Products of continuous manufacturing modular; compatible; available E FLENDER STANDARDS
Flender Standard Components WE MOVE THE WORLD Flender is a leading international manufacturer of mechanical and electrical components for power transmission equipment. With its extensive product range Flender is in a position to offer any individual drive component, but also complete drive systems for nearly all branches of industry. We put main emphasis on the four core business areas Standard Components, Applications with high engineering content, Winergy, as well as Service covering all services around power transmission equipment. In the standard components segment, Flender has a rounded off product range in the fields of industrial gear units, geared motors, couplings, and clutches. Here, we set the standards for the market and push the technical development. References from all over the globe verify our specialist experience in power transmission technology. When selecting Flender standard components you gain advantage from: The highest efficiencies; Fast availability worldwide; Leadership in technology; The known high Flender quality level; An attractive price-performance ratio; Fast service. Flender standard modular components can be combined for nearly any torque range and are compatible over all series. On the following pages we would like to convince you of the numerous advantages of the Flender standard components. Flender standard components That s the way how to equip your plant with drive systems today! 2
From 15 up to 10,000,000 Nm Torque range FLENDER gear units 620 900,000 MOTOX geared motors 30 80,000 CAVEX worm gear units 100 360,000 Couplings and clutches PLANUREX planetary gear units 22,000 2,600,000 15 10,000,000 T N (Nm) 100 1,000 10,000 100,000 1,000,000 10,000,000 3
Industrial gear units up to 900,000 Nm FLENDER GEAR UNITS The FLENDER gear unit series is a universal standard gear unit range which has been developed for the use in nearly all fields of the mechanical power transmission technology. The product range has been designed as a modular construction system enabling extraordinarily short delivery times. Important add-on pieces have already been integrated into the standard product range, so that the adaptation of a gear unit to your special requirements will have no negative effect on the delivery time. The most important features are: Helical and bevel-helical gear units; Universally applicable; Modular construction system; Fast availability worldwide; High power capacity; Worldwide tried and tested in more than 60,000 drive systems. FLENDER gear unit with bevel-helical gear stage FLENDER gear unit with helical gear stage 4
Very short delivery times Te chnical information: FLENDER GEAR UNITS Types Helical and bevel-helical gear units Sizes 24 Gear stages 1 to 4 stages Power ratings up to 4,500 kw Transmission ratios i = 1 450 Nominal torques up to 900,000 Nm Mounting positions horizontal and vertical Numerous customer-specific requirements have been standardized and included in the following subranges of the FLENDER gear unit series: Belt conveyor drives Aerator drives Bucket elevator drives Agitator drives Cooling tower drives Travelling gear drives Extruder drives Paper machine drives Water turbine drives Gear units with extended total centre distance Bevel gear units The dynamic global markets demand shorter and shorter delivery times. Flender has taken account of this trend with the new Fast Track concept. The Fast Track gear units represent a special selection from the FLENDER gear unit range and are available in eight sizes with very short delivery times ex works. Based on the technical advantages of the standardized FLENDER gear units, the helical and bevel-helical gear units of the Fast Track range thus are without competition in the field of industrial gear units. The extremely short delivery times are possible owing to an automatized order handling system in combination with assembly lines specially designed for the Fast Track series. Te chnical information: FAST TRACK -GETRIEBE Types Helical and bevel-helical gear units Sizes 8 Gear stages 2 to 4 stages Power ratings up to 200 kw Transmission ratios i = 6.3 450 Torques up to 80,000 Nm 5
