GHE-Series Single Screw Extruder Units

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1 GHE-Series Single Screw Extruder Units

3 Contents General Description 1 Design Feature.. 2 Selection Procedure 3 Thrust Bearing Data 4 Thrust Bearing Life. 5 Mechanical Capacity 9 Output Torque and Exact Ratio. 10 Thermal Capacity 11 Dimensions 12 Thrust Housing and Output Shaft..13 Lubrication.14 Shipping Specification Notes..16

General Description Premium GHE-Series Extruder Gearboxes in double reduction parallel shaft horizontal and vertical models are intended to satisfy characteristic requirements and conditions

4 General Description Premium GHE-Series Extruder Gearboxes in double reduction parallel shaft horizontal and vertical models are intended to satisfy characteristic requirements and conditions encountered in single screw extrusion process. The gear units are quite capable to transmit the high torque required for pressurising and plasticising moulding materials. They can also absorb the high axial thrust through built-in spherical roller thrust bearing. A separate critically designed axial bearing housing accommodate thrust bearings of different sizes according to application loads. The hollow output shafts mounted with the different thrust bearings have different bores to accommodate the thrust screw. The units can be offered in Left hand or Right hand configurations with horizontal and vertical mounting to meet specific mounting needs. The modular design of GHE Series gearboxes offer a great range of flexibility in the interchangeability of parts. Range: 8 sizes of units with ratio coverage ranging from 5.06/1 to 25.6/1. GHE Series gearboxes are fully metric. The units sizes upto are in unicast housing and above are in split housing. Shaft extension keyway are to IS:48. Output bores are provided with single keyway provisions. Double keyway / Splined bores can be provided against customised requirements. Optional Cooling Coil provisions for additional cooling. The units can be suited to accommodate different thrust bearings. LH and RH handing can be provided. Horizontal and Vertical mountings are possible. Page 1

5 Design Feature Gears and Pinions: Helical gears and pinions are manufactured from high quality alloy case hardening steel. Case hardened surface with softer core provides improved wear resistance and fatigue strength. Flank ground gears to precision grade ensure high standard of accuracy, long life and quiet running characteristics. Gear cases: High quality, uni-cast close-grained cast iron casing accommodates bearings and gear trains. Units are designed in double reduction version with separate thrust bearing housing to carry different spherical thrust bearings. The units upto sizes are in unicast housing and above are in horizontally split housing. Case design has been computer optimised on CAD work station to provide strengthening ribs and minimize vibrations. They have optimal wall thickness in critical load carrying areas. Inspection covers are provided for viewing gear contacts. Oil level / dipsticks, ventilators and drain plugs are fitted. Bearings: Renowned roller bearings from major manufacturers are used throughout. The thrust bearing is of self-aligning spherical roller type. The bearings selected have ample capacity to support combined radial and thrust loads. Shafting: Input shaft integral with pinion is machined from case-hardening alloy steel. Direct hardening steel is used for hollow output shaft. Cylindrical seats for bearings, wheels, seals, couplings etc. are finished by precision grinding. Fitment dimensions towards specific screw shaft requirement must be addressed during placement of order. Shaft seals: Shaft extensions are fitted with spring-loaded high quality Viton type rubber seals to prevent outflow of oil. External Dimensions: Centre Distances are chosen from ISO preferred number series. Shaft Extensions and hollow output shaft bores are to ISO metric standards. All fasteners are metric. Lubrication: Lubrication of gears and bearings is entirely selfcontained by Splash, which provides ample and positive flow of oil resulting minimum wear and noise. Cast trays inside the case guide churned lubricants towards the bearings. Holes connecting the thrust bearing housing and oil sump ensures continuous circulation of oil flowing through the spherical roller thrust bearing at the output end. Recommended oil is of viscosity grade ISO:VG-3 with EP additives. No special care is required except occasional topping up of the oil. It is not advisable to mix two equivalent brands of oil. Cooling: As a standard feature, units have provisions for fitment of cooling water coil at the bottom of oil sump either at front or rear end. Direction of Rotation: Units may be operated in either direction of rotation. Product Quality: Units are manufactured under a stringent quality system certified to ISO: 9001 guaranteeing uniformly high standard. Painting : Casting surfaces are painted with linear epoxy primer both internally and externally. External cast faces are finally finished with alkyde semi-gloss blue paint. It is resistant to dilute acids and alkalis, oils and solvents, sea water and temperatures upto o C. Preservation / Protection Premium Extruder gear units are despatched without oil. Prior to despatch they are test run with a rust preventative oil assuring adequate protection to internal parts for a period of 6 months, covering normal transport and covered storage. Note: Where gear units are to operate in abnormal conditions or where they are to stand for long period without running e.g. in plant installation, PETL (Premium Energy Transmissions Ltd.) must be notified so that suitable protective arrangement can be made. As improvement in design are being made, this specification is not to be regarded as binding in details and drawings and capacities are subject to alterations without notice. Certified drawing would be sent on request. Page 2

