Backlash-free shaft couplings: ROTEX GS backlash-free flexible shaft couplings TOOLFLEX backlash-free torsionally stiff bellow-type couplings RADEX -NC backlash-free torsionally stiff servo lamina coupling ROTEX GS TOOLFLEX RADEX-NC 0
Backlash-free shaft coupling Technical description ROTEX GS is a 3-part, axial plug-in coupling backlash-free under pre-stress. It is convincing even with critical applications by its backlash-free power transmission, its stiffness which is each adapted to the application and its optimum damping of vibrations. This principle of installation offers significant assembly possibilities which optimize the assembly times in production. ROTEX GS (straight tooth, backlash-free) The straight toothing of the spider mounted under prestress results in a smaller surface pressure and consequently higher stiffness of the coupling system. The flexible teeth compensate for misalignment but are supported radially in the inside diameter by a central web. This avoids too high internal or external deformation by high acceleration or high speeds. This is vital for a smooth operation and long service life of the coupling. Limitation by concave cams in case of too high speeds/centrifugal forces and prestress of elastomer parts Support to the axis of rotation The hub claws and the nylon teeth are chamfered to allow for a "blind assembly". The ends of the teeth have pegs arranged reciprocally to limit the axial positioning.the plug-in force varies depending on the Shore hardness and prestress of the spider (see comments in the mounting instructions KTR-N 4550). s Electric isolation due to gap dimension "s" By observing the gap dimension "s" the electrical isolation is ensured, as well as a high service life of the coupling. This fact is gaining more and more importance, due to the increasing precision of shaft encoders and the existing demand for electro-magnetic compatibility. E s The elastic spiders of the GS line are available in three different kinds of Shore hardness, identified by colour, the material being soft to hard. Due to these four spiders with different kinds of Shore hardness it is easily possible to adjust the ROTEX GS regarding the torsional stiffness and the vibration behaviour to the individual conditions of an application. Description of spider hardness [Shore] Identification Colour Material Permissible temperature range [ C] Permanent temperature Max. temperature short-term Available for coupling size 80 Sh A-GS blue Polyurethane 50 to + 80 60 to + 20 size 5 to 24 92 Sh A-GS yellow Polyurethane 40 to + 90 50 to + 20 size 5 to 55 95/98 Sh A-GS red Polyurethane 30 to + 90 40 to + 20 size 5 to 75 64 Sh D-H-GS green Hytrel 50 to + 20 60 to + 50 size 7 to 38 64 Sh D-GS green Polyurethane 20 to + 0 30 to + 20 size 42 to 75 Typical applications s of electric measuring systems backlash-free in the range of prestress s of electric measuring and control systems main spindle s - backlash-free in the range of prestress s, positioning s, main spindle s high load backlash-free in the range of prestress control s / tool spindles planetary gears / feed s high load, torsionally stiff high ambient temperat. / resistant to hydrolysis 02
Backlash-free shaft coupling Application recommendation Measurement and control systems For measurement and control systems a high torsional stiffness of the coupling is required in order to obtain positioning repeatability. The torques that arise are relatively small so that backlash-free, torsionally stiff power transmission is achieved by the elastomer pre-stress. In order to minimize the restoring forces we would recommend the spider 80 Sh A GS for such applications. Servo and positioning s ROTEX GS as an alternative to torsionally rigid couplings Torsionally rigid shaft-to-shaft connections do not only transmit the torque backlash-free and non-rigid, but also torque peaks and vibrations. For driving systems with critical vibrations, the benefit of high stiffness for torque transmission soon becomes a serious disadvantage. For applications on which torsionally rigid shaft-to-shaft connections may cause a problematic torque transmission, the optimum alternative is ROTEX GS. Backlash-free, damping vibrations, yet sufficiently torsionally rigid so that even highly dynamic servo s must not suffer from lower precision with the right sizing of the coupling. ROTEX GS TOOLFLEX RADEX-NC Main spindle s With the high torques in the field of machine tools, e. g. direct spindle s, initial small twisting (under prestress) and damping dependent on the elastomer hardness is achieved. Peak tensions and shock loads are reduced or the resonance range is shifted to non-critical speed ranges, respectively. For peripheral speeds up to 40 m/s (referred to the outside diameter of the coupling) we would recommend to use our ROTEX GS clamping ring hub. For peripheral speeds exceeding 50 m/s, ROTEX GS...P should be used. We have on hand experiences from industrial applications for peripheral speeds up to 80 m/s. Comparison of rigid connection ROTEX GS Run-up (tool contact) Torque reduction Torque [Nm] Interrupted cut ROTEX GS Rigid connection Machining operation - direction of machining Explosion protection use ROTEX GS couplings are suitable for power transmission in s in hazardous areas. The couplings are certified according to EC Standard 94/9/EC (ATEX 95) as units of category 2G and thus suitable for the use in hazardous areas of zone and 2. Please read our information in the respective Type Examination Certificate and the operating and mounting instructions under www.ktr.com. Selection: In case of use in hazardous areas the clamping ring hubs (clamping hubs without feather keyway only for use in category 3) must be selected so that there is a minimum safety factor of s = 2 between the peak torque (including all operating parameters) and the nominal torque and frictional torque of engagement of the coupling. 03
Backlash-free shaft coupling Technical data ROTEX GS Spider Shore GS Shore range Max. speed [min - ] for hub design 2.0 / 2..0 2.5 / 2.6. 6.0 2) 6.0 P 2) 70 A 0,2 0,3,78 5 43 5 80 A 0,3 0,6 3,5 0 82 38000 47700 92 A 0,5,0 5,6 6 54 98 A 0,9,7 8,3 25 296 80 A 0,7,4 8,6 26 4 7 92 A,2 2,4 4,3 43 29 27000 3400 98 A 2,0 4,0 22,9 69 42 64 D 2,4 4,8 34,3 03 630 80 A,8 3,6 7,2 52 25 9 92 A 3,0 6,0 3,5 95 262 9000 23800 98 A 5,0 0,0 5,6 55 58 64 D 6,0 2,0 74,6 224 739 80 A 3,0 6,0 84,3 252 274 2 92 A 5,0 0,0 60,4 482 470 5200 900 98 A 9,0 8,0 240,7 78 846 64 D 2,0 24,0 327,9 982 98 80 A 4,0 8,0 60,2 80 53 4 92 A 7,5 5,0 4,6 344 336 2700 5900 25400 47700 98 A 2,5 25,0 7,9 53 654 64 D 6,0 32,0 234,2 702 856 80 A 4,9 9,8 68 065 582 9 92 A 0,0 20,0 090 85 20 9550 900 9000 35800 98 A 7,0 34,0 52 2540 200 64 D 2,0 42,0 2560 380 2930 92 A 35 70 2280 400 480 24 98 64 A D 6950 8650 3800 26000 60 75 20 50 3640 5030 5980 0895 2560 3696 92 A 95 90 4080 6745 780 28 98 64 A D 5850 7350 700 22000 60 200 320 400 640 0260 9920 2077 3200 4348 92 A 90 380 6525 050 2350 38 98 64 A D 4750 5950 9550 7900 325 405 650 80 800 26300 760 4255 4400 6474 92 A 265 530 0870 5680 2430 42 98 64 A D 4000 5000 8050 5000 450 560 900 20 2594 36860 37692 62600 5570 7270 92 A 30 620 2968 8400 2580 48 98 64 A D 3600 4550 7200 3600 525 655 050 30 25759 57630 45620 99750 5930 8274 92 A 40 820 5482 2375 2980 55 98 A 350 3950 6350 900 685 370 427 6550 6686 64 D 825 650 05730 30200 9248 65 75 95 A 940 880 48520 7660 648 64 D 2800 3500 5650 