Geared motors up to 20,000 Nm MOTOX -N For many years, geared motors from Flender have been setting standards in power transmission technology. For any application you will find a suitable drive among the Flender geared motor range. Flender keeps things moving wherever quality and reliability are required. Modular design is not a new trend, but a parameter of effectiveness. For it facilitates economical, fast and reliable adaptation of a complex product to different industry-specific requirements. With MOTOX, Flender provides a product range that has been developed in accordance with a modular construction system comprising the MOTOX -N and MOTOX -G geared motors series, the MODULOG add-on motors, and the MOTOX -Drive and MOTOX-Master frequency inverters as well as the MOTOX -Starter. Size is what matters. This is why Flender backs maximum power capacity for as small as possible gear units. Here we are leading, and this represents a benefit for our customers: cost reduction. Mounting variants: Foot-mounted design Flange-mounted design Solid shaft Hollow shaft Shrink disk Splined shaft Centering flange Torque reaction arm Drive variants: Asynchronous motors EExe-, EExd(e) motors Servomotors Brakes Incremental encoders Pole changing Floating input shaft IEC-/ NEMA coupling bell housing Motor bracket MOTOX -N helical geared motor MOTOX -N bevel geared motor MOTOX -N worm geared motor 6
ATEX 95 EXPLOSION PROTECTION Guideline 94/9/EG for gear units of the MOTOX -N series The compact Flender MODULOG motors with their wide ranging functional diversity can be fitted as drive unit (see page 9). MOTOX -N geared motors can be found in nearly all industrial sectors. The food and beverage industry, the automotive industry, high stacking stores, the chemical industry, environmental technology, wood working and materials-handling technology are just a few examples. According to the latest legislation, only drives in accordance with guideline 94/9/EG (known as ATEX 95) may be used in explosion-proof location. For the respective materials processing machinery and apparata, Flender provides its MOTOX -N geared motor range in accordance with the features required in the guideline. MOTOX -N is in conformity with ATEX 95: Te chnical information: MOTOX -N Series 4 Sizes for each series up to 9 Gear stages 1 6 Output torques up to 20,000 Nm Transmission ratios 1.5 up to 70,000 Motor power rating range 0.09 160 kw For geared motors in zones 1, 2, 21, and 22; With temperature class T4 and lower; Up to max. 120 C for zones 21 and 22 (dust); Degree of protection IP65 for gases and dust; With thermal design taking into account all relevant conditions; With guard for shrink disk; Impact-resistant and dustproof; With additionally secured connecting elements. MOTOX -N parallel shaft helical geared motor MOTOX -N for ATEX 95 7
Geared motors up to 80,000 Nm MOTOX -G It is not only the modular design and fast availability what makes a modern geared motor range stand out, but also the increase in the absolute value in the power rating range. With the new MOTOX -G series, torques of the geared motor range have now been increased up to 80,000 Nm. A novelty on the geared motor market: The technology of industrial gear units and the economic efficiency of geared motors have been combined in the new MOTOX -G series to create an extraordinarily attractive product. The MOTOX -G modular design system includes bevel geared and parallel shaft helical geared motors of five different sizes each. All current connecting elements can be used on both input and output side. Motor power ratings of up to 200 kw can be installed and together with various monitoring instruments highly flexible electric drive systems can be designed. Furthermore, the assignment of MOTOX -G to the motor-integrated MOTOX -MASTER frequency inverter series or stand-alone MOTOX -DRIVE series allows in a very simple manner to change the static drive into a variable speed drive. And as also the MOTOX -G series is based on a modular construction system, fast availability is a matter of course of this high-performance product. MOTOX -G parallel shaft helical geared motor Te chnical information: MOTOX -G Types Bevel geared and parallel shaft helical geared motors Sizes F208, F228, F248, F288, F328 K208, K228, K248, K288, K328 Gear stages 3 and 4 stages Power ratings up to 200 kw Transmission ratios i = 25 450 Torques up to 80,000 Nm 8
