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4 Project Planning: 4.1 List of Application Variables
4 Project Planning: 4.1 List of Application Variables
4 Project Planning: 4.1 List of Application Variables
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You may download "Project Planning for Drives" by scanning the bar code below. Or, you
may go to the following link: www.seweurodrive.com/download/pdf/10522913.pdf
The following catalogs are also available from SEW-EURODRIVE for assistance with
project planning:
You may request a hard copy of these catalogs by calling SEW-EURODRIVE, or download
them from www.seweurodrive.com.
INFORMATION
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R, F, and K The helical (R), parallel shaft (F) and helical-bevel (K) gear units (excluding K19, K29, K39,
K49) contain 100% rolling friction and the highest efficiency. Efficiency depends on the
number of gear stages: 96% (3-stage), 97% (2-stage) and 98% (1-stage).
K..19 - K..49 These right-angle units contain 2-stage hypoid gearing that combines rolling friction with
minor sliding friction. Their efficiency ranges from 90% to 96%, depending on the ratio.
Current sizes include K19, K29, K39, and K49.
W - SPIROPLAN® The SPIROPLAN® gear units (W-series) combine rolling friction with some sliding friction,
similar to hypoid gearing. The sliding friction induces some loss and lower efficiency than R,
F or K gear units, but higher efficiency than a helical-worm (S-series).
The SPIROPLAN® gear units W37 and W47 contain a helical input stage. Therefore, they
have the highest efficiency of the SPIROPLAN® gear units (>90%), dropping only slightly for
larger ratios.
The efficiency depends on the following factors:
• Gear ratio
• Input speed
• Ambient temperature
S-series The helical-worm (S-series) gear units contain a first stage helical gear set and a second
stage worm set. Various degrees of sliding friction occurs in the worm set, depending on the
number of starts on the worm gear. Therefore, these gear units have higher losses and
lower efficiency than other SEW-EURODRIVE gear units. However, they are still
significantly more efficient than single stage worm gear units common in the industry.
The efficiency depends on the following factors:
• Gear ratio (number of starts on worm)
• Input speed
• Ambient temperature
INFORMATION
Note that the self-locking effect of helical-worm and SPIROPLAN® gear units should
not be used as the sole safety function for hoists!
7
®
SPIROPLAN W..
Ratio Range reduction 8
approx. 30 ... 75 approx. 8 %
approx. 10 ... 30 approx. 5 % 9
approx. 3 ... 10 approx. 3 %
10
The run-in period usually lasts 48 hours. Helical-worm and SPIROPLAN® gear units achieve
their rated efficiency under the following conditions: 11
• The gear unit has completed the run-in period
• The gear unit has reached nominal operating temperature 12
• The gear unit contains the recommended lubricant and fill quantity
• The gear unit is operating in the rated load range 13
14
Thermal losses In certain gear unit mounting positions (see chapter "Mounting Positions"), the first gearing
stage is completely immersed in the lubricant. When the circumferential velocity of the input 15
stage is high, considerable churning losses occur, especially in larger gear units (> size 87),
or with input speeds > 1750 rpm. As a result, the gear unit may have a reduced input HP 16
rating. Substituting synthetic oil and high temperature FKM seals often permits a higher
operating temperature and increases the HP rating.
17
To keep churning losses to a minimum, use gear units in M1 mounting position whenever
possible. For more information on gear units with AD input shaft assembly, see page 63.
18
INFORMATION 19
For thermal limitations, you may visit www.ptpilot.com. PT Pilot® uses average
conduction and convection to figure your thermal limitation. It also provides a complete 20
quotation, including all motor and gear unit options.
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J +J +J
gear apt x
IAF = -------------------------------------------------
J mot + J b + J z
Values for Jmot and Jz are available in the motor section of SEW catalogs. Jb is already
included in the value for Jmot if you select the column for brakemotor. Both Jgear and Japt are
often negligible, especially on smaller gear units.
