GEARBOX CONSTRUCTION:

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Rodger Mills
5 years ago
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Transmission division was established in 1964 with the aim provide quality products in Industrial / Rail and Marine field.

Powered by state of the art Engineering & Manufacturing ols, and high tech. infrastructure, KPCL remains in the league of its own when it comes creating Power Transmitting Solutions.

2 PROFILE: KPCL is established in 1958 under the Visionary Leadership of Mr. S. L. Kirloskar. Initial production started with Air Compressors and subsequently Transmission & Air Conditioning Divisions were established rollout the high technology products. Transmission division was established in 1964 with the aim provide quality products in Industrial / Rail and Marine field. Today with, 52+ years of experience in gear design and manufacturing, KPCL remains the leading solution provider for challenges in the field of Power Transmission. Powered by state of the art Engineering & Manufacturing ols, and high tech. infrastructure, KPCL remains in the league of its own when it comes creating Power Transmitting Solutions. Our stringent Quality norms and the Integrated Management System (ISO 9001, ISO 14001, OHSAS ) and superior workmanship have made us the leaders in Helical Reduction Gear Boxes in industries. The modular design and construction of this new series of gearboxes, offer many engineering and performance advantages using the fabricated casing suit any type of Power Transmitting Solutions. These Gear Units are available in parallel shaft helical & bevel helical units from single four stage, o/p rque up 10000kNm. The modified center distances and vertical shaft types also available on request, as a special gearbox design suit cusmer requirements. Every Product is optimized in its design parameters for most favourable ratio distribution, CD distribution, the number of teeth, module, helix angle,etc..for the rated rque. All gears are designed by expert team according DIN standard, and design validation for API / ISO / AGMA standards also computed on request. Design validations are carried out on latest software, mainly with ROMAX Designer, KISSsoft, KISSsys, ANSYS, PRO-Engineer - Creo Advanced Simulation, etc.. Tooth modifications, Tooth Stress Analysis, Balanced Specific Sliding and Contact Pattern Analysis also done ensure Appropriate Load Distribution.

3 GEARBOX CONSTRUCTION: Gears: Case hardened and profile ground Single helical gears, with optimum tip relief and face crowningassures the finest DIN quality 6 or better, assures the highest accuracy achieve quiet running characteristics and maximum rque transmission in lower Center distances(high power density). Gear casing: Fabricated Gear casings, made of E250 (IS 2062) steels - designed with 3D modelling software and analysed with FEA software ensure rigidity and stiffness. Split Casing design is adopted for easy maintenance, and the additional features also included like Inspection cover, dipstick, breather with magnetic drain plugs. The supporting ribs, Oil pockets, foot and vertical wall thickness are designed accordingly ensure vibration dampening properties. Cast Iron casings also supplied on request, when the order quantity is high. Shaft: The shaft diameters are sized based on DIN 743, and the subsequent diameter reductionsundercuts/ fillet radius- are analysed for stress concentrations. The input and output shafts are designed suit most of the standard applications, considering the connections and the additional loads in radial and axial directions. For any specific overhanging load conditions (OHL) - additional shaft extensions- Splined shafts, please contact KPCL R&E for design verifications. Bearings: All bearings are selected for optimal L10 life, take radial and axial loads from the gear pair and the deflection of the shafts using the in-house /supplier software. The taper roller bearings are preferred in smaller unit sizes, and spherical roller bearings are used in higher unit sizes. Contact KPCL R&E for any special needs. Lubrication: Sump Lubrication is the default method of lubrication. Integrated mechanical pumps and external FLS also utilised according the application needs. The common use of the mineral oil will be ISO VG 320 / ISO VG 460 grades. Synthetic oils are suggested for high reliability and critical applications. Refer the quantity of oil, grades, suggested brands in the respective tables. Gearboxes are always supplied without any lubricant and mounting bolts unless agreed specifically. Sealing: Sealing arrangements provided on Industrial Gearboxes are unique in sense that combines Radial Lip Seals with Labyrinth Arrangement increase reliability and life of Seals. Seal seating areas are normally Ground for achieving high surface finish avoid leakage paths during running. Accessories: Hold backs, Base plates, Mor mounting adaprs, Couplings, Morised units, Over running clutches, Hollow shaft shrink discs, External Lub. systems, etc...are supplied on specific request, when informed KPCL during enquiry process.

