Yantai Bonway Manufacturer

Bevel Geared Motors

Helical bevel geared motor in mining industry

K series Helical bevel geared motor in mining industry KA47DRE80M4. Geared motors are used to power a range of equipment in mining operations, from conveyors, crushing/grinding equipment to flotation tanks and pumps. The main challenge associated with powering mining equipment is the increase in the scale of operation and the consequent increase in power requirements while maintaining reliability. There are many companies that provide drives and motors for the mining industry, some of which are mining, while others involve multiple industries.

The Sogears Group has introduced a new explosion-proof certified IE4 ultra-efficient motor. The new K-type reducer is the latest development in the Sogears permanent magnet synchronous motor (PMSM) motor series. IE4 has the highest energy efficiency rating in motor technology, making the k-Series Helical bevel geared motor in mining industry a highly efficient gear reduction motor for use in explosive areas. The Motors used in explosive hazardous areas are not subject to the EU's minimum energy efficiency regulations, as explosion protection takes precedence over energy savings. Traditionally this means that overall energy efficiency has declined, but the Sogears electric motor series from 0.55 kW to 15 kW are classified as Zone 1 and Zone 21.

The K-type Helical bevel geared motor in mining industry also has the advantage of maintaining a constant speed independent of the load. Compared to induction motors, PMSM synchronous motors can greatly increase efficiency even under partial load conditions. Extremely efficient under rated operating conditions. They also have a very high power density, which provides higher system efficiency and reduces weight in the smallest installation volume for gear motors. Importantly, the Helical bevel geared motor in mining industry can produce higher torque values at the same mounting volume as conventional induction motors, a factor that saves money by specifying smaller motor sizes in some applications.

Compared with the squirrel cage motor driven by IE2 inverter, the IE4 ultra-efficient PMSM (Permanent Magnet Synchronous Motor) K series Helical bevel geared motor in mining industry can achieve energy saving of up to 40%. Protecting machines and systems from costly failures and costly downtime is essential for large-scale mining operations; so many technologies can be used to protect machines from overload. Large mechanical and rotating systems can generate enough rotational energy to cause severe machine damage during blockages, collision stops or uncontrolled braking, such as power failure. At the extremely low speeds of KA series geared motors, the system generates a lot of unnecessary torque, which can damage drive system components such as shafts, gearboxes, chains and couplings.

Gears are used to transfer power from one part of the machine to another.In a bicycle, for example, it is a gear that moves from the pedal to the rear wheel.Similarly, in a car, gears transfer power from the crankshaft (a rotating shaft of power from the engine) to a drive shaft running under the car that powers the wheels.We can connect any number of gears together and have different shapes and sizes.Whenever we transfer power from one gear to another, we can do one of two things: gear box bicycle gears speed up: if two gears are connected together, one gear is more than the second, and the second gear has to turn faster to keep up.Thus, this arrangement means that the second round turns faster than the first, but with less force.

The K series of Helical bevel geared motor in mining industry are designed for the conveyor industry of the mining industry and have excellent performance.
Helical bevel geared motor in mining industry Technical characteristics, long bearing life, higher thermal power load, and high Power/weight ratio.
Kseries can be specially designed according to customer requirements.
This is an excellent conveyor GEAR MOTOR for the mining industry.
Our factory specializes in producing rotary Helical bevel geared motor in mining industry. This product adopts double planetary speed reduction mechanism and three-speed shifting. It has the characteristics of compact structure, large output torque, low noise, high efficiency, stable operation, good impact resistance, safety and reliability, and maintenance-free. It is suitable for rotary systems such as port cranes, tower cranes, mine cranes, etc. It can also be used for transmission of other machineries..

The k series right angle helical bevel geared motor in mining industry for gear manufacturing is a combination of multi-stage helical gears, which is more efficient than single-stage worm gear motors.

The k series helical bevel geared motor in mining industry is designed on the basis of the modular combination system. It has a very large number of motor combinations, installation positions and structural solutions. It has high double torque efficiency and high life gear. It is equipped with foot mounting, flange mounting and shaft installation。

Bevel gears are also known as bevel gears and bevel gears.Used for transmission between intersecting shafts.Compared with cylindrical gears, the drive direction can be changed.Single-stage transmission ratios up to 6, up to 8.