W T V max 2 W T D 2 n t 2
J x = ----------- ---------------- J x = --------- ------ --------
39.5 n m 2 24 n m
Load There are three load classifications, based upon the inertia acceleration factor:
classification
T amax Ta fB 7
Ta = load torque 8
Tamax = maximum permissible output torque (from gear unit tables)
9
24* 16* 8*
(III)
10
1.8 1.7 1.6
1.5 11
1.7 1.6 (II)
1.4
1.5 12
fB 1.6 1.3
1.4
1.5 1.2 (I) 13
1.3
1.1
1.4
1.2 14
1.0
1.3 1.1 0.9 15
1.2 1.0 0.8
0 200 400 600 800 1000 1200 1400 16
Z [1/h] **
00656BXX 17
Figure 1: SEW service factor fB
22
From Figure 1: Using the column for 16 hr/day (round up 14 hrs/day) and load class II,
fB = 1.5.
2
• fB1 = Service factor from ambient temperature
• fB2 = Service factor based upon %ED, which is the amount of time the motor is operating 3
compared to the time that it is resting.
f B1 (I) 7
1.8
(II)
8
1.6
fB2
(III)
9
1.4 1.0
1.2 0.8
10
13
The total service factor for a helical-worm gear unit becomes:
14
f Btotal = f B f B1 f B2
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Example 2 Change example 1 to use a helical-worm gear unit with the additional conditions below.
Calculate %ED,
ED = 40/60 = 66.7%.
Using Figure 2,
fB1 = 1.40
fB2 = 0.95
Therefore, the helical-worm gear unit must have an output torque rating,
Tamax > (4200 lb-in x 2.0)
Tamax > 8400 lb-in
From the S67 gear unit table on page 582, Tamax = 4240 lb-in, which is too low.
Thus, the solution requires an S77, 28.41:1, Tamax = 8750 lb-in, as shown on page 584.
Axial force If there is no overhung load, then an axial force. FA (tension or compression) equal to 50% 2
of the overhung load given in the selection tables is permitted on the output shaft. The 50%
rule applies to the following gear units: 3
Overhung load The type of transmission component that is mounted to the output shaft has a direct impact
10
(OHL) on the overhung load. Some components impart higher forces than others, as shown by the
transmission factor, fZ in the following table.
11
Component Transmission factor fZ Comments
Gears 1.15 < 17 teeth
Chain sprockets 1.40 < 13 teeth
12
Chain sprockets 1.25 < 20 teeth
Narrow V-belt pulleys 1.75 Due to pre-tension 13
Flat belt pulleys 2.50 Due to pre-tension
Timing or toothed belt pulleys 2.00 - 2.50 Due to pre-tension 14
Gear rack pinion, pre-tensioned 2.00 Due to pre-tension
15
The following formula determines the overhung load on the output shaft of a gear unit.
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2T
F R = ----------- f z
d o 18
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Permissible OHL The basis for determining the permissible overhung loads is the calculation of the rated
bearing service life L10h of the rolling bearings (according to ISO 281).
The overhung load rating changes for every angle, and direction of rotation. Since the
rating listed in the catalog is based upon the most unfavorable angle and direction, a higher
overhung load rating is possible when considering your specific angle and rotation. In
addition, even higher loads are permitted if heavy duty bearings are installed on the output
shaft of R, F, and K gear units. Contact SEW-EURODRIVE in such cases. Use the figure
below to specify your angle of force.
X
α α FR
0° FA
0°
63214axx
= angle of force
FR = Permissible overhung load at distance, x [lbs]
FA = Permissible axial load [lbs]
INFORMATION
The overhung load values (FRa) shown in the rating tables of this catalog refer to a force
applied at the center of a standard-length solid output shaft. These values are also
based upon the most unfavorable application angle, and direction of rotation.
For OHL values of a hollow shaft gear unit, please consult SEW-EURODRIVE.
INFORMATION
Reduction of overhung loads
• Only 50% of the FRa value specified in the selection tables is permitted in mounting
position M1 with wall attachment on the front face for K and S gear units.
• Helical-bevel gearmotors K167 and K187 in mounting positions M1 to M4: A
maximum of 50% of the overhung load FRa specified in the selection tables in the
case of gear unit mounting other than as shown in the mounting position sheets.
