Bonfiglioli C series explosion-proof helical gear reducer

Bonfiglioli C series explosion-proof helical gear reducer

General Information

1.1 Symbols and Units of Measurement

Define the parameter symbols, units, and calculation formulas used for all selection calculations:

Transmission ratio ( boldsymbol {i=n1/n2} ); Service coefficient (f_s ); Environmental temperature correction coefficient (f_ {TP} ) (valid only for the worm gear box, 1 for the C helical gearbox)

Output rated torque (Mn_2 ), application required torque (Mr_2 ), calculated torque (Mc_2=Mr_2 cdot f_s )

Radial load (R_c ) (calculated) (R_n ) (licensed); Axial thrust load An

Moment of inertia: load (J-c ), motor (Jm ), reducer (JR ); Mass acceleration coefficient (K=Jc/Jm ), used to determine load levels K1/K2/K3 (uniform/moderate impact/heavy impact)

Intermittent working system I, number of starts per hour Zr; safety factor S; dynamic efficiency ( etad_d ), etc.

1.2 Introduction to ATEX Explosion proof Directive

Definition of explosive environment: Combustible gases/vapors/mists/dust mixed with air at atmospheric pressure, and flames can spread after ignition; The potential explosive environment refers to the working conditions where the above-mentioned mixture may form.

regional division

Gas zone (G) Dust zone (D) Operating conditions

0 20 long-term sustained explosive environment

Occasionally occurring during normal operation of 1 21

2 22 rarely appears, only exists for a short period of time

This series only supports zones 1 and 2 (gas); Zones 21 and 22 (dust) do not support Zone 0/20 and cannot be used for Class I mine equipment.  

Equipment group and protection type

Group I: Underground mining equipment; This product is not applicable.

Group II: Factory explosion-proof equipment, divided into Class 2 and Class 3.

Protection labels: Ex h Gb (gas 2G), Ex h Db (dust 2D); Ex h Gc (gas 3G), Ex h Dc (dust 3D); The maximum temperature level for T3 is 200 ℃, and for T4 it is 135 ℃; Surface temperature is 130 ℃/160 ℃.

Directive priority: The 2014/34/EU ATEX directive has a higher priority than the Machinery Directive 2006/42/EC, only related to explosion protection; The safety of other machinery follows the Machinery Directive.

Declaration of conformity: The product conformity certificate must strictly follow the operating manual, which can be downloaded from the official website. Failure to comply with the operating conditions will result in the certificate becoming invalid.

1.3 Use, Installation, and Maintenance

The complete requirements can be found in the user installation and maintenance manual, which should be stored on the equipment site for operators to refer to; Manufacturers can update the manual version.

1.4 Equipment selection

1.4.1 General selection process

1) Determine the service coefficient (f_s ): obtained from the load acceleration coefficient K (K1/K2/K3), hourly startup frequency Zr, and daily working hours h/d by looking up the graph; 2) Calculate the required power of the motor shaft: ( boldsymbol {P_ {r1}= frac {M {r2} cdot n2} {9550 cdot eta-d}} ); Reference for helical gear efficiency: Level 2 0.98, Level 3 0.96, Level 4 0.93. 3) There are two types of structural selection: IEC motor flange input and solid shaft HS input.

1.4.2 Selection of IEC motor interface reducer

Obtain service coefficient (f_s );

Sample rated input power (Pn_1 ge P_ {r1} times f_s );

Motor power (P_1 ge P_ {r1} );

Verify the safety factor (S=Pn_1/P_1 ge f_s );

Exception: C122/C222/C322 speed ratio i>40, Z>30 starts per hour, service factor multiplied by 1.2, re verify S.

1.4.3 Selection of Solid Input Shaft (HS) Reducer

Calculate torque (M2=M2 times f_s times f_tp ); C helical gearbox (f_ {tp}=1 ); Choose a reducer that meets the following criteria: ( boldsymbol {M2} ge M2} ).

1.4.4 Items must be reviewed after selection

Instantaneous peak torque: allows a maximum of approximately 200% (Mn_2) for a short period of time, and torque limiter is required for exceeding the tolerance;

Radial load: Actual radial load ≤ sample allowable radial load Rn;

Axial thrust load: Actual thrust ≤ sample allowable An.

