designworldonline.com motioncontroltips.

com April 2016

POWER
Transmission
REFERENCE GUIDE

Cover.indd 1 5/2/16 11:24 AM

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 Haydon Kerk® Linear Actuators...

SOLUTIONS IN MOTION
High performance, precision linear
motion technology
Size 17 -
43 mm2 (1.7-in)2
Double Stack -
external,
non-captive,
25000 Series G4, can-stack captive hybrid
captive, non-captive, external linear actuator
linear actuator steppers stepper motors
25 mm (1.0-in) diameter

Size 34 -
87 mm2 (3.4-in)2
Size 17 captive hybrid
- 43 mm2 (1.7-in)2 linear actuator
non-captive stepper motor.
hybrid linear Non-captive and
actuator with external linear
programmable also available.
IDEA™ stepper
motor drive

Size 8 -
21 mm2 (0.8-in)2
captive hybrid linear
actuator stepper motor.
Also available in Single and
Double Stack, non-captive
and external linear.

Haydon Kerk Motion Solutions hybrid and can-stack linear actuators continue to offer equipment designers new motion control solutions
that provide unmatched performance-to-size ratios, patented technologies and thousands of configuration options, and a vast experience in
customized solutions.
HYBRID actuators are available in six sizes from Size 8: 21 mm2 (0.8 -in.) to Size 34: 87 mm2 (3.4-in.) – capable of delivering up to 500 pounds
(2224 N) of force. Travels per step range from .001524 mm (.00006-in) to .127 mm (.005-in), with micro stepping capability for even finer resolution.
An integrated, programmable IDEA™ Drive is also available for Size 17 hybrids.
The G4 Series represents the industry’s most robust and most powerful CAN-STACK linear actuators. The G4 Series offers diameters of
20 mm (.79-in), 26 mm (1-in), and 36 mm (1.4-in). The can-stack product line also includes motors with diameters of 15 mm (0.59-in), 20 mm (.79-in) ,
26 mm (1-in), 36 mm (1.4-in) and Ø 46 mm (1.8-in), available with captive, non-captive or external linear lead-screws.
Haydon Kerk Motion Solutions continues to be an innovative motion control technology company with a global network of
people, facilities and services dedicated to engineering and manufacturing the world’s most advanced linear motion solutions.
For more information: www.HaydonKerk.com > Linear Actuators
Call 1 8OO 243 2715

www.HaydonKerk.com
1500 Meriden Road
Waterbury, CT 06705 U.S.A.
Telephone: 203 756 7441

Haydon Kerk 4-16.indd 3 4/29/16 9:59 AM

 REFERENCE GUIDE
Power Transmission

LISA EITEL
SENIOR EDITOR
@DW_LISAEITEL

POWER-TRANSMISSION
C
COOM
MPPO
ONNE
ENNT
TSS A
ARRE
E M
MAA II N
NSS TAY
TAY S
S
POWER-TRANSMISSION
MOTION
designs continually
evolve, but will always
design of linear systems, actuators and gearmotors, as well as subsystems
such as conveyors and robotics. Consider the section on gearmotors in
rely on mechanical devices, particularly this Reference Guide by Senior Editor Miles Budimir. Here, manufacturers
where the drive of an electric motor are predesigning and assembling more motors than ever with gearboxes
engages a load to execute machine upfront, for an ever-expanding array of ac gearmotors and servo
tasks. In fact, as the technical reviews gearmotors. Such gearmotors are increasingly accurate as well, particularly
in this 2016 Power Transmission those sporting planetary gearsets.
Reference Guide explain, applications That’s thanks in part to how manufacturers are making gearing with
for mechanical motion components only the latest approaches in design, machining and assembly. Check out
proliferate as technical innovations make the sections in this Reference Guide covering gear-design consultation,
them increasingly effective. custom gear designs and analysis, as well as general speed reducers, worm
Consider this Reference Guide’s gearing, and shaft-mount sets. These articles detail common and custom
section on bearings by Associate Editor offerings that optimize inertia matching and speed output. In fact, today’s
Mike Santora. The most common bearing software now lets designers get design-specific gearing—and other power-
applications are in heavy machinery and transmission components—at lower cost than that of general-purpose
industrial setups as always, but renewable- offerings from just a decade ago.
energy use is spurring innovations to get In fact, today’s moving designs rely on an increasingly diverse array
higher capacities as turbines push the of mechanical components to protect expensive subsystems and change
limits of bearing designs. motion-system dynamics to simplify programming. These actuators,
There’s also increased demand ballscrews, bearings, brakes, chains, collars, couplings, gearing, rails and
for complete system solutions over rack-and-pinion sets transmit power in ways that get higher performance
components, which is changing the than ever.