• Foot and flange-mounted helical gearmotors (R..F): A maximum of 50% of the
overhung load FRa specified in the selection tables in the case of torque
transmission via the flange mounting.
a 7
F xL = F Ra ------------- [lb]
b+x
8
9
FxW, based upon shaft strength:
10
3
10 - [lb] 11
F xW = c---------------
f+x
12
FRa = Permitted overhung load [lb] at the midpoint (x = I/2) of the output shaft for foot- 13
mounted gear unit. See selection tables.
x = Distance from the shaft shoulder to the point of application [in] 14
a, b, f = Gear unit constants for overhung load conversion [in]
c = Gear unit constant for overhung load conversion [lb-in] 15
Figure 3 shows the overhung load FR not located at the shaft mid-point: 16
x
17
FRa
FRa
FR FR 18
l/2
19
d
d
l x 20
63215axx
Figure 3: Overhung load, FR not located at shaft midpoint 21
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Constants for
overhung load
a b c f d l
conversion Gear unit type
[in] [in] [lb-in] [in] [in] [in]
RX/RXF57 1.71 0.93 1.34 1.35 0.750 1.57
RX/RXF67 2.07 1.08 2.14 1.56 1.000 1.97
RX/RXF77 2.38 1.20 1.73 0 1.250 2.36
RX/RXF87 2.89 1.32 6.81 1.93 1.625 3.15
RX/RXF97 3.41 1.44 12.66 2.12 2.125 3.94
RX/RXF107 4.04 1.67 21.86 2.45 2.375 4.72
R/RF07 2.83 2.05 0.41 0.43 0.750 1.57
R/RF17 3.48 2.70 0.58 0.67 0.750 1.57
R/RF27 4.19 3.21 1.38 0.46 1.000 1.97
R/RF37 4.65 3.66 1.10 0 1.000 1.97
R/RF47 5.39 4.21 2.16 0.59 1.250 2.36
R/RF57 5.81 4.43 3.34 0.71 1.375 2.76
R/RF67 6.63 5.26 2.35 0 1.375 2.76
R/RF77 6.84 5.26 3.51 0 1.625 3.15
R/RF87 8.53 6.56 7.50 0 2.125 3.94
R/RF97 10.06 7.70 10.53 0 2.375 4.72
R/RF107 11.24 8.48 18.23 0 2.875 5.51
R/RF137 13.52 10.18 54.34 1.18 3.625 6.69
R/RF147 15.83 11.69 76.56 1.30 4.375 8.27
R/RF167 17.72 13.58 111.52 0 4.750 8.27
F27 4.31 3.33 1.00 0 1.000 1.97
F37 4.86 3.88 0.95 0 1.000 1.97
F47 6.04 4.86 1.58 0 1.250 2.36
F57 6.72 5.34 4.86 1.26 1.375 2.76
F67 7.14 5.56 3.65 0 1.625 3.15
F77 8.50 6.53 6.97 0 2.000 3.94
F87 10.35 7.99 10.53 0 2.375 4.72
F97 13.78 11.02 18.50 0 2.875 5.51
F107 14.70 11.36 37.44 0 3.625 6.69
F127 17.42 13.29 83.64 0 4.375 8.27
F157 20.16 16.02 92.93 0 4.750 8.27
K37 4.86 3.88 1.25 0 1.000 1.97
K47 6.04 4.86 1.58 0 1.250 2.36
K57 6.68 5.30 6.02 1.22 1.375 2.76
K67 7.14 5.56 3.65 0 1.625 3.15
K77 8.50 6.53 6.81 0 2.000 3.94
K87 9.92 7.56 14.52 0 2.375 4.72
K97 12.56 9.80 24.78 0 2.875 5.51
K107 14.70 11.36 48.94 0 3.325 6.69
K127 17.46 13.33 73.55 0 4.375 8.27
K157 20.04 15.91 104.44 0 4.750 8.27
K167 24.47 19.55 166.39 0 6.250 9.84
K187 28.37 22.07 269.06 0 7.500 12.60
3.34 2.55 0.32 0 0.625 1.57
W10
3.88 3.09 0.39 0 0.750 1.57
W20
4.31 3.52 0.53 0 0.750 1.57
W30
4.77 3.98 0.61 0 0.787 1.57
W37
5.73 4.55 3.74 1.40 1.181 2.36
W47
Values for gear unit types not listed are available on request.