4 GEARBOX RATED CAPACITY: Mechanical Rating: The Mechanical Gear rating is computed according DIN Method B. The safety facs for Pitting and Tooth root strength are calculated using KissSoft/Romax.The scuffing and micropitting calculations also computed, based on the optimal values of oth corrections, geometrical / manufacturing lerances and oil properties. Thermal Rating: Thermal rating is done based on ISO TR guidelines, and the different thermal ratings are tabulated for Only Normal cooling by convection-by gear case. Fan - on mor side / high speed shaft.. Cooling coil - dipped in the oil sump- circulate water. Combined Fan and cooling coil. Forced lubrication system with external tank, Separate oil cooler - Shell& Tube heat exchanger also available on request. Safety facrs : Even though built with modular design, the standard gearboxes when used in different applications, the needed safety facrs differ between two applications based on the end user operating conditions and application needs. Hence the cusmer is advised provide maximum input about the gearbox fit/form/functional/safety/regulary requirements during the RFQ process select the gearbox rightly. Refer KPCL whenever assistance required. Varients / Special Needs: Horizontal -Foot mounted- Solid shaft - Helical and bevel helical gear units with single or double extension is the basic version of the design. Due the modular design and unique layout concept, the internals are interchangeable other varients, and our design and supply includes, Note : Horizontal -Foot mounted - Hollow output with key connection Horizontal -Foot mounted - Hollow output with "Shrink Disc" connection Horizontal -Shaft mounted - Hollow output with key connection Horizontal -Shaft mounted - Hollow output with "Shrink Disc" connection Horizontal -Foot mounted - Solid output with Spline connection Vertical -Wall mounted - Solid output with keyed/spline connection For any special requirements, where the values are intermediate or exceeds from the tabulated value contact KPCL R&E. Specify whether the reducer should rotate in both directions or not. If Holdback is be supplied then specify direction of rotation for proper selection of Hold Back assembly. Technology, Design Standards & Process Standards are continually being improved,hence details pertaining dimensions and rating capacities are subject alteration without notice. This is a reference document for selection, hence ask for Certified PD drawing from R&E with every Purchase Order.

8 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio Input Output Gear Unit Sizes H1 Series - Single Stage Helical Gear Units in n1 n * Gear units with ratings in red colour (bold fig.) needs Force Lubrication. Thermal Capacities PG in kw Nominal Input Gear Unit sizes Ratio Speed in n Thermal Capacities PG1 For Gear Units Without Cooling in kw Thermal Capacities PG2 For Gear Units With Fan Cooling in kw Thermal Capacities PG3 For Gear Units With Cooling coil in kw Thermal Capacities PG4 For Gear Units With Fan & Cooling Coil in kw

10 Mechanical Capacities PN in Kw Nom. Speed (rpm) Ratio Input Output Gear Unit Sizes H2 Series - Two Stage Helical Gear Units in n1 n * Gear units with ratings in red colour (bold fig.) needs Force Lubrication. Thermal Capacities PG in kw Nominal Input Ratio Speed Gear Unit sizes in n Thermal Capacities PG1 For Gear Units Without Cooling in kw Thermal Capacities PG2 For Gear Units With Fan Cooling in kw Thermal Capacities PG3 For Gear Units With Cooling coil in kw Thermal Capacities PG4 For Gear Units With Fan & Cooling Coil in kw

12 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio Input Output in n1 n * Gear units with ratings in red colour (bold fig.) needs Force Lubrication. Thermal Capacities PG in kw Nominal Ratio in Input Speed Gear Unit Sizes Gear Unit sizes H3 Series - Three Stage Helical Gear Units n Thermal Capacities PG1 For Gear Units Without Cooling in kw Thermal Capacities PG2 For Gear Units With Fan Cooling in kw Thermal Capacities PG3 For Gear Units With Cooling coil in kw Thermal Capacities PG4 For Gear Units With Fan & Cooling Coil in kw

14 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio Input Output in n1 n Thermal Capacities PG in kw Nominal Ratio in Input Speed H4 Series - Four Stage Helical Gear Units Gear Unit Sizes Gear Unit sizes n Thermal Capacities PG1 For Gear Units Without Cooling in kw

