Worm(IE2).pdf - Chapter Description GENERAL INFORMATION Page 2 Chapter Description RVS LIMIT-STOP DEVICE Page 175 1 Symbols and units of measure 2 31

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Unformatted text preview: Chapter Description GENERAL INFORMATION Page 2 Chapter Description RVS LIMIT-STOP DEVICE Page 175 1 Symbols and units of measure 2 31 General information 175 2 Definitions 3 32 Ordering codes 176 3 Maintenance 6 33 Designation 177 4 Selection 6 34 Gearmotor selection 178 5 Verification 9 35 Dimensions 181 6 Installation 9 36 Options 185 7 Storage 11 8 Conditions of supply 11 ELECTRIC MOTORS WORMGEARS 9 10 13 Design features 13 Versions 14 11 Arrangements 15 12 13 Designation Gearbox options 18 14 Lubrication 22 15 Mounting position and terminal box orientation 23 16 Overhung loads 33 17 Thrust loads 33 18 Efficiency 36 19 Non-reversing 36 20 Angular backlash 38 186 M1 High efficiency motors 187 M2 Standard electric motors 215 M3 Electric motors series K 286 20 21 Gearmotor rating charts 39 22 Speed reducer rating charts 67 23 Ratio distribution for VF/VF, VF/W, W/VF series gearboxes 89 24 Motor availability 90 25 Moment of inertia 93 26 Dimensions for gearmotors an gear units with IEC motor interface. 105 27 DImensions for gear units with solid input shaft 165 28 Accessories 169 29 Customer’ shaft 171 30 Torque limiter 172 Revisions Refer to page 296 for the catalogue revision index. Visit to search for catalogues with upto-date revisions. 1 / 296 GENERAL INFORMATION 1 SYMBOLS AND UNITS OF MEASUREMENT Symbols Units of Measure Description Symbols Units of Measure Description AN 1, 2 [N] Permissible axial force n 1, 2 [min-1] Speed fs – Service factor P 1, 2 [kW] Power fT – Thermal factor PN 1, 2 [kW] Rated power fTP – Temperature factor PR 1, 2 [kW] Power demand i – Gear ratio RC 1, 2 [N] Calculated radial force I – Cyclic duration factor RN 1, 2 [N] Permissible overhung load JC [Kgm2] Mass moment of inertia to be driven S – Safety factor JM [Kgm2] Motor mass moment of inertia ta [°C] Ambient temperature JR [Kgm2] Mass moment of inertia for the gear unit tf [min] Work time under constant load K – Mass acceleration factor tr [min] Rest time Kr – Transmission element factor ηd – Dynamic efficiency M 1, 2 [Nm] Torque ηs – Static efficiency Mc 1, 2 [Nm] Calculated torque Mn 1, 2 [Nm] Rated torque Mr 1, 2 2 / 296 [Nm] Torque demand 1 value applies to input shaft 2 value applies to output shaft This symbol indicates important technical information. This symbol refers to the angle the overhung load applies (viewing from drive end). This symbol indicates situations of danger which, if ignored, may result in risks to personal health and safety. The symbol shows the page the information can be sorted from. 2 DEFINITIONS 2.1 TORQUE Symbol refers to weight of gearmotors and speed reducers. Figure for gearmotors incorporates the weight of the 4-pole motor and for life lubricated units, where applicable, the weight of the oil. kg Rated torque Mn2 [Nm] The torque that can be transmitted continuously through the output shaft, with the gear unit operated under a service factor fs = 1. Rating is speed sensitive. Required torque Mr2 [Nm] The torque demand based on application requirement. It is recommended to be equal to or less than torque Mn2 the gearbox under study is rated for. Calculated torque Mc2 [Nm] Computational torque value to be used when selecting the gearbox. It is calculated considering the required torque Mr2 and service factor fs , as per the relationship here after: Mc2 = Mr2 2.2 fs Mn2 (1) POWER Rated input power Pn1 [kW] The parameter can be found in the gearbox rating charts and represents the kW that can be safely transmitted to the gearbox, based on input speed n1 and service factor fs= 1. 