FLENDER GEAR UNITS OVER 1,000,000 VERSIONS, BUT ONLY ONE ORIGINAL Our range of Flender helical gear units includes the right solution for your application. flender.com
Gear Units Helical Gear Units THE ORIGINAL IS THE BASIS FOR EVERY POSSIBILITY Flender helical and bevel-helical gear units are advanced gear solutions, which satisfy the most varied, sometimes extreme requirements, achieve the highest degree of efficiency and are totally reliable. For decades, plant operators in all conceivable industries have used our helical and bevel-helical gear units to achieve high plant availability and low life cycle costs. Besides having the most comprehensive range of industrial gear units in the world, Flender also offers customer- and application-specific gear units for special applications. We are able to create solutions for just about any requirement with regard to mechanical drive technology in industry and raw-materials extraction in a way that only an original can. From small to large. From universal... 2
Helical Gear Units Gear Units Originals withstand the test of time. Not because they were the first, but because they are special in terms of what they are and what they can do. Originals are forever young, because that which remains vital stays original; that is, the innovative product is always new.... to specific. 3
Gear Units Helical Gear Units GREAT EXPERTISE IN YOUR INDUSTRY TOO. Each industry has its own conditions. Every application has its own specific requirements. We are looking forward to meeting your challenges. We probably already have the right solution at hand. Here are a few examples: Minerals and Mining Cement Plastics and Rubber Perfectly coordinated drive system Low maintenance effort and cost, sealing due to dirt in surroundings Absorption of high axial forces, suitability for explosion protection Environmental & Recycling Pulp and Paper Industrial Cranes Highest possible reliability, rugged design Suitability for centrally located lubrication Quick availability, version with double drive shaft 4
Helical Gear Units Gear Units Chemicals Power Generation Metals Absorption of forces from the manufacturing process Effective cooling, speed adjustment for motor to fan Harsh working conditions, high peak loads Harbour Cranes Specific axle clearance, frequent start-up Oil and Gas Flexible adaptation to speed requirements Water and Waste water Absorption of external forces, oil-retaining pipe required 5
Gear Units Helical Gear Units THE UNIVERSAL SOLUTION Innovative technology combined with a proven modular design our universal gear units are exceedingly powerful, versatile and robust. Which is why they can be found in hundreds of thousands of applications around the world. With Flender helical and bevel-helical gear units, you benefit from technology that is both innovative and well proven, a first-rate price-performance ratio, exquisite quality and short delivery times. For decades, Flender helical and bevel-helical gear units have been completing well over 400,000 drive functions all over the world. Every day, they provide the highest capacity, withstand tremendous loads and ensure a high level of plant availability. All our gear units assure high energy efficiency due to optimum efficiency levels and low power-toweight ratios. Their high quality and proven technology guarantee low life cycle costs. The universal gear solution Standardized helical and bevel-helical gear units are crucial today because of their high availability, quality and attractive priceperformance ratio. Our reliable and quickly available drive solutions have set the standard for machine manufacturers and plant constructors for many years. Price, performance availability this range of models has it all. Variety of options and flexibility The different designs of our gear units are perfectly enhanced by many standardized options such as motor lanterns, non-return devices and a long-lasting seal for operation in the dirtiest environments. For this reason, our product range provides a nearly unlimited variety of design options. Additional cooling solutions for selected gear units (for example fans, larger housing surfaces or separate cooling systems) are optional. The gear units compact design, the possibility of horizontal or vertical installation, the various installation configurations (baseor shaft-mounted gear units) and the easy fitting of additional components guarantee maximum flexibility in plant construction. 6
