Your partner for smart solutions ZUVERLÄSSIG ANTREIBEND EFFIZIENT

Transcription

1 Your partner for smart solutions ZUVERLÄSSIG ANTREIEND EFFIZIENT

2 ZAE gets you moving We at ZAE are specialised in the development and manufacture of innovative drive systems. Our product range includes both highperformance standard gear units and individual solutions designed according to customer specifications. The perfect drive system for every application CONTENTS Company focus Products evel helical gear units Worm gear units Worm helical gear units evel gear units Geared motors Servo gear units Customised gear units Worm gear sets Production

3 COMPANY FOCUS ATH ALTONAER-TECHNOLOGIE- HOLDING ZAE operates independently in the market under the umbrella of ATH. Operating profits are largely reinvested to offer room for innovation. Distributed profits mainly flow into charitable organisations. ZAE is a company rich in tradition that has stood for decades for... EXPERIENCE We have a wide range of technical expertise and application experience. This puts us in a position to meet rising demands for short development lead times and high product quality. ZAE CHARITALE FOUNDATIONS Shareholders of ATH Altonaer- Technologie-Holding GmbH are the charitable foundation urkhard Meyer Stiftung and Fritz Landmann Stiftung Vermögensverwaltungsgesellschaft mbh. The urkhard Meyer Stiftung was called into being in through the contribution of privately held shares primarily to promote science and research in the field of childhood cancer as well as overlapping the mission of the Landmann Stiftung vocational training. esides income from ATH, money raised through employee collections has been donated to Forschungsinstitut Kinderkrebs-Zentrum Hamburg (Research Institute Children's Cancer Centre Hamburg) for a number of years. QUALITY At ZAE quality plays a central role all along the value chain: The focus on quality starts with provision of competent customer advice and continues with engineering design and test bench trials in our development department. Qualified production and assembly staff provide the guarantee for high-quality products. Quality is the decisive factor in the success of all our standard and customised solutions! FLEXIILITY & SPEED The ability to integrate drive solutions quickly and easily into the corresponding application translates into a competitive edge. We take this into account through our close contact with the customer during the tendering and development phase as well as with our lean processes. Through this we can noticeably reduce our delivery times. ATH MORE RESEARCH MORE HOPE ATH Altonaer-Technologie-Holding GmbH, Hamburg, has been acting as a management holding for four midsize mechanical engineering companies since 2. RELIALE DRIVING EFFICIENT

4 PRODUCTS evel helical gear units Efficiency up to % Ratios of :1 :1 Modular ZAE design for IEC, servo and NEMA motors Zero-backlash couplings Servo gear units Efficiency up to % Ratios of :1 :1 Quiet running, optimum vibration damping properties Diverse motor adaptations Zero-backlash couplings 2 Worm gear units and worm helical gear units Centre distances of 0 0 mm Efficiency up to % Ratios of :1 :1 Quiet running, optimum damping properties Self-locking versions possible High overload capacity Customised gear units Customised gear units Short development lead times Also for small batches 2 evel gear units Optionally available in stainless steel unit sizes Torques to Nm Low-friction bearings Optional reinforced bearings Diverse motor adaptations Worm gear sets Customised high-precision worm gear sets and standard gear sets Centre spacing to 0 mm Module size to 0 mm Worm gears made from bronze, other materials optionally available Worm shafts hardened and ground 2 Geared motors Single- and multi-stage versions Customer-specific adaptations possible Modular ZAE design for IEC, servo and NEMA motors Testing services -D CAD Tech. documentation Rapid prototyping Finite element analysis ZAE Sprinting from idea to mass production 22,2

