Precision in Accuracy

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1 Your addition in transmission. Precision in Accuracy MELIOR MOTION PRECISION GEARBOX PSH-D SPECIAL PRECISION GEARBOXES

The Premium Group Premium Stephan Hameln, Germany Design,

and industrial gearboxes Premium Stephan Shendra, India

Design, development and production of worm and industrial gears

development and production of variable and constant speed fluid

2 The Premium Group Premium Stephan Hameln, Germany Design, development and production of precision gearboxes, geared motors and industrial gearboxes Premium Stephan Shendra, India Production of geared motors Premium Transmission Pune, India Design, development and production of worm and industrial gears up to 4,000,000 Nm Premium Transmission Aurangabad, India Design, development and production of variable and constant speed fluid couplings Premium Transmission Falta, India Development and production of industrial gearboxes

Premium Stephan Hameln The foundations were laid over 100 years ago: In the small mill belonging to the Stephan family in the 1890 s, everything already centered around the perfect drive system.

3 Premium Stephan Hameln The foundations were laid over 100 years ago: In the small mill belonging to the Stephan family in the 1890 s, everything already centered around the perfect drive system. And this is how it has remained though we have of course grown in the meantime. Since 2011 Premium Stephan is part of the International Premium Transmission Ltd. Group. In Hamelin / Germany, we develop and produce premium precision gearboxes for the robotic and automation industry as well as geared motors, industrial gearboxes and customised gearboxes. This enables us to offer customers tailored solutions, from a standard gear unit, through products adapted for specific applications, to custom-made gear units. The MELIOR MOTION range is another exciting innovation from Premium Stephan. With its unique zero backlash system, it raises the bar in drive technology. CONTENTS Gearbox overview 5 MELIOR MOTION zero backlash precision gearboxes 6 Structural design 7 Performance table 8 9 Mass moment of inertia 10 Executions 11 Dimensions Input options Technical information Mounting positions 24 Order code 25 Precision gearbox PSH-D 26 General information 26 Technical data 27 Dimensions 28 Special precision gearboxes 29 Other gearbox solutions 30 3

4 2016 Premium Stephan Hameln All technical information was correct at the time of going to print. As we are continuously developing our products, we reserve the right to make modifications. This document is subject to occasional errors. Please note that legal claims cannot be asserted as a result of incorrect specifications, illustrations or descriptions. Any exact, specific requirements must be agreed with us. Specifications and features listed in the catalogue are subject to a written contract. All drawings, texts, photos or any other illustrations in this catalogue are protected property of Premium Stephan Hamelin, branch office of Premium Stephan B.V.. Any form of use in printed or electronic media without our permission is prohibited. 4

Precision gearboxes overview Product Applications MELIOR MOTION Standard

Printing industry Packaging machines Turntables Medical industry many more

applications in automation industry Special precision gearboxes Robotics

5 Precision gearboxes overview Product Applications MELIOR MOTION Standard precision gearbox range, zero backlash Robotics Automation Machine tools Printing industry Packaging machines Turntables Medical industry many more PSH-D Precision gearbox, low backlash and very compact Delta Robots other applications in automation industry Special precision gearboxes Robotics Automation Machine tools Printing industry Packaging machines Turntables many more 5

MELIOR MOTION zero backlash precision gearboxes With 30 years experience in the development and production of highly precise precision gearboxes for industrial robots, the new compact gear range

Picture 1: MELIOR MOTION sub-assembly, hollow shaft With a backlash of 0.1 arcmin, the MELIOR MOTION range can be considered as zero backlash gearbox.

6 MELIOR MOTION zero backlash precision gearboxes With 30 years experience in the development and production of highly precise precision gearboxes for industrial robots, the new compact gear range MELIOR MOION has been presented to the market. The unique advantages convince in robotics applications, as well as in medical industry, machine tools and other automation industries. Picture 1: MELIOR MOTION sub-assembly, hollow shaft With a backlash of 0.1 arcmin, the MELIOR MOTION range can be considered as zero backlash gearbox. They are available in seven sizes, each as sub-assembly or fully enclosed gearbox unit and as solid or hollow shaft version. Sub-assemblies can be directly integrated into your drive system or machine design. As an alternative, we offer fully enclosed gearboxes which are filled with a standard mineral oil. Geared motors can be supplied on request. Picture 2: MELIOR MOTION fully enclosed gearbox, solid shaft with motor flange and coupling for easy motor adaption Hollow shafts up to 75 mm dia. allow a feed-through of cables or similar. SPECIALS Patented self-adjusting solution to regulate wear throughout the lifetime of the gearbox Newly developed main bearing where bearing running surface is integrated in gear components High quality, dynamic sealing Optimized macro and micro geometry for highest precision 6

MELIOR MOTION Structural design MELIOR MOTION gearboxes are designed as planetary gearboxes with an additional integrated helical stage. FEATURES YOUR ADDITION Backlash 0.1 arcmin Lost Motion 0.