3 / 296 2.3 EFFICIENCY Dynamic efficiency [ηd] The dynamic efficiency is the relationship of power delivered at output shaft P2 to power applied at input shaft P1: d = P2 P1 (2) It may be worth highlighting that values of rated torque Mn2 given in the catalogue take the dynamic efficiency into consideration. Values of ηd are calculated for gearboxes after a sufficiently long running-in period. After the running-in period the surface temperature in operation reduces and finally stabilises. The operating temperature is affected by both the duty and the ambient temperature and may result into values, measured onto the gear case in the area of the worm shaft, in the range of 80-100 °C without this affecting the operation of the gear unit adversely. If however, surface temperatures in the 90-100 °C range are to be expected it is recommended that oil seals in Fluoro elastomer compound are specified at the time of order through option PV. Static efficiency [ηS] Efficiency applicable at start-up of the gearbox. Although this is generally not a significant factor for helical gears, it may be instead critical when selecting worm gearmotors operating under intermittent duty (e.g. Hoisting). 2.4 GEAR RATIO [ i ] The value for the gear ratio is referred to with the letter [ i ] and calculated through the relationship of the input speed n1 to the output speed n2: i= 2.5 n1 n2 (3) MOMENT OF INERTIA Jr [kgm2] Moments of inertia specified in the catalogue refer to the input shaft of the gear unit and, as such, they can be simply added to the inertia of the motor, when this is combined. 4 / 296 2.6 SERVICE FACTOR [ fs ] This factor is the numeric value describing reducer service duty. It takes into consideration, with unavoidable approximation, daily operating conditions, load variations and overloads connected with reducer application. In the graph below, after selecting proper “daily working hours” column, the service factor is given by intersecting the number of starts per hour and one of the K1, K2 or K3 curves. K_ curves are linked with the service nature (approximately: uniform, medium and heavy) through the acceleration factor of masses K, connected to the ratio between driven masses and motor inertia values. Regardless to the value given for the service factor, we would like to remind that in some applications, which for example involve lifting of parts, failure of the reducer may expose the operators to the risk of injuries. If in doubt, please contact Bonfiglioli’s Technical Service. Starts per hour Acceleration factor of masses, [ K ] This parameter serves for selecting the right curve for the type of load. The value is given by the following ratio: K= Jc = Jc K= Jm Moment of inertia of driven masses referred to motor drive shaft Jm = Motor moment of inertia Jc Jm (4) K ≤ 0,25 K1 Uniform load 0.25 < K ≤ 3 K2 Moderate shock load 3 < K ≤ 10 K3 Heavy shock load K > 10 please contact Bonfiglioli’s Technical Service 5 / 296 3 MAINTENANCE Life lubricated gearboxes do not require any periodical oil changes. For other types of gearboxes, the oil must be first changed after approx. 300 hours of operation, carefully flushing the gear unit using suitable detergents. Do not mix mineral oils with synthetic oils. Check oil level regularly and change oil at the intervals shown in the table. Oil change interval [h] Oil temperature [°C] mineral oil synthetic oil < 65 8000 25000 65 - 80 4000 15000 80 - 95 2000 12500 4 SELECTION 4.1 Selecting a gearmotor a) Determine service factor fs as formerly specified. b) Determine power required at gearbox input shaft: Pr1 = Mr2 n 2 [kW] 9550 d (5) c) Consult the gearmotor rating charts and locate the table corresponding to normalised power Pn: Pn Pr1 6 / 296 (6) Unless otherwise specified, power Pn of motors indicated in the catalogue refers to continuous duty S1. For motors used in conditions other than S1, the type of duty required by reference to CEI 2-3/IEC 34-1 Standards must be mentioned. For duties from S2 to S8 in particular and for motor frame 132 or smaller, extra power output can be obtained with respect to continuous duty. Accordingly the following condition must be satisfied: Pr1 fm Pn (7) The adjusting factor fm can be obtained from table here