4 DESIGN WORLD 4 • 2016 www.designworldonline.com

DW half p
Editorial_PTGuide_V3.LE.MD.indd 4 4/29/16 10:20 AM
 WWW.MOTIONCONTROLTIPS.COM

So use this Reference Guide as a review of basic component

functions or as an update on what’s new in power-transmission
designs—and to get instructions on how to make the most of
proliferating features to meet evolving motion-system requirements.
As mechanical designs change, count on us Design World
editors to bring you technology updates to help you specify and
integrate the right components. We invite your feedback and
requests for technical information. There are innumerable ways
to reach us: Email me at leitel@wtwhmedia.com or tweet to
@DW_LisaEitel, @Linear_Motion and @Motion_Control.
Connect with our Design World Network Facebook page at
facebook.com/DesignWorldNetwork, and let us know what
designs you’re using or are looking to apply.
WEBINAR ALERT
Also look out for the 2016 Motion Systems Handbook and TRENDS TO WATCH
2016 Motion Casebook coming to you in August and November for IN MOTION CONTROL
complete coverage of electronic and programming technologies
for motion designs, as well as real-world application examples DOWNLOAD ON DEMAND:
and illustrations to inform your next build. In the mean time, also bit.ly/1Lxaexl
find all our motion-technology news announcements (as well as
technical archives) on our motion tips sites—motioncontroltips.
com, linearmotiontips.com, sensortips.com, bearingtips.com and
couplingtips.com.

Get a Free Power Basics Poster

tlec-2015_power-poster-final-cmyk-HIRES.pdf 1 11/9/15 2:54 PM

One Instrument, One Solution

Line Voltage, Current, and Power – The Basics
LINE VOLTAGE LINE CURRENT LINE POWER
MDA800 Series
Motor Drive Analyzers
8 channels, 12-bits, 1 GHz

SINGLE-PHASE THREE-PHASE SINGLE-PHASE SINGLE-PHASE THREE-PHASE

Single-phase line voltage consists of one voltage Three-phase line voltage consists of three voltage vectors. B Like voltage, the single-phase current vector rotates Electric Power
vector with: • By definition, the system is “balanced” at a given frequency • “The rate at which energy is transferred to a circuit” P=V * I Three-phase, Resistive Loads Three-phase, Non-resistive Loads
• Typically, 50 or 60 Hz The resulting time-varying “rotating” I
• Magnitude (voltage) • Vectors are separated by 120° • Units = Watts (one Joule/second)
current vector appears as a sinusoidal For purely resistive loads As with the single-phase case, Power is not the simple
• Angle (phase) • Vectors are of equal magnitude 120° waveform N V
ω (rad/s) or
At any given moment in time, the current magnitude For purely resistive loads • PA = VA-N * IA multiplication of voltage and current magnitudes, and
• Sum of all three voltages = 0 V at Neutral freq (Hz) Resistive load
is I*sin(α) • P = I2R = V2/R = V * I • PB = VB-N * IB subsequent summation for all three phases.
Typically, the single-phase is referred to as “Line” voltage, and Neutral
is referenced to neutral. Typically, the three phases are referred to as A, B, and C, 120° A • I = magnitude of current vector • The current vector and voltage vector are in perfect phase • PC = VC-N * IC
but other conventions are also used: • α = angle of rotation, in radians • PTOTAL = PA + PB + PC
• 1, 2, and 3
Neutral Line • L1, L2, and L3 120° V B-N
V B-N
IB
• R, S, and T Phase Angle Power Factor

The three voltage vectors rotate at a given frequency C

freq (Hz)
Phase Angle (φ) Power Factor (PF, or λ) IB
Line
• Typically, 50 or 60 Hz for utility-supplied voltage Neutral
• Indicates the angular difference between the • cos(φ) for purely sinusoidal waveforms IA N
N V A-N
current and voltage vectors • Unitless, 0 to 1, V A-N φ
The single-phase voltage vector rotates at a given frequency
The resulting time-varying “rotating” voltage vectors appear • Degrees: - 90° to +90° • 1 = V and I in phase, purely resistive load
• Typically, 50 or 60 Hz for utility-supplied voltage IC IA
as three sinusoidal waveforms • Or radians: -π/2 to + π/2 • 0 = 90° out of phase, purely capacitive IC
At any given moment in time, the voltage magnitude is V * sin(α) • Separated by 120° or purely inductive load
• Of equal peak amplitude • Not typically “signed” – current either PT O T A L ≠ VA - N * IA + VB - N * IB + VC - N * IC
• V = magnitude of voltage vector PT O T A L = VA - N * IA + VB - N * IB + VC - N * IC V C-N
• α = angle of rotation, in radians
Voltage value = VX*sin(α) THREE-PHASE leads (capacitive load) or lags
(inductive load) the voltage
V C-N