000 75 2350 850 8989 8870 95 A 920 3840 7950 50450 8650 64 D 2350 2950 4750 8950 2400 4800 82320 36377 923 ) Static and dynamic torsional stiffness with 0,5 x T KN 2) Higher speeds on request T KN Torque [Nm] T K max Static Dynamic torsion torsion spring spring stiffness ) stiffness ) [Nm/rad] [Nm/rad] Radial stiffness C r [N/mm] Weight [kg] each spider hub Mass moment of inertia J [kgm 2 ] each spider hub 0,2 0,06 0,002 x 0-3 x 0-3 x 0-6 x0-6 3 0,7 0,085 0,04 x 0-3 x 0-3 x 0-6 x0-6 9,8 0,49 0,079 x 0-3 x 0-3 x 0-6 x0-6 4 2,3,3 0,39 x 0-3 x 0-3 x 0-6 x0-6 20 4,6 2,8 0,457 x 0-3 x 0-3 x 0-6 x0-6 66 7 20,4,49 x 0-3 x 0-3 x 0-6 x0-6 32 8 50,8 7,5 x 0-3 x 0-3 x 0-6 x0-6 253 29 200,3 6,5 x 0-3 x 0-3 x 0-6 x0-6 455 49 400,6 44,6 x 0-3 x 0-3 x 0-6 x0-6 850 79 2246 00 x 0-3 x 0-3 x 0-6 x0-6 2520 98 3786 200 x 0-3 x 0-3 x 0-6 x0-6 3800 5 7496 300 x 0-3 x 0-3 x 0-6 x0-6 4500 20 2000 500 x 0-3 x 0-3 x 0-6 x0-6 780 340 26000 2000 x 0-3 x 0-3 x 0-6 x0-6 The size of the coupling has to be such that the permissible coupling load is not exceeded in any operating condition (see coupling selection on page 05).. Definitions and factors for coupling selection Prestress: The flexible prestress varies depending on the coupling size, the spiders/spider material and the production tolerances. As a result there is the axial plug-in force varying from low as sliding seat or with a torsionally soft spider to heavy with a high amount of prestress or torsionally rigid spider. T KN Rated torque of coupling [Nm] Torque which can be transmitted continuously over the entire permissible speed range, taking into account the operating factors (S t, S d ). T Kmax Maximum torque of coupling [Nm] Torque which can be transmitted during the full service life of the coupling as dynamic load 0 5 or as alternating load 5 0 4, taking into account the operating factors (S t, S d, S A ). T R Friction torque [Nm] Torque which can be transmitted by the frictionally engaged shaft-hub-connection. T AN Constantly occurring max. driving torque T AS Maximum driving torque [Nm] Peak torque in case of shock by the driving A. C. motor, for example during acceleration or breakdown torque of the A. C. motor. T S Peak torque [Nm] Peak torque on the coupling, calculated from max. driving torque T AS, rotational inertia coefficient m A or m L and opertaing factor S A. S t Temperature factor Factor considering the lower loading capacity or larger deformation of an elastomer part under load particularly in case of increased temperatures. In case of temperatures exceeding 80 C we would recommend to use the RADEX -NC (see page 27). S d Torsional stiffness factor Factor considering the different demands on the torsional stiffness and fatigue strength of the coupling dependent on the application. In case of using the spider 64 Sh D-GS and reversing S d has to selected in case of couplings made of aluminium. For positioning s with increased demand on torsional stiffness (e.g. gearbox with low transmission) we would recommend the use of the TOOLFLEX or RADEX -NC (see page 9 and 27). S A Operating factor Factor considering the occurring shocks or starts each minute, depending on the use m A(L) Rotational inertia coefficient of driving side (load side) Factor taking into account the distribution of masses in case of and load side shocks and vibration excitation. 04
Backlash-free shaft coupling Coupling selection 2. Factors Temperature factor S t Torsional stiffness factor S d Operating factor S A 30 C + 40 C + 60 C + 80 C + 30 C main spindle S t,2,4,8 See note on page 04. See note on page 04. *When using the 64 Sh D-GS spider at least factor 4 3. Calculation formula Rated driving torque J L m A = J A + J L S 2 J Schl = m Schl [kgm 2 ] ( 2 ) P AN/LN [kw] T N [Nm] = 9550 n [/min] J A m L = J A + J L The size of the coupling must be selected so that the following conditions are met. T KN T N S t S d 4. Example of calculation (positioning ) Threaded spindle Main spindle of machine tool 2 5* J A J L Positioning (x - y axis) 3 8* Peak torque *Starts/minute 0,0 m 2 J Schl = 030 kg = 26 0-4 kgm ( 2 2 ) Shock on driving side T S = T AS m A S A Shock on load side T S = T LS m L S L T KN T S S t S d Ambient temperature 40 C, 60 starts/minute required, high torsional stiffness. Coupling selection: ROTEX GS clamping ring hub - axial plug-in jaw coupling backlash-free under prestress with frictionally engaged shaft-hub-connection. Moment of inertia of slide and work piece reduced to driving axis. and Shaft encoders Angle encoders 0 = Moment of inertia of driving side = Moment of inertia of load side Details of driving side Servo motor Rated torque T AN = 43 Nm Max. torque T AS = 44 Nm Moment of inertia J Mot = 08 0-4 kgm 2 Driving shaft d = 32 k6 without feather key positioning * S A light shock loads 60,0 average shock loads 60 300,4 heavy shock loads 300,8 For the factors please see the tables at the top. Details of n side Ball spindle J SP = 38 0-4 kgm 2 Screw pitch s = 0 mm Driven shaft d = 30 k6 without keyway Mass of slide and work piece m Schl = 030 kg ROTEX GS TOOLFLEX RADEX-NC Selection of temperature, stiffness and operating factor: S t (40 C) =,2 S d = 4 S A =,0 Coupling selection: Selection according to rated torque (pre-selection) T KN T AN S t S d T KN 43 Nm,2 4 T KN 206,4 Nm Coupling selection: ROTEX GS 38-98 Sh A-GS - clamping ring hub design T KN 325 Nm Review of max. driving torque T KN T S S t S d with T S = T AS m A S A and J L m A = J A + J L J L = (J Sp + J Schl + /2 J K ) J L = (38 + 26 + 9,6) 0-4 kgm 2 = 73,8 0-4 kgm 2 J A = J Mot + /2 J K = (08 + 9,6) 0-4 kgm 2 = 7,6 0-4 kgm 2 J L 73,8 0-4 m A = = m A = 0,385 J A + J L (7,6 + 73,8) 0-4 T S = T AS m A S A = 44 Nm 0,385,0 = 55,44 Nm ROTEX GS 38 98 Sh A-GS T KN = 325 Nm T KN = T S S t S d = 55,44 Nm,2 4 T KN 266, Nm Check of torque transmission of clamping ring hub for shaft diameter ø 30. T R > T AS Figures for T R see table on catalogue page 0. Transmittable torque Ø 30 H 7 / k 6 = 436 Nm > 44 Nm Selection of ROTEX GS 38 98 Sh A-GS, clamping ring hub design is permissible. 05
Backlash-free shaft coupling Hub designs Due to the numerous applications of ROTEX GS for many different mounting situations, this coupling system is available with various hub designs. These designs mainly differ in that they offer either positive or frictionally engaged (backlash-free) connections, but mounting situations like, for example, hollow shaft tacho, shaft encoder installation or similar applications are covered, too. Design.0 with keyway and fixing screw Positive power transmission; permissible torque depends on the permissible surface pressure. Not suitable for backlash-free power transmission for heavily reversing operation. Design. without keyway, with setscrew Non-positive torque transmission, suitable for backlash-free transmission of very small torques. (No ATEX release) Design 2.0 clamping hub, single slotted, without keyway Frictionally engaged, backlash-free shafthub-connection. Transmittable torques depend on the bore diameter. Design 2.0 up to size 9 as standard. (Only for ATEX category 3) Design 2. clamping hub, single slotted, with keyway Positive power transmission with additional frictional tightness. The frictional tightness avoids or reduces reversal backlash. Surface pressure of the keyway connection is reduced. Design 2. up to size 9 as standard. Design 2.5 clamping hub, double slotted, without keyway Frictionally