1. Design, manufacture and installation of straight and helical bevel gears are relatively simple, but the noise is relatively large, and they are used for low-speed transmission (<5m/s);Straight bevel gear transmission power up to 370 kilowatts, circular speed of 5 m/s.Helical bevel gear drives smoothly and has high bearing capacity, but it is difficult to manufacture and less used.

2, curved bevel gear with smooth transmission, small noise and large bearing capacity, used for high-speed heavy load occasions.The bevel gear transmission runs smoothly, the transmission power can reach 3,700 kilowatts, the circumferential speed can reach more than 40 meters/second.

Bevel gear is divided into ruler bevel gear, and spiral bevel gear。

Bevel gear machining

Bevel gear is mainly used for the transmission of two shafts intersection, the Angle between the two shafts is usually 90°, can also be less than 90°.Bevel gear in the general bevel gear planer and other special machine tools processing, in the absence of bevel gear machine tools, can be used in the milling machine bevel gear milling cutter processing, the use of forming tools and dividing device in the milling machine processing.Due to the existence of dividing error and tool installation error, generally can only be processed 9 ~ 10 grade accuracy of gear.In addition, the processing process needs to do a number of discontinuous teeth, the productivity is also low, only used for single small batch production and repair work processing accuracy is not high gear.

Processing methods and procedures

1, choose bevel gear milling cutter.Because the diameter of the large end and the small end of the bevel gear is not equal, so the large end, the small end of the base circle diameter is not equal, the large end of the involute tooth shape is more straight, the small end is more curved.The bevel gear tooth shape that mill out with form milling cutter, if want to accord with big end, cannot accord with small end.Therefore, in the milling machine with bevel gear milling cutter processing bevel gear, the tooth shape of the whole tooth is not all accurate, so the accuracy is lower.

Bevel gear is designed according to the parameters of the big end, so the tooth shape curve of bevel gear milling cutter should be manufactured according to the big end.In addition, because the bevel gear small end slot is narrow, standard bevel gear small end slot width for the big end 2/3, so bevel gear milling cutter thickness should be made according to the small end, and also should be slightly thinner than the small end slot.Bevel gear milling cutter and ordinary cylindrical gear milling cutter different, in order to prevent the wrong selection, bevel gear milling cutter on the side printed with "" mark.

Because the tooth of bevel gear is on the conical surface, the tooth shape curve of bevel gear milling cutter should be the same as the tooth shape on the section perpendicular to the dividing conical surface.Bevel gear milling cutter also like cylindrical gear milling cutter, each module according to the degree of tooth curve bending is divided into eight cutter.What differ is to want to press equivalent tooth number to choose.The equivalent number of teeth should be calculated first

2, workpiece clamping and adjustment.Before workpiece clamping, the tooth blank should be checked, and the tooth blank Angle and back cone Angle should be checked with universal protractor.Check the distance from the base level to the outer circle;Check the outer diameter of the tooth blank.

Workpiece clamping: according to the structure shape is different, bevel gear commonly used clamping method is the shaft and nut clamping, spindle spindle spindle spindle spindle spindle spindle spindle spindle spindle taper hole matching with a tension screw fastening on the dividing head.The work piece covers the cylindrical part of the core axis. After alignment with the dial indicator, tighten with the nut (see the picture below).For smaller diameter and large taper Angle or small end groove bottom and hole surface is very close to the bevel gear, in order to avoid milling teeth when the nut or even spindle damage, can use taper 1∶8 000 ~ 1∶1 000 micro cone spindle clamping, specific should be determined according to the tolerance grade of aperture factors.

On the cone Angle and the diameter of the larger, the end of the step or the aperture of the larger parts can be clamped, can directly use the dividing head of the three jaw self-centering chuck clamping.

Alignment of workpiece when clamping.If bevel gear using special spindle or spring chuck clamping, generally do not need to carry out alignment.If using the micro cone spindle clamping, generally do not need to find, if necessary, the bevel gear can be the end of the large end of the inspection and find.In the use of chuck and clearance fit spindle clamping, the need to find the workpiece big end and small end radial circular runout, and the end of the big end circular runout.

Adjust the dividing head.When the dividing head is installed on the work table, it is necessary to make the spindle axis consistent with the feed direction, and then turn the dividing head spindle into a cutting Angle, the size of which is equal to the Angle of the root cone.