• VX = magnitude of phase voltage vector

• α = angle of rotation, in radians Three-phase, Any Load QB
B
By definition, the system is “balanced”
VB
• Vectors are separated by 120˚ Apparent Power for each Phase
• Vectors are of equal magnitude
Voltage • |S|, in Volt-Amperes, or VA Reactive Power for each Phase
Voltages can be measured two ways: SB
ω (rad/s) or
VA-B • Sum of all three currents = O A at neutral (provided 120° Current • Q, in Volt-Amperes reactive, or VAr PB φ
freq (Hz) • Line-Line (L-L) ω (rad/s) or • = VRMS * IRMS for a given power cycle
freq (Hz)
Neutral Line • Also referred to as Phase-Phase there is no leakage of current to ground) • Q = S2 - P2 PA
Neutral Real Power for each Phase
• e.g. from VA to VB, or VA-B 120° A Single-phase, Non-resistive Loads SC
φ
Like voltage, three-phase current has three different line • P, in Watts • PTOTAL = PA + PB + PC QA
• Line-Neutral (L-N) Neutral φ
SA
120° VA current vectors that rotate at a given frequency • = instantaneous V * I for a given • STOTAL = SA + SB + SC PC
• Neutral must be present and accessible • Typically, 50 or 60 Hz for utility-supplied voltage For capacitive and inductive loads power cycle • QTOTAL = QA + QB + QC
• e.g. from VA to Neutral, or VA-N 120°
VA-N • P ≠ V * I since voltage and current are P≠V*I QC
• VL-L conversion to VL-N not in phase
• Magnitude: VL-N * 3 = VL-L N V
The resulting time-varying “rotating” voltage vector appears as • Phase: VL-N - 30° = VL-L C φ Line-Line Voltage Sensing Case
a sinusoidal waveform with a fixed frequency
• For inductive loads I
VC • The current vector “lags” the voltage Voltage is measured L-L
• 50 Hz in Europe AC Three-Phase “Utility” Voltage Like voltage, the resulting time-varying “rotating” Inductive load B B
Line-Line Voltage Measurements 480VAC , Measured Line-Line • Neutral point may not be accessible, or
• 60 Hz in US 800
current vectors appear as three sinusoidal waveforms vector angle φ VA-B VB-N
• Either 50 or 60 Hz in Asia • Separated by 120° • Purely inductive load has angle φ = 90° • L-L voltage sensing may be preferred IB IB
Important to Know VA-N
I
600
• Other frequencies are sometimes used in non-utility • Of equal peak amplitude for a balanced load
supplied power, e.g.
• Voltage is stated as “VAC”, but this is really VRMS 400 P≠V*I Current is measured L-N VB-C
A A
φ N

Volts (Peak), Line-Line

• Rated Three-phase voltage is always Line-Line (VL-L) 200 Current value = IX*sin(α) • Capacitive Loads IC IA
IC
N IA
• 400 Hz
• Line-Line is A-B (VA-B), B-C (VB-C), and C-A (VC-A) • The current vector “leads” the voltage
N V L-L voltages must be transformed to L-N reference:
• 25 Hz 0 • IX = magnitude of line current vector VC-A
• Line-Line is sometimes referred to as Phase-Phase • α = angle of rotation, in radians vector by angle φ Capacitive load
-200
Calculations are straightforward, as described above: C C
• VPEAK(L-L) = 2 * VL-L -400
• Purely capacitive load has angle φ = 90° VC-N
• 679 V in the example to the right • PTOTAL= PA + PB + PC
-600 Line Current Measurements • STOTAL = SA + SB + SC
• VPK-PK(L-L) = 2 * VPEAK(L-L)
-800
Single-phase Real, Apparent and Reactive Power • QTOTAL = QA + QB + QC
Time A-B Voltage
B-C Voltage
Important to Know
Important to Know 480 VAC Example C-A Voltage
• Current is stated as “lAC”, but this is really IRMS AC Three-Phase "Line" Currents
• Line currents can represent either current Apparent Power Two Wattmeter Method – 2 Voltages, 2 Currents with Wye (Y or Star) or Delta (∆) Winding

Imaginary Power
• Voltage is stated as “VAC”, but this is really VRMS
15

• Rated Voltage is Line-Neutral Line-Neutral Voltage Measurements through a coil, or current into a terminal 12 • |S|, in Volt-Amperes, or VA
AC Three-Phase “Utility” Voltage 9
• = VRMS * IRMS for a given power cycle
• VPEAK = 2 * VAC (or 2 * VRMS ) 800
480VAC , Measured Line-Neutral (see image below) depending on the three-phase 6 S Q
Voltage is measured L-L on two phases
PTOTAL = VA-C * IA + VB-C * IB
If a neutral wire is present, three-phase voltages winding connection