7 MELIOR MOTION Structural design MELIOR MOTION gearboxes are designed as planetary gearboxes with an additional integrated helical stage. FEATURES YOUR ADDITION Backlash 0.1 arcmin Lost Motion 0.6 arcmin Self-regulating tooth contact system Fully-loaded lifetime of 20,000 operating hours High torques in output, acceleration and emergency stops Superior tilting and torsion stiffness Low vibrations Lowest breakaway torque Use of a standard mineral oil Low heat development Low moments of inertia Efficiency > 90% Small weight Compact design Low noise Highest precision for your application Superior accuracy also for small torques Constant precision throughout the whole lifetime Longer lifetime, greatly reduced maintenance costs More safety for your application Allows positioning straight-to-the-point High repeatability Better controllability of the whole system Reduced cost of lubrication Longer lifetime of components and lubricant Excellent dynamic performance Use of motors / systems with less energy consumption Lighter overall system Smarter periphery design Reduced noise exposure at workplaces MELIOR MOTION 7

8 MELIOR MOTION Performance tables Gearbox Nominal Nominal Acceleration Emergency Max. Permissible Max. Ratio output torque stop torque output average permissible 1) torque 2) speed 3) input speed input speed 3) [Nm] [Nm] [Nm] [1/min] [1/min] 4) [1/min] PSC056-V , ,000 6,000 PSC080-V 50, 56, 63, 748 1,047 2, ,500 5,000 PSC112-V 71, 80, 90, 1,100 1,540 3, ,500 5,000 PSC160-V 100, 112, 1,370 1,918 4, ,500 5,000 PSC224-V 125, 140, 1,719 2,406 6, ,000 4,500 PSC300-V 160, 180, 2,540 3,555 8, ,500 4,000 PSC400-V 200 3,305 4,625 11, ,000 3,500 PSC056-H , ,000 6,000 PSC080-H 35,5, 40, 45, 748 1,047 2, ,500 5,000 PSC112-H 50, 56, 63, 1,100 1,540 3, ,500 5,000 PSC160-H 71, 80, 90, 1,370 1,918 4, ,500 5,000 PSC224-H 100, 112, 1,719 2,406 6, ,000 4,500 PSC300-H 125, 131,5 2,540 3,555 8, ,500 4,000 PSC400-H 3,305 4,625 11, ,000 3,500 Efficiency under full load > 90% Lifetime Noise level Lubrication Paint 20,000 operating hours < 70 db(a) Sub-assemblies: delivery without oil Sub-assemblies: no paint Backlash [arcmin] 0.1 Lost Motion [arcmin] 0.6 Angular transmission accuracy [arcsec] < 50 1) Preferable ratios in bold letters; exact ratios iex on request 2) Referring to 3,000 times during lifetime 3) higher max. speeds are possible - please contact us 4) based on nominal outut torque and ambient temperature of 20 C 5) valid at +/-50% up to 100% of nominal torque 6) Referring to n2=5 min-1 7) The weight refers to sub-assemblies, ratio 50:1 8

9 Max. Tilting Torsional Max. Max. Max. Max. Power Weight bending stiffness stiffness axial force radial force axial force radial force density 7) moment 5) static static dynamic dynamic 6) 6) [Nm] [Nm/arcmin] [Nm/arcmin] [kn] [kn] [kn] [kn] [Nm/kg] [kg] 1, ,865 1, ,230 1, ,930 2, ,280 3, ,620 4,505 1, ,350 6,250 1, , ,865 1, ,230 1, ,930 2, ,280 3, ,620 5, ,350 7,813 1, fully enclosed gearboxes: filled with standard mineral oil, viscosity 320 fully enclosed gearboxes: RAL 9005 silk-mat General: Size-V = solid shaft version Size-H = hollow shaft version calculations are based on output speed of n2=15 min-1 All indicated values are subject to tolerances of approx. 10% MELIOR MOTION 9

10 MELIOR MOTION Mass moments of inertia The moments of inertia in kgcm² are related to the input. Size i nenn V V V V V V V Size i nenn H H H H H H H The moments of inertia are based on the gearbox with input pinion, option R. Housing is fixed and output shaft turns. 10