Helical Gear Units Gear Units More than 1,000,000 variants, one original. The Flender helical and bevel-helical gear unit portfolio is by far the most comprehensive range of industrial gear units in the world. It includes a multifaceted range of universal gear units, applicationspecific gear units and customerspecific solutions. THE POSSIBILITIES OFFERED BY THE MODULAR SYSTEM Sizes: 26 ----------------------------------------------------------------- Nominal capacity: up to 4,500 kw ----------------------------------------------------------------- Nominal output torque: up to 1,400,000 ----------------------------------------------------------------- Nominal transmission ratios: i = 1.25 to 450 ----------------------------------------------------------------- Mounting positions: horizontal and vertical ----------------------------------------------------------------- 7
Gear Units Helical Gear Units UNIVERSAL GEAR UNITS The huge modular system with its finely spaced series of helical and bevel-helical gear units probably already includes the right solution close to your desired torque. Nominal torque range Monoblock design Divided housing design DESIGNS AND SIZES TYPE SIZE 03 04 05 06 07 08 09 10 11 12 13 14 Helical gear unit H1 Nominal torque class T2N 3,300 9,600 17,800 Type Size H1 03 H1 05 H1 07 H1 09 H1 11 H1 13 Ratio range (i) 1 : 1.25 5.6 1 : 1.25 5.6 1 : 1.25 5.6 1 : 1.25 5.6 1 : 1.6 5.6 1 : 1.6 5.6 28,700 50,600 75,700 Helical gear unit H2 Helical gear unit H3 Helical gear unit H4 Bevel-helical gear unit B2 Bevel-helical gear unit B3 Bevel-helical gear unit B4 Nominal torque class T2N 3,500 6,700 11,200 14,400 20,300 25,600 Type Size H2 03 H2 04 H2 05 H2 06 H2 07 H2 08 H2 09 H2 10 H2 11 H2 12 H2 13 H2 14 Ratio range (i) 1 : 6.3...22.4 1 : 6.3 22.4 1 : 6.3 22.4 1 : 8 28 1 : 6.3 22.4 1 : 8 28 1 : 6.3 22.4 1 : 8 28 1 : 6.3 22.4 1 : 8 28 1 : 6.3 20 1 : 8 25 Nominal torque class T2N 11,600 15,500 21,700 27,200 Type Size H3 05 H3 06 H3 07 H3 08 H3 09 H3 10 H3 11 H3 12 H3 13 H3 14 Ratio range (i) 1 : 25 90 1 : 31.5 112 1 : 25 90 1 : 31.5 112 1 : 25 90 1 : 31.5 112 1 : 25 90 1 : 31.5 112 1 : 22.4 90 1 : 28 112 Nominal torque class T2N 21,700 27,200 Type Size H4 07 H4 08 H4 09 H4 10 H4 11 H4 12 H4 13 H4 14 Ratio range (i) 1 : 100 355 1 : 125 450 1 : 100 355 1 : 125 450 1 : 100 355 1 : 125 450 1 : 100 355 1 : 125 450 Nominal torque class T2N 6,200 9,400 12,000 19,000 23,800 Type Size B2 04 B2 05 B2 06 B2 07 B2 08 B2 09 B2 10 B2 11 B2 12 B2 13 B2 14 Ratio range (i) 1 : 5 18 1 : 5 18 1 : 6.3 22.4 1 : 5 18 1 : 6.3 22.4 1 : 5 18 1 : 6.3 22.4 1 : 5 18 1 : 6.3 22.4 1 : 5 18 1 : 6.3 22.4 Nominal torque class T2N 3,600 6,700 11,600 15,500 21,700 27,200 Type Size B3 03 B3 04 B3 05 B3 06 B3 07 B3 08 B3 09 B3 10 B3 11 B3 12 B3 13 B3 14 Ratio range (i) 1 : 20...71 1 : 12.5 71 1 : 12.5 71 1 : 16 90 1 : 12.5 71 1 : 16 90 1 : 12.5 71 1 : 16 90 1 : 12.5 71 1 : 16 90 1 : 12.5 71 1 : 16 90 Nominal torque class T2N 11,600 15,500 21,700 27,200 Type Size B4 05 B4 06 B4 07 B4 08 B4 09 B4 10 B4 11 B4 12 B4 13 B4 14 Ratio range (i) 1 : 80 315 1 : 100 400 1 : 80 315 1 : 100 400 1 : 80 315 1 : 100 400 1 : 80 315 1 : 100 400 1 : 80 315 1 : 100 400 33,700 35,700 35,700 29,900 35,700 35,700 42,200 43,800 44,200 38,000 43,800 44,200 59,300 63,500 61,600 54,000 63,500 61,600 73,800 77,200 78,000 66,300 77,200 78,000 86,000 88,000 90,700 81,100 90,700 90,700 107,000 109,000 113,000 101,000 113,000 113,000 8