Line Current (Peak)

• 169.7 V in the example below • Note that the both voltages are measured with
φ
3

may also be measured Line-Neutral

600 Real Power STOTAL= VRMSA-C * IRMSA + VRMSB-C * IRMSB
• VPK-PK = 2 * VPEAK • IPEAK = 2 * IRMS 0 reference to C phase
• If rectified and filtered • VL-N = VL-L/ 3 400 • P, in Watts
• 14.14A for a 10 ARMS current in the example QTOTAL = STOTAL2 - PTOTAL2

Volts (Peak), Line-Neutral

-3

• = instantaneous V * I for a given power cycle

• VDC = 2 * VAC = VPEAK
AC Single-Phase “Utility” Voltage
• 277 VAC (VRMS) in this example 200
to the right
-6
P Real Power
Current is measured on two phases
B IB
• The two that flow into the C phase
-9
120VAC • VPEAK = 2 * VL-N 0
• IPK-PK = 2 * IPEAK
200

• 392 V in the example to the right

-12
Reactive Power
Note: Any distortion present on the Line voltage
B
150 -200
IB
-15
• Q, in Volt-Amperes reactive, or VAr
Volts (Peak), Line-Neutral

100
• VPK-PK = 2 * VPEAK B IB Time
and current waveforms will result in power Mathematical assumptions:
• Q = S2 - P2
-400
B VB-C
50 A Current
measurement errors if real power (P) is • Σ(IA + IB + IC) = 0 VB-C
-600
IB B Current
• Does not “transfer” to load during a power cycle, A

Identify 3-phase electrical and motor

120 VAC Example
0

If all three phases are rectified and filtered

C Current
calculated as |S|*cos(φ). To avoid measurement • Σ(VA-B + VB-C + VC-A) = 0 N IA
just “moves around” in the circuit
-50
-800
A errors, a digital sampling technique for power
-100 • VDC = 2 * VL-N * 3 = VPEAK * 3 = 679 V Time A-N Voltage
N IA
B-N Voltage IC
10 ARMS Example calculations should be used, and this technique is This is a widely used and valid method VA-C C A
in the example to the right
-150 C-N Voltage
C A IA
-200
Three-phase Rectified DC IC IA also valid for pure sinusoidal waveforms. for a balanced three-phase system C VA-C
Time
480 VAC Example C

“Not True” RMS “True” RMS Three-Phase Winding Connections Digital Sampling Technique for Power Calculations� • The digital samples are grouped Formulas Used for Per-cycle Digitally Sampled Calculations mi + Mi - 1

B
Period 1
Mi = 18 points
Period 2
Mi = 18 points
into measurement cycles (periods)
• For a given cycle index i…. mi + Mi - 1
Real Power
(P, in Watts)
Pi = 1
Mi Σ Vj * Ij
Power Factor (λ) λi =
Pi

Σ
B • The digitally sampled voltage 1 j=mi Si
waveform is represented as having a VRMS VRMSi = V j2
Mi
VPK-PK Wye (Y) 3-phase Connection Delta (∆) 3-phase Connection set of sample points j in cycle index i j=mi Apparent Power Si = VRMSi * IRMSi
• Neutral is present in the winding • Neutral is not present in the • For a given cycle index i, there are
A winding (in most cases) (S, in VA)
• But often is not accessible N Mi sample points beginning at mi
• Most common configuration and continuing through mi + Mi -1. magnitude Φi = cos-1λi
mi = point 7 mi = point 25 mi + Mi - 1
• Voltage, current, power, etc.

Σ
1 V magnitude Qi = S i2 - P i2
VRMS =
2 2
PK-PK VRMS = VAC2
C
C A values are calculated on each IRMS IRMSi = 1 I j2 Reactive Power
Phase Angle (φ)
Sign of Φi is positive if the fundamental voltage
cycle index i from 1 to N cycles. Mi (Q, in VAR) Sign of Qi is positive if the fundamental voltage vector leads the fundamental current vector
For one power cycle For one power cycle j=mi vector leads the fundamental current vector

teledynelecroy.com/motor-drive-analyzer | teledynelecroy.com/contactus

mechanical static and dynamic power

© 2015 Teledyne LeCroy, Inc. All rights reserved.

behaviors. Built on an 8 channel, 12-bit, 1 GHz oscilloscope

platform for power section and embedded control debug –
complete test capability.