5 EVEL HELICAL GEAR UNITS Product concept The new ZAE bevel helical gear units were developed with high energy efficiency in mind. Through optimised gear sets as well as low-friction bearings and oil seals, efficiencies of up to % are achieved. Ratios of :1 to :1 are available in 2- or -stage combinations. The contemporary design and smooth surfaces lend themselves well to applications where hygiene is of the utmost importance. Overview High efficiency up to % Low-cost modular system Wide range of ratios from :1 to :1 Modular motor mounting for IEC, servo and NEMA motors Diverse mounting possibilities Output side compatible to ZAE worm gear units Smooth, easy-to-clean surfaces Split-hub coupling with no backlash for easy motor mounting Precision-machined gear sets for exceptionally smooth running Synthetic lifetime lubrication, optionally with food-grade synthetic oil Types E 222 E 2 Performance data for bevel helical gear units with n 1 = min -1 Available standard ratios: 2-stage:.:1 1:1 20.:1.:1 -stage: :1 0:1 :1 :1 :1 2:1 :1 :1 :1 :1 1:1 :1 Output torques: Gear size 222 / 22 2 / 22 / 2 22 / 2 Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max All gear sizes are represented below by means of exemplary versions. Type 222/22 Hollow shaft (symbolic) A D 1 D D 2 F G 2 L 1 L 2 M S T V T 2 U V 1 Type D 1V D E G 1 H L L 222 ME S T U U 22 V 22 X D 2 D 22 E 1 G 22 I L 22 L 22 N T T 22 U V U 2 V 2 Application examples Drive for demanding hygienic applications Drive for an applicator E 222 E 22 E 2 E E 22 E 2 E 22 E Mx Mx Mx Mx M1x M1x M1x M1x Dimensions D 22, G 22, L 22, L 222, T 22, U 22 and V 22 apply to 2-stage versions. Dimensions D 2, G 2, L 2, L 22, T 2, U 2 and V 2 apply to -stage versions. Only one of the illustrated shaft journals is present.

6 11 Types M 222 M 2 Types S 222 S 2 Performance data for bevel helical gear units with n 1 = min -1 Available standard ratios: 2-stage:.:1 1:1 20.:1.:1 -stage: :1 0:1 :1 :1 :1 2:1 :1 :1 :1 :1 1:1 :1 Output torques: Performance data for bevel helical gear units with n 1 = min -1 Available standard ratios: 2-stage:.:1 1:1 20.:1.:1 -stage: :1 0:1 :1 :1 :1 2:1 :1 :1 :1 :1 1:1 :1 Output torques: Gear size 222/22 2/ 22/2 22/2 Gear size 222/22 2/ 22/2 22/2 Output torque rating T 2 allowable Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max Momentarily allowable peak torque T 2 max All gear sizes are represented below by means of exemplary versions. All gear sizes are represented below by means of exemplary versions. Hollow shaft (symbolic) Hollow shaft (symbolic) Type 222/22 Type 222/22 Type Motor D D D M F F M G I 2 I L M T M U M M 222 M 22 M 2 M M 22 M 2 M 22 M 2 1 /1 1 /1 1 /1 1 / M M M M M M M M M M1 M M M M1 M M M M1 M1 M1 M1 For other dimensions see E types on page Type Square F F M D D M L M G I 2 S 222 S 22 S 2 S S 22 S 2 S 22 S For other dimensions see E types on page. Dimensions D, F M, F and L 2 are adapted accordingly for the specific motor to be mounted

7 WORM GEAR UNITS Product concept ZAE worm gear units are high-performance industrial gear units for use in mechanical and plant engineering. These gear units are characterised by quiet operation, robustness against load spikes and a high power density. Types M 00 M 0 Performance data for worm gear units with n 1 = min -1 Available standard ratios: i = :1.:1 :1 1.:1 1:1 20:1 2. :1 0:1 0:1 :1 2:1 2:1 :1 Output torques: Gear size 0 1 Today's worm gear units have synthetic lifetime lubrication with minimal maintenance requirements and are nearly wear-free. Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max Overview Centre distances of 0 0 mm High efficiency up to % Ratios of :1 :1 Quiet running, optimum vibration damping properties Low-backlash version High overload capacity Self-locking versions possible Diverse motor adaptations Synthetic lifetime lubrication, optionally with food-grade synthetic oil All gear sizes are represented below by means of exemplary versions. Hollow shaft (symbolic) Application examples Comparison: centre distance 00 mm vs. 0 mm Precision grinding machine for wafers Conveyor belt drive in bottle filling Type Motor ME M 00 M 0 M 0 M /1 /1 /1 0 A Dk D 1 k L D H 2 L 1 D H D H D D H M L M E E 1 F F M F G G 1 G H H O P S Mx Mx Mx 22 Mx1