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Selecting the
gear unit 11
Determine the gear unit type
From the gear unit selection tables with AM adapter, determine the gear unit size based upon: 12
• the maximum output torque (Tamax)
• gear ratio (i)
13
Check the maximum permissible overhung load value on the output shaft (FRa)
14
Check the maximum permissible input power at the adapter (Pm) using the chart above and/or
the equation below. 15
Is the required gear ratio available with the required adapter size? 16
17
Input power (Pm) The maximum input power (Pm) shown in this catalog corresponds to 1750 rpm. For input 18
at alternate speed speeds other than 1750, use the formula below to calculate the maximum input power.
19
RPM new
P new = P m -------------------------- 20
1750
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Backstop If the application requires only one direction of rotation, the AM adapter can be configured
AM../RS with a backstop. Backstops with centrifugal lift-off sprags are used. The advantage of this
design is that above a certain speed (lift-off speed), the sprags move around inside the back-
stop without making contact. Therefore, the backstop is suited for high speeds and operates
maintenance free, wear-free, and without losses.
Dimensions:
The backstop is completely integrated inside the adapter. Therefore, the dimensions are the
same with or without backstop.
Locking torques:
Type Maximum locking Minimum
torque of the backstop lift-off speed
[lb-in] [rpm]
AM80/90/RS,
575 820
AM143/145/RS
AM100/112/RS,
3760 620
AM182/184/RS
AM132/RS,
7525 530
AM213/215/RS
AM160/180/RS,
12830 480
AM254/286/RS
AM200/225/RS,
17260 450
AM324-365/RS
AM250/280/RS 17260 450
If torque limiting is desired for compound gear units (ex: R77R37..), the AR adapter 2
containing a torque limiting coupling should preferably be placed between the two gear units
(ex: R77AR95R37...) rather than placed at the motor. Please contact SEW-EURODRIVE if 3
you intend to use a torque limiting coupling with a compound gear unit.
4
Selecting the If torque limiting is required for a single gear unit (ex:R77), the AR adapter is placed between
gear unit the gear unit and motor. The sizes of the AR adapters correspond to those of the AM
adapters for IEC motors. 5
This means you can select the gear unit using the selection tables for IEC AM adapters.
Then, substitute the unit designation "AM" with "AR" and determine the required slip torque. 6
The slip torque should be about 1.5 times the rated torque of the drive. When determining 7
the slip torque, bear in mind the maximum permissible output torque of the gear unit as well
as the variations in the slip torque of the coupling (+/-20%) which are a feature of the design. 8
When you order a gear unit with adapter and torque limiting coupling, please specify the
required slip torque of the coupling. If you do not specify, it will be set according to the 9
maximum permissible output torque of the gear unit.
10
Slip torque
values
Type Pm1) [HP]
MR2) [lb-in] 11
Option 1 Option 2 Option 3
AR71 .50 9 - 53 54 - 142 - 12
AR80 1.0 9 - 53 54 - 142 -
AR90 2.0 9 - 53 54 - 142 150 - 285
13
AR100 4.0 44 - 115 124 - 708 -
AR112 5.4 44 - 115 124 - 708 -
14
AR132S/M 10 133 - 1150 - -
AR132ML 12.5 133 - 1150 - -
AR160 20 265 - 750 760 - 1770 -
15
AR180 30 265 - 750 760 - 2660 -
1) Maximum rated power of the mounted electric motor at 1750 rpm
16
2) Adjustable slip torque according to cup springs
17
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20
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Speed monitor SEW-EURODRIVE recommends monitoring the speed of the coupling using a speed mon-
option /W itor to avoid uncontrolled slippage of the coupling and the associated wear on the friction
ring pads.
The speed of the output end coupling half is detected in a proximity-type method using a
trigger cam and an inductive encoder. The speed monitor compares the pulses with a
defined reference speed. The output relay (NC or NO contact) trips when the speed drops
below the specified speed (overload). The monitor is equipped with a start bypass to
suppress error messages during the startup phase. The start bypass can be set within a time
window of 0.5 to 15 seconds.
Reference speed, start bypass and switching hysterisis can be set on the speed monitor.
The following figure shows the adapter with torque limiting coupling and speed monitor,
[8]
[1] [2] [3] [4] [5] [6] [7]
65931AXX
Connection The encoder is connected to the slip monitor using a two or three-core cable (depending on
the encoder type).
