Bonfiglioli 300M Modular planetary gearboxe

Bonfiglioli 300M Modular Planetary Gearbox

This series combines the high torque advantages of the 300 series planetary gears with the transmission efficiency advantages of HDO bevel gears, targeting heavy industry equipment, with a maximum continuous output torque of up to 1200 kNm. The manual contains a complete set of selection and application materials, including basic instructions, design features, selection calculations, installation, lubrication and storage, product configuration, a full range of optional accessories, performance and thermal power data sheets, moment of inertia, external dimensions and weight.

General Basic Information

1. Parameter symbol definition

Define the complete set of selection parameter symbols, distinguish between input shaft (subscript 1) and output shaft (subscript 2), including: torque, power, speed, service coefficient (f_s ), allowable radial force (R_n ), allowable axial force (A_n ), basic thermal power (P_ {TB} ), fan heat dissipation power (P_ {TFAN} ), moment of inertia, ambient temperature, oil temperature, and efficiency.

2. Overall product design

There are 10 specifications for the machine base: 11, 13, 15, 16, 17, 18, 19, 21, 23, 25; Divide into L2/L3 different gear stages.

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

Product advantages: high power density, high torque output, compact structure, low noise; Support a large number of customized options: backstop, special seal, temperature sensor, various cooling and heating systems, forced lubrication, high-end bearings, etc.

3. Installation specifications

The box is firmly fastened to suppress vibration; It is recommended to configure hydraulic couplings and torque limiters for impact and locked rotor conditions.

Protect the machined surface and oil seal lip before painting to avoid paint corrosion of rubber seals.

Priority given to ISO H7 tolerance for output shaft accessories; Provide rust prevention protection for the assembly joint surface.

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

Confirm the oil level and product before commissioning; Outdoor use must increase protection and avoid exposure to sunlight and rain.

4. Lubrication

Standard solution: Oil bath splash lubrication;

Boundary conditions: output speed<1rpm, input speed>1800rpm, need to contact the technical department of Bangfeili for evaluation;

AB6 installation position (output shaft vertically upward) cannot rely on splash lubrication and must be equipped with MOP motor pump for forced lubrication, which can also be replaced by MCR independent cooling unit;

The gearbox does not contain lubricating oil when it leaves the factory and is filled on-site by the user; Prohibition of mixing mineral oil with synthetic oil;

It is recommended to check the oil level monthly for intermittent operation and increase the inspection frequency for continuous operation; The sample provides a viscosity selection reference based on Shell oil products.

5. Storage

Prohibit outdoor high humidity storage; The bottom of the box is padded with boards and cannot directly contact the ground;

Apply rust inhibitor to coupling surfaces such as shaft extensions and flanges; Long term storage requires placing the breathing plug in the highest position of the container and filling the container with oil;

Two long-term storage kits are available for ordering:

SLM and SLP cannot be used simultaneously; If stored for more than 2 years, it must be re inspected by Bangfeili Service Center; Before operation, it is necessary to drain the anti rust solution and add formal working lubricating oil.

SLM: Anti rust protective fluid compatible with mineral oil and PAO synthetic oil;

SLP: Anti rust protective fluid compatible with PAG polyethylene glycol oil;

6. Supply conditions and painting

Assemble according to the installation posture specified in the order before leaving the factory, and complete factory testing; The coupling mating surface is not painted and is equipped with motor flange fasteners;

Default anti-corrosion grade C3, color RAL7042 traffic gray; Upgradeable to C4 high anti-corrosion level, supporting customization of multiple RAL color numbers.

7. Service coefficient (f_s )

The table provides service coefficients based on load type (uniform impact K1/moderate impact K2/strong impact K3), number of starts per hour, and total operating hours of the equipment. The service coefficient is used to compensate for load fluctuations and impacts, ensuring the service life of gears and bearings.

8. Selection process (applicable for motor drive, other prime movers need to consult the manufacturer)

Calculate the transmission ratio (i=n1/n2 );

Reverse calculate the input required power from the output required torque;

Select the service coefficient (f_s ) based on the operating conditions, satisfying (P_ {n1} ge P_ {r1} × f_s );

Select models with similar transmission ratios and rated input power that meet the conditions in the sample performance table; The document comes with a complete selection record table, which is used to collect items such as operating conditions, loads, ambient temperature, altitude, installation location, and options.

9. Mandatory verification items after selection

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

Verification of backstop: When configuring the backstop, the actual input torque must not exceed the maximum allowable input torque of the backstop (M {1max} ), while ensuring that the operating speed is greater than the minimum disengagement speed (n {1min} ).

Calculation formula for radial and axial load verification (R_c= frac {2000 · M · Km} {d} ); To calculate the radial force (R_c ), it is necessary to reduce it by taking into account the distance between the load application point and the shaft shoulder, which is less than the allowable radial load of the aircraft model; Upper limit of axial load: (A_n le 0.2 × R_ {n1} ).

Reference conditions for thermal power verification: input speed of 1500/1800rpm, ambient temperature of 20/40 ℃, AB3 horizontal installation, altitude ≤ 1000m, ISO VG220 oil.

Basic thermal power (P_ {TB} ≥ ) Actual input power (P_ {r1} );

If the basic thermal power is insufficient, the cooling options must be activated: FAN forced fan, SR water-cooled coil, MCRA air-cooled oil station, MCRW water-cooled oil station.

Product body and configuration

Model code example: 3/H 11L2-030.3-FP-L-1-VP-160-AB3

3/H: Series; Machine base number; L2/L3 gear series; Transmission ratio i; output form FP (friction hollow shaft)/FZP (axial locking spline hollow shaft); Output side L/R; Version 1/2; Input format VP solid shaft/G IEC bell jar/NG NEMA bell jar; Suitable for motor base; Install position AB3 horizontally/AB6 vertically upwards.

The output layout is divided into Version 1 and Version 2, and the output side is divided into left L and right R, supporting CW clockwise and CCW counterclockwise rotation.

Motor adapter: Supports IEC and NEMA standard motors, using a bell housing and elastic coupling structure. The sample table lists the motor specifications that each machine base is allowed to match.

All optional accessory modules

1. Thermal management attachments

FAN shaft end forced fan: Input shaft drives the cooling fan to increase thermal power; If the input speed is below 900rpm and the heat dissipation effect is significantly reduced during intermittent working conditions, it is not recommended; There is interference between some machine bases and TK labyrinth seals.

SR water-cooled coil: only suitable for AB3 horizontal installation; Limit the pressure, flow rate, and inlet temperature of the waterway.

MCRA (oil air cooling) and MCRW (oil water cooling) independent oil cooling units: calculation of excess dissipated power (P_s ) selection; AB6 vertical installation condition mandatory matching; Integrated pump, filter, temperature control, pressure monitoring, providing external dimensions.

MOP motor pump forced lubrication: standard for AB6 installation position; Equipped with an oil pump, 60 μ m filter, and minimum pressure monitoring to ensure oil supply for high-level bearings.

HE oil heater: used in low-temperature environments, 220VAC, with built-in temperature control, optional PT100 connected to PLC system to reduce low-temperature starting resistance.

2. Mechanical and sealing accessories

OD oil drain valve kit: KIT1 compatible with AB3, KIT2 compatible with AB6, convenient for maintenance and oil change.

A backstop (one-way locking): used to prevent load reversal (belt conveyor, lifting equipment); Centrifugal detachable maintenance free; Ordering requires specifying the free rotation direction CW/CCW; It is necessary to ensure that the speed is greater than the minimum disengagement speed (d_ {1min} ), otherwise the roller cannot disengage and cause wear.

PBB high-end brand bearings;

Sealing: VS Fluororubber Oil Seal; TK Taconite labyrinth seal (for high dust conditions, some machine bases are not optional);

DBF breathing filter with desiccant: it can isolate moisture and dust, and the discolored gel indicates that it needs to be replaced, and the opening pressure is 0.017bar.

3. Monitoring, installation, and certification

Temperature monitoring: TG bimetallic temperature control switch (90 ℃± 5 ℃ alarm); PT100 analog temperature probe.

TA torque arm: withstands counter torque, supports multi angle installation at 0 °/90 °/180 °/270 °, and provides dimensions for each machine base.

Certificate options: AC compliance certificate; CC inspection certificate; CT type test certificate.

Technical Data Chapter

Prepare data tables for performance and thermal power meters based on input speeds of 1500rpm and 1800rpm, respectively; The parameters include: transmission ratio i, output speed n2, continuous rated output torque Mn2, rated input power Pn1; Basic thermal power PTB (20 ℃/40 ℃), with fan thermal power PTFAN (20 ℃/40 ℃); Static maximum allowable torque M2max.

Differentiation: Mn2max is the allowable torque for continuous operation; M2max is designed to withstand static/quasi-static torque and does not allow continuous loading.

Conversion of moment of inertia to input shaft, reference configuration: solid input shaft+FP contraction disk hollow output; Covering all machine bases and speed ratios.

Size and weight: The appearance, foundation, and output hollow shaft size of the reducer body; IEC bell jar adapter millimeter size; NEMA adapter imperial size; Static load limit of motor; User made material, tolerance, and keyway design suggestions for the output shaft.

Core Risk Warning

AB6 outputs vertically upwards, and it is strictly prohibited to rely solely on splash lubrication. A forced lubrication MOP/MCR cooling unit must be configured.

Does not come with lubricating oil when leaving the factory; SLM/SLP storage fluid is not equal to working oil and must be replaced when put into operation.

Radial loads must be reduced in distance; The upper limit of axial load is 0.2 times the allowable radial load.

The backstop must meet the minimum disengagement speed, otherwise early damage may occur.

FAN fans have poor cooling performance when the input speed is below 900rpm, so they should be carefully selected.

The complete selection must be completed: initial selection of torque power+radial axial load verification+thermal power verification. If the thermal capacity is insufficient, cooling accessories must be added.