hole circle diameter e1 [mm]: Fixing hole diameter s1 [mm]: Flange square f [mm]: Motor minal torque [Nm]: Motor maximum torque [Nm]: Gearbox data: ZF-Servoplan size: - ZF-Servoplan ratio [i]: Keyed output shaft (/): Reduced backlash (/): Ordering number (see page 18): asis of quotation (batch size): Projected annual volume: Subject to technical change without tice. For studies, please request installation drawings; only the data contained therein is binding. Please refer also to our homepage: industrial-drives.zf.com

20 ZF Friedrichshafen G Special Driveline Techlogy Ehlersstrasse Friedrichshafen/Germany Phone: +49(0) Fax: +49(0) industrial-drives@zf.com Internet: Print: d Subject to technical change without tice. For studies, please request installation drawings; only the data contained therein is binding.