engaged, backlash-free shafthub-connection. Transmittable torques depend on the bore diameter. Design 2.5 from size 24 as standard. (Only for ATEX category 3) Design 2.6 clamping hub, double slotted, with keyway Positive power transmission with additional frictional tightness. The frictional tightness prevents or reduces reversal backlash. Surface pressure of the keyway connection is reduced. Design 2.6 from size 24 as standard. Type 2.8 short clamping hub with axial slots without feather key Frictionally engaged, backlash-free shafthub-connection, good properties of concentric running due to symmetrical arrangement and cams without slots. Design 2.8 up to size 24 as standard. (Only for ATEX category 3) Type 2.9 short clamping hub with axial slots with feather key Positive-locking power transmission in addition frictionally engaged. Smooth power transmission due to cams without slots. The surface pressure of the feather key combination is reduced. Type 2.9 from size 24 as standard. Design 6.0 clamping ring hub Integrated frictionally engaged shaft-hub-connection for transmission of higher torques. Screw fitting on elastomer side. For details about torques and dimensions see page 0. Suitable for high speeds. Design 6.0 P precision clamping ring hub Design equal to 6.0, but highly accurate machining with slight modifications of design, see page. Design 7.5 split claming hub without feather keyway for double-cardanic connections Frictionally engaged, backlash-free shafthub connection for the radial assembly of the coupling. Transmittable torques dependent on bore diameter. Torque indicated on page 5. Design 7.6 split clamping hub with feather keyway for double-cardanic connections Positive shaft-hub connection with additional frictional engagement for the radial assembly of the coupling. The frictional engagement avoids or reduces the reverse backlash. The surface pressure of the feather key connection is reduced. Special designs on request of customers Design 6.5 clamping ring hub Design equal to 6.0, but clamping screws on the outside. For example for radial disassembly of the intermediate tube (special design). Special hub designs for hollow shaft s Expansion hub ROTEX GS hub with CLAMPEX KTR 50 06
Backlash-free shaft coupling Basic programme 7 9 2 4 9 24 Hub design. 2.0.0. 2.0 2..0. 2.0 2..0. 2.0 2. 6.0 6.0 P.0 2.0 2. 6.0 P 37.5 6.0 P.0 2.5 2.6 6.0 P 50 6.0 P.0 2.5 28 2.6 6.0 6.0 P.0 38 2.5 6.0 6.0 P un-/pilot bored [mm] according to ISO fit H7 / feather keyway with thread according to DIN 6885 sheet - JS9 2 3 4 5 6 6,35 7 8 9 9,5 0 2 4 5 6 8 9 20 22 24 25 28 30 32 35 38 40 42 ROTEX GS TOOLFLEX RADEX-NC Taper bores for Fanuc motors: GS 9 :0 Ø ; GS 24 :0 Ø 6 Hub design s [mm] 28 30 32 35 38 40 42 45 48 50 55 60 42 6.0 48 6.0 55 6.0 65 6.0 75 6.0 = Pilot bored clamping hubs = Standard bore Unbored hubs up to size 65 available from stock. Further dimensions on request 07
Backlash-free shaft coupling Miniature couplings Backlash-free shaft connections for measurement swith small torques Single cardanic coupling in three parts Axial plug-in ability - easy blind assembly, without any time-consuming screw connections Small dimensions - low flywheel mass Maintenance-free, easy to check visually Different elastomer hardness of spiders Available from stock for all usual shaft dimensions acc. to ISO fit H7 (apart from clamping hub), keyway, from Ø 6 mm acc. to DIN 6885 sheet - JS9 Approved according to EC Standard 94/9/EC (only for hub design.0 and 2.) Basic programme see page 07 Hub designs (see page 06): Design.0 Design. Design.2 with keyway without keyway without keyway and setscrew with setscrew without setscrew Setscrew to DIN EN ISO 4029 Clamping hub with capscrew DIN EN ISO 4762 (ROTEX 5 DIN 84) Design 2.0 Clamping hub without keyway, (only category 3), torques depending on bore diameter Design 2. Clamping hub with keyway Hub design d min d max d max d max.0.,.2 2.0, 2. Dimensions [mm] Setscrew Clamping screw D H d H L l ; l 2 E b s a G t M t e Ø D K Hub material Aluminium (Al - H) T A [Nm] 5 7 9 2 4 2 3 4 4 5-7 0 2 5 5 7 2 6 5 7 2 6 0 4 20 25 30 - - 7,2 8,5 0,5 5 22 30 34 35 5 7 0 5 8 0 2 3 4 6 8 0 0 0,5,0,0,0,5 4,0 6,0,5 3,5 2,0 M2 M3 M4 M4 M4 2,5 3,5 5,0 5,0 5,0 M,2 M2 M2,5 M3 M3 2,5 3,5 5,0 5,0 5,0 3,5 5,0 7,5 9,0,5,4 6,5 23,4 27,5 32,2-0,37 0,76,34,34 Bores and the corresponding transmittable torques of the clamping hub design 2.0 [Nm] Ø 2 Ø 3 Ø 4 Ø5 Ø 6 Ø 7 Ø 8 Ø 9 Ø 0 Ø Ø 2 Ø 4 Ø 5 Ø 6 5 * * * * 7 0,8 0,9 0,95,00,0 9 2, 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2 3,6 3,8 4,0 4, 4,3 4,5 4,7 4,8 5,0 4 4,7 4,8 5,0 5, 5,3 5,5 5,6 5,8 6, 6,3 6,5 Other designs ROTEX GS for hollow shaft connections ROTEX GS-CF ROTEX GS with interference fit hub ROTEX GS with expansion hub ROTEX GS with external clamping ring hub Order form: ROTEX GS 4 80 Sh A- GS.0 Ø 2 2.0 Ø 0 Coupling size Spider hardness Hub design Hub design 08
Backlash-free shaft coupling MONITEX coupling monitoring p. 274 NEW Backlash-free shaft connection under prestress for spindle s, elevating platforms, machine tool s, etc. Single cardanic coupling in three parts Axial plug-in ability - easy blind assembly, without any time-consuming screw connections Small dimensions - low flywheel mass Maintenance-free, easy to check visually Different elastomer hardness of spiders Available from stock for all usual shaft dimensions acc. to ISO fit H7 (apart from clamping hub), keyway, from Ø 6 mm acc. to DIN 6885 sheet - JS9 Approved according to EC Standard 94/9/EC (only for hub design.0 and 2./2.6) Basic programme see page 07 Hub designs: (see page 06) Design.0 with keyway and thread. without keyway, with thread Design 4.2 with CLAMPEX KTR 250 ROTEX GS TOOLFLEX RADEX-NC ROTEX GS 5-38 ROTEX GS 42-75 Design up to size 9 as standard 2.0 single slot without keyway (only for category 3) 2. single slot, with keyway Design from size 24 as standard 2.5 double slot, without keyway (only for category 3) 2.6 double slot with keyway Design 2.0, 2.5 Torque depending on bore diameter Unbored Finish ) bores Dimensions [mm] Setscrew Clamping screws d min. d max. D D H d H L l, l 2 M, N E b s a G t M t e D K T A [Nm] Hub material Aluminium (Al-H) 9 6 24 40 8 66 25 6 2 2,0 3,0 M5 0 M6 2,0 4,5 46 0,5 24 8 28 55 27 78 30 8 4 2,0 3,0 M5 0 M6 0,5 20,0 57 0,5 28 0 38 65 30 90 35 20 5 2,5 4,0 M8 5 M8,5 25,0 73 25 38 2 45 80 38 4 45 24 8 3,0 4,0 M8 5 M8 5,5 30,0 83 25 Hub material (Steel St-H) 42 4 55 85 95 46 26 50 28 26 20 3,0 4,0 M8 20 M0 8 32,0 94 69 48 5 62 95 05 5 40 56 32 28 2 3,5 4,0 M8 20 M2 2 36,0 05 20 55 20 74 0 20 60 60 65 37 30 22 4,0 4,5 M0 20 M2 26 42,5 20 20 65 22 80 5 35 68 85 75 47 35 26 4,5 4,5 M0 20 M2 33 45,0 24 20 75 30 95 35 60 80 20 85 53 40 30 5,0 5,0 M0 25 M6 36 5,0 47,5 295 Ø8 Bores and the corresponding transmittable torques of the clamping hub design 2.0/2.5 [Nm] Ø0 Ø Ø4 Ø5 Ø6 Ø8 Ø9 Ø20 Ø22 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Ø48 Ø50 Ø55 Ø60 Ø65 Ø70 Ø75 Ø80 9 25 27 27 29 30 3 32 32 34 30 2) 32 2) 24 34 35 36 38 38 39 40 4 42 43 45 46 28 80 8 8 84 85 87 89 9 92 97 99 02 38 92 94 97 98 99 02 04 05 09 2 3 42 232 238 244 246 255 260 266 48 393 405 43 42 55 473 65 75 ) depending on hub design 2) 2 x clamping screw M4 05 09 8 22 23 26 30 274 283 288 294 30 309 434 445 454 462 473 486 494 54 486 498 507 54 526 539 547 567 587 608 507 58 526 535 547 559 567 587 608 627 648 02 24 48 63 20 239 278 36 354 393 Order form: ROTEX GS 24 98 Sh A-GS 2.5 Ø 24.0 Ø 20 Coupling size Spider hardness Hub design Hub design 09