16 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio Input Output in n1 n * Gear units with ratings in red colour (bold fig.) needs Force Lubrication. Thermal Capacities PG in kw Nominal Ratio in Input Speed B2 Series - Single stage bevel with Single Stage Helical Gear Units Gear Unit Sizes Gear Unit sizes n Thermal Capacities PG1 For Gear Units Without Cooling in kw Thermal Capacities PG2 For Gear Units With Fan Cooling in kw Thermal Capacities PG3 For Gear Units With Cooling coil in kw Thermal Capacities PG4 For Gear Units With Fan & Cooling Coil in kw

18 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio input Output in n1 n * Gear units with ratings in red colour (bold fig.) needs Force Lubrication. Thermal Capacities PG in kw Nominal Ratio in Input Speed B3 Series - Single stage bevel with Two Stage Helical Gear Units Gear Unit Sizes Gear Unit sizes n Thermal Capacities PG1 For Gear Units Without Cooling in kw Thermal Capacities PG2 For Gear Units With Fan Cooling in kw Thermal Capacities PG3 For Gear Units With Cooling coil in kw Thermal Capacities PG4 For Gear Units With Fan & Cooling Coil in kw

20 Mechanical Capacities PN in kw Nom. Speed (rpm) Ratio Input Output in n1 n Thermal Capacities PG in kw Nominal Ratio in Input Speed B4 Series - Single stage bevel with Three Stage Helical Gear Units Gear Unit Sizes Gear Unit sizes n Thermal Capacities PG1 For Gear Units Without Cooling in kw

MANUFACTURING SETUP: Kirloskar Pneumatic is equipped with state of the art Gear manufacturing facilities including 3 /5 Axis CNC Milling and Turning centres, Special purpose machines like Schiess

KPCL also has its own Foundry Shop and in-house Heat Treatment shop for the Volume Hardening and Case Carburising & Hardening of gear components, which helps in achieving the highest standard of

CUSTOM BUILT GEARBOXES FOR INDUSTRIES: KPCL offers cusmized gearboxes for industry specific applications in -cement -sugar - steel sponge iron & rolling mill -rubber - chemical paper process industry

All our cusm built gearboxes can be supplied with identical principal centre distance, centre height and mounting position of the existing gearbox of any make - for easy replacement, whilst

23 MANUFACTURING SETUP: Kirloskar Pneumatic is equipped with state of the art Gear manufacturing facilities including 3 /5 Axis CNC Milling and Turning centres, Special purpose machines like Schiess Kopp Profile Milling Machines, Hofler Gear Hobbing & Gear Grinding machines, which contributes for superior quality gears. KPCL also has its own Foundry Shop and in-house Heat Treatment shop for the Volume Hardening and Case Carburising & Hardening of gear components, which helps in achieving the highest standard of quality. The brand new Wenzel gear profile testers and the Accurate 3 axis CMM and the SCADA control on the manufacturing process- controls and ensures the Quality Level in all aspects. CUSTOM BUILT GEARBOXES FOR INDUSTRIES: KPCL offers cusmized gearboxes for industry specific applications in -cement -sugar - steel sponge iron & rolling mill -rubber - chemical paper process industry hydro-turbine- wind turbinemarine applications. All our cusm built gearboxes can be supplied with identical principal centre distance, centre height and mounting position of the existing gearbox of any make - for easy replacement, whilst increasing power and reliability. KPCL has plenty of experience supply special gearboxes used in Crane applications, mainly for Hoisting, Long travel, and Cross travel applications. KPCL manufacture speed increaser gearboxes for small Hydro and Wind turbine gear boxes in two ranges, namely, sub mega watt ( kw) & mega watt class. KPCL also supplies interchangeable segmental gears form Girth gears (Gear diameter above 2 meter) mainly used in kilns, rotary drums, mill drives in cement/steel/sugar industries. Apart from direct head office (Pune) support, our Branch Sales Offices and network of spare parts sckiest / dealers, throughout the country ensure upkeep of every single Kirloskar Pneumatic product justify company s commitment the tal cusmer satisfaction.

More Detail about Helical & Bevel Helical Reduction Gear Boxes.

More Detail about Helical & Bevel Helical Reduction Gear Boxes. For Inspection & Checking of these Housings we have Brown & Sharpe (USA) CNC CMM with full automatic rotating Renishaw Probe Head with Inspection