Bonfiglioli C-A-F-S Series IE2-IE3-IE4 three series reducers

General Basic Information

1. Symbols and measurement units

Define the complete set of selection calculation symbols: service coefficient \ (f_s \), thermal correction coefficient \ (f_t \), speed ratio i, inertia \ (J-c \) load/\ (Jm \) motor/\ (JR \) reducer, torque \ (M2} \) demand/\ (M2} \) calculation/\ (M2} \) rated; Input/output power, radial load calculation/allowable, axial thrust (A_n); Work system parameters and efficiency (dynamic efficiency \ (\ eta-d \), static efficiency \ (\ eta_2 \)); Simultaneously provide both imperial and metric units.

2. Temperature boundary conditions (mineral oil benchmark)

Operating environment temperature: -10 ℃ to+40 ℃; Storage temperature -10 ℃~+50 ℃

The maximum continuous surface temperature of the shell is 100 ℃; The maximum continuous oil temperature of lubricating oil is 95 ℃; It is not recommended to operate continuously at 80-95 ℃ for a long time.

Low temperature and high temperature conditions must be matched with corresponding lubricating oil viscosity and sealing materials; Standard nitrile rubber seals have temperature applicable boundaries, and fluorine rubber seals should be used for extreme temperatures.

3. Torque, power, and heat capacity

Under the condition of rated output torque \ (M2} \): \ (f_s=1 \), the output torque can be continuously transmitted, and the value varies with the input speed. Calculate the torque (M2=M2 × Fs), and the selection requirement is that M2 ≥ M2. Instantaneous peak load upper limit: It is not allowed to exceed \ (200 \% M2} \), and torque limiters are recommended for systems with large impacts; Switching between dual speed motors can generate high impact torque.

Thermal capacity \ (P_t \): The reducer is allowed to transmit power under S1 continuous working mode in an environment of 20 ℃. The environmental temperature and intermittent working system need to be multiplied by the thermal correction coefficient \ (f_t \), and the verification condition is: \ (P_ {r1} ≤ P_t × f_t \).

Important rules: Under working conditions with a deceleration greater than level 2 and a speed ratio of i>45, the thermal capacity is generally greater than the mechanical capacity, and the risk of hot air is low; In the case of a two-stage gearbox and high-speed input conditions, thermal capacity often becomes a bottleneck in selection. Many projects only check mechanical torque and ignore thermal capacity, which can cause high oil temperature, deterioration of lubricating oil, and premature damage to oil seals.

4. Efficiency and transmission ratio

Dynamic efficiency reference: Level 2 95%, Level 3 93%, Level 4 90%;

Transmission ratio \ (i=n1/n2 \), the sample table is a rounded approximate speed ratio, and the document provides an exact ratios table in a separate section for accurate output speed calculation.

5. Rotational inertia

The inertia value is based on the input shaft of the reducer and is used for system start stop impact and inertia matching calculation.

6. Service coefficient \ (f_s \) (selection core)

Mass acceleration coefficient \ (K=Jc/Jm \), divided into load levels:

K1 uniform load: K ≤ 0.25;

K2 moderate impact: 0.25 ＜ K ≤ 3;

K3 heavy impact load: 3 ＜ K ≤ 10;

If K>10, it is necessary to contact the manufacturer for evaluation, and it is not allowed to directly apply charts.

\The value of (f_s \) refers to three major variables: daily operating hours, hourly startup times \ (Z_r \), and K load level; The document comes with a massive industry application service coefficient lookup table, covering mixers, fans, crushers, cranes, hoists, papermaking, textile, and conveying equipment. Lifting equipment belongs to high-risk loads, and its service coefficient is significantly higher than that of ordinary working conditions.

7. Lubrication system

Lubrication method: Oil bath splash lubrication.

Supply oil injection rules: C05-C41, A05-A41, F10-F41 factory pre injection oil; C51, A50, F51, and larger machine bases do not require oil injection at the factory, but are filled on-site by the customer.

The factory specifies the installation posture and oil filling amount for ordering; The factory equipped transportation sealing plug must be replaced with a vent plug when put into operation on site, otherwise the pressure inside the shell will increase and oil leakage will occur.

It is strictly prohibited to mix mineral oil with PAG and PAO synthetic oil; Provide a viscosity selection chart for lubricating oil, matching mineral oil/PAG synthetic/PAO synthetic oil according to ambient temperature; There is a maintenance free PAG oil version with a long lifespan.

8. Complete selection and verification process

There are two selection modes: ① Gear motor (complete set of motor and reducer); ② Independent reducer with IEC/NEMA/servo/solid input shaft HS.

Selection and Collection Form A7: Clarify the speed, required torque, radial/axial load, load distance, inertia, ambient temperature altitude, working system S1-S8, start stop frequency, installation posture, motor specifications, and options.

