ELECON-TGW

Crowned & Barrelled Gear Type Coupling BALLIMONT®

ALWAYS A STEP AHEAD IN TECHNOLOGY

Layout and working principles

GEar type couplings are torsionally rigid. Due to the spe-cial design of their teeth, they compensate for axial, ra-dial and angular misalignments of the connected machin-ery.

Special Features

Small outside dimensions, large bores, low weights, lowmoments of inertia, large permissible misalignments,crowned and barrelled teeth. The assembly is selfcentringand hermetacally sealed through either double-lippedseals or O-rings (smaller sizes only).

From size 670 upwards, the maximum lubricant level doesnot exceed the height of the sealing lip in the lower part ofthe coupling.

Layout and working principles

The hub teeh which are crowned and barrelled and whichhave permit angular,axial and radial misalignments withinspecified limits.

Due to movement between the teeth under running con-ditions either oil or grease lubrication is necessary. (Con-sult ELECON for lubricant to be used).

The coupling housing is selfcentring owing to the invo-lute tooth form. The tooth tolerances are such that partsare interchangeable.

Normally displacements occure in combinations. Thepermissible angular displacement per hub for all couplingsof ordinary design is ±10. In clutch couplings the maxi-mum angular displacement per hub must not exceed ±0.50

In special cases larger angular displacements can beachieved rthrough modified toothe crowning. Generally,the smaller the displacement, the higher the torque trans-mitting capacity of the couplings.

Types of misalignment

Operating Factors

table 1

factor of driven machine f1 f1 f1daily daily dailyduty duty duty

(h) (h) (h)

driven machines 8 16 24 driven machine 8 16 24 dirven machine 8 16 24lifts slews 1,25 1,3 1,4 strip reels 1,6

freight elevators normal duty 1,25 1,35 1,5 winches 1,25 1,3 1,4 sheet shears 1,6

freight elevators heavy duty 1,35 1,5 1,7 metal working Sheet manipulators 1,35

elevators 1,35 1,5 bending machines 1,35 bloom conveying plants 1,6 1,9 1,9

excavators and stackers sheet straightening machine 1,4 wire reels 1,35

bucket chain excavators (fixed chain) 1,4 1,5 1,7 crank presses 1,5 capstan handles 1,5

bucket chain excavators (loose chain) 1,25 1,35 1,5 shears 1,35 revolving turrets, cont. casting 1,25

travels (track) 1,4 1,4 1,4 forging presses 1,5 de-scaling crushers 1,4

travels (rail) 1,4 1,4 1,4 punches 1,5 lifting tables 1,4

bucket wheel stackers mixers walking beam conveyers 1,5

bucket whels 1,4 1,5 1,6 mixers, liquids 1 1 1,1 chain transporters 1,4

(clearing.lime/coal) mixers, semiliquids 1,1 1,25 1,35 billet shears 1,5

slew drives 1,25 1,3 1,4 mixers, granular material 1,1 1,25 1,35 cooling beds 1,25

wiches 1,25 1,3 1,4 concrete mixers 1,1 1,25 1,35 straightening presses 1,7

mining, rock earth industry mills roll straighteners 1,35 1,6 1,6

jaw crushers 1,6 hammer mills 2 plate trimmimg shears 1,4

pit fans 1,4 ball mills 1,9 winding turret 1,25

cone crushers 1,6 pendulum mills 1,9 winding tractors 1,25

chain tramways 1,4 impact mills 2 cropping shears 1,5

rotary crushers 1,6 roll mills 1,9 rope tractors 1,4

joiting machines 1,5 roll crushers 1,9 s-rolls,high speed 1,25

scale breakers 1,6 Oil insustry s-rolls,low speed 1,1

wagon pushers 1,4 filter presses 1,35 roller transporters 1,35

crushing rolls 1,5 pipeline pumps 1,35 positioning and tilting mech. 1,6 1,9 1,9

Chemical industry scavenging pumps 1,35 hot and cold saws 1,5

agitators, constant density 1 1 1,1 paper machines live-roller tables 1,35

agitators, ciscous liquids 1,1 1,25 1,35 couchers 1,35 1,5 1,5 machine tools

wire pulls 1,25 1,35 1,5 horizontal rollers 1,35 1,5 1,6 turning movement 1,1 1,25 1,35