Helical Gear Units Gear Units 15 16 17 18 19 20 21 22 23 24 25 26 27 28 130,000 173,000 245,000 H1 15 H1 17 H1 19 1 : 2 5.6 1 : 2.8 5.6 1 : 4 5.6 143,000 160,000 195,000 230,000 292,000 335,000 410,000 458,000 640,000 725,000 860,000 1,030,000 1,230,000 1,400,000 H2 15 H2 16 H2 17 H2 18 H2 19 H2 20 H2 21 H2 22 H2 23 H2 24 H2 25 H2 26 H2 27 H2 28 1 : 6.3 20 1 : 7.1 22.4 1 : 6.3 20 1 : 7.1 22.4 1 : 6.3 20 1 : 7.1 22.8 1 : 7.1 20 1 : 8 22.4 1 : 6.3 20 1 : 7.1 22.4 1 : 6.3 20 1 : 7.1 22.4 1 : 8 20 1 : 9 22.4 153,000 173,000 200,000 240,000 300,000 345,000 420,000 470,000 640,000 725,000 860,000 1,030,000 1,230,000 1,400,000 H3 15 H3 16 H3 17 H3 18 H3 19 H3 20 H3 21 H3 22 H3 23 H3 24 H3 25 H3 26 H3 27 H3 28 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 1 : 22.4 90 1 : 25 100 153,000 173,000 200,000 240,000 300,000 345,000 420,000 470,000 640,000 725,000 860,000 1,030,000 1,230,000 1,400,000 H4 15 H4 16 H4 17 H4 18 H4 19 H4 20 H4 21 H4 22 H4 23 H4 24 H4 25 H4 26 H4 27 H4 28 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 1 : 100 355 1 : 112 400 132,000 148,000 195,000 230,000 B2 15 B2 16 B2 17 B2 18 1 : 5 18 1 : 5.6 20 1 : 5.6 18 1 : 7.1 20 153,000 173,000 200,000 240,000 300,000 345,000 420,000 470,000 640,000 725,000 860,000 1,030,000 1,230,000 1,400,000 B3 15 B3 16 B3 17 B3 18 B3 19 B3 20 B3 21 B3 22 B3 23 B3 24 B3 25 B3 26 B3 27 B3 28 1 : 12.5 71 1 : 14 80 1 : 12.5 71 1 : 14 80 1 : 12.5 71 1 : 14 80 1 : 12.5 71 1 : 14 80 1 : 20 71 1 : 22.4 80 1 : 20 71 1 : 22.4 80 1 : 20 71 1 : 22.4 80 153,000 173,000 200,000 240,000 300,000 345,000 420,000 470,000 640,000 725,000 860,000 1,030,000 1,230,000 1,400,000 B4 15 B4 16 B4 17 B4 18 B4 19 B4 20 B4 21 B4 22 B4 23 B4 24 B4 25 B4 26 B4 27 B4 28 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 1 : 80 315 1 : 90 355 9
Gear Units Helical Gear Units THE SPECIAL SOLUTION Flender has been a partner to industries and has known the customers and their markets for decades already. Right from the start, we consistently used information gained from practice in order to keep developing our modular gear unit building blocks. Today, Flender offers you by far the largest number of application-specific solutions for industry and raw-material extraction. In the very rare cases in which we cannot offer a solution based on our modular system, we can also create customer-specific solutions. We provide a solution for any drive function and develop something new that is not featured in the catalog customeroriented, with expertise and high quality. For many applications, the solutions offered consist of established, standardized components. In this way, with our standard and application solutions, you benefit from a high level of operational reliability, an excellent priceperformance ratio and short delivery times. 10
Helical Gear Units Gear Units Developed for special tasks: selfaligning conveyor drive systems from Flender bring their strengths to bear especially in confined spaces. 11
Gear Units Helical Gear Units THE WORLD S MOST COMPREHENSIVE PORTFOLIO OF APPLICATION SOLUTIONS 12
Helical Gear Units Gear Units TECHNICAL INFORMATION Designation Design Type Sizes Nominal capacity in kw Nominal output torque in Nominal transmission ratio Water turbine gear units Helical gear unit H2WV 3,550 6.328 13, from 5 to 17 10,000195,000 Bevel-helical gear unit B2WV 2,550 522.4 Gear units with auxiliary drive (for bucket conveyors) Bevel-helical gear unit B3 T3 15, from 4 to 18 1,800 6,700240,000 2571 Conveyor belt gear units Bevel-helical gear unit B2 15, from 4 to 18 4,600 6,10023,000 522.4 B3 27, from 4 to 28 4,800 6,0001,400,000 12.540 T3 9, from 4 to 12 780 6,00077,200 12.540 B3_E 10, from 13 to 22 4,500 90,700470,000 12.540 B3_A 8, from 7 to 14 1,200 21,700113,000 12.540 Cooling tower gear units Paper machine gear units Aerator gear units Helical gear unit H2NV 6.328 On 8, from 105 to 112 On request request Bevel-helical gear unit B2NV 522.4 Helical gear unit H1SH 9, from 2 to 17 4,950 2,900245,000 1.255.6 H2PH 4 (5, 7, 9, 11) 1,480 10,70059,300 6.322.4 Bevel-helical gear unit B2PV 11, from 8 to 18 4,600 6,100230,000 514 Helical gear unit H2BV, H3BV 12, from 5 to 16 1,073 10,500173,000 6.3112 Bevel-helical gear unit B3BV 1,660 9,400173,000 12.590 Agitator gear units Helical gear unit H2_V, H3_V, H4_V 14, from 5 to 18 3,560 10,000240,000 6.3450 Hoisting gear units with large overall axle clearance Helical gear unit K3, K4 10, from 5 to 14 990 11,000109,000 14250 8, from 215 to 222 3,100 168,000540,000 18140 Angular gear units (for chassis, etc.) Bevel-helical gear unit W3, W4 10, from 3 to 12 635 3,50075,000 12.5400 Crusher gear units Helical gear unit H3SH 6, from 509 to 514 from 90 to 315 35,000120,000 20, 28, 31.5 Conveyor drives Bevel-helical gear unit B3, B3_E, B3_A, T3 Drive unit packages consisting of: SINAMICS motor, Flender coupling, Flender helical-bevel gear unit and protective hoods mounted on swing base Single-screw extruder Helical gear unit E2, E3 11, from 4 to 12, 14, 16 1,675 6,300160,000 6.3112 13