• Maximum cable length: 500 m with a line cross section of 1.5 mm2
• Standard supply cable: 3-core / 2 m
• Route the signal lines separately (not in multicore cables) and shield them, if necessary.
• Degree of protection: IP40 (terminals IP20)
• Operating voltage: AC 220 V or DC 24 V
• Maximum switching capability of the output relay: 6 A (AC 250 V)
11
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52250AXX 15
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Centering The input shaft assembly can be configured with a machined centering shoulder as an option.
shoulder AD../ZR This allows the customer to locate the exact center of the input shaft for proper alignment.
Backstop AD../RS The input shaft assembly can be supplied with a backstop if only one direction of rotation is
permissible. Backstops with centrifugal lift-off sprags are used. The advantage of this design
is that above a certain speed (lift-off speed), the sprags move around inside the backstop
without making contact. Therefore, the backstop is suited for high speeds and operates
maintenance free, wear-free, and without losses.
Dimensions:
The backstop is completely integrated inside the cover. Therefore, there is no difference in
dimensions between an input shaft assembly with or without a backstop (see dimension
sheets in the "Input shaft assembly AD" chapter).
Locking torques:
Type Maximum backstop locking torque Minimum lift-off speed
[lb-in] [rpm]
AD2/RS 575 820
AD3/RS 3760 620
AD4/RS 7525 530
AD5/RS 12830 480
AD6/RS 17260 450
AD7/RS 17260 450
AD8/RS 17260 450
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Permissible Permissible weights for installed components (pulley, sprockets, belts, etc).
Weights
Motor mounting platform
DRE Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P
DRE80S 12
DRE80M 12
DRE90M 12 25
DRE90L 12 25
DRE100M 25
DRE100L 25
DRE100LC 25
DRE112M 25
DRE132S 25
DRE132M 50
DRE132MC 50
DRE160S 50 90
DRE160M 90
DRE160MC 90
DRE180S 90
DRE180M 90
DRE180L 90
DRE180LC 90
DRE200L 135
DRE225S 135
DRE225M 135
DVE250 225
DVE280 225
50494AUS 5
Please contact SEW-EURODRIVE if the mounting position you require is shown in this
column. By considering the actual operating conditions, SEW-EURODRIVE can calculate 6
the thermal limit rating based upon the specific application. Often, alternate measures are
available (ex: using FKM seals and a synthetic lubricant with higher thermal stability) to 7
increase the thermal rating of the gear unit.
8
The following data is required for recalculation:
9
Gear unit type ... R, S, K, F, or W
16
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INFORMATION
You may also visit our online selection program at www.ptpilot.com. PT Pilot 18
automatically calculates your oil sump temperature based upon your mounting position
and ambient temperature. When applicable, PT Pilot® adds synthetic oil and FKM seals
for proper protection against heat.
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X < 500mm?
X
?
End of
Project Planning
02457BUS
RM57
FRa [N] 400 400 400 400 400 405 410 415 4
FAa [N] 18800 15000 11500 9700 7100 5650 4450 3800
FRa [N] 575 575 575 580 575 585 590 600
RM67 5
FAa [N] 19000 18900 15300 11900 9210 7470 5870 5050
FRa [N] 1200 1200 1200 1200 1200 1210 1210 1220
RM77
FAa [N] 22000 22000 19400 15100 11400 9220 7200 6710
6
FRa [N] 1970 1970 1970 1970 1980 1990 2000 2010
RM87
FAa [N] 30000 30000 23600 18000 14300 11000 8940 8030 7