MELIOR MOTION Executions Gearbox sub-assembly

Hollow shaft version Delivery with oil filling

Standard: NBR, Viton on request Output flange

11 MELIOR MOTION Executions Gearbox sub-assembly Fully enclosed gearbox unit Solid shaft version Hollow shaft version Delivery with oil filling Food-proof oil Shaft seals Output options Standard: NBR, Viton on request Output flange Output with pinion Other possibilities on request MELIOR MOTION 11

12 Gearbox size PSC056-V-E (Solid shaft, sub-assembly) Gearbox size PSC056-H-E (Hollow shaft, sub-assembly) 6,6 (16x) 6,6(16x) 22,5 (16x) 22,5 (16x) ,5 1,75 16 X 25,25 34,8 14,05 16 X 24,5 158h H7 48,5 72 Achsabstand distance 159h7 180h8 158 h H H6 38 h11 85 Achsabstand distance 159h7 180 h8 Antriebsachse drive shaft 84, ,3 Antriebsachse drive shaft M8(12x) M10(10x) ,

13 MELIOR MOTION Dimensions Gearbox size PSC080-V-E (Solid shaft, sub-assembly) Gearbox size PSC080-H-E (Hollow shaft, sub-assembly) 6,6 (20x) 6,6(20x) 18 (20x) 18 (20x) X 19 X 23,5 27,75 37,75 26,25 2,25 16,5 177h H7 54,5 85 Achsabstand distance 178h7 177h H H6 48 h11 95 Achsabstand distance 178h7 200h8 Antriebsachse drive shaft Antriebsachse drive shaft M8 (16x) M10(10x) MELIOR MOTION 13

14 Gearbox size PSC112-V-E (Solid shaft, sub-assembly) Gearbox size PSC112-H-E (Hollow shaft, sub-assembly) 9 (16x) 9(16x) 22,5 (16x) 22,5 (16x) ,25 21,5 X 31,5 37,25 21,5 X 31,25 2,5 12,5 202h7 128,5 90H7 60,5 95 Achsabstand distance 203h7 232h8 202h H H6 55 h11 107,5 Achsabstand distance 203h7 232h8 Antriebsachse drive shaft ,5 Antriebsachse drive shaft ,5 M10 (16x) M12(15x) ,5 105,

15 MELIOR MOTION Dimensions Gearbox size PSC160-V-E (Solid shaft, sub-assembly) Gearbox size PSC160-H-E (Hollow shaft, sub-assembly) X 34,75 2,5 218 h H7 67,5 105 Achsabstand/distance 219 h7 248 h8 Antriebsachse drive shaft 13 9 (20x) 9 (20x) 18 (20x) 18 (20x) X 34 12,5 218 h H H6 60 h Achsabstan/distance 219 h7 248 h8 114 ±1 131,75 Antriebsachse drive shaft M12(15x) M10 (20x) MELIOR MOTION 15

16 Gearbox size PSC224-V-E (Solid shaft, sub-assembly) Gearbox size PSC224-H-E (Hollow shaft, sub-assembly) 9(20x) 9 (20x) 18 (20x) 18 (20x) , X 37 40, X h H Achsabstand distance 234 h7 263 h8 233 h H H6 65 h11 123,5 Achsabstand distance 234 h7 263 h8 Antriebsachse drive shaft 138,5 Antriebsachse drive shaft 122, M10 (20x) M10(20x)

17 MELIOR MOTION Dimensions Gearbox size PSC300-V-E (Solid shaft, sub-assembly) Gearbox size PSC300-H-E (Hollow shaft, sub-assembly) 29 X 36 3, h H7 91,5 125 Achsabstand distance 265 h7 301 h8 Antriebsachse drive shaft 137,5 1 M12 (20x) 13 11(20x) 11(20x) 18 (20x) 18 (20x) X 47, h H ,5 H6 76 h Achsabstand distance 265 h7 157 Antriebsachse drive shaft ,5 M12(20x) 13 34, MELIOR MOTION 17

18 Gearbox size PSC400-V-E (Solid shaft, sub-assembly) Gearbox size PSC400-H-E (Hollow shaft, sub-assembly) 11(24x) 11(24x) 15 (x24) 15 (24x) X 45, X h H Achsabstand distance 293 h7 329 h8 292 h H H6 85 h Achsabstand distance 293 h7 329 h8 Antriebsachse drive shaft Antriebsachse drive shaft M12 (24x) M16(15x)