after. Intermittence ratio I= tf tf + tr 100 (8) tf = work time at constant load tr = rest time DUTY fm S2 S3* S4 - S8 Cycle duration [min] Cyclic duration factor (l) 10 30 60 25% 40% 60% 1.35 1.15 1.05 1.25 1.15 1.1 Please contact us * Cycle duration, in any event, must be 10 minutes or less. If it is longer, please contact our Technical Service. Next, refer to the appropriate Pn section within the gearmotor selection charts and locate the unit that features the desired output speed n2, or closest to, along with a safety factor S that meets or exceeds the applicable service factor fs. fs (9) Mn 2 Pn1 = M2 P1 (10) S The safety factor is so defined: S= 7 / 296 As standard, gear and motor Combinations are implemented with 2, 4 and 6 pole motors, 50 Hz supplied. Should the drive speed be different from 2800, 1400 or 900 min-1, base the selection on the gear unit nominal rating. 4.2 Selecting a speed reducer a) Determine service factor fs. b) Determine the computational torque Mc2: Mc2 Mr2 fs (11) c) Determine the required gear ratio: i= n1 n2 (12) d) Consult the «Speed reducer rating charts» and locate the frame size that, for drive speed n1 and gear ratio closest to [i] features a rated torque Mn2 that satisfies the following condition: Mn2 Mc2 Check applicability of the electric motor selected at chapter: «Motor availability». 8 / 296 (13) 5 VERIFICATION After the selection of the speed reducer, or gearmotor, is complete it is recommended that the following verifications are Conducted: a) Maximum torque The maximum torque (intended as instantaneous peak load) applicable to the gearbox must not, in general, exceed 300% of rated torque Mn2. Therefore, check that this limit is not exceeded, using suitable torque limiting devices, if necessary. For three-phase switch-pole motors, it is recommended to pay attention to the switching torque which is generated when switching from high to low speed, because it could be significantly higher than maximum torque. A simple, economical way to minimize overloading is to power only two phases of the motor during switch-over (power-up time on two phases can be controlled with a time-relay): Switching torque Mg2 = 0.5 x Mg3 Mg2 Switching torque with two phase power-up Mg3 Switching torque with three-phase power-up b) Radial loads Make sure that radial forces applying on input and/or output shaft are within permittend catalogue values. If they were higher consider designing a different bearing arrangement before switching to a larger gear unit. Catalogue values for rated overhung loads refer to mid-point of shaft under study. Should application point of the overhung load be localised further out the revised loading capability must be adjusted as per instructions given in this manual. c) Thrust loads Actual thrust load must be found within 20% of the equivalent overhung load capacity. Should an extremely high thrust, or a combination of radial and axial load apply, consult Bonfiglioli Technical Service. d) Starts per hour For duties featuring a high number of switches the actual starting capability in loaded condition [Z] must be calculated. Actual number of starts per hour must be lower than value so calculated. 6 INSTALLATION 6.1 General instructions a) Make sure that the gearbox is securely bolted to avoid vibrations in operation. If shocks or overloads are expected, fit hydraulic couplings, clutches, torque limiters, etc. 9 / 296 b) Before being paint coated, any machined surfaces and the outer face of the oil seals must be protected to prevent paint drying out the rubber and jeopardising the sealing function. c) Parts fitted on the gearbox output shaft must be machined to ISO H7 tolerance to prevent interference fits that could damage the gearbox itself. Further, to mount or remove such parts, use suitable pullers or extraction devices using the tapped hole located at the top of the shaft extension. d) Mating surfaces must be cleaned and treated with suitable protective products before mounting to avoid oxidation and, as a result, seizure of parts. e) Prior to putting the gear unit into operation make sure that the equipment that incorporates the same complies with the current revision of the Machines Directive 2006/42/CE. f) Before starting up the machine, make sure that oil level is suitable for the mounting position specified for the gear unit and the viscosity is adequate. g) For outdoor installation provide adequate guards in order to protect the drive from rainfalls as well as direct sun radiation. 