Backlash-free shaft coupling Clamping ring hubs Backlash-free shaft coupling with integrated clamping system Applicable to, for example, forward feed main spindle s of machine tools, press rollers, etc. High smoothness of running, application up to a peripheral speed of 40 m/s For high friction torques (consider the selection in case of explosion protection use) Easy to assemble due to internal clamping screws up to Ø 50 mm according to ISO fit H7, from Ø 55 mm according to ISO fit G7 Approved according to EC Standard 94/9/EC (Explosion Certificate ATEX 95) Bores d /d 2 and the corresponding transmittable friction torques T R of clamping ring hub in [Nm] ) Ø6 Ø0 Ø Ø4 Ø5 Ø6 Ø9 Ø20 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Ø48 Ø50 Ø55 Ø60 Ø65 Ø70 Ø80 4 8,6 3,8 4,7 22,7 9 4 45 62 68 67 83 90 24 48 67 74 72 90 97 2 20 43 28 42 54 89 88 237 250 280 307 30 353 389 38 269 337 356 398 436 442 50 533 572 65 644 42 399 445 506 470 566 58 647 630 728 836 858 48 650 685 809 84 926 96 0428253 55 98 954 0520408522038359646662960 Tack thread M between clamping screws 65 568 569 768 833 968 2049 2438 2495 2898 75 2246 2338 2500 2620 3082 379 3657 4235 The transmittable torques of the clamping connection consider the max. clearance with shaft fit k6 / bore H7, from Ø55 G7/m6. With bigger clearance the torque is reduced. As shaft material steel or spheroïdal iron with a yield point of approx. 250 N/mm 2 or more can be used. If hollow shafts are used, the strength must be checked (see KTR mounting instructions, KTR Standard 4550 at our homepage www.ktr.com). Torques [Nm] ) 92 Sh A-GS 98 Sh A-GS Dimensions [mm] T KN T Kmax T KN T Kmax D H 3) d H L l ;l 2 l 3 E b s a M Clamping screws Number z T A [Nm] 4) Hub material Aluminium (Al-H) optionally steel Clamping ring material Steel (St-H) M Weight per hub with max. bore [kg] Mass moment of inertia per hub with max. bore [kgm 2 ] 4 7,5 5 2,5 25 30 0,5 50 8,5 3,5 3 0,5 2,0 M3 4,34 M3 0,049 0,07 x 0-4 9 0,0 20 7 34 40 8 66 25 8 6 2 2,0 3,0 M4 6 3 M4 0,20 0,3 x 0-4 24 35,0 70 60 20 55 27 78 30 22 8 4 2,0 3,0 M5 4 6 M5 0,280,35 x 0-4 28 95,0 90 60 320 65 30 90 35 27 20 5 2,5 4,0 M5 8 6 M5 0,450 3,3 x 0-4 38 90,0 380 325 650 80 38 4 45 35 24 8 3,0 4,0 M6 8 0 M6 0,950 9,60 x 0-4 Hub and clamping ring material Steel (St-H) 42 265 530 450 900 95 46 26 50 35 26 20 3,0 4,0 M8 4 35 M8 2,30 3,7 x 0-4 48 30 620 525 050 05 5 40 56 4 28 2 3,5 4,0 M0 4 69 M0 3,08 52,0 x 0-4 55 375 750 685 370 20 60 60 65 45 30 22 4,0 4,5 M0 4 69 M0 4,67 03,0 x 0-4 65 - - 940 2) 880 2) 35 68 85 75 55 35 26 4,5 4,5 M2 4 20 M2 6,70 9,0 x 0-4 75 - - 920 2) 3840 2) 60 80 20 85 63 40 30 5,0 5,0 M2 5 20 M2 9,90 396,8 x 0-4 ) Please note coupling selection on pages 04, 05, 6 2) Figures for 95 Sh A - GS 3) ØD H + 2 mm with high speeds for expansion of spider 4) In case of using the spider 64 Sh D-GS resp. short dimensioning we recommend the application of clamping ring hubs made of steel. Swing module Shaft encoder Servo motor ROTEX GS for connection of swing module servo motor shaft encoder ROTEX GS with clamping ring hub and torque limiter KTR-SI Order form: ROTEX GS 24 98 Sh A-GS 6.0 Ø 24 6.0 Ø 20 Coupling size Spider hardness Hub design Hub design 0
Backlash-free shaft coupling Type P according to DIN 69002 Backlash-free, highly accurate shaft coupling with integrated clamping system Developed specifically for stub spindles on multiple spindle heads according to DIN 69002 Application on main spindle s with high speeds, peripheral speeds of 50 m/s and more (please consult with KTR Engineering Department) For high friction torques (consider the selection in case of explosion protection use) Easy to assemble to due internal clamping screws Approved according to EC Standard 94/9/EC Certificate ATEX 95) ROTEX GS TOOLFLEX RADEX-NC Tack thread M between clamping screws As shaft material steel or spheroidal iron with a yield point of approx. 250 N/mm 2 or more can be used. If hollow shafts are used, the strength must be checked (see KTR mounting instructions, KTR Standard 4550 at our homepage www.ktr.com). 4 P 9 P 37,5 9 P 24 P 50 24 P 28 P 38 P 42 P 48 P 55 P Torque [Nm] 2) Dimensions [mm] Hub and clamping ring material steel (St-H) 98 Sh A-GS 64 Sh D-GS T KN T Kmax T KN T Kmax d ) D H 3) d H L l ;l 2 l E b s a d d 2 d 3 2,5 25 6 32 4* 32 0,5 50 8,5 5,5 3 0,5 2 7 7 4 28 7 34 6* 37,5 8 66 25 2 6 2 2 3 20 9 7 34 2 42 9* 40 8 66 25 2 6 2 2 3 23 22 43 86 54 08 24* 50 27 78 30 25 8 4 2 3 28 29 60 20 75 50 25* 55 27 78 30 25 8 4 2 3 30 30 60 320 200 400 35* 65 30 90 35 30 20 5 2,5 4 40 40 325 650 405 80 40 80 38 4 45 40 24 8 3 4 46 46 450 900 560 20 42 95 46 26 50 45 26 20 3 4 52 55 525 050 655 30 45 05 5 40 56 50 28 2 3,5 4 52 60 685 370 825 650 50 20 60 60 65 58 30 22 4 4,5 55 72 8,5 9,5 9,5 2,5 2,5 4,5 6,5 8,5 20,5 22,5 Transmittable torque of clamping ring hub Ø d [Nm] ) Tightening torque of clamping screws T A [Nm] ) * Standard spindle shaft diameter 2) Please note coupling selection on pages 04, 05, 6 3) Ø D H + 2 mm with higher speed for expansion of spider Weight per hub with bore Ø d norm [kg] Mass moment of inertia J with bore Ø d norm [kgm 2 ] 25,89 0,08 0,0 0-3 60 3,05 0,6 0,037 0-3 7 3,05 0,9 0,046 0-3 08 4,9 0,33 0,36 0-3 70 8,5 0,44 0,20 0-3 506 8,5 0,64 0,438 0-3 82 4,32,325 0-3 709 35 2,23 3,003 0-3 340 69 3,09 5,043 0-3 50 69 4,74 0,02 0-3 Selection for stub spindles Spindle ROTEX GS P Dimensions d D H l / l 2 L E 25 x 20 4 P 4 32 8.5 50 3 32k x 25 9 P37.5 6 37.5 25 66 6 32g x 30 9 P 9 40 25 66 6 40 x 35 24 P50 24 50 30 78 8 50 x 45 24 P 25 55 30 78 8 63 x 55 28 P 35 65 35 90 20 Tool side Spindle bearing Driving side (gearbox or motor) ROTEX GS type P with central coolant supply for stub spindles and multiple spindle heads Order form: ROTEX GS 24 P 98 Sh A-GS 6.0 Ø 25 6.0 Ø 25 Coupling Type Spider hardness Hub Finish Hub Finish size design bore design bore
Compact design NEW Up to /3 shorter High performance Design with axial slot, patent pending Good concentric running properties Uniform power transmission due to cams without slots Improved balancing quality ROTEX GS 7-9 compact single slotted ) design 2.0 ROTEX GS 24-38 compact axially slotted design 2.8 Torque [Nm] 92Sh A 98Sh A 64Sh D d max. D H D K L l, l 2 E b s t e M 7,2 2,0 2,4 7 4 6,6 8 5 8 6 2,5 5,0 M2 0,37 9 3,0 5,0 6 9 20 2,3 24 7 0 8 3,5 6,7 M2,5 0,76 2 5,0 9,0 2 2 25 26,2 26 7 2 0 3,5 8,3 M3,34 4 7,5 2,5 6 6 2) 30 30,5 32 9,5 3 0,5 4,5 9,6 M4 2,9 9 0 7 2 24 2) 40 45,0 50 7 6 2 2 9 4,0 M6 0 24 35 60 75 32 55 57,5 54 8 8 4 2 20,0 M6 0 28 95 60 200 35 65 69,0 62 2 20 5 2,5 2 23,8 M8 25 38 90 325 405 45 80 86,0 76 26 24 8 3 6 30,5 M0 49 Ø3 Ø4 Ø5 Ø6 Ø7 Ø8 Ø9 Ø0 Ø Ø2 Ø4 Ø5 Ø6 Ø8 Ø9 Ø20 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 7 0,8 0,9,0,0, 9,9 2,0 2, 2,2 2,3 2,4 2 3,4 3,6 3,7 3,9 4, 4,2 4,4 4,6 4,7 Bores and the corresponding transmittable torques of clamping hub design 2.0/2.8 4 7, 7,4 7,7 8,0 8,2 8,5 8,8 9, 5,8 2) 5,9 2) 6, 2) Dimensions [mm] 9 24,3 25,0 25,7 26,3 27,0 28,4 29,0 29,7 3, 3,7 32,4 25,0 2) 24 2 23 25 30 32 34 38 40 42 5 53 59 63 68 28 54 58 62 70 74 78 93 97 09 6 24 36 38 92 99 7 23 48 54 73 85 97 26 234 247 259 278 ) ROTEX GS compact size 7 to 9 axially slotted on request 2) 4 with screw M3, size 9 with screw M5 T A [Nm] Order form: ROTEX GS 38 Compact 98 Sh A-GS Design 2.8 Ø 28 Design 2.8 Ø 45 Coupling size Design Spider Hub Finish Hub Finish design bore design bore 2