6 Selection Procedure Premium GHE-Series extruder gearing size is determined against rated output torque capacity in consideration with necessary service factor. The thrust bearing size is selected thereafter against its suitability in terms of basic dynamic load rating. 1.0 Selection Of Reducer: 1.1 Gearbox ratio = Input speed / Output speed 1.2 Select the nearest nominal ratio and corresponding actual ratio from the available chart. 1.3 Determine the demand torque at output based on consumed load (*) and output rpm Demand torque (Nm) = 9550 x Absorbed power (kw)* / Output speed (rpm) (* In absence of consumed load, take motor power) 1.4 Get required output torque of the gearbox by multiplying the demand torque with necessary mechanical service factor. The minimum service factor is recommended to be between 1.5 and 2.0 depending upon the operating duration and loading character. Required output torque (Nm) = Demand torque (Nm) x Service factor Also, Required Mechanical Power Capacity = Absorbed Power x Service Factor 1.5 From the Mechanical Capacity / Output Torque rating table select a suitable size wherein the rated Output Torque / Mechanical Capacity meets or exceeds the required Power Capacity / Torque under point 1.4 with the predetermined ratio. 2.0 Check for Thermal Rating: 2.1 Thermal ratings are listed for: Gearbox with auxiliary cooling through cooling water coil. 2.2 Determine the thermal service factor from table. 2.3 Calculate the required thermal power capacity on the basis of absorbed power (*) and thermal service factor corresponding to specified ambient temperature and running hours. Required thermal power (kw) = Absorbed power (kw) / Thermal service factor. (* In absence of Absorbed / Consumed load, take Motor power) 2.4 Check the type of cooling by referring to thermal rating table. The required Thermal power must be equal to or less then the Thermal capacity of the gearbox as tabled in Page Check for Thrust Bearing: 3.1 The screw diameter, working pressure, screw rpm and thrust bearing life expectancy are to be specified by the extruder manufacturers. 3.2 Calculate the thrust load (Fa) from the following relationship: Fa = Л x Ds² x Pa / 000 where, Fa = Thrust load from extruder (kn) Ds = Extruder screw diameter (mm) Pa = Working pressure (bar) 3.3 Calculate the thrust bearing capacity (Ca) on the following basis: Ca = 1.06 x Fa x (60 x Ln x Ns / 10 6 ) 3/10 where, Ca = Required bearing capacity (kn) Fa = Thrust load from extruder (kn) Ln = Bearing life expectancy (hrs) Ns = Speed of extruder screw (rpm) Page 3

7 Selection Procedure 3.4 Check the basic dynamic load rating (C) from the thrust bearing given below. The calculated capacity (Ca) must be equal to or less than the catalogue rating (C). If, the value of (C) is not available for a particular type size, select for the next higher bearing available. In absence of next higher bearing, next higher sized gearbox may be required for accommodating a larger thrust bearing to satisfy the dynamic capacity. Thrust Bearing Data Thrust Bearing Size Load Rating C (kn) Unit Applicability 29412E E E E E E E E E E E E 0 294E E E 29436E E 2480 Page 4