Motor engineering MODULOG An essential part of a geared motor is the drive. With the new MODULOG motor series Flender shows that a modular construction system is not necessarily restricted to gear units. The name MODULOG indicates that it is a clearly structured modular system with which a powerful motor can be individually assembled from some standard components. Owing to a well thought-out manufacturing and assembly concept almost any option is possible without affecting the standard delivery time. The most important part of the modular system is the flanged-shaft system which can be individually configured on the motor B-side. This facilitates functional extensions like, for example, brakes, backstops, encoders, forced-air cooling, and handwheel which can be combined at almost any option. The possibility to mount frequency inverters directly to the motor allows configuring decentralized, controllable drive units which help to significantly reduce operating costs in many applications. And with the MODULOG motor series, Flender goes even further: in the range between 1.1 and 30 kw, class EFF 2 is already standard for the motors; and in the power rating range from 37 up to 90 kw even class EFF 1. Optionally, the highest class EFF 1 is also available in the lower power rating range, so that with MODULOG highly efficient motors are available over the entire power rating range. The advantage for you is obvious: Lower operating cost and at the same time longer service life of the motors. MODULOG motors in combination with MOTOX gear units form a modular unit with optimized efficiency allowing numerous mounting options, standard delivery times, and at the same time a significant reduction in operating costs. MODULOG motor 9
Decentralized power transmission equipment MOTOX -DRIVE MOTOX -MASTER MOTOX -STARTER MOTOX -Drive three-phase current drive converters round-off the modular MOTOX geared motor system for variable speed drives. To plan, commission and operate the most varied drive applications, you can select from among various control methods and extensive technology and communication options. With the application of intelligent decentralized power transmission equipment, for all MOTOX geared motors significant cost-saving potentials can be created. The installation concept without switch cabinet is a further step towards cost reduction through decentralizing. With the MOTOX -Master frequency inverter for the MODULOG modular design motor and with the MOTOX -Starter, Flender provides the best possible components for decentralized power transmission technology. The sturdy housings can be either directly integrated into the motor or fastened near the motor and connected by means of a cable. With it, space is created in the switch cabinet, expensive wiring saved, and more room given for plant extensions. Te chnical information: MOTOX -DRIVE Power rating range 0.12 315 kw Mains voltage 100 690 V MOTOX -MASTER Power rating range 0.12 7.5 kw Mains voltage 208 500V MOTOX -STARTER Power rating range 0.12 4.0 kw Mains voltage 380 480 V MOTOX -Master with MOTOX -Nhelical geared motor MOTOX -Starter with MOTOX -Nbevel-helical geared motor 10
Industry-related solutions SUBRANGES Every industry has its own requirements, needs specific solutions and specialist advice. We provide optimum solutions for your special drive applications based upon our many years of wide-ranging experience and knowledge. The MOTOX modular construction system is the ideal basis for reliable drives with long service life. Our product portfolio covers the following industry-specific solutions in different sizes: MOTOX cooling tower drives featuring silent running; MOTOX extruder drives with very long bearing life even under extreme axial forces; MOTOX agitator drives with the highest degree of oil tightness owing to a dry well principle ; MOTOX monorail suspension railways with integrated coupling to interrupt the flux of force; MOTOX crane travelling gear drives, powerful and compact; MOTOX CarWash drives with long service life; maintenance-free; with high resistance to washing agents. MOTOX crane travelling gear drive MOTOX extruder drive MOTOX agitator drive MOTOX CarWash drive MOTOX monorail suspension railway drive 11