Adjustment of milling depth.After the workpiece and dividing head are adjusted, first adjust the milling cutter's middle face to the axis through the workpiece (tool to the center), and then make the milling cutter contact to wipe the big end cone (with the big end as the benchmark), and exit the workpiece, raise the table a big end tooth full height (2.2m), you can start milling middle tooth groove.Large modulus of the workpiece, in depth can be divided into several cutter milling.

In order to prevent the cutting dividing head spindle suddenly raised and cause accidents, the direction of the knife is best from the big end milling to the small end.

Bevel gear deviation milling principle and method

The principle of

The teeth and grooves of bevel gears are contractive, that is, wide at the big end and narrow at the small end.In processing, although the dividing head has been turned into a root cone Angle, so that the outer cone surface of the bevel gear is slightly higher than the small end, when milling, the big end is cut deeper than the small end, the big end of the slot width is also slightly wider than the small end, but the difference can not meet the requirements, also need to mill the two sides of the big end slot more.In the milling machine milling bevel gear, the first feed milling out of the middle tooth groove, the big end of the tooth shape has been obtained, but the size of the groove width did not meet the requirements, so, each tooth groove generally to mill three cutter, in order to achieve the big end tooth groove on both sides of more milling to some purposes, milling bevel gear tooth groove on both sides of the residual machining called deviation milling.The principle of partial milling is: on the one hand, the workpiece deflection;On the other hand, move the table so that the small end tooth groove is re-aligned with the milling cutter.By using the deviation between the big end and the small end in the direction perpendicular to the feed (transverse) when the workpiece is deflected, the milling allowance is gradually increased from the small end to the big end, and the big end is more milling.

At present, there are a lot of milling methods when milling bevel gears, but because the ratio of cone distance and tooth width (R/b) is not consistent, as well as the different parameters of pitch Angle and tooth number, any one of the methods can not be applied to all bevel gears processing, therefore, only according to the specific situation, and try to correct in the cutting.The method of combining rotation and offset is often used in milling.[2]

methods

The first method: first calculate the offset S, the workpiece rotation around its axis determined by the test cut.

The second method: first count the rotation of the indexing head handle N, and the offset S of the table is determined by the test cut.

The third method is to combine the deflection Angle and offset of the dividing head in the horizontal plane.First, the deflection Angle of dividing head and workpiece in the horizontal plane is calculated.

Correction method for tooth thickness during deviation milling

After the two sides of 2 ~ 3 teeth are offset milling with the above method, the large and small ends of the teeth should be detected.If the actual measured value does not match the value indicated on the drawing or calculated value, the rotation and offset shall be corrected according to the following principles:

1, if the size of the small end is accurate and the large end is still residual, should increase the amount of rotation (or deflection Angle) and offset, so that the difference is increased, so that the small end is no longer milling.

2, if the size of the big end is accurate and the small end tooth thickness is still residual, it should reduce the amount of rotation (or deflection Angle), so that the offset can be reduced more.So that the small end is also milling some, and the big end is no longer milling.

3, if the size of the large end and small end are still residual, and the residual is the same, only to reduce the offset, so that the large end and small end are milling some.

4, if the size of the small end is accurate and the size of the big end is too small, should reduce the amount of rotation (or deflection Angle), offset appropriately reduced, so that the small end is no longer milling, and the big end is less cut than the original.

5, if the size of the big end is accurate and the size of the small end is too small, should increase the amount of rotation (or deflection Angle), the offset increased more, make the small end less milling than the original.If in milling middle slot, small end tooth thickness is too small, then need to replace the milling cutter or manufacturing special milling cutter to process.

bevel gear manufacturing process

1. Firstly, the principle of rolling cutting is used to make the processed gear and the imaginary spade gear repeatedly do relative rolling cutting. The cutter is a planer with two straight cutting edges, mounted on the tool rest, and reciprocating linear motion with the tool rest.

2. The tool rest is installed on the shaking table to form an imaginary spade gear.The processed gear is mounted on the spindle of the gear box. The gear box is moved so that the cone top of the processed gear is coincident with the cone top of the imaginary gear box, and the tooth root Angle is parallel to the surface through which the tool tip passes.

3, in the teeth cutting table and the processed gear respectively around the axis line for mutual adaptation of the coordinated movement, that is, like two bevel gear meshing, under such installation, the processed gear.

4, the axis line and shaking table rotation axis line intersection in a point, the intersection point is the center of the machine tool.This mutual movement enables the planer to get the correct involute profile.