6.2 Commissioning of W gear units Gear units type W63, W75 and W86 feature a side cover carrying a blank plug for transportation purposes. Prior to putting the gearbox into service the blank plug must be replaced by the breather plug that is supplied with each unit. See figure below: Note that the blind plug MUST BE LEFT IN PLACE when the reducer is fitted in mounting position B6. 10 / 296 7 STORAGE Observe the following instructions to ensure correct storage of the products: a) Do not store outdoors, in areas exposed to weather or with excessive humidity. b) Always place boards, wood or other material between the products and the floor. The gearboxes should not have direct contact with the floor. c) In case of long-term storage all machined surfaces such as flanges, shafts and couplings must be coated with a suitable rust inhibiting product (Mobilarma 248 or equivalent). Furthermore gear units must be placed with the fill plug in the highest position and filled up with oil. Before putting the units into operation the appropriate quantity, and type, of oil must be restored. 8 CONDITIONS OF SUPPLY Gear units are supplied as follows: a) configured for installation in the mounting position specified at the time of order; b) tested to manufacturer specifications; c) mating machined surfaces come unpainted; d) nuts and bolts for mounting motors are provided; e) shafts are protected during transportation by plastic caps; f) supplied with lifting lug (where applicable). 11 / 296 12 / 296 WORMGEARS 9 DESIGN FEATURES 9.1 Key features common to all Bonfiglioli worm gears − Symmetrical hollow output shaft for facilitated mounting of the gear unit and plug-in shafts (aftersales kit only) on either side. − Ground finished wormshafts and precise machining lend optimal efficiency and extremely low noise in operation. − Numerous product configurations allow for foot, flange or shaft mounting. Torque arm is available as an option. − Extensive customisation possible through the range of standard options available. 9.2 Key features of VF-style worm gears − Die cast aluminium gear cases for VF27, VF30, VF44 and VF49. Sturdy cast iron for VF130 through VF250. The latter group is paint coated with thermo setting epoxy powder. 9.3 Key features of W-style worm gears − Rigid monobloc gear case made from Aluminium. − The cubic shape of the gear case and machining of all sides lend extreme flexibility for the installation of the gearbox and ancillary devices. − The integral gearmotor configuration is lightweight, compact and price effective. − Input shaft oil seal of W63, W75 and W86 units is located internally, and made from a Fluoro elastomer compound for improved durability and extended lifetime.                              13 / 296 10 VERSIONS VF_ W_ N VF 27 ... VF 250 Foot mounted, underdriven A U VF 27 ... VF 250 Universal gear case Foot mounted, overdriven V W 63 ... W 110 VF 27 ... VF 250 Foot mounted, wormshaft vertical F VF 27 ... VF 185 Standard flange F1 F2 FA 1 FA 2 FA UF 2 UF VF 44 ... VF 49 Extended output flange FC UF 1 W 63 ... W 110 Standard mounting flange VF 130 ... VF 185 Short flange FR FC 1 FC 2 FR 1 FR 2 VF 130 ... VF 185 Short flange and reinforced bearings P VF 30 ... VF 250 Side cover for shaft mounting P1 = P2 P1 P2 (VF 30...VF 250) (VF 130...VF 185) VF 30 ... VF 49 VF 210, VF 250 UFC 2 UFCR 2 UFC W 63 ... W 110 Mounting flange reduced in length U VF 30 ... VF 49 Foot mount 14 / 296 UFC 1 UFCR 1 UFCR W 75 Mounting flange reduced in length and diameter 