Design DKM double cardanic Backlash-free, double cardanic shaft connection Double cardanic design allowing for absorption of larger radial displacements Axial plug-in ability - easy blind assembly Maintenance-free Simple to check visually according to ISO fit H7 (apart from clamping hub), keyway, from Ø 6 mm according to DIN 6885 sheet - JS9 Approved according to EC Standard 94/9/EC (Explosion Certificate ATEX 95) Hub designs see page 06 ROTEX GS TOOLFLEX RADEX-NC Unbored Finish bore Dimensions [mm] D D H d H d H l ;l 2 M; N l l 2 L DKM E b s a d min d max Hub material Aluminium (Al-H) Spacer material Aluminium (Al-H) 5 DKM 2 5 0 5 3 3 23 5 4 0,5 4,0 7 DKM 3 7 4 7 4 20 34 8 6,0 6,0 9 DKM 4 9 20 7,2 0 5 25 45 0 8,0,5 2 DKM 4 2 25 8,5 6 30 52 2 0,0 3,5 4 DKM 4 5 30 0,5 8 34 56 3 0,5 2,0 9 DKM 6 24 40 8,0 8 25 0 42 92 6 2 2,0 3,0 24 DKM 8 28 55 27,0 27 30 6 52 2 8 4 2,0 3,0 28 DKM 0 38 65 30,0 30 35 8 58 28 20 5 2,5 4,0 38 DKM 2 45 80 38,0 38 45 20 68 58 24 8 3,0 4,0 Hub material Steel (St-H) Spacer material Aluminium (Al-H) 42 DKM 4 55 85 95 46 46 50 28 22 74 74 26 20 3,0 4,0 48 DKM 5 62 95 05 5 5 56 32 24 80 92 28 2 3,5 4,0 55 DKM 20 74 0 20 60 60 65 37 28 88 28 30 22 4,0 4,5 Other designs: ROTEX GS - DKM as hollow shaft design ROTEX GS - CF - DKM ROTEX GS - DKM in combination with torque limiter KTR-RU Order form: ROTEX GS 38 DKM 92 Sh A-GS.0 Ø 38 2.5 Ø 32 Coupling Design Spider hardness Hub design Hub design size 3
Intermediate shaft couplings Design ZR/ZR2 Backlash-free intermediate shaft coupling Application, for example, on lifting spindle elements, parallel linear systems, overhead gantry robots, handling machines For connection of larger shaft distances and a maximum speed of 500 /min Spacer part to be disassembled radially Design ZR for torques up to the maximum friction torque of clamping hub, design ZR2 for higher torques according to ISO fit H7 (apart from clamping hub), keyway, from Ø 6 mm according to DIN 6885 sheet - JS9 Hub designs see on page 06 Design ZR Design ZR2 Un- d d bored min max Dimensions [mm] ZR D H l ; l 2 L E b s B L R L R L ZR d R min. Cap screw DIN EN ISO 4762 8.8 Tightening torque Friction torque M x I T A [Nm] T R [Nm] 4 ZR 9 ZR 24 ZR 28 ZR 38 ZR 4 5 6 24 8 28 0 38 2 45 30 35 3 0,5,5 40 25 66 6 2 2,0 4,0 55 30 78 8 4 2,0 6,0 65 35 90 20 5 2,5 7,5 80 45 4 24 8 3,0 2,0 please mention for inquiries and orders 7 L R +22 0 L R +50 28 L R +60 45 L R +70 80 L R +90 4x2,5 20x3,0 25x2,5 35x4,0 40x4,0 M3x2,34 6, M6x6 0,5 34 M6x20 0,5 45 M8x25 25 05 M8x30 25 23 4 ZR2 9 ZR2 24 ZR2 28 ZR2 38 ZR2 42 ZR2 48 ZR2 55 ZR2 65 ZR2 Other designs: Un- d d bored min. max. 4 5 6 24 8 28 0 38 2 45 4 55 5 62 20 74 22 80 Dimensions [mm] ZR2 D H l ; l 2 l 3 L E b s B L R2 L R2 L ZR2 min. 30 26 50 3 0,5,5 09 L R2 + 22 40 25 26 67 6 2 2,0 4,0 55 30 38 86 8 4 2,0 6,0 65 35 45 00 20 5 2,5 7,5 80 45 45 4 24 8 3,0 2,0 95 50 52 28 26 20 3,0 23,0 05 56 70 54 28 2 3,5 24,5 20 65 80 75 30 22 4,0 26,0 35 75 80 85 35 26 4,5 30,5 please mention for inquiries and orders 20 56 77 92 24 26 288 387 L R2 + 50 L R2 + 60 L R2 + 70 L R2 + 90 L R2 + 00 L R2 + 2 L R2 +30 L R2 + 50 Precision tube C 2 d R Nm [ 2 rad ] ) For inquiries and orders please mention the shaft distance dimension L R /L R2 along with the maximum speed to review the critical whirling speed. CLAMPEX KTR 250 Clamping set Clamping screws DIN EN ISO 4762 2.9 µtot. = 0,4 size M x I Tightening torque T A [Nm] 0x2,0 68,36 0x6 M4x0 5,2 2x2,0 30 2x8 M4x0 5,2 20x3,0 954,9 20x28 M6x8 7,0 25x2,5 8 25x34 M6x8 7,0 32x3,5 567 32x43 M6x8 7,0 40x4,0 870 40x53 M6x8 7,0 45x4,0 7486 45x59 M8x22 4,0 55x4,0 33543 55x7 M8x22 4,0 60x4,0 44362 60x77 M8x22 4,0 ROTEX ZRG with bearing for higher speeds ROTEX GS ZR for vertical assembly Order form: ROTEX GS 24 ZR 200 98 Sh A-GS.0 Ø 24 2.5 Ø24 De- sign Coupling size Shaft distance dimension [L R /L R2 ] Spider hardness Hub design Hub design 4
Intermediate Shaft Couplings with Aluminium Tube Design ZR3 Use with lifting machines, in handling units, robotic palletisers etc. Easy, radial coupling assembly because of split coupling hub Exchange of spiders without displacing the and n side Standard lengths are possible up to 4 m without intermediate bearing dependent on speed and size Positive and frictionally engaged torque transmission Low mass moment of inertia due to use of aluminium Can be combined with other hub forms (clamping or clamping ring hubs) according to ISO fit H7, keyway according to DIN 6885 sheet - JS9 ROTEX GS TOOLFLEX RADEX-NC Dimensions [mm] 9 24 28 38 42 48 Finish bore d max. D H 40 8 20 d min. 0 4 8 22 22 28 38 45 50 55 55 65 80 95 05 l 25 30 35 45 50 56 L 49,0 59,0 67,0 83,5 93,0 03,0 l 3 7,5 22,0 25,0 33,0 36,5 39,5 E 6 8 20 24 26 28 L R General min. max. 98 2965 3 3456 3 3950 63 3934 80 3927 202 392 L ZR min. max. 33 3000 57 3500 8 4000 229 4000 253 4000 28 4000 d R 40 50 60 70 80 00 D K 47 57 73 84 94 05 t 8,0 0,5,5 5,5 8,0 8,5 e 4,5 20 25 30 32 36 Capscrew DIN EN ISO 4762 8.8 T A [Nm] M 6 0 M 6 0 M 8 25 M 8 25 M0 49 M2 86 98 Sh A-GS Coupling torques [Nm] ) T KN T K max. GTShub 2) J Mass moment of intertia [0 3 kgm 2 ] ZR-hub J 2 Pipe/ meter J 3 stat. torsion spring stiffness ZW 3) C 2 [Nm 2 /rad] ROTEX GS 98 Sh A-GS T KN Coupling torques [Nm] ) T K max. GTShub 2) J Mass moment of intertia [0 3 kgm 2 ] ZR-hub J 2 Pipe/ meter J 3 stat. torsion spring stiffness ZW 3) C 2 [Nm 2 /rad] 9 24 28 0 35 95 20 70 90 0,02002 0,07625 0,7629 0,0304 0,0448 0,095 0,329 0,673,99 3243,6 663,8 84, 38 42 48 90 265 30 380 530 620 0,50385,266,87044 0,2572 0,5523,834 2,972 4,560 9,25 29290,4 44929,7 958,2 ROTEX GS 9 24 28 38 42 48 Ø 8 7 Bores and the corresponding transmittable friction torques of split hub without keyway [mm] Ø 0 Ø Ø 4 Ø 5 Ø 6 Ø 8 Ø 9 Ø 20 Ø 22 Ø 24 Ø 25 Ø 28 Ø 30 Ø 32 Ø 35 Ø 38 Ø 40 Ø 42 Ø 45 2 2 23 23 30 30 54 32 32 58 34 34 62 38 38 70 70 40 40 74 74 42 42 78 78 47 86 86 36 99 5 93 93 49 27 53 97 97 55 226 59 09 09 74 253 7 7 86 27 24 24 98 290 36 36 27 37 48 48 235 344 56 248 362 63 260 380 75 279 407 ) Transmissible torque acc. to 92 Sh-A GS. The coupling is normally supplied with 98 Sh-A GS. 2) At d max. 3) Torsional spring stiffness with an intermediate pipe of a length of m, L Pipe being = L ZR - 2 L For enquiries and orders please mention the shaft distance dimension L R along with the maximum speed to review the critical speed. Ø 46 285 46 Ø 48 297 434 Ø 50 30 452 Ø 55 498 Order form: ROTEX GS 24 ZR3 200 mm 98 Sh A-GS 7.5 Ø 24 mm 7.5 Ø 24 mm Coupling size Type Shaft distance dimension [L R ] Spider hardness Hub design without keyway Finish bore Hub design without keyway Finish bore 5
