proper coupling selection: what you’re probably missing

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Before We Start

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Meet your Speakers MODERATOR FEATURED SPEAKER

Randy Kingsbury Vice President of Sales and Marketing Helical Products Company

Mike Santora Associate Editor Design World

FEATURED SPEAKER

Robert Collins Technical Sales Engineer Servometer

ProperCouplingSelec/on

#1 Step Consider the coupling an integral part of your

system during the design phase. Not an afterthought when assembling.

__________________________

ProperCouplingSelec/on

#1 Step Consider the coupling an integral part of your

system during the design phase. Not an afterthought when assembling.

__________________________ There are many types of couplings offering

different torque capacities, varying misalignment capabilities, overall dimensions

(diameter & length) and materials.

ProperCouplingSelec/on

#1 Step Consider the coupling an integral part of your

system during the design phase. Not an afterthought when assembling.

__________________________ There are many types of couplings offering different torque capacities, varying misalignment capabilities,

overall dimensions (diameter & length) and materials.

There is no governing body for couplings.

ProperCouplingSelec/on

  GeneralKnownso Sha6Diameterso TorqueRequired

 Torque(lbin)=(63000*HP)/RPM Torque(Nm)=9.5488xPower(kW)/Speed(RPM)

o TorsionalFlexibility deg/lbinordeg/Nm

o Misalignment

ProperCouplingSelec/on

  TolerancesStackUp  Example:ResonanceOscillator

Motor,Mount,Base,BearingBlock,Bearings,Sha6  Motor 0.002  MotorMount +-0.005  Base 000  BearingBlock +-0.005  Bearings 0.0005  Sha6 0.0005

___________________________Maximumtotal 0.013

ProperCouplingSelec/on

 Misalignmento Angular

ProperCouplingSelec/on

 Misalignmento Parallel

ProperCouplingSelec/on

  OtherConsidera/onso AxialMo/on

 ThermalExpansion Thrustloading

ProperCouplingSelec/on

  OtherConsidera/onso AxialMo/on

 ThermalExpansion Thrustloading

o Iner/a Accelera/on Decelera/on

ProperCouplingSelec/on

  OtherConsidera/onso Iner/a

 Accelera/on Decelera/on

ProperCouplingSelec/on

  OtherConsidera/onso  AxialMo/on

  ThermalExpansion  Thrustloading

o  Iner/alloading  Accelera/on  Decelera/on

o  Environmental  Temperature  Chemical  Medical

o  Speed/RPM

ProperCouplingSelec/on

  Abachmento SetScrewo SetScrewwithkeywayo Clamp(IntegralorRemovableCap)

ProperCouplingSelec/on

  Abachmento SetScrewo Clamp(IntegralorRemovableCap)o SetScrewwithkeyway

  BoreStyleo 1or2Flatso HexBoreo Spline

ProperCouplingSelec/on

  Price$$$o Acouplingcanbetoobig(excessiveiner/a).

ProperCouplingSelec/on

  CustomSolu/onso Quan//es>25o CanbelessexpensivethanStandardCouplings

ProperCouplingSelec/on

  CustomCouplings

ProperCouplingSelec/on

ProperCouplingSelec/on

  Thankyouo Heli-Cal.com&MachinedSprings.com

Stock & Custom Engineered Bellows Couplings

1.  Servometer Bellows Coupling Construction 2.  Standard Bellows Couplings Available 3.  Custom Bellows Couplings Available 4.  Examples of Applications 5.  Pitfalls of Proper Coupling Selection 6.  Geometry Requirements 7.  Torque Requirements 8.  Flexible Movement Considerations 9.  Mutual Exclusivity for Bellows Couplings 10.  Operational Environments 11.  Guidelines for Specifying a Custom Design

Bellows couplings are an assembly of two end pieces and a thin walled metal bellows. The thin walled Metal Bellows are made by electroplating Nickel metal onto a precision-machined mandrel and then chemically removing the mandrel so that all that remains is the electroformed bellows. Servometer produces parts using our signature Nickel-Cobalt Alloy, FlexNickel® It can be used with other surface finishesincluding copper, gold, and silver or a combination depending upon media compatibility and conductivity.