Worm gear units up to 360,000 Nm CAVEX For more than 50 years, the name CAVEX stands for Flender s worm gear unit range which has been successfully operating in many different industrial applications all over the globe. In cooperation with our customers and suppliers we have continually developed our CAVEX worm gear units and adapted them to the changing market requirements. The latest CAVEX series stands out owing to its high power capacity and compact design in combination with a long service life. The low-noise, vibration reducing gearing is not susceptible to shocks and allows large transmission ratios in just one gear stage. The load carrying capacity of the gearing could be considerably increased by applying the latest lubricants so that today efficiencies of up to 95% are achieved. The CAVEX series comprises 18 sizes and is available as both single-stage and multistage variant, the torque range of the series lying between 100 and 360,000 Nm. Te chnical information: CAVEX Sizes per series 18 Gear stages single- and multistage Power ratings up to 800 kw Transmission ratios i = 3 4,600 Torques up to 360,000 Nm For customer-specific applications, such as reel changers or drum filters, in addition to the standard product range also gear unit combinations comprising MOTOX -N parallel shaft helical or bevel geared motors and CAVEX worm gear units are available today. These drives are very compact covering a transmission ratio range of up to i = 30,000. CAVEX worm gear unit 12
Planetary gear units up to 2,600,000 Nm PLANUREX The upper power rating range of the standard Flender product range is covered by the PLANUREX planetary gear unit series. Torques of up to 2,600,000 Nm can be transmitted. This product has been standardized and is available in 27 sizes, which results in short delivery times and an attractive price level. PLANUREX is made in five basic designs: as two or three stage planetary gear units or combined with helical, bevel, bevel-helical gear units or worm gear stages for transmission ratios up to 4000:1. All types and sizes are optionally available as shaft-mounted design or with solid shaft. Owing to these technical features, PLANUREX is universally applicable in many industrial branches. From a technological point of view, remarkable features of PLANUREX are, above all other things, high power capacity und at a relatively low weight, high efficiency, and low-noise running. Te chnical information: PLANUREX Sizes 27 Gear stages 2 and 3 stages plus gear unit combinations Power ratings 13,000 kw Transmission ratios up to i = 4,000 Torques up to 2,600,000 Nm PLANUREX planetary gear unit 13
Couplings and clutches up to 7,200,000 Nm COUPLINGS AND CLUTCHES As Europe s biggest coupling manufacturer, Flender makes mechanical couplings covering a torque range between 15 and 10,000,000 Nm. Approximately 300,000 couplings and clutches are sold every year, based upon 80 years of wide-ranging experience and knowledge derived from our latest research programmes. Our product range covers flexible and highly flexible couplings, gear couplings, all-steel couplings, fluid couplings, clutches, and torque limiters. Furthermore, Flender provides a wide range of application-related solutions. Thus, Flender ensures reliable connections in nearly all industrial sectors. Stocks in more than 40 countries ensure the fast availability of our standard products. Gain the advantage from procuring all the products and services of the known high Flender quality level without delay from one source. Take advantage of the possibilities Flender offers you with its wide range of couplings. N-EUPEX BIPEX RUPEX 14
Te chnical information: Product Types Sizes Torques Coupling type Examples of applications N-EUPEX 8 23 up to 62,000 Nm Pin coupling Pumps and compressors BIPEX 3 13 up to 3,700 Nm Claw coupling For fitting into bell housings RUPEX 6 26 up to 1,300,000 Nm Pin and bush coupling Cement mills ELPEX 9 12 up to 90,000 Nm Ring coupling Shredders ELPEX -S 7 11 up to 40,000 Nm Rubber disk coupling Diesel engines ELPEX -B 3 15 up to 14,500 Nm Rubber tyre coupling Blowers ZAPEX 19 43 up to 7,200,000 Nm Gear coupling Metallurgical engineering ARPEX 11 82 up to 1,500,000 Nm All-steel coupling Wind turbines FLUDEX 4 16 up to 1,500 Nm Fluid coupling Conveyor drives PLANOX 7 10 up to 30,000 Nm Clutch Power generating systems FLUDEX ELPEX-B ZAPEX-ZW ARPEX 15
Flender e.store Another element of the modular Flender programme is Flender e.com which supports you in selecting and configuring standard Flender products directly at the Internet; enquiring about prices and delivery dates; ordering products; and querying the state of your order. Gain the advantages from this new way of purchasing. To obtain more information visit www.flender.com or send an E-mail to sales@flender.com. We will be happy to assist you. Your contact: A. Friedr. Flender AG Alfred-Flender-Strasse 77 46395 Bocholt phone: +49 (0) 28 71 920 fax: +49 (0) 28 71 92 25 96 www.flender.com W 200 EN 2003-12