Backlash-free shaft coupling Displacements Due to its design the ROTEX GS is able to absorb axial, angular and radial misalignment, without causing any wear or premature failure of the coupling. As the spider is only stressed under pressure it is ensured that the coupling will remain backlash-free even after a longer operation period. ROTEX GS ROTEX GS Axial misalignment L Kupplungstechnik Kupplungstechnik Kr Ka In case of pure angular misalignment the imagined bisecting lines of the shafts intersect in the middle of the coupling. Up to a certain permissible extent this displacement can be absorbed by the coupling without any danger of extensive restoring forces. Radial misalignment As an example, axial misalignment may be produced by different tolerances of the connecting elements during the assembly or by alteration of the shaft length if fluctuation of temperature occurs. As the shaft bearings usually cannot be axially stressed to a big extent, it is the task of the coupling to compensate for this axial misalignment and to keep the reaction forces low. ROTEX GS Angular misalignment In case of larger displacements (especially radial displacements) the ROTEX GS DKM double cardanic design should be applied in order to avoid excessive restoring forces. Kupplungstechnik Radial misalignment results from parallel displacement of the shafts towards each other, caused by different tolerances at the centerings or by mounting of the power packs on different levels. Due to the kind of misalignment the largest restoring forces are produced here, consequently causing the highest stresses for the adjacent components. Displacement standard design Displacements DKM ROTEX GS GS [mm] [mm] [degrees] [mm] [mm] [degrees] spider Axial Radial Angular Axial Radial Angular Ka 2) Kr Ka 2) Kr Kr 70 0,4,2 0,7,2 80 + 0,4 0,2, + 0,4 0,5, 5 92 0,2 0,06,0 0,4 0,4,0 98 0,04 0,9 0,3 0,9 80 0,5, 0,23, 92 + 0,6 0,0,0 + 0,6 0,2,0 7 98 0,3 0,06 0,9 0,6 0,9 0,9 64 0,04 0,8 0,7 0,8 80 0,9, 0,29, 92 + 0,8 0,3,0 + 0,8 0,26,0 9 98 0,4 0,08 0,9 0,8 0,24 0,9 64 0,05 0,8 0,2 0,8 80 0,20,0 0,35, 92 + 0,9 0,4,0 + 0,9 0,32,0 2 98 0,4 0,08 0,9 0,9 0,29 0,9 64 0,05 0,8 0,25 0,8 80 0,2, 0,40, 92 +,0 0,5,0 +,0 0,37,0 4 98 0,5 0,09 0,9,0 0,33 0,9 64 0,06 0,8 0,29 0,8 80 0,5, 0,49, 92 +,2 0,0,0 +,2 0,45,0 9 98 0,5 0,06 0,9,0 0,4 0,9 64 0,04 0,8 0,36 0,8 24 92 0,4,0 0,59,0 +,4 +,4 98 0,0 0,9 0,53 0,9 0,5,0 64 0,07 0,8 0,47 0,8 28 92 0,5,0 0,66,0 +,5 +,5 98 0, 0,9 0,60 0,9 0,7,4 64 0,08 0,8 0,53 0,8 38 92 0,7,0 0,77,0 +,8 +,8 98 0,2 0,9 0,69 0,9 0,7,4 64 0,09 0,8 0,6 0,8 42 92 0,9,0 0,84,0 + 2,0 + 2,0 98 0,4 0,9 0,75 0,9,0 2,0 64 0,0 0,8 0,67 0,8 48 92 0,23,0 0,9,0 + 2, + 2, 98 0,6 0,9 0,82 0,9,0 2,0 64 0, 0,8 0,73 0,8 55 92 0,24,0,0,0 + 2,2 + 2,2 98 0,7 0,9 0,9 0,9,0 2,0 64 0,2 0,8 0,8 0,8 65 95 + 2,6 0,8 0,9 64,0 0,3 0,8 75 95 + 3,0 0,2 0,9 64,5 0,5 0,8 2) The Ka figures mentioned above have to be added to the length of the corresponding coupling type. Shaft misalignment ROTEX GS... DKM Axial misalignment Radial misalignment Angular misalignment L Ka This design reduces the restoring forces arising with radial misalignment to a minimum, due to the double-jointed operation, additionally the coupling is able to compensate for higher axial and angular misalignment. The above-mentioned permissible displacement figures of the flexible ROTEX GS couplings are standard values, taking into account the coupling load up to the rated torque T KN of the coupling and an operating speed n = 500 min - along with an ambient temperature of + 30 C. The displacement figures may, in each case, merely be used individually - if they occur simultaneously they may only be used proportionately. The ROTEX couplings are in a position to compensate for radial and angular displacements. Careful and accurate alignment of the shafts increases the service life of the coupling. 6
Design ZR-ZR3 Displacements and technical data Axial displacements ROTEX GS 98Sh A-GS [mm] Axial K a Displacements [mm] Radial K r ) [degrees] Angular Radial displacements K r = (L ZR - 2 l - E) tan Angular displacements [degree] 4 9 24 28 38 42 48 55 65 +,0 -,0 +,2 -,0 +,4 -,0 +,5 -,4 +,8 -,4 +2,0-2,0 +2, -2,0 +2,2-2,0 +2,6-2,0 5,6 4,67 4,48 4,30 3,92 3,73 3,5 3,9 2,80 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 Calculation of total torsion spring stiffness: C total = [Nm/rad] 2 L + pipe C C 2 L ZR - 2 L with L pipe = [m] 000 C = torsion spring stiffness for spider page 04 C 2 = from table page 4/5 ) Radial displacements based on coupling length L ZR = 000 mm 2) L = L ZR - 2 l 2 ROTEX GS TOOLFLEX RADEX-NC Chart of critical speeds for design ZR3 ROTEX GS 9 ROTEX GS 24 ROTEX GS 28 ROTEX GS 38 ROTEX GS 42 ROTEX GS 48 Operating speed [/min] Example: ROTEX GS 9 Operating speed: 500 /min Max. permissible shaft distance dimension: 700 mm Operating speed = n krit /,4 Shaft distance dimension L R [mm] 7
TOOLFLEX Backlash-free torsionally rigid metal bellow-type couplings ROTEX GS TOOLFLEX RADEX-NC 9
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling The TOOLFLEX is a coupling system that has proven successfully many times (metal bellowtype coupling). Its most important features are the good compensation for displacements (axial, radial and angular), the high torsional stiffness as well as the easy and fast assembly of the clamping hub. Examples of applications: Machine tools, positioning systems (e. g. ball roll spindles with high pitch), indexing tables, planet gears with low transmissions for precise positioning Proven joint procedure, ensuring: non-positive, backlash-free connection of the aluminium hubs with the multilayer bellows made from stainless steel safe torque transmission of every bellow layer into the hub fatigue strength in high temperature ranges up to max. 280 C and in case of influences of media or critical operating conditions Proven shaft-hub connection Clamping hubs with two slots, ensuring: easy assembly of the clamping hubs through radial clamping screw no deformation of the bellow when tightening the clamping screw by two slots in the hub bore tolerance F7 for easier assembly onto the shaft clamping hub with two slots 20
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling Coupling selection Normally the TOOLFLEX is selected according to the nominal torque (T KN ) shown in the list of technical data, like all other coupling systems. In all cases the torque (T KN ) must exceed the maximum torque to be transmitted. This should mainly be considered in connection with servo motors because their accelerating torques both positive and negative can exceed the nominal torque of the coupling by a significant amount. Judgement calculation P max TAS [Nm] = 9550 n T KN [Nm] T AS/LS k P max = max. engine performance [kw] n = engine speed [min - ] T AS T LS k = peak torque of the engine [Nm] = peak torque of load side [Nm] = operating factor k =.5 with uniform movement, k = 2 with ununiform movement, k = 2.5-4 with shocking movement For s in machine tools (servo motors) k values of.5-2 must be used. When selecting servo motors the calculations are made with the torque values of the engine suppliers and not with P max. When dimensioning the coupling please use the respective data of the manufacturer considering the servo controller to be used. ROTEX GS TOOLFLEX RADEX-NC Accelerating torque ( side / load side) T KN > T S T S = T AS m A k J L ma = J A + J L T S = T LS m L k J A ml = J A + J L T S m A m L J A J L = accelerating torque ( or n side) = -side shock = n-side shock = moment of inertia of the side = moment of inertia of the n side Torsional stiffness Transmission error of the metal bellow due to torsional strain 80 T AS = C T C T = torsional angle [degrees] = torsional stiffness of the coupling [m/rad] Natural frequency The natural frequency of the coupling must be above or below the frequency of the unit. Valid for the mechanical spare model of the 2-mass-system: J L + J A fe = C T [Hz] 2 J L J A f e = frequency of the 2-mass-system [s - ] f r = exciting frequency of the [s - ] Valid in practice: f e 2 f r Note: In case of values exceeding T KN only limited alternating load figures are possible. In this torque range there can be remaining deformations of the bellow and fatigue fractures can occur. 2