Learn more about the MDA800 and sign up to

receive a Power Basics Poster for free:
teledynelecroy.com/static-dynamic-complete

MDA800 Series
Motor Drive Analyzers

tlec-mda-poster-designworld.indd 1 2/5/16 2:04 PM

Editorial_PTGuide_V3.LE.MD.indd 5 4/29/16 10:37 AM
 REFERENCE GUIDE
NEW MEDIA/WEB/
GRAPHICS EDITORIAL BUSINESS DEVELOPMENT

Director, Creative Services Editorial Director Web Development Manager Business Development
Mark Rook Paul J. Heney B. David Miyares Manager
mrook@wtwhmedia.com pheney@wtwhmedia.com dmiyares@wtwhmedia.com Patrick Curran
@wtwh_graphics @dw_Editor @wtwh_WebDave pcurran@wtwhmedia.com
@wtwhseopatrick
Art Director Managing Editor Web Development Specialist
Matthew Claney Leslie Langnau Patrick Amigo Online Coordinator
Power Transmission

mclaney@wtwhmedia.com llangnau@wtwhmedia.com pamigo@wtwhmedia.com Jennifer Calhoon

@wtwh_designer @dw_3Dprinting @amigo_patrick jcalhoon@wtwhmedia.com
@wtwh_Jennifer
Graphic Designer Executive Editor Digital Marketing Specialist
Allison Washko Leland Teschler Andrew Zistler
azistler@wtwhmedia.com
awashko@wtwhmedia.com lteschler@wtwhmedia.com Director, Audience
@wtwh_allison @dw_LeeTeschler Development
Bruce Sprague
Controller
Senior Editor bsprague@wtwhmedia.com
Brian Korsberg
Traffic Manager Miles Budimir
bkorsberg@wtwhmedia.com
Mary Heideloff mbudimir@wtwhmedia.com
mheideloff@wtwhmedia.com @dw_Motion
MARKETING
Production Associate Senior Editor
Tracy Powers Mary Gannon Marketing Manager
tpowers@wtwhmedia.com mgannon@wtwhmedia.com Stacy Combest
2014 Winner
@dw_MaryGannon scombest@wtwhmedia.com
@wtwh_Stacy
VIDEO
Senior Editor
Lisa Eitel Marketing & Event
Videographer Coordinator
leitel@wtwhmedia.com
John Hansel Jen Kolasky
@dw_LisaEitel
jhansel@wtwhmedia.com jkolasky@wtwhmedia.com
@wtwh_Jhansel @wtwh_Jen
Associate Editor
Mike Santora
Videographer Marketing Coordinator
msantora@wtwhmedia.com
Kyle Johnston Lexi Korsok
@dw_MikeSantora
kjohnston@wtwhmedia.com lkorsok@wtwhmedia.com
@wtwh_Kyle @medtech_Lexi
Assistant Editor
Michelle DiFrangia
Videographer Digital Marketing Specialist
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Alex Barni Josh Breuler
@wtwh_Michelle
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@wtwh_Joshb

Digital Marketing Intern 2011 - 2015

Aly Ryan
aryan@wtwhmedia.com
@wtwh_Aly

CONNECT
WITH US!
Follow the whole team on twitter @DesignWorld

6 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

StaffPage_PTGuide_V1.indd 6 4/29/16 5:34 PM

 What’s Inside
Matters
The PITTMAN Difference ®

On the outside, this looks like an ordinary DC motor. In fact, this particular motor
is not a standard off-the-shelf part, but designed exactly to a customer’s specific
technical requirements. PITTMAN has an experienced team of engineers focused
on providing the perfect motor assembly to our customers demanding motion
applications.

• Special brush formulation for use in a very low humidity environment

• Bearing system to handle higher than normal axial loads
• Very tight balancing spec to minimize audible noise and vibration at high speeds
• Unique magnet charge pattern to minimize cogging at low speeds
• Specially chosen surface-mount components inside the motor to meet
an aggressive EMC requirement
• Numerous integrated spur and planetary gearboxes, encoders, brakes and drives

When evaluating DC motor choices, it’s what’s inside that matters.

www.Pittman–Motors.com
343 Godshall Drive, Harleysville, PA 19438
USA: +1 267 933 2105
Europe: +33 2 40 92 87 51
Asia: +86 21 5763 1258

Pittman (AMETEK) 3-16.indd 7 4/29/16 10:00 AM

 M OT I O N CO N T R O LT I P S . CO M

INSIDE VOL 2
NO 2 P04
Power-transmission
components are
mainstays

PTDA Updates ..............................................10

Actuators
Electrical ..................................................14
Rigid Chain ..............................................18
Ballscrews .....................................................20
Bearings ......................................................24
Belts, Pulleys ...........................................28
Brakes, Clutches ...................................31
Cabling ................................................32
Chain, Roller, Sprocket .......................34
Compression Springs ........................38
Couplings ..........................................41
Drives ................................................50