According to the number and modulus of the workpiece, it is determined to use single tooth method or double tooth method planing gear.For single small batch production, the general use of single tooth method planing gear.

1.K series helical bevel geared motor in mining industry technical parameters

K series helical bevel geared motor in mining industry output speed: 0.1~530

k series helical bevel geared motor in mining industry output torque: ≤18000N.m

k series helical bevel geared motor in mining industry motor power: 0.12~200KW

specialty

1) high strength

The shell is made of high-grade cast iron and the bearing part is made of tapered roller bearing

(2) low noise · high efficiency

The bevel gear is made of special steel after surface carburizing and quenching

(3) flexible installation direction

Assembly in various directions can be achieved by selecting the shaft configuration. However,

It can not be used under the standard condition, please refer to no

(4) lubricating oil filling finished

Finished filling of high grade lubricating oil before delivery

(5) ratio

The transmission ratio is 1/1, 1/2. Customers can choose according to the purpose

S lubrication

The product is filled and sealed with a standard amount of lubricating oil before delivery

Model lube oil volume lube oil type

Fourth, k series helical bevel geared motor in mining industry connection code and form:

K-foot mounting, shaft extension coupling

KA-shaft mounting, foot support

K series helical bevel geared motor in mining industry product characteristics

Highly modular design: It can be easily equipped with various types of motors or other power inputs. The same type of machine can be equipped with a variety of power motors. It is easy to realize the combined connection between each model.

At present common gear box according to the form of structure can be divided into seven categories, namely involute cylindrical gear, cycloid pin wheel fixed shaft drive, circular arc cylindrical gear drive, bevel gear drive and hypoid gear drive, worm drive, involute planetary gear drive, non-circular gear drive.Different gear structures have different advantages and disadvantages in terms of transmission speed ratio, transmission efficiency, rotational speed, lubrication requirements, working reliability and cost efficiency, etc., and the following factors should be comprehensively considered when selecting equipment:

How to choose the right gear box?

Steps/methods

1, the work of the gear box structure and power parameters requirements, such as transmission structure size, mass, power, speed, efficiency, transmission ratio, load characteristics;

2. Performance requirements of the working machine on the gear box, such as: working reliability, service life, noise, vibration, temperature rise and transmission accuracy;

3. Advanced, reasonable, economical and universal interchangeability of gear box technology;

4. Low cost, high efficiency, high precision and high reliability of gear products.

Right angle helical bevel geared motor in mining industry for gear manufacturing Transmission ratio: fine division and wide range. The combined model can form a large gear ratio, that is, the output is extremely low. 3.k series helical bevel geared motor in mining industry installation form: the installation position is not limited.

4.k series right angle helical bevel geared motor in mining industry for gear manufacturing has high strength and small volume: the box body is made of high-strength cast iron. The gear and gear shaft adopts gas carburizing and quenching refining process, so the bearing capacity per unit volume is high.

Bevel gear processing method is mainly milling and planing;

Milling: milling machine milling teeth, milling teeth machine milling teeth;

The main plane: umbrella teeth plane.In addition, spiral umbrella tooth milling, umbrella tooth grinding machine and so on.

If it is a single request is not too high can be processed by copying method requires use of forming tool cutting edge is consistent with the cross section shape of the slot of the gear processed on milling machine with single tooth forming milling cutter for armored artifacts dividing head cock the Angle: dividing head cock the Angle is equal to the root cone busbar with cone gear axis Angle (Angle) and the cutting Angle.

The principle of gear meshing is used to make one of a pair of meshing gear pair into a cutter and the other into a workpiece and force the cutter and the workpiece to do strict meshing transmission so that the machining accuracy is high and the production efficiency is high

5.k series helical bevel geared motor in mining industry has long service life: under the condition of correct selection (including selection of appropriate use factor) and normal use and maintenance, the life of main parts of helical bevel geared motor in mining industry (except wearing parts) is generally not less than 20,000 hours. . Consumables include lubricants, oil seals, and bearings.

With Best Regards,
Cherry Zhang ( Sales Department; Miss. )
NER GROUP CO.,LIMITED
Yantai Bonway Manufacturer Co., Ltd
Tel:+86-535-6330966
Mobile:+86-18865558975
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Add:No.5 Wanshoushan Road Yantai city Shandong Province, China