8 Thrust Bearing Life, L 10 Allowable Axial load [kn] Allowable Axial load [kn],000,000 hrs hrs Speed of the extruder screw [rpm] Speed of the extruder screw [rpm] Page 5

9 Thrust Bearing Life, L 10,000,000 hrs hrs Allowable Axial load [kn] Allowable Axial load [kn] Speed of the extruder screw [rpm] Speed of the extruder screw [rpm] Page 6

10 Thrust Bearing Life, L 10,000,000 hrs hrs Allowable Axial load [kn] Allowable Axial load [kn] Speed of the extruder screw [rpm] Speed of the extruder screw [rpm] Page 7

11 Thrust Bearing Life, L 10 50,000 50,000 hrs hrs Allowable Axial load [kn] Allowable Axial load [kn] Speed of the extruder screw [rpm] Speed of the extruder screw [rpm] Page 8

12 Mechanical Capacity Page Nominal Ratio Mechanical Capacities (kw) Input Speed rpm Nominal Output Speed rpm Unit Size

13 Output Torque and Exact Ratio Page 10 Exact ( Actual ) Ratio Unit Size Nominal Ratio Unit Size Nominal Ratio Rated Output Torque (knm)

14 Thermal Capacity Thermal ratings are a measure of the gear units ability to dissipate heat. If they are exceeded the lubricant overheat and breakdown resulting in gear failure. GHE-Series extruder gearboxes have inbuilt cooling coil as its standard fitment. Cooling coils connections for water inlet and outlet pipes are provided in front and rear ends for water flow in either direction. Cooling coils are suitable for fresh, brackish or sea water with flow in either direction. Connections are therefore interchangeable. Fittings for cooling coils supplied with gear units are to suit Ø12mm copper pipe which is to be provided by the customers and is not under PETL s scope of supply. The ratings mentioned below for cooling coil are based on a cooling water inlet temperature of C. Nominal Ratio Input Speed rpm Unit Size Units with cooling coil Nominal Ratio Input Speed rpm Unit Size to To Thermal Service Factor (Relative to ambient temperature and duration of operation) With Cooling Coil: Ambient Temp. C 10 Running Time in any Hour 100% 80% 60% % % Page 11

Dimensions Y Z Handing VU Handing VO Handing HL ØV Handing HR Input Shaft Detail # Dimension upto Cooling coil Socket head Both Direction of rotation available

127 363 110 1 4 110 165 3 135 5 135 210 553 150 237 614 170 4 198 224 243 494 266 293 324 280 154 174 194 215 239 267 298 144 190 265 280 0 164 190 224 260 284

5 165 5 210 7 5 555 634 690 778 870 980 175 5 5 2 14 14 14 22 22 26 4xM12 4XM12 4XM12 4XM16 4XM16 4XM 4XM 4XM24 25 25 42 52 57 65 70 80 36 50 55 70 80 22.009 21.

011 M6X16 M6X16 M8X M8X M16X32 M16X32 M16X32 *M24X50 M24X50 50 60 80 80 80 *110 80 *110 110 110 * 43 53 73 73 73 *102 73 *102 102 102 *1 24.5 24.4 28.0 27.8 35.

000 *13.957 10.000 9.964 *14.000 *13.957 14.000 13.957 *16.000 *15.957 16.000 15.957 *.000 *17.957 All dimensions are in millimeters.