After the initial selection is completed, a full set of reviews must be carried out: mechanical capacity verification, thermal capacity verification, radial cantilever load verification, axial thrust verification, and peak torque verification; If the conditions exceed the sample range, contact Bangfeili Technology.

9. Cantilever radial load&axial thrust load

Radial load calculation formula \ (R_c=\ frac {2 · T · Kr} {d} \)

Kr coefficient: Chain 1.0; Gear 1.25; V-belt 1.5; Flat belt 2.0; D is the pitch diameter of the transmission component.

Sample allowable reference condition: The load application point is at the midpoint of the axis extension; The load is offset towards the shaft end, and the allowable load needs to be reduced using \ (\ frac {a} {b+x} \). The further the load is, the lower the allowable load.

Axial thrust: under the condition of simultaneous rated radial load, (A_ {n1}=0.2R_ {n1}, A_ {n2}=0.2R_ {n2}); The maximum allowable pure axial thrust without radial load is 0.5Rn; Simultaneously overloaded in both radial and axial directions, the manufacturer needs to evaluate the bearings.

10. Installation, storage, supply, and painting

Installation: Supports various standard installation positions B3/B6/B7/B8/V1/V3/B5/B51/B52/B53; The installation posture must be consistent with the order; Output shaft accessory hole tolerance ISO H7; Protect the machined surface of the oil seal before painting; The servo motor clamping adapter SC has a dedicated torque step for installation.

Storage: It is prohibited to store items outdoors in damp conditions, and the workpieces should be elevated and lifted off the ground; Long term storage processing surface for rust prevention; For storage exceeding 6 months, it is recommended to lubricate and replace the vent plug with a new plug; Restart and prohibit solvents from contacting the oil seal.

Supply conditions: According to the ordered installation posture configuration, the mating surface is not painted, and the shaft is equipped with a protective cap;

Anti corrosion coating: Standard C2; optional C3, C4, C5M marine anti-corrosion, supports RAL series colors.

​C-series inline helical gear reducer

Product positioning: Input/output coaxial, 2-4 stage helical gear; Machine base C05-C100.

Shell: C05-C32 aluminum alloy shell; C36 and above cast iron shell.

Version: P-NP Foundation; F-NF flange; U-NU UNIBOX universal box body; UF-NUF comes with an assembly flange.

Input configuration: IEC flange, NEMA flange, servo SK/SC clamping adapter, HS/NHS solid input shaft.

Option: SO without factory oil injection; LO factory oil injection; DL output dual oil seal, DV input dual oil seal; VV/PV fluororubber oil seal; RB low back gap.

The content includes: model code, installation posture diagram, bolt specifications; Gear motor power and torque meter; Independent gearbox power meter; Motor adaptation list; The moment of inertia of each machine base; Accurate speed ratio; Complete set of dimensional drawings and tables.

A-series oblique cone spiral bevel gear right angle reducer

Product positioning: Input/output 90 ° right angle commutation; 2/3 level transmission; Machine base A05-A90; Suitable for vertical layout equipment.

Version: Foot, flange, UNIBOX box; Multiple input interfaces IEC/NEMA/servo adapters, solid axis HS.

Chapter content: Structural features, model naming, installation posture, terminal box angle definition; Cantilever load, axial thrust; Output shaft arrangement; Performance table of gear motor and independent reducer performance; Motor adaptation, moment of inertia, precise speed ratio, complete set of engineering dimensions; Customized output shaft and accessory chapters for customers.

F series hollow shaft suspension reducer

Product positioning: Hollow output shaft, directly mounted on the equipment spindle, relying on the torque arm to absorb the reaction torque; Mostly used for spiral and belt conveyors.

Machine base F10-F90; 2-3 levels of deceleration; Foundation/flange/UNIBOX shell; Supports IEC/NEMA, servo adapters, and solid input shafts.

Chapter content: Design features, model codes; Installation posture; Axial thrust of cantilever load; Rated charts for gear motors and independent reducers; Motor adaptation, inertia, precise speed ratio; External dimensions; enclosure; Customer customized output shaft.

Chapter M of the motor section

This chapter is applicable to BN-BE-BX-BY three-phase asynchronous motors (IE1/IE2/IE3/IE4 energy efficiency) and can be combined with C/A/F to form a complete set of gear motors.

M1-M2 symbols and general introduction; M3 mechanical characteristics; M4 variant options; M5 Machinery; M6 electrical characteristics;

M7-M9 brake: FD direct loss electric brake, FA AC brake; Rectifiers NB/SB/NBR/SBR; Manually release R to automatically reset, RM can lock and hold release; The brake is only suitable for static holding.

M10 release system; M11 offers a variety of options, including PTC/KTY/PT1000 thermal protection, check valve AL-AR, independent forced air cooling U1/U2, encoder, insulated bearing, anti condensation heater, and dual output shaft PS;

M12 motor matching comparison table; Rated performance and external dimensions of M13-M18 energy efficiency motors.