Gear Units Helical Gear Units CONDITION MONITORING AND FLENDER GEARLOG Tools for predictive maintenance The availability of machines and equipment is a basic requirement for productivity. For those wanting to increase availability a predictive maintenance strategy is indispensable. To avoid unscheduled downtimes any fault causes must be detected early. Servicing work can then be scheduled to prevent any interruption to the production. To enable this we offer you two tools: Condition monitoring analyses the machine s condition and early identifies indicators that show that the gear unit could become damaged if it continues to be operated without intervention. FLENDER GEARLOG logs actual load data. Evaluation of the results enables optimised future drive solutions that conform closely to requirements. The two systems supply the basis for condition-based maintenance. With this you can continuously monitor the condition of your machine s mechanical components right across the system. So changes caused by wear or other causes can be identified from the recorded trend lines and rectified early before they cause a system stoppage. With condition monitoring and FLENDER GEARLOG we set standards for tomorrow an important step towards the digital factory that will in future link together all of the actors machines, products and people along the entire value-adding chain. What do I take and when? To measure wear on rotating machines condition monitoring systems that employ sensors to measure vibration, temperature and speed are used. On dispersed or small machines measurements are best carried out using a mobile vibration measuring system. Where the machine loads sustained are of interest and field experience is to be gained for optimum machine design, the FLENDER GEARLOG is the right tool. If desired, both functionalities can be combined in a single system. The experts at Flender would be pleased to advise you. The insights gained increase the transparency of operating load data overall and so can be used to optimise gear unit design. In this way not only can the availability of a system be increased, processes are improved too. 14
Helical Gear Units Gear Units Tools for predictive maintenance Condition Monitoring Load Monitoring Condition Monitoring Systems Vibration, torque, temperature, speed, pressure, misalignment Mobile Measurement Vibration, temperature, speed FLENDER GEARLOG Torque, speed, temperature THE ADVANTAGES OF PREVENTIVE MAINTENANCE: Improvement of your processes thanks to complete transparency of operating load data Lowering of investment costs thanks to use of optimum gear unit sizes Strengthening of system failure safeguards thanks to individual optimisation of components Boosting of productivity thanks to higher performing gear unit solutions Improvement of energy efficiency thanks to optimum gear unit dimensioning Lowering of life cycle costs thanks to reduction of servicing and sparepart costs Increase in availability thanks to reduced downtime and servicing 15
FLENDER BY YOUR SIDE. All sectors of industry and raw-material extraction know Flender drive technology and the people behind it as highly capable and reliable. They require a flexible, forward-thinking partner for consulting and development that is at the same time a globally positioned, committed business partner. This is how we understand our mission. In the future, we want to again stand at our customers side under the name Flender, as part of the Siemens corporation. --------------------------------------------------------------- Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany Article No.: PDMD-B10080-00-7600 Printed in Germany Dispo 27904 WÜ W-PDMD8-HP-XX201 BR 01182.5 flender.com Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract.