Bonfiglioli VF-W IE2-IE3 Worm Gear Reduction Motor: Complete Selection, Verification, and On site Implementation Technical Guide

Bonfiglioli VF-W IE2-IE3 Worm Gear Reduction Motor: Complete Selection, Verification, and On site Implementation Technical Guide

Boundary between product system and core technical parameters

VF-W products are divided into two major worm gear product lines: VF series and W series. They also support VF/VF, VF/W, and W/VF combined two-stage worm gear, achieving a large transmission ratio; Supporting BN, BE, BX, M, ME, MX series IE2/IE3 high-efficiency IEC motors, and also supporting solid input shaft HS adaptation to third-party motors.

Machine base cover: VF27-VF250; W63‑W110。 The shell of the VF small machine base is made of die cast aluminum alloy, and the shell of the large-sized VF130 and above is made of cast iron; The W series integral aluminum alloy box has multiple surfaces that can be processed and has high installation freedom.

Working temperature boundary: When using synthetic lubricating oil, the ambient temperature ranges from -30 ℃ to+50 ℃; Mineral oil -10 ℃~+40 ℃. The maximum temperature of the casing during continuous operation is ≤ 100 ℃, with an upper limit of 95 ℃ for oil temperature. Long term operation within the range of 80-95 ℃ is not recommended and requires evaluation of heat dissipation or upgrading of sealing components. When starting at low temperatures, starting at full load will exacerbate wear and tear. It is recommended to run with no-load preheating.

Output backlash: Different machine bases have inherent angular backlash, with W110 having backlash as low as 9 'and VF large machine bases having backlash of 10-15'; Worm gears and worms cannot achieve complete self-locking, and high-speed ratios are only static and irreversible. Under vibration conditions, they may slip back. External brakes must be installed for lifting and vertical loads, and worm gear self-locking cannot be relied on for safety protection.

Standardized selection calculation process (sample specified steps)

There are two scenarios for selection: integrated gearbox motor (with IE2/IE3 motors) and independent gearbox (solid input shaft, external drive). The calculation logic of the two is different and must be strictly distinguished, and cannot be mixed.

2.1 Definition of Key Basic Parameters

(M {r2} ): Actual working conditions require output torque (M2) rated output torque of gearbox (M2) Calculate torque;

(f_s ) operating condition utilization coefficient (K=J-c/Jm) mass acceleration factor (Z_r ) number of startups per hour;

The dynamic efficiency and worm gear efficiency decrease significantly with the increase of speed ratio, and the efficiency loss cannot be ignored in the selection of high reduction ratio.

K-factor load grading: K1 uniform load K ≤ 0.25; K2 moderate impact 0.25 ＜ K ≤ 3; K3 strong impact 3 ＜ K ≤ 10; If K>10, it is necessary to contact the manufacturer's technical support. The operating condition coefficient (f_s ) is obtained by referring to the sample curve chart, taking into account the daily operating hours and the number of starts and stops per hour.

2.2 Selection steps for integrated reduction motor

Based on the load characteristics, determine the mass acceleration factor K and obtain the operating condition coefficient (f_s );

Calculate the required power at the input end of the gearbox: (P_ {r1}= frac {M {r2} × n2} {9550 × η d_d} );

Differentiated working system: S1 continuous working system directly selects the rated power of the motor; S2-S8 intermittent working system, using intermittent correction coefficient (f_m );

Select the rated power of the motor from the performance table (P_n ≥ P_ {r1}/f_m );

Check the safety factor: (S=M2/M2 ≥ f_s ), S must be greater than or equal to the operating condition factor, which is the criterion for determining the qualification of the selection.

2.3 Selection steps for independent gearbox (HS solid input shaft)

Obtain the operating condition coefficient (f_s );

Calculate the torque (M2=M2 × Fs );

The selected transmission ratio i must meet the following criteria: (M2 ≥ M2);

After completing the selection, a complete set of checks must be carried out, and the qualification of the selection form does not mean that the on-site working conditions are qualified.

Four mandatory verifications after selection (projects are most likely to be overlooked)

Even if the torque power table meets the conditions, failure to verify the following four items will still result in premature bearing damage and shaft breakage.

Peak instantaneous torque verification: The instantaneous impact load should generally not exceed (150% M2); To achieve 300%, written permission from Bonfly Technology is required. Switching between high and low speeds of a variable pole three-phase motor can generate a huge switching impact torque. It is recommended to switch between two phases and reduce the switching torque by half to avoid damaging the worm gear pair due to the impact.

Radial Overhung Load Verification: The sprocket and pulley outputs will generate radial forces. The calculated radial force (R_c ) must be less than the allowable cantilever load (R_n ) of the sample. Note that the reference of the sample is the load acting on the midpoint of the axis extension; If the installation point of the load is offset outward, the radial load is allowed to be reduced according to geometric parameters and cannot be directly calculated using table values.

Axial thrust load verification: Simultaneously bearing rated radial load, allowing axial thrust (A_n=0.2 × R_n ); Under ideal conditions without radial load, the maximum allowable thrust can be increased to 0.5 × Rn. If the axial force is large, it is necessary to choose FR reinforced bearing version or contact the manufacturer for evaluation.

Start stop frequency verification: For frequent start stop conditions, it is necessary to calculate the allowable number of starts per hour, rather than simply looking at static torque parameters.

Common pitfalls in selection: only consider the rated output torque and ignore the radial force of the cantilever; Vertical B5/V5/V6 installation without checking the oil level; High speed gear worm ignores dynamic efficiency and chooses lower motor power; Vertical load requires self-locking of the worm gear and does not come with a brake system.

Key points for on-site installation and debugging practice

Base and fastening: The installation base of the reducer must be flat and rigid to prevent vibration and impact during operation; There is a risk of impact and stalling. It is recommended to install hydraulic couplings and torque limiters for overload protection. When spraying paint, it is necessary to protect the processing surface and oil seal lip. The paint solvent will corrode the rubber oil seal, directly causing oil leakage failure in the later stage.

Tolerance of output shaft accessories: The sprocket and coupling inner holes installed on the output shaft must have ISO H7 tolerance, and violent tapping is strictly prohibited during assembly. Disassembly should use a special puller for the threaded hole on the shaft end, and hammering the shaft end is prohibited to avoid damage to the internal bearings and worm gear pairs. Apply anti rust and anti jamming agent to the assembly surface to prevent it from biting during long-term operation.

Ventilation plug replacement (of utmost importance): W63/W75/W86 factory assembly and transportation blind plugs must be replaced with accompanying ventilation plugs before the equipment is put into operation; Only the B6 installation posture retains blind plugs, and if the ventilation plug is not replaced due to errors, the internal pressure will increase during operation and the oil seal is prone to oil leakage.

The installation posture cannot be changed arbitrarily: order B3/B6/B7/B8/V5/V6, corresponding to the factory oil injection amount; Changing the installation orientation and oil level on site without authorization can cause insufficient lubrication and burn out the worm gear pair. Changing the installation position requires written confirmation from the manufacturer and refilling with the corresponding amount of oil.

Compliance requirements: After the whole machine is integrated, it needs to meet the mechanical directive 2006/42/CE, and the oil level should be confirmed to match the installation posture before leaving the factory; Outdoor use must be equipped with a rainproof and sun proof protective shell.

Lubrication System and Maintenance Strategy

VF-W is divided into lifetime maintenance free oiled models and factory unfilled models. VF27-VF49, W63-W86 factory pre filled Shell Omala S4 WE320 synthetic PAG oil; VF130-250 and W110 standards do not require oil injection at the factory, and customers need to add oil on-site or choose the LUB filling option for ordering.

Mixing of oil products is prohibited: Mineral oil, synthetic PAG oil, and food grade lubricating oil cannot be mixed with each other.

Inspection cycle: check the oil level monthly under intermittent working conditions; Continuous operation increases inspection frequency. Lifetime lubrication models operate under conditions of no water ingress or impurity pollution, and do not require oil change throughout their entire lifespan; Once water enters, emulsifies, or metal debris is mixed in, the oil must be changed immediately.

Oil selection: The standard for conventional operating conditions is VG320; VFL/WL models are required to use VG460; Adjust viscosity in low temperature environment; The food industry uses KLUBERSYNTH UH1 food grade series lubricants.

Sealing upgrade option: PV full shaft fluororubber oil seal can be ordered under high temperature conditions to improve temperature resistance and aging resistance.

Special configuration selection and ordering code prompts

EP anti-corrosion strengthening series VF-EP/W-EP: aimed at food, medicine, corrosive and humid environments, with strengthened anti-corrosion coatings, can support C3/C4 corrosion level coating, RAL multiple colors to choose from, to meet washing and cleaning conditions.

Attachment list: Torque arm TA series, protective cap SC, plug-in solid output shaft, RB double extension input shaft; RVS limit stop device; FR reinforced axial bearing version.

Complete elements of ordering code: machine base number, version type, output shaft aperture, transmission ratio, input configuration HS/IEC flange, installation position B3/V5, etc; All additional options (oil seal, anti-corrosion grade, torque arm, lubricant type) need to be written in the order, and any missing options will default to standard configuration.

Quick troubleshooting approach

Abnormal high temperature: prioritize checking the oil level and oil type; Next, check if the actual load exceeds the selected safety factor; Insufficient heat dissipation during continuous operation, evaluate environmental ventilation. Long term operation at 80-95 ℃ oil temperature accelerates the aging rate of oil seals exponentially.

Oil seal leakage: First check if the vent plug is installed correctly; Secondly, whether the installation posture is consistent with the order; Confirm again whether the oil seal has been corroded or aged by paint; The increase in pressure is the most common cause of oil leakage in vertical reducers.

Abnormal increase in noise: Check the rigidity and alignment of the base; Assess whether there is overload; The internal worm gear pair is worn, and oil samples are taken to observe whether there is metal powder.

Vertical load sliding: Remember that the worm gear cannot be used as a safety self-locking mechanism, and the high-speed ratio in the vibration environment will also retract, requiring an external brake.