11 ARRANGEMENTS For combined worm gear units, unless otherwise specified at the time of ordering, the arrangements highlighted in grey in the diagrams below will be configured at the factory. CW1 CCW1 CW2 CCW2 CW3 CCW3 CW4 CCW4 U UF_ UFC_ UFRC_ N A V F1 FA1 FC1 FR1 F2 FA2 FC2 FR2 P1 P2 Shaft-mount cover 15 / 296 For units with the HS input (free shaft), all the mounting options shown are available. For units with the P (IEC), certain mounting options can be obtained only by using IEC flanges (B5 or B14) of the same size or smaller than those shown in following table. VF/VF30/44 VF/VF30/49 VF/W30/63 VF/W44/75 VF/W44/86 VF/W49/110 W/VF63/130 W/VF86/150 W/VF86/185 VF/VF130/210 VF/VF130/250 A, N, V, P1 F-FA A, N, V, P1 F-FA U UF-UFC U UF-UFC-UFCR U UF-UFC U UF-UFC N A V F1 FC1-FR1 P1 F2 FC2-FR2 P2 N A V F1 FC1-FR1 P1 F2 FC2-FR2 P2 N A V F1 FC1-FR1 P1 F2 FC2-FR2 P2 N A V P N A V P # Consult our Technical Service 16 / 296 CW1 CCW1 CW2 CCW2 CW3 CCW3 CW4 CCW4 63B14 63B14 63B14 63B14 63B14 63B14 63B14 63B14 63B14 63B14 63B5-63B14 63B5-63B14 63B5-63B14 63B5-63B14 63B5-63B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 71B5-71B14 80B5-80B14 80B5-80B14 80B5-80B14 80B5-80B14 80B5-80B14 71B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 71B5-90B14 71B5-90B14 90B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 — 90B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 90B5-90B14 71B5-90B14 90B5-90B14 90B5-90B14 90B5-90B14 112B5-112B14 112B5-112B14 71B5-112B14 71B5-112B14 71B5-112B14 71B5-112B14 71B5-112B14 112B5-112B14 112B5-112B14 112B5-112B14 112B5-90B14 112B5-90B14 71B5-112B14 112B5-112B14 112B5-112B14 71B5-90B14 90B5-112B14 71B5-90B14 112B5-112B14 71B5-90B14 112B5-112B14 112B5-112B14 71B5-90B14 112B5-112B14 112B5-112B14 90B5-112B14 112B5-112B14 112B5-112B14 90B5-112B14 90B5-112B14 90B5-112B14 112B5-112B14 90B5-112B14 112B5-112B14 112B5-112B14 112B5-112B14 112B5-90B14 90B5-112B14 90B5-112B14 112B5-112B14 90B5-112B14 112B5-112B14 112B5-112B14 90B5-112B14 90B5-112B14 # 132B5 112B5-112B14 # 132B5 # # 132B5 # 132B5 # 132B5 90B5-112B14 112B5-112B14 112B5-112B14 112B5-112B14 112B5-112B14 # # 132B5 132B5 132B5 # # # 132B5 132B5 132B5 11.1 Terminal box position N N W E W N S S S E CW1 CCW1 E S W N CW3 CW2 CW4 S N W W S S N W E E E W N S W E E N CCW3 CCW2 CCW4 17 / 296 12 DESIGNATION GEAR UNIT W 63 L1 UF1 — 24 S2 — B3 ..... ..... 20 OPTIONS MOUNTING ARRANGEMENT CW (1, 2, 3, 4) CCW (1, 2, 3, 4) VF/VF, VF/W, W/VF 15 MOUNTING POSITION VF 27...VF 49 VFR 44, VFR 49 W, WR VF 130...VF 250 VFR 130...VFR 250 VF/VF VF/W W/VF B3 B3 (default), B6, B7, B8, V5, V6 23 B3 (default), B6, B7, B8, V5, V6 MOTOR MOUNTING B5 B14 (VF 30...VF 250, VFR 49...VFR 250, W, WR) (VF 30…VF 49, W) 90 91 INPUT CONFIGURATION VF VFR W WR P27 (VF 27 only), P56...P225 P63, P80...P160 P71...P132 VF/VF VF/W W/VF P(IEC) P63...P112 P56, P63, P56...P80 P71...P112 P90...P132 M S_ S44 (VFR 44 only) S1...S3 M 90 91 91 S1...S3 165 ... 168 HS GEAR RATIO SHAFT BORE W 75 D30 (default), D28 (on request) VF/W 44/75 VERSION 14 TORQUE LIMITER VF, VFR W, WR L1, L2 VF/VF LF 172 GEAR FRAME SIZE VF VFR W, WR 27, 30, 44, 49, 130, 150, 185, 210, 250 44, 49, 130, 150, 185, 210, 250 63, 75, 86, 110 GEAR TYP VF, W VFR, WR VF/VF, VF/W, W/VF 18 / 296 Worm gearbox Helical-worm gear unit Combined gearbox VF/VF VF/W W/VF 30/44, 30/49, 130/210, 130/250 30/63, 44/75, 44/86, 49/110 63/130, 86/150, 86/185 MOTOR BRAKE BN 63A 4 230/400-50 IP54 CLF ..... W FD 3.5 R SB 220 SA ..... OPTIONS BRAKE SUPPLY RECTIFIER TYPE M NB, SB, NBR, SBR K — BN NB, SB, NBR, SBR BRAKE HAND RELEASE M R, RM K R BN R, RM BRAKE TORQUE BRAKE TYPE M FD, FA K FC BN FD, FA, BA TERMINAL BOX POSITION M ME W (default), N, E, S K W (default), N, E, S BN BE W (default), N, E, S VERSION M ME — K B5 BN BE B5, B14 INSULATION CLASS CL F standard CL H option DEGREE OF PROTECTION IP55 standard (IP54 - brake motor) VOLTAGE-FREQUENCY POLE NUMBER 2, 4, 6, 2/4, 2/6, 2/8, 2/12, 4/6, 4/8 MOTOR SIZE M ME 1SC...3LB...
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