FRa [N] 2980 2980 2980 2990 3010 3050 3060 3080
RM97
FAa [N] 40000 36100 27300 20300 15900 12600 9640 7810 8
FRa [N] 4230 4230 4230 4230 4230 4230 3580 3830
RM107
FAa [N] 48000 41000 30300 23000 18000 13100 9550 9030 9
FRa [N] 8710 8710 8710 8710 7220 5060 3980 6750
RM137
FAa [N] 70000 70000 70000 57600 46900 44000 35600 32400
10
FRa [N] 11100 11100 11100 11100 11100 10600 8640 10800
RM147
FAa [N] 70000 70000 69700 58400 45600 38000 32800 30800
FRa [N] 14600 14600 14600 14600 14600 14700 - -
11
RM167
FAa [N] 70000 70000 70000 60300 45300 36900 - -
12
fBmin = 2.0; L10h = 25,000 h
Output speed na [rpm]
13
< 16 16-25 26-40 41-60 61-100 101-160 161-250 251-400
FRa [N] 410 410 410 410 410 415 415 420 14
RM57
FAa [N] 12100 9600 7350 6050 4300 3350 2600 2200
FRa [N] 590 590 590 595 590 595 600 605 15
RM67
FAa [N] 15800 12000 9580 7330 5580 4460 3460 2930
RM77
FRa [N] 1210 1210 1210 1210 1210 1220 1220 1220 16
FAa [N] 20000 15400 11900 9070 6670 5280 4010 3700
FRa [N] 2000 2000 2000 2000 2000 1720 1690 1710
RM87 17
FAa [N] 24600 19200 14300 10600 8190 6100 5490 4860
FRa [N] 3040 3040 3040 3050 3070 3080 2540 2430
RM97
FAa [N] 28400 22000 16200 11600 8850 6840 5830 4760
18
FRa [N] 4330 4330 4330 4330 4330 3350 2810 2990
RM107
FAa [N] 32300 24800 17800 13000 9780 8170 5950 5620 19
FRa [N] 8850 8850 8850 8830 5660 4020 3200 5240
RM137
FAa [N] 70000 59900 48000 37900 33800 31700 25600 23300 20
FRa [N] 11400 11400 11400 11400 11400 8320 6850 8440
RM147
FAa [N] 70000 60600 45900 39900 33500 27900 24100 22600 21
FRa [N] 15100 15100 15100 15100 15100 13100 - -
RM167
FAa [N] 70000 63500 51600 37800 26800 23600 - -
22
Conversion The following conversion factors and gear unit constants apply to calculating the permissible
factors and gear overhung load FxL at point x 1000 mm for RM gearmotors:
unit constants
Gear unit type a b cF (fB = 1.5) cF (fB = 2.0) FF
RM57 1047 47 1220600 1260400 277
RM67 1047 47 2047600 2100000 297.5
RM77 1050 50 2512800 2574700 340.5
RM87 1056.5 56.5 4917800 5029000 414
RM97 1061 61 10911600 11124100 481
RM107 1069 69 15367000 15652000 554.5
RM137 1088 88 25291700 25993600 650
RM147 1091 91 30038700 31173900 756
RM167 1089.5 89.5 42096100 43654300 869
Additional weight
of RM gear units
Type Additional weight of RM compared to RF
(compared to the smallest RF flange)
weight [lbs]
RM57 +26
RM67 +35
RM77 +55
RM87 +66
RM97 +113
RM107 +194
RM137 +245
RM147 +369
RM167 +431
DUO10A 2
diagnostic unit
DUO10A Technical data
CLP mineral oil. Tmax = 100 °C 3
OIL1
Bio oil Tmax = 100 °C
Designations and
12
part numbers
Designation Description Part number
13
DUO10A Evaluation unit (basic unit) 1 343 875 1
14
15
16
17
18
DUO10A-PUR-M12-5m 5 m PUR cable with 1 connector 1 343 877 8
DUO10A-PVC-M12-5m 5 m PVC cable with 1 connector 1 343 878 6
DUO10A Angle bracket 1 343 880 8
19
DUO10A D = 34 Mounting clamp 1 343 879 4
20
21
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Mounting on Adapter for mounting the PT1000 temperature sensor in screw plug holes:
standard gear
Complete adapter for PT1000 sensor Part number
units (R, F, K, S)
M10 1 1 343 903 0
M12 1.5 1 343 904 9
M22 1.5 1 343 905 7
M33 2 1 343 906 5
M42 2 1 343 907 3
Mounting base for installing the diagnostic unit at the gear unit with an angle bracket:
Mounting base with sealing ring Part number
M10 1 1 343 441 1
M12 1.5 1 343 827 1
M22 1.5 1 343 829 8
M33 2 1 343 830 1
M42 2 1 343 832 8