TOOLFLEX Metal bellow-type couplings Basic programme Basic programme TOOLFLEX miniature 5 7 9 2 Hub design.. 2.5. 2.5. 2.5 [mm] according to ISO fit F7 2 3 4 5 6 6,35 7 8 9 9,5 0 2 4 6 Basic programme TOOLFLEX M and S 6 20 30 38 45 55 Pilot bore [mm] according to ISO fit F7 5 6 6,35 7 8 9 0 2 4 5 6 8 9 20 22 24 25 28 30 32 35 38 40 42 45 48 50 55 Type M and S sleeve dimensions for FANUC engines 2 Sleeve size 2 Dimensions [mm] L l D H D d +0,05 b JS9 t +0, Taper 6 2 20 6 0,9 4 2,2 :0 30 3 35 30 5,8 5 7,9 :0 Notice For TOOLFLEX size 6-20 For TOOLFLEX size 30-45 Basic programme TOOLFLEX KN 30 38 45 55 Pilot bore [mm] according to ISO fit F7 4 5 6 8 9 20 22 24 25 28 30 32 35 38 40 42 45 48 Standard bore Further dimensions on request 22
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling Miniature couplings Backlash-free, torsionally stiff NEW Maintenance-free Low mass moment of inertia Easy assembly due to tolerance F7 Temperature range - 30 C to + 00 C ROTEX GS TOOLFLEX RADEX-NC TOOLFLEX Type. TOOLFLEX Type 2.5 TOOLFLEX Design /2) Torque T KN [Nm] Technical data of type with fixing screw (type.) Dimensions [mm] Perm. displacements General Fixing screw d min. d max. D H L l ;l 2 M t number 3) z S 5 5 0, 2 5 0 ) 0,30 0,0 0,7 97 0,0027 6 M2,8 M 7 2) 0,40 0,5,0 75 0,003 S 8 7,0 3 8 5 ) 0,30 0,0 0,7 390 0,005 7 M3 2,0 M 20 2) 0,40 0,5,0 300 0,006 S 2 9,5 4 0 20 ) 0,35 0,5,0 750 0,00 8 M3 2,5 2 M 24 2) 0,50 0,20,5 580 0,0 S 27,5 2 2,0 5 4 25 ) 0,40 0,5,0 270 0,07 M4 2,8 2 M 3 2) 0,60 0,20,5 980 0,09 Circumferential speed v max = 25 m/s Technical data of type with clamping screw (type. 2.5) TOOLFLEX Torque Dimensions [mm] Perm. displacements Torsional Weight 4) General Clamping screw stiffness Design /2) T KN T d min. d max. D H L l 3 ;l 4 M t e D A Axial Radial Angular [Nm] K [Nm] [mm] [mm] [degrees] [Nm/rad] [kg] 7 S 24,0 3 7 5 0,3 0, 0,7 390 0,007 9 M2 3,2 5,0 6,5 0,37 M 26 2) 0,4 0,5,0 300 0,008 9 S 30,5 3 9 20 0,35 0,5,0 750 0,04 M2,5 3,5 7, 2,5 0,76 M 33 2) 0,5 0,2,5 580 0,05 2 S 34,5 2,0 4 2 25 0,4 0,5,0 270 0,025 3 M3 4,0 8,5 26,5,34 M 38 2) 0,6 0,2,5 980 0,027 Axial [mm] ) Design S = 4 shafts 2) Design M = 6 shafts 3) Quantity each hub, from size 9: 2x20 offset 4) Figures refer to the complete coupling with max. bores Circumferential speed v max = 20 m/s Radial [mm] Angular [degrees] Torsional stiffness [Nm/rad] Weight 4) [kg] Note: The coupling must be selected in a way that the nominal torque exceeds the maximum torque to be transmitted (accelerating or peak torque). In case of values exceeding T KN (collision, trouble) only limited alternating load figures are possible. In this torque range there can be permanent deformation of the bellow and fatigue fractures can occur. Order form: TOOLFLEX 7 M 2.5 d - Ø4 2.5 d - Ø6 Coupling size Hub design Hub design component component 2 23
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling Type M Backlash-free, torsionally stiff Non-positive bellow-hub connection Frictionally engaged clamping hubs Maintenance-free Suitable for high temperatures due to flanged insert connection (max. 280 C) Well-resistant to corrosion due to bellow made from stainless steel and aluminium clamping hubs Thread M Feather keyway acc. to DIN 6885 optionally G (DIN EN ISO 4762) TOOLFLEX d min. d max. L l ;l 2 E D H M D 3 t e T A [Nm] 6 5 6 49 7,0 5 32 M4 35,0 5 2,0 2,9 20 8 20 62 2,5 9 40 M5 43,5 6 4,5 6 30 0 30 72 23,0 26 55 M6 58,0 7 9 0 38 4 38 8 25,5 30 65 M8 72,6 9 25 25 45 4 45 03 32,0 39 83 M0 89,0 30 49 55 3) 5 55 25 40,0 45 00 M2 06,0 4 37 20 TOOLFLEX 6 5 4900 7 3050 29 92 ±0,5 0,20,5 6 20 5 950 3 6600 42 26 ±0,6 0,20,5 44 30 35 8700 7 4800 65 55 ±0,8 0,25 2,0 306 38 65 7350 254 24900 72 22 ±0,8 0,25 2,0 448 45 50 5750 0 64000 88 492 ±,0 0,30 2,0 25 55 3) 340 4800 557 9600 07 598 ±,0 0,30 2,0 3300 TOOLFLEX Torque T KN [Nm] General Clamping screws Speed n ) [min - ] Moment of inertia 2) [x0-6 kgm 2 ] Torsional stiffness [Nm/rad] Ø5 Ø6 Ø7 Ø8 Ø9 Ø0 Ø Ø2 Ø4 Ø5 Ø6 Ø8 Ø9 Ø20 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Ø50 Ø55 6 8,5 8,8 9, 9,4 9,7 9,9 0,2 0,5,,4,7 Dimensions [mm] Axial spring stiffness [N/mm] 20 7,6 8, 8,6 9,0 9,5 20,5 2,0 2,4 22,4 22,9 23,3 Radial spring stiffness [N/mm] Technical data 30 33 34 35 36 36,4 38 38,5 39 42 42,5 44,5 46 Perm. displacements 38 84 85 87 92 93 97 99 0 05 09 45 57 65 67 73 77 8 87 93 97 200 206 55 3) 397 40 43 42 429 44 453 462 470 482 502 522 Axial [mm] Radial [mm] Bore range and respective torques of frictional engagement of the clamping hub [Nm] Angular [degrees] ) With v= 25 m/s 2) Figures refer to the complete coupling with max. bores 3) Hubs from steel welded with bellow Note: The coupling must be selected in a way that the nominal torque exceeds the maximum torque to be transmitted (accelerating or peak torque). In case of values exceeding T KN (collision, trouble) only limited alternating load figures are possible. In this torque range there can be permanent deformation of the bellow and fatigue fractures can occur. Mass 2) [x0-3 kg] Order form: TOOLFLEX 30 M d - Ø25 d 2 - Ø30 Coupling size Component Component 2 24
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling Type S Short design Higher stiffness of torsion spring Lower mass moment of inertia Thread M Feather keyway acc. to DIN 6885 optionally ROTEX GS TOOLFLEX RADEX-NC G (DIN EN ISO 4762) TOOLFLEX Dimensions [mm] General Clamping screws d min. d max. L l ;l 2 E D H M D 3 t e T A [Nm] 6 5 6 45 7,0 32 M4 35,0 5 2,0 2,9 20 8 20 55 2,5 2 40 M5 43,5 6 4,5 6 30 0 30 63 23,0 7 55 M6 58,0 7 9 0 38 4 38 69 25,5 8 65 M8 72,6 9 25 25 45 4 45 86,5 32,0 22,5 83 M0 89,0 30 49 55 3) 5 55 40,0 3 00 M2 06,0 4 37 20 TOOLFLEX Torque T KN [Nm] Speed n ) [min - ] Moment of inertia 2) [x0-6 kgm 2 ] Torsional stiffness [Nm/rad] Axial spring stiffness [N/mm] Radial spring stiffness [N/mm] Technical data Perm. displacements 6 5 4900 0 4500 43 38 ±0,3 0,5,0 6 20 5 950 30 9600 63 89 ±0,4 0,5,0 2 30 35 8700 4 7800 97 233 ±0,5 0,20,5 243 38 65 7350 243 37400 08 38 ±0,6 0,20,5 35 45 50 5750 933 95800 32 738 ±0,9 0,25,5 824 55 3) 340 4800 5036 4400 60 894 ±,0 0,25,5 323 ) With v= 25 m/s 2) Figures refer to the complete coupling with max. bores 3) Hubs from steel welded with bellow Info: Torques of frictional engagement of the clamping hub shown under Type M (page 24) Axial [mm] Radial [mm] Angular [degrees] Mass 2) [x0-3 kg] Other designs: Type for FANUC-Motors Order form: TOOLFLEX 30 S d - Ø25 d 2 - Ø30 Coupling size Component Component 2 25
TOOLFLEX Metal bellow-type couplings Backlash-free, torsionally stiff and maintenance-free coupling Type KN Backlash-free, torsionally stiff NEW Non-positive bellow-hub connection High friction torques Maintenance-free Good properties of concentric running with high speeds TOOLFLEX S-KN TOOLFLEX Torque T KN [Nm] Dimensions [mm] L L ges. Clamping screw Pull-off threads 4 shafts 6 shafts 4 shafts 6 shafts l ;l 2 D H D D 2 T d min. d max. M A Number Number T 4) M A ) 2) ) 2) [Nm] z z [Nm] 30 35 2 22 48 57 54 63 22 50 43 47 M4 2,9 2 M4 6,2 38 65 2 28 56 68 63 75 26 60,5 52 56 M5 6 2 M5 6,4 45 50 5 40 74,5 9 82,5 99 34 82 68 77 M6 4 2 M6 6 3 55 3) 340 5 56 95,5 09 06 20 40 97 95 95 M8 35 2 M8 6 6 TOOLFLEX Ø2 Ø4 Ø5 Ø6 Ø9 Ø20 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Ø48 Ø50 Ø55 Ø56 30 37 50 58 66 7 79 Bore range d and the corresponding transmittable torques T R of frictional engagement of the clamping hub [Nm] 38 52 7 8 92 30 03 49 6 202 45 3 30 47 208 230 332 230 288 33 376 45 53 589 55 3) 74 98 279 309 445 483 606 696 792 585 690 764 843 967 0 94 445 498 ) Design S = 4 shafts 2) Design M = 6 shafts 3) Hubs from steel welded with bellow 4) After assembly of the clamping screws (M) tighten the pull-off thread (M ) to the torque T A indicated. Other designs: TOOLFLEX KN for FANUC engines Order form: TOOLFLEX 38 S-KN d - Ø5 d 2 - Ø22 Coupling size component component 2 26