rotary drums calenders 1,35 1,5 1,5 planing machines,metal 1,25 1,35 1,5

rotary kilns 1,1 1,25 1,35 glue presses 1,35 1,5 1,6 horizontal saw-mills 1,35 1,5 1,6

cooling drums 1,1 1,25 1,35 wet ends 1,35 1,5 1,5 wood-grinding machines 1,25 1,35 1,5

drying drums 1,1 1,25 1,35 wet presses 1,35 1,5 1,5 centrifuges 1,25 1,36 1,5

threshers 1,1 1,25 1,35 suction formers 1,35 1,5 1,5 tackles 1,25 1,3 1,4

conveying plants suction rollers 1,35 1,5 1,5

shaft sinking machine 1,35 1,5 1,7 dry-glazing calenders 1,35 1,5 1,6

bucket belts 1,1 1,25 1,25 drying cylinders 1,35 1,5 1,6

rubber belt conveyers, light 1 1,1 1,1 reversing suction presses 1,35 1,5 1,5

rubber belt conveyers, heavy 1,1 1,25 1,25 presses

band bucket elevtors 1 1,1 1,1 folding presses 1,4 1,4 1,5

trolley conveyers 1,1 1,25 1,25 briqueting presses 1,4 1,4 1,5

coilers 1,25 1,25 1,25 eccentric presses 1,4 1,4 1,5

bucket chain conveyers 1,25 1,35 1,35 forging presses 1,4 1,4 1,5

apron feeders 1,25 1,35 1,35 brick presses 1,4 1,4 1,5

screw conveyers 1,1 1,25 1,35 pumps

trough chain conveyers 1,1 1,25 1,35 centrifugal pumps, liquids 1 1 1,1

blowers, fans, generators centrifugal pumps, semiliquids 1,1 1,1 1,25

axial blowers 1 1,1 1,25 pisotn pumps (U1:100-200) 1,25 1,35 1,5

rotary piston blowers 1,1 1,25 1,35 piston pumps (U<100) 1,4 1,5 1,6

radial blowers 1 1,1 1,25 cargo pumps 1,15 1,25 1,35

exhaust fans,ind.-draft fans 1,1 1,25 1,35 propeller pumps 1,25 1,35 1,5

turbo blowers 1 1,1 1,25 sand pumps 1,25 1,35 1,5

light generators 1 1 1,1 rotary pumping plants 1,35 1,5 1,6

generators, puslsating load 1,1 1,25 1,35 shaking machines 1,35 1,5 1,6

welding generators 1,35 1,4 1,6 swing sieves 1,1 1,25 1,35

rubber and plastics machines textile industry

extruders 1,25 1,35 1,5 bobbin winding machine 1,1 1,25 1,35

rubber calenders 1,25 1,35 1,5 printing and dyeing machines 1,1 1,25 1,35

rubber kneading machines 1,25 1,35 1,5 tan liquor vessels 1,1 1,25 1,35

rubber rolling machines 1,25 1,35 1,5 calenders 1,1 1,25 1,35

mixers 1,25 1,35 1,35 willowing machines 1,1 1,25 1,35

wood working machinery looms 1,1 1,25 1,35

decorticating drums 1,25 1,35 1,35 compressors, vents

frames 1,1 1,1 1,25 rotary piston compressors (U1:100-200) 1,35 1,5 1,6

iron and steel industry rotary piston compressors (U<100) 1,4 1,6 1,6

blast furnace blowers 1,35 1,35 1,35 vent N/n<0,05 1 1 1,1

inclined skip hoists for blast furnaces 1,5 1,5 1,6 vent N/n>0,05-0,1 1 1,1 1,25

cranes vent N/n>0,1 1,1 1,15 1,35travels 1,1 1,25 1,35 rolling millshoists 1,25 1,35 1,5 working roller, tables

table 2

driven machine factor f2

electric motorsturbines 1,0

piston engines, 4-6 cyl.degree of non-uniformity 1,151:100 to 1:200

piston engines, 1-3 cyl.degree of non-uniformity 1,3to 1:100

The indicated factor are values basedon experience.

