Bonfiglioli 3/H series heavy-duty modular gearbox

Bonfiglioli 3/H series heavy-duty modular gearbox

General Information

1. Symbols and measurement units

Complete definition of all selection parameters: output/input torque, calculated torque, rated torque, required torque, speed, power, allowable radial/axial force, service factor (f_s ), thermal power (basic thermal power (P_ {TB} ), fan cooling thermal power (P_ {TFAN} ), moment of inertia, environment/oil temperature, efficiency, etc; Distinguish between input axis (subscript 1) and output axis (subscript 2) parameters.

2. Overall design features

Combining planetary gears and spiral bevel gear composite structure, balancing high torque, high power density, compact appearance, and low noise;

There are a total of 10 specifications for the machine base: 11, 13, 15, 16, 17, 18, 19, 21, 23, 25;

The gear adopts alloy steel carburizing, quenching and grinding process, with tooth profile modification to reduce noise and improve load-bearing capacity; Input shaft quenching and grinding;

Support a large number of customized options: backstop, various seals, sensors, auxiliary cooling and heating, forced lubrication, special bearings, etc.

3. Installation requirements

The box must be securely fastened to avoid vibration; It is recommended to equip hydraulic couplings and torque limiters for impact/locked rotor conditions;

Protect the machined surface and oil seal lip before painting to prevent paint damage to the rubber seal;

Recommended ISO H7 tolerance for output shaft accessory holes; Ensure rust prevention and protection on the mating surface;

The entire equipment must comply with the Machinery Directive 2006/42/EC;

Check the oil level and product before commissioning; Outdoor use requires protection from direct sunlight and rain.

4. Lubrication

The standard is oil bath splash lubrication;

If the output speed is less than 1 rpm and the input speed is greater than 1800 rpm, it is necessary to contact Bangfeili Technology;

The installation posture of AB6 (vertical output upward) cannot rely on splash lubrication. It is mandatory to use MOP motor pump for forced lubrication, or MCR independent cooling unit can be used as a substitute;

The gearbox does not come with lubricating oil when it leaves the factory, and the user needs to add it on-site; Prohibition of mixing mineral oil with synthetic oil;

Refer to Shell oil products and select the oil viscosity grade based on the ambient temperature; Intermittent operation checks the oil level monthly, while continuous operation increases the frequency of checks.

5. Storage

Prohibit storage in open air and high humidity environments; The box is padded with wooden blocks and does not directly touch the ground;

Apply rust inhibitor to flanges and shaft extensions; Long term storage requires placing the breathing plug at the highest position and filling the container with oil;

Ordering optional SLM (mineral oil compatible long-term storage) and SLP (polyethylene glycol synthetic oil compatible) long-term storage kits; Storage for more than 2 years must be rechecked by the Bangfeili Service Center.

6. Supply conditions and painting

Pre install and factory test according to the designated installation location specified in the order; The coupling mating surface is not painted; Equipped with motor flange matching bolts;

Basic anti-corrosion grade C3 (RAL7042 traffic ash); Optional upgrade to C4 heavy-duty anti-corrosion, supporting RAL multi-color customization.

7. Service coefficient (f_s )

The table provides service factors based on load type (uniform/moderate/strong impact), number of starts per hour, and total operating time. The service coefficient is used to compensate for load fluctuations, shocks, and lifespan requirements. The load is divided into K1 uniform, K2 moderate impact, and K3 strong impact.

8. Selection (sizing)

This selection process is aimed at motor drive conditions; Other prime movers require technical support consultation.

Determine the transmission ratio (i=n1/n2 )

Calculate the required input power by reverse calculating the output torque of the load (M2)

Select service coefficient (f_s ), (P_ {n1} ge P_ {r1} × f_s )

Select a gearbox in the sample data table that is close to the transmission ratio and meets the conditions of rated input power (P_ {n1} ). The document comes with a complete selection calculation form template, which collects information on application conditions, loads, ambient temperature, altitude, installation posture, and options.

9. Verification after selection is crucial

After the selection is completed, four checks must be completed:

Motor matching verification: confirm the compatibility of the motor flange; If the motor power is much greater than the rated power of the gearbox, it is recommended to configure a torque limiter.

Check the backstop: When selecting a backstop, check the maximum input torque and ensure that it does not exceed the allowable limit of the backstop.

Radial load verification (R_c= frac {2000 · M · Km} {d} ) (R_c ) To calculate the radial force, it must be less than the allowable radial load of the gearbox at the installation distance (R_x ); The distance between the load application point and the shoulder position will significantly reduce the allowable radial load. The sample provides reduction factors for different offset distances of each machine base; Upper limit of axial load: (A_n ≤ 0.2 × R_ {n1} ).

The basic thermal power (P_ {TB} ) for thermal power verification must be greater than the actual input power (P_ {r1} ).

If (P_ {TB}<P_ {r1} ), additional cooling options must be added: forced fan FAN, cooling coil SR, independent oil cooling unit MCRA/MCRW;

Reference conditions for thermal power data: Input 1500/1800 rpm, environment 20/40 ℃, AB3 horizontal installation, altitude ≤ 1000 m, ISO VG220 oil.

3/H Gear Unit Body

11 Design Features

Machine base 11-25, L2/L3 represent different levels of configuration; Distinguish between continuous maximum transmission torque (M2 max) and static maximum bearing torque (M2 max); Carbonized grinding bevel gear+planetary combination.

12 Product Configuration

Basic model code: Example 3/H 11L2-030.3-FP-L-1-VP-160-AB3

Series: 3/H; Machine Base; Level L2/L3; Transmission ratio i; Output form FP/FZP; Output side L/R; Version 1/2; Input type VP/G/NG; Motor frame; Installation positions AB3/AB6.