19 MELIOR MOTION Dimensions A D2 E C D1 Fully enclosed gearbox units, Solid shaft B X Gearbox A B C D1 D2 X Size (mm) (mm) (mm) (mm) (mm) (mm) PSC056-V PSC080-V PSC112-V PSC160-V PSC224-V PSC300-V depending on servo motor PSC400-V A D2 C D1 Fully enclosed gearbox units, Hollow shaft B X Gearbox A B C D1 D2 E X Size (mm) (mm) (mm) (mm) (mm) (mm) (mm) PSC056-H PSC080-H PSC112-H PSC160-H PSC224-H depending on servo motor PSC300-H PSC400-H MELIOR MOTION 19

20 The basic sketches below show the possible motor adaptions. Motor adaption C Intermediate shaft Motor adaption P Free input shaft Motor adaption R Pinion on motor shaft 20

21 MELIOR MOTION Input options Motor adaption K Motor flange and coupling Abtriebswelle Getriebe Melior Motion Flanschdeckel Motor adaption B With bevel gear centric or eccentric adaption Kegelradvorstufe Wellendichtring Kupplung Motor data sheet with dimensions needs to be provided. Centric motor adaption with reduced ratio is available on request. MELIOR MOTION 21

22 Torsional stiffness Torsional stiffness is defined as the quotient of applied output torque and generated torsion angle and is given in Nm/arcmin. The input shaft of the gearbox is being blocked, the output is loaded and unloaded with continuously increasing torque. The torsion angle on the output records the torque and results in the hysteresis curve which provides the torsional stiffness Figure: hysteresis curve on example PSC160-V Torsional stiffness (practical test) Backlash, Lost Motion Winkelminuten [arcmin] Drehmoment [Nm] The torsional backlash is the angle tolerance of torsion of the output shaft in relation to the input shaft at zero torque. The measurement is done when input shaft is blocked. The torsional backlash can also be seen in the hysteresis curve. Lost Motion, also called positioning error, means the torsional angle on the output which is reached if all outer loads are removed. The measurement is taking place at +/-3% of nominal torque. 2 1,75 1,5 1,25 22 Figure: hysteresis curve on example PSC160-V Backlash, Lost Motion (practical test) Winkelminuten [arcmin] 1 0,75 0,5 0,25 0-0,25-0,5-0, ,25-1,5-1, ,0-150,0-100,0-50,0 0,0 50,0 100,0 150,0 200,0 Drehmoment [Nm]

23 MELIOR MOTION Technical information Tilting stiffness The tilting torque is a result of the axial and radial forces. The tilting stiffness is defined as quotient of applied tilting torque and tilting angle between output and housing flange. The tilting stiffness is given in Nm/arcmin. 4,0 Winkelminuten [arcmin] 3,0 2,0 1,0 0,0 Figure: Measurement tilting stiffness on example PSC160-V (practical test) -1,0-2,0-3, ,0 Drehmoment [Nm] Angular transmission accuracy The angular transmission error is equal to the variations in ratio measured between the input and output during one revolution of the output shaft. The error for example is caused by production tolerances and results in angular deviations or deviations in ratio. The angular transmission accuracy is given in [arcsec] Gleichlauf [arcsec] Figure: Measurement angular transmission accuracy on example PSC160-V (practical test) -20 Drehrichtung: CW Drehrichtung: CCW -30 Drehwinkel Abtrieb ][ MELIOR MOTION 23

24 MELIOR MOTION Mounting positions V1 Input on top V3 Input on bottom B5 Input horizontal low HO Input horizontal top HS Input horizontal side 24

25 MELIOR MOTION Order code PSC 112 H E 100 R V1 0 0 Premium Stephan Compact Gear Sizes: 056, 080, 112, 160, 224, 300, 400 see pages 8 9 Execution: V = Solid shaft H = Hollow shaft see pages 8 9 Version: E = sub-assembly B = fully enclosed gearbox M = geared motor (on request) see pages Ratio: see pages 8 9 Input: C = intermediate shaft P = free input shaft R = pinion on motor shaft K = motor flange and coupling B = with bevel gear see pages Mounting position: V1, V3, B5, HO, HS see page 24 Output: 0 = no flange 1= flange (to specify) 2 = pinion 3 = special see page 11 Others: 0 = standard 1= special (to specify) For motor adaption motor data sheet has to be provided. MELIOR MOTION 25

Precision gearbox PSH-D The precision gearbox PSH-D originally was designed for the use in Delta Robots.

On Delta Robots varying product weights and differing pick & place distances play an important role when designing a gearbox.