Plants not mentioned or deviations fromnormal conditions on request.

If V o.5 ≤ m/sec at the hub f3diameter “C” the values indicatedabove can be multiplied by f3=0.85

1. Determining coupling size

1.1 Effective torque Teff = 955.Peff [da Nm]n

1.2 Coupling size to be chosen Tkn≥Teff . f1 . f2 . f3 [da Nm]

2. Itermidiate hollow shaft couplings

2.1 Moment of inertia IR = Da4-Di4 [cm4]20,38

2.2 Deflection of the hollow shaft f = m.L3 [cm]7,83.E.I

R

2.3 Critical speed of the hollow shaft nk = 300 [1/min]√f

3 Intermidiate shaft couplings

3.1 Moment of inertia Iw = Da4[cm4]

20,38

3.2 Deflection of the shaft f = m.L3[cm]

7,83.E.Iw

3.3 Critical speed of the shaft nk = 300 [1/min]√f.

4. Maximum radial displacement of the couplings Intermediate hollow shaft andintermediate (solid) shaft.

4.1 Kr1 = 0,0175 (O+F) (hollow shaft)

4.2 Kr = 0,0175 (O+F) (shaft)

Selectionm of Crowned toothed couplingsTeff = effective torque of the driven machine [da Nm]

Peff = effective popwer of the driven machine [kW]

n = coupling speed [1/min]

f1 = driven machine factor (table 1)

f2 = driven machine factor (table 2)

f3 = 0.85 for v ≤ 0.5 m/sec

TKN = torque that can be constantly transmitted throughout the whole range ofspeeds, and indicates size in addition

Tkmax = torque that can be temporarily transmitted ≥ 105 times as an instanta-neous shock torque in the same direction or, resp. ≥ 5. 104 times as analternating shock torque

IR = moment of inertia [cm4]

Da = outer diameter hollow or solid shaft [cm]

Di = hollow shaft bore

f = deflection [cm]

m = weight [kg]

L = length [cm]

E = modulus of elasticity 20,6.106 [N/cm2]

nk = critical speed [1/min]

Kr = maximum radial displacement [mm]

O+F = auxiliary variables according to dimensions sheet

Calculation example

Given:

Cement mill drive (impact pulverizers)Driven by electric motor Pmot = 1250 kWMill power Peff = 1135 kWMaximum torque Tmax = 25280 daNmCoupling speed n = 109.5 1/minDistance between tha shaft faces N = 5600 mmRequired paralleled displacement ± 40 mm

a) Design

Effective torqueTeff = 955 . 13 [daN] Tmot = 955 . 1250 [da Nm]

109,5 109,5

Teff = 9898 [daNm] Tmot = 10902 [da Nm]

Operating factorts according to table 1 on page 3f1 = 2; f2 = 1; f3 = 1; da V>0.5 [m/sec]f1 f2 f3 = 2

required Tkn = 9898 . 2 = 19797 [da Nm]selected: BRW 21200 with a Tkn = 21200 [da Nm]

b) Maximum radial displacement

Kr = 0,0175 )O+F)

O=N-2 (R-L) = 5600-2 (305-290) = 5570 [mm]

Kr = 0,0175 (5570+78) = 98,84 [mm] ≥ 40 [mm]

c) Deflection of the intermediate hollow shaft

L = O = 5570 [mm]; mm=1139 [kg]

f = 1139.5573 [cm]

783 . 20 600 000 . 74 890

f = 0,0163 [cm]

d) Critical bending speed of the intermediate hollow shaft

nk = 300 [1/min]√0,0163

nk = 2350 [1/min] > 109,5 [1/min]

Crowned toothed couplings with single housing type BZWE

Size Tk max PkN/n Diameter Lengths Max.