   Diameters from ¼” to 2.4”    Lengths from 0.48” to 2.4”    Torque range from 2 in-oz up to 4,000 in-oz    Temperature Range from -58° F up to 260° F    Zero Backlash    Low Windup/High Torsional Stiffness    100,000,000 Cycle Life Rating within rating limits

(Compression, Bending, and Offset are MUTUALLY EXCLUSIVE)

}  Form, Fit and Function Optimized for Your Application ◦  Bore sizes ◦  Unique ends or flanges ◦  Unique Performance Values ◦  Increased Torque ◦  Operating Temp up to 300°F

}  It’s all about geometry. }  Torque requirements will match bore

size. }  My last bellows coupling broke so I need

either higher torque or a different design. ◦  Cycle life -100,000,000 cycles determined by:

�  1 rotation = 2 cycles �  Amount of Compression, Offset, Bending �  NO EXCURSIONS

}  Operational environment is not important.

}  Speed of rotation is not important. }  I don’t have enough time for a

custom design.

}  Design Envelope Restricts Selection ◦  Outside Diameter �  Custom solutions with thicker walls might

meet higher torque requirements with smaller diameters.

◦  Overall Length �  Bellows Couplings are “Hollow” �  Larger diameter may be necessary. �  Set-Screw Bellows Couplings are shorter

than clamping style.

}  Torque of Motor is NOT the Maximum Torque. ◦  Gearboxes provide a multiplier to the

available torque at the input shaft = to the speed ratio.

◦  Starting Torque of Motor can be 3X – 5X of standard operating Torque.

◦  When a Bellows Coupling is used in compression only 75% of allowable coupling Torque rating should be considered Maximum Allowable

◦  Pulleys and Moments of Inertia must be considered to calculate maximum instantaneous torque.

}  Compression, Offset, Bending are Mutually Exclusive. ◦  % of above properties with respect to

maximum allowed when added must not exceed 100% ◦  Bellows Couplings are quite flexible

but should not be abused.

}  More Compression/Offset/Bending Required ◦  Coupling can be de-rated

(less than 100,000,000 cycles) to achieve a more flexibility for reduced life.

}  Compression on Bellows Coupling ◦  Use 75% of Maximum Torque

Allowed.

Product Specs

Parallel Offset

Bending Compression Allowable Torque

Comments

FC-1@ 1 X 108 Cycles

0.076” 31° 0.107” 2 in-oz Allowable

Example 1 0 (0%)

31° (100%)

0 (0%)

2 in-oz All Angular Full Torque

Example 2 0 (0%)

15.5 (50%) 0.05 (50%)

1.5 in-oz 50/50 Mix 75% of rated Torque

FC-1 @ 1 X 104

cycles

0.144” 58.9° .203” 2 in-oz Increased Movement for 10,000 cycles

}  Temperature ◦  Max operating temp for Servometer bellows

couplings is 260°F ◦  Min Operating Temp for Servometer Bellows has

not yet been determined. }  Corrosion Resistance ◦  Servometer Bellows Couplings are an assembly

�  Material: Servometer FlexNickel �  303 Stainless Steel Hubs (Aluminum also available) ◦  Servometer Bellows Couplings typically suitable

for high PH environments.

}  Collect ALL pertinent information ◦  Temperature of Operation ◦  Corrosion Potentials (Materials of Construction) ◦  Type of Movement (How much of each?)

�  Offset (even small amounts can count) �  Compression �  Bending ◦  Max Torque ◦  Speed of Rotation

}  Standard or Custom }  Know your Geometry }  Torque Requirements }  Flexibility Requirements }  Operational Environment }  Guidelines for Custom Parts

Cedar Grove, NJ, 973.785.4630

servometer.com http://buy.servometer.com

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Questions? MODERATOR FEATURED SPEAKER

Randy Kingsbury Vice President of Sales and Marketing Helical Products Company RKingsbury@hel-cal.com

Mike Santora Associate Editor Design World msantora@wtwhmedia.com

FEATURED SPEAKER

Robert Collins Technical Sales Engineer Servometer RobertC@servometer.com

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