8 1 Types M G M G Types E G E 00 G Performance data for worm gear units with n 1 = min -1 Available standard ratios: i = :1.:1 :1 1.:1 1:1 20:1 2. :1 0:1 0:1 :1 2:1 2:1 :1 Output torques: Performance data for worm gear units with n 1 = min -1 Available standard ratios: i = :1.:1 :1 1.:1 1:1 20:1 2. :1 0:1 0:1 :1 2:1 2:1 :1 Output torques: Gear size Gear size 1 00 Output torque rating T 2 allowable Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max Momentarily allowable peak torque T 2 max All gear sizes are represented below by means of exemplary versions. All gear sizes are represented below by means of exemplary versions. Hole pattern size Hollow shaft (symbolic) Hole pattern size 1 Type Motor ME A C C 1 Dk D 1 L D H 2 L 1 D H D H D D H S M L G M F F F 1 H M G G 2 H 1 I R S 1 Hollow shaft (symbolic) M G M 1 G M 0 G M G M 1 G M G /1 /1 1 /1 1 / Mx22 2 M1x Mx0 2 M1x0 0 M1x0 M20x Type ME E G E 1 G 1 E 00 G 00 A C C D 1 m D 1V m 0 1 L L D 2 H D D H E E F G G G 2 H H 1 2 I K 1 L 2 L 1 2 N O 1 1 R S S T T 2 M20x M2x. M2x 2 T T V T U 2 h U h U v h U JS V V 1 2 0

9 WORM HELICAL GEAR UNITS Product concept These gear units combine the advantages of worm gear units with those of spur gear units: In the high revs range of the first gear stage, the multiplestart worm shaft runs at efficiencies of up to % at lubrication-favourable gear unit ratios. Here the worm gear stages have optimum vibration damping properties that provide optimised smooth running. Noise-optimised spur gear sets run in the downstream second or third gear reduction stage with equally good efficiency at low speeds. Profile unit sizes 2 or gear stages in one casing Quiet running Ratios of :1 0:1 Output torques to approx. 00 Nm Diverse motor adaptations Synthetic lifetime lubrication, optionally with food-grade synthetic oil Types M 0 M 1 Performance data for worm helical gear units with n 1 = min -1 The gear units are available with the range of ratios specified below. Output torques: Gear size Range of ratios i Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max Gear size Range of ratios i Output torque rating T 2 allowable Momentarily allowable peak torque T 2 max Type 0 Type 1/11 Type /1 Hollow shaft (symbolic) Type Motor ME A A 1 1 D 1 k D H 2 L 1 D H E E 1 E 2 F 1 G 1 G H H 1 I S O L 1 S Application examples M 0 1 and M 1 M Mx1 Mx1 Mx1 Mx1 Stage drives e.g. on a cruise liner Turning drive for unwinding unit in coating machines M 2 M 21 M M 1 M M m m Mx Mx2 x Mx20 M1x2 x M20x M2x

10 EVEL GEAR UNITS Product concept evel gear units are used when unfavourable installation conditions necessitate a direction change in the drive and/or a low ratio is required. The bevel gear sets have spiral toothing and are manufactured from alloy case-hardened steel. All gear unit housings are cubeshaped and feature machined surfaces and mounting holes on all six sides. A centring bore is also provided on three sides. ZAE also offers stainless steel bevel gear units for use in applications with stringent hygiene standards. These gear units are suitable for use in: - food and beverage industry - packing and packaging industry - chemical and pharmaceutical industry. Profile unit sizes Powers to kw for continuous duty, momentary to 1 kw allowable standard ratios from 1:1 :1 Low-friction bearings Optional reinforced bearings Modular motor mounting for IEC, servo and NEMA motors Diverse mounting possibilities Split-hub coupling with no backlash for easy motor mounting Synthetic lifetime lubrication, optionally with food-grade synthetic oil Types W 0 W 2 Version with free input shaft, gear configuration W / MW / SW Model 0001 Model 0002 Model 000 Model 000 Optional The performance data apply to gear unit types W, MW and SW. Type W 0 Type W Type W 1 Type W 1 Type W 1 Type W 2 n Ratio 1 P [min -1 1 T 2 P ] T 1 T 2 P allowable allowable 2 max T 1 T 2 P allowable allowable 2 max T 1 T 2 P allowable allowable 2 max T 1 T 2 P allowable allowable 2 max T 1 T 2 allowable allowable 2 max T allowable allowable 2 max [kw] [kw] [kw] [kw] [kw] [kw] i = 1: i = 2: i = : i = : Thermal power limit. kw. kw. kw 1. kw 1. kw kw 1 Type A C D j D 2 H D E F f F 1 G G 1 G 2 L L 2 S T T U h U JS S X Application examples evel gear units made from cast iron Stainless steel version Gear unit for servo mounting Ram adjustment in transfer press W M x W 1 * M x W M x22. W Mx 1 1. W M1x0. W M1x. * output side.

11 20 21 Types MW 0 MW 2 Types SW 0 SW 2 With coupling and mounting flange for standard IEC motors, various versions For performance data and models see type W. With coupling and mounting flange for servo motors, various versions For performance data and models see type W. Hollow shaft (symbolic) Hollow shaft (symbolic) Type MW 0 MW MW 1 MW 1 MW 1 MW 2 Motor 1 /1 /1 /1 1 / A C D j L D M L M D H D E F f F F M G 1 G 2 G G I 2 L M S T Mx 20. Mx1 2. Mx22 Mx 1 M1x0 M1x TM UM JS V U h X Type SW 0 SW SW 1 SW 1 SW 1 SW 2 A C D j L D M L M D H D E F f F Vk F M G 1 G 2 G G I 2 L M M M M M M M M M M M M M M1 M1 M1 M S T Mx 20. Mx1 2. Mx22 Mx 1 M1x0 M1x T M UM JS V U h X

12 GEARED MOTORS Product concept The ideal drive solution can be selected based on the requirements profile. ZAE gear units generally have an interface allowing for modular motor mounting. The following types of geared motors can be supplied at short notice: bevel helical geared motors single-stage worm geared motors helical worm geared motors ETA drive geared motor worm helical geared motors (2- or -stage) duplex worm geared motors bevel geared motors. Overview Single- and multi-stage versions Customer-specific adaptations possible Modular ZAE design for IEC, servo and NEMA motors PERFORMANCE DATA AND OVERVIEW OF TYPES Worm geared motors and duplex worm geared motors, types M and DM Gear size 0 Input power P 1 [kw] Output speeds [min -1 ] Gear size 1 1 Input power P 1 [kw] Output speeds [min -1 ] Helical worm geared motors, type GM Gear size 1 Input power P 1 [kw] Output speeds [min -1 ] Worm helical geared motors, type M Gear size 0 1 / 11 2 / 21 / 1 / 1 Input power P 1 [kw] Output speeds [min -1 ] evel helical geared motors, type M Gear size 222 / 22 2 / 22 / 2 22 / 2 Input power P 1 [kw] Output speeds [min -1 ] Type M (0 ) Type M ( 00) 2 Type M (222 2) Type M (0 1) Application examples evel helical gear unit with servo motor Worm helical gear unit Worm geared motor in a paper cutting machine Helical worm geared motor as a turn drive Type GM ( ) Type DM ( 1) The drawings represent only a few of the possibilities for geared motors. All further information is available upon request.

13 SERVO GEAR UNITS Product concept ZAE right angle servo gear units are individually adapted on the input side for each servo motor. A second drive shaft end is optionally available, e.g., for mounting of an encoder. Overview Optional low-backlash version Optimum material pairing for exceptionally smooth running High ratio in one stage Outstanding oscillation and vibration damping properties Universal mounting Synthetic lifetime lubrication, optionally with foodgrade synthetic oil Split-hub coupling with no backlash High efficiency up to % Types S 00 A S 1 A Performance data for servo gear units with n 1 = min -1 Available standard ratios: i = :1.:1 :1 1.:1 1:1 20:1 2. :1 0:1 0:1 (:1 2:1 2:1 :1) Output torques Gear size 0 1 Output torque rating T2allowable at min-1 Output torque rating T2allowable at 0 min-1 Maximum allowable input speed All gear sizes are represented below by means of exemplary versions. Application examples Servo gear unit with split-hub coupling and output-side clamping set Drive on a production line for door frames Linear drive for feeder systems Type ME S 00 0 S 0 S 0 S 0 S S 1 1 A D F M G K x K 1 min 2 max 2 x min 2 max x min 2 max 1 x min max 2 x 1 min max min max 1 D H 2 L M O 1 D 0 max 22 0 max max 0 22 max 0 max 1 max 2 E E 1 I F 1 P S Mx Mx Mx Mx Mx22 2 M1x2 H H U T D A H 2 E E For other dimensions see page 1. Dimensions D, F M, F, I 2 and I are adapted accordingly for the specific motor to be mounted.

14 CUSTOMISED GEAR UNITS Product concept Individual requirements necessitate individual solutions! Thanks to decades of experience in implementing specific requirements in customised designs we can rapidly develop and produce complete drive solutions. With state-of-the-art manufacturing facilities we can produce customised gear units at low cost in all quantities from small batches to thousands of gear units annually. A few examples of our numerous special solutions are illustrated here. A good example of an application-optimised drive is the ETA drive geared motor. Development focus was on achieving high efficiency as well as smooth, easy-to-clean surfaces. This drive is hence optimally designed for meeting stringent hygienic standards. Examples 2 Screw jack for adjusting the height of a bottle filler Customised gear unit for width adjustment on a woodworking machine Servo geared motor with integrated electronics for a labelling machine ETA drive geared motor (left) Lightweight version of self-locking worm helical gear unit evel gear unit in configuration as length cutting unit in the manufacture of brushes Worm gear unit designed for momentary peak torque Pneumatic gear shifter for a bottle inspection device Main drive on a precision grinding machine Three-stage helical worm gear unit for adjustment of label dispensers

15 WORM GEAR SETS 2 Product concept At our Hamburg plant worm gear units are produced for a variety of applications. We provide a wide range of standard products with centre distances of 0 00 mm and can also offer custom-built gear sets manufactured according to your individual specifications. Standard worm gear sets The worm shafts are made from hardened and ground 1MnCrSG. Various worm shaft versions are available. Apart from the worm shaft with cylindrical shaft end and feather key groove, a version with toothed shaft end is available. The short shaft end has a toothed shaft profile according to DIN 2 for the corresponding K coupling. Worm gear sets as per customer drawing Individual gear sets up to a centre distance of 0 mm and module 0 can be made according to customer drawings. The standard ZK profile is an alternative to other flank forms. Compression fitting for steelwork Standard gear set Worm gear sets in a metering pump system Worm gear sets in a metering pump system Special worm gear set for a rotary crane Gleason Pfauter P1/0 for worm gears to centre distance 0 mm Gear set type MO C M 2 L 2 Example: Gear set type SO øa øg øh ød M2 Centre spacing 0 00 mm Ratio :1 :1 Single- or double-sided version Self-locking version available T 1 V 1 U 1 øu DR thread centring device T S øk N øx R øw øv L Y ød M1 øx R øk Q øm R centring ME Z

16 0 1 PRODUCTION PHILOSOPHY We strive to deliver the best quality in the shortest time. The extraordinarily high manufacturing depth afforded by our main production facilities in Hamburg helps us do this. With the exception of hardening and casting, all component processing steps are performed here. Thus we can always guarantee optimum manufacturing processes, quality and response times. PRODUCTION CAPAILITIES The following is a brief overview of our current production capabilities. This basis is continuously being upgraded and extended. Turning, milling, complete machining Several machining centres are available for machining. The latest additions were two Heller H00 machining centres with 2 pallet storage positions and loading by a Schuler Loadmaster. We also have numerous other machining centres and CNC turning centres, for example: Index G, G00 and VG Okuma L1 Hessap DVT diverse turning centres Hüller Hille machining centres Gear cutting (hobbing) Gear diameters to 0 mm and modules to 0 mm can be produced on our hobbing machines. The following machines are available: Gleason Pfauter PE 1, GP, P0/0 and P1/0 Honing Honing can be used as an alternative to grinding to optimise the running behaviour of spur gears. Spur gears ranging from module 0. to module with tooth widths of up to 0 mm can be honed on the Fässler K00. Grinding The quality of a gear unit mainly depends on the quality of the gear sets. We take this core task into our own hands. The teeth on our worm shafts are ground on Klingelnberg machines. Our inventory currently comprises: Klingelnberg HNC S and Klingelnberg H Cylindrical grinding We have a number of Studer machines including the Studer S and the Studer S1 for cylindrical grinding. RELIALE DRIVING EFFICIENT

17 A PARTNER WITH IDEAS ZAE-AntriebsSysteme GmbH & Co KG Schützenstraße 221 Hamburg Germany T + (0)0 0 F + (0)0 2 info@zae.de ZAE TREIT AN UND EWEGT Sustainability initiative partner for machinery and plant engineering