TKN shock countinuous A B3) B3( B max radial Moments Max.Continuous continuous min max press C L M1) N Ka displace Weight of adm.

keyway fit ment2 inertia speedKr

da Nm da Nm kW/1/min mm mm mm kg kgm2 1/min

BZWE 63 112 0,066 108 20 50 56 70 55 70 5 ± 1,2 0,7 4,5 0,0057 8500BZWE 112 190 0,117 120 25 55 62 78 65 80 5 0,8 7,1 0,0125 7500BZWE 190 355 0,199 144 30 67 76 95 75 95 6 ± 1,5 0,9 10,8 0,026 6200BZWE 300 540 0,314 165 35 82 92 115 85 110 8 1,0 17,5 0,06 5200BZWE 560 1000 0,586 200 45 98 110 140 100 125 8 1,2 28,5 0,137 4500BZWE 900 1600 0,942 226 50 113 128 162 110 135 8 ± 2 1,3 42,5 0,263 3800BZWE 1500 2650 1,57 266 60 134 150 190 125 155 8 1,5 60 0,488 3300BZWE 2240 4000 2,35 296 70 156 174 220 140 170 8 1,6 81 0,813 3000BZWE 3000 5300 3,14 324 80 166 186 235 160 190 12 1,9 113 1,40 2700BZWE 3750 6700 3,93 350 85 178 200 252 180 220 12 ± 3 2,2 150 2,30 2500BZWE 5600 10000 5,86 390 100 207 232 292 200 240 12 2,4 213 3,95 2100BZWE 7500 13200 7,85 426 115 228 256 322 220 260 12 2,7 280 6,03 2000BZWE 10600 19000 11,1 464 130 250 280 352 240 280 12 2,9 368 9,58 1800BZWE 14000 25000 14,6 512 145 278 312 392 260 300 12 ± 3,5 3,1 455 14,25 1600BZWE 18000 31500 18,8 550 160 300 335 422 280 335 15 3,3 574 20,5 1500BZWE 21200 37500 22,2 584 180 313 351 442 290 345 15 3,4 656 26,5 1400BZWE 26500 47500 27,7 616 210 325 375 472 310 370 20 3,7 794 36,5 1300BZWE 30000 53000 31,4 648 260 345 400 502 330 395 20 3,9 964 52,0 1250BZWE 35500 63000 37,2 682 250 365 423 532 350 415 20 ± 4 4,2 1160 67,5 1150BZWE 45000 80000 47,1 750 265 390 455 570 380 455 25 4,6 1300 92,5 1100

1) Required space tp change the seals and to align without aligning device Modification of dimensions and construction reserved2) Maximum angular misa;iognment per coupling half ±10 = max. radial

misalignment. The continuous torque rating (2) is then approx. 60% of the valuementioned above.

3) Keyway according to DIN 6885 sheet 1

Crowned toothed couplings for shaft connections type BZWG

Diameter Lengths

Size Tk max PkN/n A B3) B3) BTkN shock contin min max max C D L M1 N1 N2 N3 N4 Kacontinuous uous