18
Gearing .............................................54
Gearmotors ........................................66
Leadscrews...........................................68
Linear Motion ........................................70
Locking Devices, Shaft Collars .................75
Lubrication ..................................................78
Motors ..........................................................80
Positioning Stages ........................................84
Seals .............................................................86
Shock, Vibration Damping ............................88

Cover photography by
Miles Budimir

8 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Contents_PTGuide_V1.indd 8 5/3/16 10:42 AM

 Affordable Power Transmission
high-quality components at low prices!

SureMotion® Drive Couplings • Jaw / Spider Couplings start at $10.50

Reduce the unwanted stress caused by shaft misalignment with our new • Double Loop Couplings start at $34.00
line of high-quality drive couplings. These drive couplings come in a • Oldham Couplings start at $14.25
variety of styles, torque ranges and coupling capabilities each designed • Beam-Style Servo Couplings start at $42.00
to enhance system performance and prevent costly failures. • Bore Reducers start at $7.00

NEW!

Worm Gearboxes Precision Gearboxes Synchronous Drives

IronHorse® worm gearboxes are built to If it is precision you need, our SureGear Our SureMotion line of synchronous drive
withstand the toughest applications while family of precision gearboxes is an components provide dependable speed
delivering reliable speed reduction and excellent solution. They are available and torque changes without unwanted
increased torque output. in a wide range of ratios and styles, and slippage and speed variations.
• Aluminum gearboxes provide high-precision motion control • Drive pulleys start at $5.25
start at $88.00 at an incredible price.
• Drive belts start at $2.00
• Cast Iron gearboxes • Servomotor gearboxes
start at $147.00 start at $398.00
• Small NEMA motor gearboxes
start at $209.00

Research, price, buy at: www.automationdirect.com/power-transmission

Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

AutomationDirect_PTGuide4-16.indd 9 4/29/16 10:32 AM

 Power Transmission

REFERENCE GUIDE
The PTDA Spring Governance Meetings attracted nearly 90 volunteer senior
leaders to Charleston, S.C., along with more than 45 Next-Gen members who
took part in the PTDA 2016 Leadership Development Conference. Attendees
played Businessopoly, the name PTDA gave to an interactive, hands-on board
game that teaches executive management skills.

PTDA POWER TRANSMISSION

D I S T R I B U T O R S A S S O C I AT I O N

UPDATES MIKE SANTORA • ASSOCIATE EDITOR • @DW_MIKESANTORA

2016 LEADERSHIP DEVELOPMENT CONFERENCE

The Power Transmission Distributors Association (PTDA) held its 2016 Leadership Development Conference
in early March in the Historic District of Charleston, S.C.
PTDA members continuously seek ways to bring their future management team up-to-speed so they
can step into a supervisory role ready to excel. The 2016 Leadership Development Conference fulfilled
that need. Designed for emerging power transmission/motion control leaders who want to enhance their
management skills, network in small group settings, and learn best practices that support business results,
those that participated in this year’s conference benefited from two sessions:

• “Ready. Get Set. Lead”—a dinner program by Randy Disharoon, director global accounts, Rexnord
Industries, on how to quickly ramp up younger leaders for success to kick-off the conference
• “Businessopoly”—a full-day, interactive, team-oriented business simulation game, led by industry
veteran Michael Cinquemani, president and CEO, Master Power Transmission.

Cinquemani said, “We are going to really challenge people to give them a deeper understanding of their
decision-making: how it affects the profit and loss statement, the balance sheet, the statement of cash
flows, and then review their results compared to their initial plans.”