1.4.5 Mandatory operating conditions for ATEX equipment

Environmental temperature: -20 ℃~+40 ℃;

The installation method must be consistent with the installation position indicated on the order nameplate, and any changes to the installation position must be approved by the official Bangfeili; Prohibit arbitrary tilting installation;

The maximum speed of the supporting motor shall not exceed 1500 min ⁻¹;

When using a frequency converter to drive, the motor must be adapted to the frequency conversion condition, and the frequency converter setting must not exceed 1500rpm or overload the reducer;

Fully follow the original factory manual for installation and maintenance procedures.

1.4.6 Service Coefficient (f_s )

Comprehensive daily running time, hourly startup frequency, and load impact level K1/K2/K3; The safety margin should be increased for lifting hazardous loads.

C-series explosion-proof inline helical gear reducer

2.1 Structural characteristics of ATEX explosion-proof models

Configure regular oil level check plugs; Pre filled synthetic lubricating oil suitable for ordering and installation positions at the factory;

Standard configuration of fluororubber sealing ring, with dual sealing ring for output shaft;

No plastic components; The nameplate indicates the equipment category and explosion-proof protection type.

The specifications cover C12, C22, C32, C36, C41, C51, C61, with a rated output torque of 56-1600Nm.

2.2 Model Version

P: Foot installation; F: Flange installation; U: UNIBOX universal box body; UF: UNIBOX with assembly flange.

2.3 Ordering Code

Encoding example: C 51 2 P 51.4 HS B3 2D3D-130

C: Product series (inline helical gears); 51: Machine base specifications; 2: Deceleration levels (2/3/4 levels)

Version (P/F/U/UF); Speed ratio; Input configuration: HS solid shaft/IEC motor flange; Installation positions B3/B5/V1, etc;

Explosion proof options:

2D3D-160: Dust 2D/3D, maximum surface temperature of the shell ≤ 160 ℃

2D3D-130: Dust 2D/3D, maximum surface temperature of the shell ≤ 130 ℃

2G3G-T3: Gas 2G/3G, temperature level T3 (200 ℃)

2G3G-T4: Gas 2G/3G, temperature level T4 (135 ℃)

2.4 Installation position

P-foot models: B3, B6, B7, B8, VA, VB;

F flange models: B5, B51, B53, B52, V1, V3.

2.5 Lubrication

Add long-life synthetic oil at the factory, and match the oil quantity with the ordered installation location; Sealed oil plugs for transportation must be replaced with breathable plugs before on-site debugging; C12/C22/C32 has no overflow oil level plug. Refer to the operation manual for oil level inspection.

2.6 Allowable cantilever load (radial+axial)

Radial load R: generated by external transmission such as pulleys and sprockets; Provide the calculation formula (R_ {c}= frac {2000 cdot M cdot Kr} {d} ).

When the load is not on the axis centerline, a position correction factor a/b is required;

The table shows the dimensions of the input and output shafts a/b/c for each machine base.

Axial thrust load An: (An_1=0.2 cdot Rn1; An_2=0.2 cdot Rn2 ) This condition is based on the simultaneous presence of the rated radial load; If there is no radial load, the allowable value for pure axial thrust is 0.5 times Rn; if the axial load is too large, contact the manufacturer for evaluation.

2.7 Performance parameter table of reducer

The sample provides all machine bases of C12~C61, with 2/3/4 stage deceleration: output speed n2, rated output torque Mn2, rated input power Pn1 under the condition of input speed n1=1400r/min, allowable radial load Rn1 on the input shaft, and allowable radial load Rn2 on the output shaft; Simultaneously label the explosion-proof options corresponding to each speed ratio.

Note: The table values only represent the output part of the gearbox; The IEC input terminal should also refer to the maximum installable motor power in the motor adaptation section.

2.8 Adaptation Motor Information

Geometric compatibility: IEC motor frame numbers P63~P180 that can be matched with each frame;

Maximum installable power: In addition to geometric compatibility, the input flange itself has a power limit, and the selection must meet both requirements.

2.9 Rotational inertia

Provide the high-speed side moment of inertia Jr corresponding to each base, speed ratio, and different IEC motor flanges, in units of (10 ^ {-4} kg cdot m ^ 2 ), for starting impact and inertia matching calculations.

2.10 Outline dimension drawings and dimension tables

All models from C12 to C61, including P foot, F flange, U universal box, UF flange box; Divided into IEC motor input version and HS solid input shaft version; All mechanical dimensions including shaft diameter, keyway, flange, foot, total length, installation holes, etc.