15 Dimensions Y Z Handing VU Handing VO Handing HL ØV Handing HR Input Shaft Detail # Dimension upto Cooling coil Socket head Both Direction of rotation available Size A A1 B B1 C C1 C2 C3 D E G G1 H J L M P R S T T1 U V V1 W W1 Z Y xM12 4XM12 4XM12 4XM16 4XM16 4XM 4XM 4XM *38.0 * *.0 * *50.0 * *55.0 * *65.0 * M6X16 M6X16 M8X M8X M16X32 M16X32 M16X32 *M24X50 M24X * * * * * * *41.0 * *48.5 * *53.5 * *59.0 * *48.5 * * * * * * * *.000 * All dimensions are in millimeters. *Dimensions shown in italics correspond to nominal reduction ratio of upto 10.3/1 as applicable. Upto size, unicast housing; and above, horizontally split housing. For Output shaft and thrust bearing housing details refer to table of Thrust Housing and Output Shaft. Page 12

16 Thrust Housing and Output Shaft Page 13 Output Shaft Thrust Bearing Housing Thrust Bearing Unit Size K MX E E E MX E Y1 Z1 V4 N K X2 X1 N1 X d V3 D1 N4 N3 N2 Q F M36 M36 M36 M M M M16 M MX33 MX33 MX33 MX33 M12X21 M12X21 M12X21 M12X E E E E E E E E E E E E E E E E E E E E E E E E All dimensions are in millimeters.

17 Lubrication and Lubricant Premium GHE-Series Extruder Gearboxes are lubricated through positive splash by transfer of oil thro gears. All units are provided with combined dipsticks and ventilators and drain plugs. Recommended Lubricants are shown in the adjacent column. Oil capacities are shown below against each units Page 15 for both vertical and horizontal application. These are approximate as exact quantities vary with ratios. New gear units are supplied without oil. Before operating it is essential to ensure that they are filled to the correct oil levels, as indicated by marking on dipsticks, with lubricants recommended by PETL. Overfilling can cause overheating and leakage. Correct lubricant is most important and it should be noted that EP oils are recommended in all instances. Lubricants listed are suitable for normal ambient temperatures and operating duties. All gear units in this range are designed to operate under full load to a maximum temperature of 110 C. Higher temperature upto a maximum of 1 C are acceptable on the basis of peak loads of shot duration only. In certain applications these maximum temperatures may be exceeded by the use of special lubricants. Such cases, or others where extreme conditions are to be met, e.g. low temperature operation on unusual loading conditions, should be referred, with full details, to PETL for recommendations. Recommended lubricants are based on information provided by oil suppliers and responsibility cannot be accepted for the quality or suitability of oil supplied, nor to any mechanical defect resulting from unsatisfactory lubrication due to the use of sub-standard oil. Recommended Lubricant ISO VG3 Brand Grade Greaves Greaves Traxol 32 Bharat Petroleum Cabol 3 or Amocam 3 Castrol Alpha ZN 3 Gulf Harmony 3 Hindustan Petroleum Enklo 3 Indian Oil Servomesh SP 3 Veedol Avalon 3 Esso Petroleum Co. Ltd. Sparton EP 3 Shell Group Omala Oil 3 Balmer Lawrie Protomac SP 3 Recommended Lubricant Use Greaves Traxol Lubricant oil G-32 for optimizing gear performance and service life. Available at all PETL outlets. Page 14

18 Shipping Specification and Oil quantity Thrust Bearing Size Net Weight and Gross Weight (in bracket) in kg (approx.) 29412E 29413E 29414E 29415E 29416E 29417E 294E 294E 29422E 29424E 29426E 29428E 294E 29432E 29434E 29436E 29438E 85 (95) 89 (99) 94 (103) 108 () 113 (1) 1 (138) () 4 (228) 210 (235) 274 (7) 281 (314) 289 (323) 322 (362) 329 (371) 337 (375) 348 (388) 433 (488) 439 (494) 447 (502) 4 (509) 574 (634) 581 (641) 590 (650) 602 (662) 812 (892) 832 (912) 851 (931) 872 (952) Mounting Oil Capacities in litres (approx.) Horizontal Vertical Page 15

D E X Series. Extruder Gear Box. Dharam Power Transmission Equipments Pvt. Ltd.

D E X Series. Extruder Gear Box. Dharam Power Transmission Equipments Pvt. Ltd. D E X Series Extruder Gear Box Dharam Power Transmission Equipments Pvt. Ltd. General Description Omex' DEX-Series Extruder Gearbox in double reduction parallel shaft horizontal and vertical models are