10 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

PTDAUpdates_PTGuide_V3.indd 10 4/29/16 10:38 AM

 PTDA WELCOMES
SIX NEW MEMBERS
PTDA has recently welcomed six
new member companies.
DISTRIBUTOR MEMBER
MJ May Material Specialists
(South Holland, Ill.) distributes
mechanical PT components,
bearings, motors, motor/motion
control, electrical/electronic
drives, material handling,
hydraulics/pneumatics, and PT
accessories. President Walter
Lopez said, “As a small business
looking to grow in the power
transmission market, it was a no-
brainer for us to join. The access
to manufacturers and opportunity
to strengthen established
relationships will greatly benefit us
in our quest to become a premier
distributor of power transmission
products.”
iwis Drive Systems (Indianapolis,
Ind.) manufactures chains and
sprockets. “iwis joined PTDA to
increase our network within the
industrial distribution arena. The
fact is, we have made significant
investments into new products
and value added services and
PTDA represents a powerful
tool for us to capitalize on these
initiatives,” said Kody Fedorcha,
VP, sales and marketing.
Rosta USA Corporation (South
Haven, Mich.) is a manufacturer of
motor bases.
Wittenstein (Bartlett, Ill.)
manufactures couplings, gearing,
motors, motor/motion control
products and linear motion
components. Tom Coyle,
director of sales NA, said, “We
are pleased to be a part of this
association. My goals as a member of PTDA are to leverage the wide
network of distributor organizations and contacts, gain access and new
perspectives to industry economics and trends, and finally to increase
exposure of Wittenstein,”
PTDA 2016 CANADIAN CONFERENCE
Registration is still open for the PTDA 2016 Canadian Conference, to
be held June 9-10, 2016, at The Westin Ottawa in Ottawa, Ontario. For
the 15th year, members of the Canadian power transmission/motion
control (PT/MC) industry gather for business networking, market-driven
education, a manufacturer industry showcase and more.
Networking opportunities abound at the PTDA 2016 Canadian
Conference. Participants have many opportunities to meet channel
partners—both new and established—in comfortable settings such as
the Industry Showcase Welcome Reception, featuring tabletop exhibits
from every registered PTDA manufacturer member company.
Along with networking, business market-driven education takes
center stage. Participants will hear information targeted to solve the
most vexing needs of the industry including information on corporate
culture, hiring, knowledge transfer and an update on the Canadian
mining industry. For more information about the Canadian Conference,
please visit www.ptda.org/CanadianConference.

MANUFACTURER MEMBERS
Auburn Bearing & Manufacturing
(Macedon, N.Y.) manufacturers
bearings. “We chose to join PTDA
because a vast majority of our
sales are through an established
network of distributors across
the marketplace. PTDA will assist
us in expanding that network
even further,” said Peter Schroth,
president.

Helical Products Company,

a location of MW Industries,
(Rosemont, Ill.) manufactures
spring couplings and retaining
rings. Robert Jack, VP marketing
and strategic planning, said, “The
opportunity to network with both
manufacturers and distributors in
our industry is very valuable to us,
and we look forward to being an
active member and forging many
new relationships in the years to Jim LaHaie, president, W.C. DuComb Co. and John Masek, SVP, Bearing Service Inc., took advantage
come." of PTDA’s complimentary Regional Networking Events and an optional Detroit Tigers game last year.
In 2016, complimentary PTDA Regional Networking Events are coming to Minneapolis, Chicago
and Cincinnati and are open to any employee of a PTDA member company or a prospective member
company.

motioncontroltips.com | designworldonline.com 4 • 2016 DESIGN WORLD — MOTION 11

PTDAUpdates_PTGuide_V3.indd 11 4/29/16 10:39 AM

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 REFERENCE GUIDE
Power Transmission

ELECTRIC ACTUATORS:
SMART DESIGNS EXCEL

LISA EITEL
MANY
applications call for converting rotary motion into motion that
SENIOR EDITOR moves in a straight line. For these applications, linear electric or
@DW_LISAEITEL electromechanical actuators handle the task efficiently. In fact, today’s actuators are
so efficient that the variety available for different design needs has proliferated. That
means that actuators today are easier than ever to integrate into machinery; they’re
also less costly.
Electric actuators turn an electric motor’s power into linear motion in one of
three ways: through a linear motor, belt or screw drive. Linear motors are the most
technologically advanced and efficient method of directly transmitting the power of
the motor into the motion of the actuator. Instead of the rotor rotating in the stator,
the rotor travels in a linear, flat-array fashion along the stator.
Belt drive actuators are less costly, but can still move loads at fairly high linear
speeds. Because the motor is separate from the drive, the mechanical advantage
can increase thrust speed. The disadvantage of belt drives is that they wear over
time and require maintenance.

14 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

ElectricActuators_PT2016_V3.indd 14 4/29/16 10:40 AM

 ELECTRIC ACTUATORS

Linear positioning actuators of extremely long stroke

lengths — such as this LoPro linear actuator from Bishop-
Wisecarver — typically use belt drives. Polyurethane
belting is quiet and delivers long mechanical actuation
with good accuracy and high speeds. LoPro actuators are
three to 8 m long, but units to 15 m are possible.