RADEX -NC Backlash-free torsionally rigid servo lamina couplings ROTEX GS TOOLFLEX RADEX-NC 27
RADEX -NC Servo lamina coupling Backlash-free, torsionally rigid and maintenance-free couplings The RADEX -NC is a line particularly developed for the servo. In this coupling a package of torsionally rigid steel laminae that are soft in bending ensures a reliable compensation for axial, angular and radial shaft displacements. As all-metal coupling - the laminae are made from stainless steel - the RADEX -NC can even be used with high temperatures (up to 200 C) and under aggressive ambient conditions. The RADEX -NC is manufactured in 6 sizes from size 5 to 35 for max. torques of up to 200 Nm. The hubs are frictionally engaged clamping hubs made from aluminium (size 42 made from steel) and are thus backlash-free even in a reversing. A typical application of the RADEX -NC are backlash-free worm gear pairs with low transmissions. The rigidity of the coupling must be converted by reason of the transmission of the gearbox from the side to the n side. Here the transmission itself has a decisive influence because it is squarely included in the calculation. This converted rigidity is added in line to the gearbox stiffness in order to get the total rigidity. In case of transmissions that are lower than i = 8 we recommend to use the RADEX -NC due to the loss of rigidity of the total system if flexible couplings are used. Engine Coupling Gearbox The opposite diagram shows the influence of backlash and torsion angle on the train. By reason of the high torsional rigidity of the RADEX -NC the torsion angle under torque is very low. Contrary to the flexible ROTEX and ROTEX GS a damping of torsional vibrations etc. is not possible. Sense of rotation right Sense of rotation left Torque ROTEX ROTEX GS RADEX -NC Backlash Backlash = 0 Backlash = 0 Torsional backlash Torsional backlash Torsional backlash Explosion protection use RADEX -NC couplings are suitable for power transmission in s in hazardous areas. The couplings with feather key are approved according to EC Standard 94/9/EC (ATEX 95) as units of category 2G/2D and are thus suitable for use in hazardous areas in zones G, G2, D2 and D22. Please see our Certificate and our operating and mounting instructions on our web site www.ktr.com. Selection: In case of use in hazardous areas the clamping hubs without feather key, only for use in category 3 (with feather key for category 2), must be selected in a way that there is a minimum safety factor of s = 2 between the peak torque (including all operating parameters) and the nominal torque and frictional torque of engagement of the coupling. 28
RADEX -NC Servo lamina coupling Coupling selection. Drives without periodic torsional vibrations For example centrifugal pumps, fans, screw compressors, etc. The coupling selection requires that the rated torque T KN and the maximum torque T Kmax are reviewed.. Loading by rated torque Taking into account the operating factor S B the permissible rated torque must be at least as big as the rated torque T KN of the machine. T KN T N S B (For operating factor S B see table below) 2. Drives with periodic torsional vibrations For s subject to dangerous torsional vibrations (e. g. diesel engines, piston compressors, piston pumps, generators, etc.) it is necessary to perform a torsional vibration calculation (please consult with our Engineering Department). 2. Loading by rated torque Taking into account the operating factor S B the permissible rated speed must be at least as large as the rated torque T N of the machine. T KN T N S B.2 Loading by torque shocks The permissible maximum torque T Kmax of the coupling must be at least as big as the sum of the peak torque T S and the rated torque T N of the machine. This is valid in case that the rated torque of the machine is superimposed by a shock (e. g. starting of the engine). For s with A. C. motors and large masses on the load side we would recommend calculations by our simulation programme (please consult with our Engineering Department). T Kmax (T N + T S ) 2.2 Passing through resonance The peak torque T SR arising while passing through resonance must not exceed the permissible maximum torque of the coupling T Kmax. T Kmax T SR 2.3 Loading by vibratory torque The permissible vibratory torque of the coupling T KW must not be exceeded by the maximum periodic vibratory torque of the machine T W. ROTEX GS TOOLFLEX RADEX-NC T KW T W Explanation of the above-mentioned coupling torques Description Code Explanation Description Code Explanation Rated torque of coupling T KN Torque which can be transmitted continuously over the entire speed range of the coupling Maximum torque of coupling T Kmax Torque which can be transmitted during the entire life of the coupling 0 5 times as spike load or 5 x 0 4 times as alternating load. Guidelines for operating factor S B Application Construction machinery Agitators Centrifuges Conveyors Elevators Fans/Blowers Generators Calanders Crushers Textile machinery Rolling mills S B 2-2,5 2 2,5 2 2,5 2 2,5 Application S B Woodworking machinery,5 Mixers and extruders 2 Stamps, presses 2,5 Machine tools 2 Grinders 2,5 Packaging machines Roller s 2,5 Piston pumps 2,5 Centrifugal pumps,5 Piston compressors 2,5 Turbo compressors 2 29
RADEX -NC Servo lamina coupling Standard types Backlash-free torque transmission Higher torsional rigidity Backlash-free shaft-hub-connection Low mass moment of inertia High speeds Operating temperature up to 200 C Compact type Approved according to EC Standard 94/9/EC (Explosion Certificate ATEX 95) (without feather key only for category 3) Type DK Type EK Technical data Displacement type DK Displacement type EK T KN [Nm] T K max. [Nm] Max. speed [min - ] Torsional rigidity [Nm/rad] Type EK Type DK Radial [mm] Axial [mm] Angular for each lamina [ ] Radial [mm] Axial [mm] Angular for each lamina [ ] 5 0 5 20 25 35 42 2,5 7,5 20 30 60 00 80 5 5 40 60 20 200 360 25000 20000 6000 2000 0000 9000 7000 2400 5600 2000 30000 60000 72000 20000 200 2800 6000 5000 30000 36000 60000 0,0 0,4 0,6 0,25 0,30 0,40 0,50 0,4 0,8,0,2,6 2,0 2,8 0,2 0,4 0,5 0,6 0,8,0,4 5 0 5 20 25 35 42 Dimensions [mm] Clamping screw Mass moments of inertia Max. d /d 2 D A l /l 2 L DK E DK L EK s t M T A [Nm] DK [kgm 2 ] EK [kgm 2 ] 0 5 20 25 35 40 55 26 35 47 59 70 84 04 2 6 2 24 32 35 40 34 44 55 67 88 98 6 0 2 3 9 24 28 36 26,5 35 45 52 69 77 9 2,5 3 3 4 5 7 3,5 5,0 6,8 6,5 9,0 0,5 0,5 M2,5 M4 M6 M6 M8 M0 M0 0,8 3 0 0 25 49 69 0,000004 0,00004 0,000054 0,0009 0,00046 0,000 0,0075 0,000003 0,0000 0,00004 0,0005 0,00035 0,0008 0,0062 5 0 5 20 25 35 42 Pilot bored 2,5 4,5 5,5 7,5 9,5,5 5,0 Transmittable torque of the RADEX -NC clamping hub [Nm] for standard bores 3 5 8 0 2 4 5 6 9 20 24 25 28 30 32 35 38 40 45 50 55 2,2 2,3 8 2,4 9 2,5 0 28 0 30 36 3 37 32 38 82 32 39 83 34 40 87 55 35 4 88 57 44 93 65 285 45 94 67 287 98 73 296 00 77 30 03 8 307 06 87 35 93 323 97 329 343 357 370 Order form: RADEX -NC 20 DK Ø 20 Ø 25 Coupling size Type Bore d Bore d 2 30