With the development of a high precision gearbox which may be used in robotics and automation industry, highly dynamic drive systems with constant precision can be offered.

26 Precision gearbox PSH-D The precision gearbox PSH-D originally was designed for the use in Delta Robots. However, it may also be used in any other application where highest precision in combination with fast reverse movements is required. On Delta Robots varying product weights and differing pick & place distances play an important role when designing a gearbox. The challenges involve very high cycle numbers and short, highly dynamic motions in a high duty cycle. With the development of a high precision gearbox which may be used in robotics and automation industry, highly dynamic drive systems with constant precision can be offered. The gearbox has a hollow shaft to allow a feed-through of cables. A variable motor interface allows individual motor adaption. The precision gearbox PSH-D is a helical gearbox with a special tooth profile which guarantees a very low backlash which remains on a constantly low level throughout the whole lifetime of the gearbox. The housings are made of high-grade aluminium alloy which makes a contribution to the low weight. Only bearings from well-known bearing manufacturers are used to secure the highest possible quality. The gearboxes can be assembled in any mounting position and are also available in solid shaft version. Pictures: Precision gearbox PSH-D 26

27 Precision gearbox PSH-D PSH-D Technical data Scope of ratios Number of stages Output torque (equivalent torque) Max. output torque Emergency stop torque Rated input speed Max. input speed Admissible radial force (dynamic) Backlash Lifetime Torsion stiffness Weight approx. Efficiency Noise level Nm Nm Nm min-1 min-1 N arcmin hours Nm/arcmin kg % db(a) 20,044 51, ,800 6,000 1, (for i=51,698) 30, >95 % 68 FEATURES Very low backlash Compact design Low noise level Low friction High stiffness High efficiency Gearbox with hollow shaft Motor adaption via lantern and coupling Special tooth profile allows fast reverse movements Lifetime lubrication YOUR ADDITION Constant precision throughout the whole lifetime of the gearbox Smarter periphery design Reduced noise exposure at workplaces Higher energy efficiency Allows positioning straight-to-the-point Use of motors/systems with less energy consumption With hollow shaft allowing a feed-through of cables Easy motor adaption for all standard servo motors S1 duty cycle is possible Maintenance-free PRECISION GEARBOX PSH-D 27

28 Dimensions PSH-D Note: Dimensions C-K depend on the servo motor which is being used 28

Some examples are shown below: SP191 Robotic gearbox Dimensions: Hollow shaft: Backlash: custom-made 80 mm 0.

29 Special precision gearboxes Premium Stephan offers a big range of tailored solutions especially designed for your application. From custom-made gear units throughout optimization or modification of standard gear units we develop and manufacture precision gearboxes based on planetary, helical or bevel gearboxes. Some examples are shown below: SP191 Robotic gearbox Dimensions: Hollow shaft: Backlash: custom-made 80 mm 0.1 arcmin Ratio: 100 / 130:1 Torque: Mmax = 2000 Nm SP244 gearbox for linear axis Dimensions: Backlash: custom-made < 4 arcmin Ratio: 10:1 Torque: Special feature: Mmax = 800 Nm with output pinion for rack and pinion applications SP224 Positioning gearbox Dimensions: Backlash: custom-made < 0.1 arcmin Ratio: bis 130:1 Hollow shaft: Positioning accuracy: up to 95 mm dia. +/ mm SPECIAL PRECISION GEARBOXES 29

30 Further gearbox solutions Convince yourself of our other gearbox solutions. Geared motors with output torques up to 25,000 Nm. Industrial gearboxes up to 750,000 Nm and special gearboxes with output torques up to 4,000,000 Nm are available. MI Geared motor MK Geared motor MP Geared motor MH Industrial gearbox Constant fluid coupling Special gearboxes 30

31 For further information please visit our website: 31

247 902 Fax: +49 51 51 780 441 Mail: martina.zaremba@premium-stephan.

32 Your addition in transmission. Our product specialists are looking forward to hearing from you: Martina Zaremba International Sales Manager Precision Drives Phone: Mobil: Fax: Mail: Matthias Nentwig Business Unit Manager Precision Drives Phone: Mobil: Fax: Mail: Premium Stephan Hameln Branch office of Premium Stephan B.V. 06 / Ohsener Str , D Hameln Phone: Fax: Mail: info@premium-stephan.com

Precision Drives Precision Gears Performance in Accuracy

Precision Drives Precision Gears Performance in Accuracy Precision Gears Performance in Accuracy Your addition in transmission. The foundations were laid over 100 years ago: In the small mill belonging to the Stephan family in the 1890s, everything already