da Nm da Nm kW/1/min mm mm mm kg kgm2 1/min

BZWG 63 112 0,066 136 20 50 56 70 98 55 70 5 21 37 67 ± 1.2 1,4 5,5 0,009 8500BZWG 112 190 0,117 150 25 55 32 78 106 65 80 5 28 51 81 1,6 7,4 0,0142 7500BZWG 190 355 0,199 180 30 67 76 95 130 75 95 6 30 54 93 ± 1.5 1,8 12 0,0325 6200BZWG 300 540 0,314 200 35 82 92 115 150 85 110 8 38 68 109 2,1 18 0,0575 5200BZWG 560 1000 0,586 225 45 98 110 140 200 100 125 8 44 80 130 ± 2 2,5 32 0,1625 4500BZWG 900 1600 0,942 254 50 113 128 162 226 110 135 8 50 92 142 2,8 48 0,3375 3800BZWG 1500 2650 1,57 288 60 134 150 190 266 125 155 8 55 105 160 3,1 68 0,60 3300BZWG 2240 4000 2,35 322 70 156 174 220 296 140 170 8 60 115 176 3,5 92 1,00 3000BZWG 3000 5300 3,14 362 80 166 186 235 324 160 190 12 70 130 192 ± 3 4,0 130 1,78 2700BZWG 3750 6700 3,93 382 85 178 200 252 350 180 220 12 75 140 224 4,5 170 2,80 2500BZWG 5600 10000 5,86 435 100 207 232 292 390 200 240 12 85 155 247 5,0 234 4,63 2100BZWG 7500 13200 7,85 470 115 228 256 322 426 220 260 12 90 170 272 5,4 305 7,18 2000BZWG 10600 19000 11,1 520 130 250 280 352 464 240 280 12 105 195 301 ± 3,5 6,0 405 11,50 1800BZWG 14000 25000 14,6 575 145 278 312 392 512 260 300 12 115 212 327 6,5 510 17,75 1600BZWG 18000 31500 18,8 632 160 300 335 422 550 280 335 12 120 225 148 7,0 670 26,75 1500BZWG 21200 37500 22,2 660 180 313 351 442 584 290 345 15 120 230 357 7,2 755 33,75 1400BZWG 26500 47500 27,7 715 210 325 375 472 616 310 370 20 135 245 382 ± 4 7,7 929 48,0 1300BZWG 30000 53000 31,4 750 230 345 400 502 648 330 395 20 145 270 410 8,2 1110 65,8 1250BZWG 35500 63000 37,2 790 250 365 423 532 682 350 415 20 150 280 430 8,7 1280 83,8 1150BZWG 45000 80000 47,1 850 265 390 455 572 750 380 455 25 165 305 9,5 1560 118,8 1100BZWG 56000 100000 58,6 910 290 410 494 620 812 410 485 25 120 215 ± 4,5 9,3 2180 198 1000BZWG 67000 118000 70,1 980 320 445 533 670 860 430 510 25 125 230 9,7 2520 265 940BZWG 75000 132000 78,5 1020 330 465 556 700 908 450 530 25 130 235 10,1 2910 333 900BZWG 90000 160000 94,2 1070 340 475 573 720 948 470 560 25 135 245 10,5 3280 395 875BZWG 106000 190000 111 1120 370 510 613 770 1000 490 580 25 140 255 11,0 3730 513 820BZWG 118000 212000 123 1160 390 530 636 800 1028 510 610 30 150 270 ± 5 11,5 4150 610 790BZWG 132000 236000 138 1210 410 550 660 830 1078 530 630 30 155 280 12,0 4700 775 760BZWG 150000 265000 157 1270 440 570 692 870 1128 550 660 30 160 290 12,4 5310 937 725BZWG 170000 300000 178 1300 460 590 716 900 1168 570 680 30 165 300 12,8 5910 1110 700BZWG 190000 335000 199 1350 490 615 748 940 1228 590 710 30 170 310 13,3 6570 1370 670BZWG 212000 375000 222 1380 510 640 780 980 1258 610 730 30 175 320 13,7 7170 1572 650

1) Required space to change the seals. A maximum of 1/3 of this space Modification of dimensions and construction reservedis necessary for alignment.

2) Maximum angular misalignment per coupling half ±10 = max radial misalignmentThe continuous torque rating (2) is then approx. 6o% of the value mentioned above.

3) Keyway according to DIN 6885 sheet 1.

