Sizing software calculates the RMC Torque… Why???
> Limiting factor for electrical equipment : Temperature
(I²t)… That’s why RMS torque is calculated, as
𝑇𝑚𝑜𝑡𝑜𝑟 = 𝐾𝑡 ∗ 𝑖𝑎 , the RMS torque is an image of the
heating. The gearboxes are subject to
cyclic stresses
> Limiting factor for a mechanical component : Stresses, S-N curves
that can be static or cyclic.
Our gearbox!
- When cyclic, the « fatigue » phenomenon appears :
cyclically loaded parts fail even when the stress load
magnitude never exceeds static strength!
- For ferrous alloys, if the magnitude of cyclic stress is limited
enough, it will never fail
- This is represented in S-N curves (Acceptable stress as a
function of the number of cycles)
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Source : [Link]
Output shaft Carrier
Planetary gearbox : How does it work?
> The input shaft (motor side) is connected to the sun gear
> Planet gears follow the sun rotation, being caught
between this sun & the internal ring gear.
> The planet gears are mounted on the carrier, that rotates Internal ring
the output shaft. gear (fixed)
> There can be several stages, when high gearing ratio
are requested. Planet gears
> Increasing the number of stages :
- Increase backlash & reduces efficiency
- But allows to increase the gearing ratio
> Typically, gearing ratio :
- 3 to 10 : one stage
- 9 to 100 : 2 stages
- 60 to 512 : 3 stages Sun gear
2
Source : [Link]
The gear teeth, even when the motor is
running at constant speed, will be subject
to a cyclic stress : each tooth is loaded on
engagement and then becomes unloaded.
This happens 3 times per revolution in a 3-
Planetary gearbox : How is it made? planets gearbox
Lubrification
Planetary For a motor running at an average speed
gears of 400 rpm (like our card assembly
Sun machine), running 8-hours a day, this
gear involves 3 ∗ 400 ∗ 8 ∗ 60 = 576.000 𝑐𝑦𝑐𝑙𝑒𝑠/
𝑑𝑎𝑦!
Motor
mechanical
Carrier & adaptation
This fatigue limit is reached after about
Ring gear output 2*10^6 cycles (for ferrous materials),
shaft so after about 3 days of working
Bearings
S-N curves
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S-N curves
Sizing software calculates the RMC Torque… Why???
> In the orange area, the curve can be approximated by :
1
Stress = (N : number of cycles)
𝑁1/𝐸
with 𝐸 being influenced by the alloy & the loading type and As long as Stress < fatigue
going from 6 to 80. It is empirically determined & defines the limit, the gearbox should
theoretically never fail!
slope in a log plot.
> In fact, the limiting components in the gearbox are the
bearings. They don’t have the same behavior as tooth,
because of the high-pressure load between the rolling
elements & races and will fail even if the fatigue limit of
tooth is respected.
> Their slope factor 𝐸 is equal to 3 for ball bearings, and 3.33
for roller bearings.
> NB : Bearing can be oversized
to avoid to be the limiting element!
4
Source : Motion System Design August 2002 – Precision
gearhead torque rating for automation and robots
Basic dynamic load
rating.
3
Sizing software calculates the RMC Torque… Why??? 𝐶𝑝 1.000.000
𝐿10𝑁 = ∗
𝑆𝑡𝑟𝑒𝑠𝑠 𝑛𝑁 ∗ 60
> Bearings are typically sized, designed, and rated for a lifetime
Vendor (30.000 hours) with assigned a certain statistical probability of
data Number of
failure (𝐿10𝑁 = 10% chance of failure), for a specified magnitude of working hours
Vendor
data
the load 𝐶𝑝 & a nominal speed 𝑛𝑁 for 1.000.000
> 𝐶𝑝 , the basic dynamic load rating, corresponds to the bearing revolutions
radial load which will give a basic rating life of 1.000.000 revolutions
𝐿10𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 =
> The real lifetime (expressed in hours) depends on the average 3
𝑇𝑁 𝑛𝑁
Application speed 𝑛 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 & on the ratio between the applied torque 𝑇𝑎𝑝𝑝 & the 𝐿10𝑁 ∗ ∗
𝑇𝑎𝑝𝑝 𝑛𝐴𝑣𝑒𝑟𝑎𝑔𝑒
reality reference 𝑇𝑁 ,
> The cubic factor comes from the slope related to bearing in the
previous plot. 1 1
> The cyclic stress on the bearing depends on the torque delivered Stress = 1/𝐸 =
𝑁 1.000.0001/3
and is thus not constant. An average torque value is thus
1
calculated using a Root Mean Cubic formula because of the cubic → 1.000.000 =
𝑆𝑡𝑟𝑒𝑠𝑠 3
factor related to the bearing endurance limit slope. It is an image of 5
the stress on the bearings of the gearbox.
Sizing software calculates the RMC Torque… How???
> The average speed 𝑁𝑖 on each part of the motion is taken into
account in this calculation 3 σ𝑛𝑖=1 𝑁𝑖 𝑡𝑖 𝑇𝑖 3
𝑇𝑅𝑀𝐶 =
> There are several ways to calculate this average torque value, σ𝑛𝑖=1 𝑁𝑖 𝑡𝑖
depending on the manufacturer & gearbox type :
- The exponent is 3 for a ball bearings, and 3.33 for roller bearings.
- Some manufacturers include dwell time in the calculation, others
10/3 σ𝑛𝑖=1 𝑁𝑖 𝑡𝑖 𝑇𝑖 10/3
𝑇′𝑅𝑀𝐶 =
don’t. σ𝑛𝑖=1 𝑁𝑖 𝑡𝑖
- You can find up to 7 different ways to calculate this RMC torque!
6
Gearbox frame size
➔ Influence on the
acceptable load & on
backlash & stiffness
Which info are available in a vendor technical documentation?
𝐿10
Number of stages…
➔ Influence on 𝜂,
on the backlash,
torsional stiffness &
𝐽𝑔𝑒𝑎𝑟𝑏𝑜𝑥
Output
shaft Several 𝐿10
Dynamic
Static
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Used to define the number of
available rotations depending
on the applied torque
Which info are available in a vendor technical documentation?
Acceptable
RMC torques
Input speed as an image of
the heating of the gearbox
+ no-load torque
Source : KPR’s part of this course! (not included8in
catalog)
What should you pay attention to when selecting a gearbox, supposing the gearing ratio
is defined?
> To ensure the gearbox life :
- Input speed
- Application torques (Nominal, max, emergency)
> To reach the application requirements :
- Backlash
- Torsional Stiffness
> To ensure the connection to the load & motor :
- Max input shaft diameter
- Output shaft characteristics
> To decrease the energy consumption
& required motor torque :
- Efficiency
- Inertia 9
From 150+ to 1000+ €, depending
Gearbox commercial offer : on frame size, ratio, options, .. From 350+ to 2000+ €
> Economy & precision line :
- Straight gears vs helical gears : contact ratio PLE PSN
(number of teeth in mesh at any given time) PLN
PLQE WPLE
is more than doubled ➔ Reduced backlash,
WPLN
increased load sharing ➔ longer teeth life
WPLQE Economy Precision
Line PLHE
Line
PLPE
WGN
PLFE
Base Options Motor mounting PLFN
WPLPE PSFN
HLAE
> Within the lines :
- Several designs, several frame size,
several output flanges, allowing more or
less radial forces, with or without angular
stage, … 10