Output: FP=Friction connection hollow shaft; FZP=Axial locking spline hollow shaft.

Input: VP solid input shaft; G=IEC motor bell cover+elastic coupling; NG=NEMA motor bell cover+elastic coupling.

Installation position: AB3 level; AB6 outputs vertically upwards. AB6 posture forced lubrication MOP/MCR.

Optional suffix codes: cooling, check valve, seal, sensor, torque arm TA, coating, long-term storage, certificate.

Output layout: Version 1, Version 2, output side L (left) R (right), supports clockwise/counterclockwise rotation.

13-15 Input/Output Configuration&Motor Adaptation

Output: FP friction hollow shaft (standard supply), FZP spline axial locking hollow shaft;

Input: Solid shaft VP; IEC bell jar G; NEMA bell jar NG;

The table lists the IEC and NEMA motor frame numbers that each frame can be adapted to. The motor power exceeds the capacity of the gearbox, it is recommended to use a torque limiter.

Complete set of optional variants

16.1 Auxiliary thermal management equipment

FAN forced air cooling: Input shaft drives cooling fan to increase thermal power; Attention: When the input speed is below 900   rpm, the intermittent working condition of the fan significantly reduces its effectiveness and is not recommended for use. Partial machine bases have mutually exclusive FAN and TK seals.

SR cooling coil (water-cooled): only horizontally installed in AB3, integrated inside the box; The maximum pressure of the waterway is 8 bar, the minimum flow rate is specified, and the maximum inlet temperature is 20 ℃.

Independent cooling units MCRA (oil air cooling), MCRW (oil water cooling)

Used for conditions where the basic thermal power is insufficient; Provide a calculation formula to calculate the excess power that needs to be dissipated (P_s );

AB6 vertical installation must be equipped with a cooling unit and a built-in MOP pump;

Including pumps, filters, temperature control, pressure switches, providing heat exchange power and external installation dimensions for various models.

MOP motor pump forced lubrication: AB6 attitude standard configuration; Including motor pump, 60 micron filter, and minimum pressure monitoring; Ensure high position bearing oil supply.

HE heater: increases oil temperature and reduces starting resistance in low-temperature environments; 220VAC electric heating, with temperature control switch, optional PT100 connected to PLC.

16.2 OD oil drain valve

Maintain oil drain kit, divided into KIT1 (AB3 horizontal) and KIT2 (AB6 vertical), for easy oil change.

16.3 A backstop (one-way locking)

Prevent load reversal, applied to lifting and belt conveying; Centrifugal release type, maintenance free;

Need to specify the free rotation direction CW/CCW; The sample provides the maximum allowable input torque M1max and minimum idle speed n1min for each speed ratio; It is necessary to ensure that the operating speed is higher than n1min, to ensure that the centrifugal roller is disengaged and to avoid wear and tear;

Partial speed ratios are not supported, please check the table to confirm.

16.4-16.7 Sealing, bearings, breathing, sensors

PBB: High end brand bearings;

Sealing: VS Fluororubber Oil Seal; TK Taconite maze+grease chamber seal, high dust environment, some machine bases are unusable;

DBF breathing filter with desiccant: absorb moisture to prevent dust from entering the box, and gel discoloration indicates that it needs to be replaced; Open pressure 0.017   bar;

TG bimetallic temperature control switch (90 ℃± 5 ℃ alarm); PT100 temperature probe simulates temperature measurement.

16.8 TA torque arm

Torque reaction force support arm, corresponding size to different machine bases; Supports multi angle installation at 0 °/90 °/180 °/270 °.

16.9-16.10 Surface Protection and Coating

C3 is the standard; C4 is used in coastal and chemical high corrosion conditions;

Multiple RAL colors are available, default RAL7042.

16.11 Long term storage options SLM/SLP

SLM+SLP cannot be selected simultaneously. SLM is compatible with mineral/PAO oil; SLP is compatible with polyethylene glycol PAG synthetic oil. Supply anti rust protective fluid, which must be emptied and filled with the specified working fluid before operation. If stored for more than 2 years, it must be inspected by the manufacturer.

16.12 Certificate Options

AC: Certificate of Compliance;

CC: Inspection certificate, sampling for appearance, size, and no-load sealing inspection;

CT: Type certificate, sampling for noise, surface temperature, fastener torque, and complete functional testing of optional components.

Technical Data Sheet

17 Performance and Thermal Power

A large performance table, separated by input speeds n ₁=1500   rpm and 1800   rpm; Each line of parameters: transmission ratio i, output speed n ₂, continuous output rated torque Mn2, rated input power Pn1; Basic thermal power PTB (20 ° C/40 ° C environment), with fan thermal power PTFAN (20 ° C/40 ° C); Static maximum torque M2max. Covering all machine bases: 3/H   11 L2、13L2、15L2、15L3、16L2、16L3、17L2、17L3、18L2、18L3、19L2、19L3、21L3、23L3、25L3。

Key distinction: (M {n2max} ) continuous allowance (M {2max} ) Static/quasi-static maximum capacity, unable to operate continuously.

18 Moment of inertia of inertia

Converted to the moment of inertia of the input shaft, condition: solid input shaft+hollow output of FP contraction disk; All machine bases, all speed ratios table, unit: kg · m ^ 2 × 10 ^ {-4} .

Dimensions and weights

The appearance, foundation, output hollow shaft, and flange size of each machine base gearbox body, with different versions L/R and Version 1/Version 2;

Complete set of millimeter size IEC flexible coupling motor adapter with bell jar;

NEMA bell jar adapter imperial size;

Maximum static load for motor installation;

User customized output shaft design reference (material, tolerance, keyway suggestions).