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Crowned toothed couplings for shaft connections type BZGR

Size Tk max PkN/n A B3) B3) B C D L M1) Ka P RTkN shock contin- min max maxContin- uous key pressuous way fit

da Nm da Nm kW/1/min mm mm kg kgm2 1/min

BZGR 63 112 0,066 136 20 50 56 70 98 55 70 ± 1,2 22 72 75 5.5 9,009BZGR 112 190 0,117 150 25 55 62 78 106 35 80 29 89 90 7,4 0,0142BZGR 190 355 0,199 180 30 67 76 95 130 75 95 ± 1,5 31 101 105 12 0,0325BZGR 300 540 0,314 200 35 82 95 115 150 85 110 38 118 320 18 0,0575BZGR 560 1000 0,586 225 45 98 110 140 200 100 125 ± 2 45 140 140 32 0,1625BZGR 900 1600 0,942 254 50 113 128 162 226 110 135 50 155 155 48 0,3375BZGR 1500 2650 1,57 288 60 134 150 190 266 125 155 56 175 175 68 0,60BZGR 2240 4000 2,35 322 70 156 174 220 296 140 170 62 195 195 92 1,00BZGR 3000 5300 3,14 362 80 166 186 235 324 160 190 ± 3 72 225 230 130 1,78BZGR 3750 6700 3,93 382 85 178 200 252 350 180 220 77 250 255 170 2,80BZGR 5600 10000 5,86 435 100 207 232 292 390 200 240 82 275 275 234 4,63BZGR 7500 13200 7,85 470 115 228 256 322 426 220 260 88 300 300 305 7,18BZGR 10600 19000 11,1 520 130 250 280 352 464 240 280 ± 3.5 104 335 340 405 11,5BZGR 14000 25000 14,6 575 145 278 312 392 512 260 300 114 365 370 510 17,75BZGR 18000 31500 18,8 632 160 300 355 422 550 280 335 119 390 395 670 26,75BZGR 21200 37500 22,2 660 180 313 351 442 584 290 345 119 400 400 755 33,75BZGR 26500 47500 27,7 715 210 325 375 472 616 310 370 ± 4 132 430 435 929 48,0BZGR 30000 53000 31,4 750 230 345 400 502 648 330 395 142 460 465 1110 65,8BZGR 35500 63000 37,2 790 250 365 423 532 682 350 415 147 485 490 1280 83,8BZGR 45000 80000 47,1 850 265 390 455 572 750 380 455 162 530 540 1560 118,8BZGR 56000 100000 58,6 910 290 410 494 620 812 410 485 ± 4.5 117 515 520 2180 198BZGR 67000 118000 70,1 980 320 445 533 670 860 430 510 124 540 545 2520 265BZGR 75000 132000 78,5 1020 330 465 556 700 908 450 530 129 565 570 2910 333BZGR 90000 160000 94,2 1070 340 475 573 720 948 470 560 134 590 600 3280 395BZGR 106000 190000 111 1120 370 510 613 7701000 490 580 139 615 620 3730 513BZGR 118000 212000 123 1160 390 530 636 8001028 510 610 148 640 650 4150 610BZGR 132000 236000 138 1210 410 550 660 8301078 530 630 ± 5 153 665 670 4700 775BZGR 150000 265000 157 1270 440 510 692 8701128 550 660 158 690 700 5310 937BZGR 170000 300000 178 1300 480 590 716 9001168 570 680 163 715 725 5910 1100BZGR 190000 335000 199 1350 490 615 748 9401228 590 710 168 740 750 6570 1370BZGR 212000 375000 222 1380 510 640 780 9801258 610 730 173 765 775 7170 1572

Modification of dimensions and construction reserved1) Required space to change the seals

2) Maximum angular misalignment per coupling half ± 10 = maximum radial misalignment 3) Keyway according to DIN 6885 sheet 1of the shaft to be connected. 4) Weight ans moments of inertia without intermediate

The continuous torque rating (2) isthen approx. 60% of the value mentioned above. hollow shafts.

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