Most screw drives take the form
of either rod-style actuators or rodless
cylinders. A motor transmits power
through a coupler or pulley arrangement
to rotate the screw and translate a nut
along the screw axis. Attached to this
nut is either the rod or saddle of the
actuator. Screw drives can use roller, ball
or leadscrews.
Electric actuators have several
benefits over hydraulic or pneumatic
actuators. For one, the operation
is cleaner because they operate
without the need for fluids or ancillary
equipment. They have the ability to
integrate power, control and actuation
mechanisms into one device. And they
combine force, velocity and positioning
in a single, compact motion control
device.
Another advantage is the ability
to constantly monitor feedback directly
from the motor and adjust performance
accordingly. Though not necessary for
every application, closed-loop operation
has the ability to adjust and correct
variances in the operation, resulting in
repeatable and accurate motion with
every move.
Today, the prices for drives for
electric actuators have come down,
which has opened new application
uses for the linear actuator. So, electric
actuators are more viable for applications
where hydraulic, pneumatic and manual
operations once ruled.
In many applications, servomotors
are replacing induction motors because
of their performance and energy efficiency. Direct drives are replacing
traditional motor-gearbox combinations because of their high dynamic
performance, high precision and long life. And electric actuators are replacing
pneumatic cylinders in many applications for similar reasons.
But the biggest improvements in the last five to ten years can be found
in the control systems integrated with electric actuators. Faster bus systems,
like industrial Ethernet and real-time communication, make the use of electric
actuators simpler.
Servo systems require fast communication and exchange of real-time
data between the drive and the overlaid machine control. The bus was always
the bottleneck in these systems. Now, with the much higher data rates and
real-time capacity of industrial Ethernet, the integration and the use of electric
actuators is easier. Stepper and servo drive options with Ethernet protocols
(Ethernet IP, Modbus, TCP) turn single-axis actuators into simple, low-cost
motion devices with infinite positioning, precise control and longer life.
Electric linear actuators are an alternative to pneumatic cylinders in several
applications because of the flexibility they deliver in the design of production
processes and production monitoring systems. In conveying applications,
for example, diverting and sorting functions are more
frequently controlled using electric actuators. Typically,
pneumatic actuators have been used, but the required
manual adjustments were often subject to human error.
Plus, the pneumatic actuators could only handle a small
amount of variability in product sizes. Electric actuators
are flexible by design.
For example, material handling
applications have experienced an
increase in the variety and variability
of package sizes. In packaging
machines, consumer
products manufacturers are
Tolomatic ERD hygienic
all-stainless-steel
electric cylinders have
a roller-screw option that
boosts maximum thrust to
7,868 lbf (35.6 kN) for better life and
performance under high duty cycles than
ballscrew models.

motioncontroltips.com | designworldonline.com 4 • 2016 DESIGN WORLD — MOTION 15

ElectricActuators_PT2016_V3.indd 15 4/29/16 10:40 AM

 REFERENCE GUIDE

producing more package sizes with the

same manufacturing lines, which require
equipment to be adaptable enough to
Power Transmission

handle different product sizes and types.

Electric actuators easily handle these
variability requirements and, over the life of
the motion system, can be less expensive.

SELECTING AN ELECTRIC ACTUATOR

The process for selecting an electric
actuator is similar to one for hydraulic
or pneumatic actuators, with a few
differences. Here are the essentials.
Start with the motion profile. This
establishes the demands for velocity and
time as well as force (or torque) and the
required travel distance. This is also the
place to determine the maximum stroke
needed as well as maximum and minimum
speed requirements.
Then calculate the load. This can have
many different components including
inertial load, friction load, the external
applied load, as well as the gravitational
load. Load calculations also depend on the
orientation of the actuator itself, whether
it’s horizontal or vertical.
Duty cycle is another important factor.
This is defined as the ratio of operating
time to resting time and is usually
expressed as a percentage. The cycling
rate may be in seconds, minutes, hours
or even days, and knowing the operating
hours per day may also be necessary.
Knowing the duty cycle helps the engineer
estimate the system life requirements
and can also eliminate problems such as
overheating, faster wear and premature
component failure due to an incorrectly
sized actuator.
Know the positional accuracy and
precision demanded by the application.
The actuator’s precision should meet or
exceed the application’s requirements
for accuracy, backlash, and straightness
and flatness of linear motion. This directly
impacts the cost of the system; if the
NSK’s MCM Series Monocarrier includes a ballscrew, linear
guide and supports in one compact structure. It boosts
accuracy and reduces installation time, and some versions are
available through a Quick Ship Program.
application doesn’t demand high
accuracy or precision, then there is no
need to buy a more expensive actuator
when a less expensive one will satisfy
the demands of the application.
Aside from the technical
specifications mentioned above, there
is also the need to select the proper
configuration for the actuator in the
final design. This includes mounting
considerations and the need for any
other external components, such as
holding brakes and communication and
power cables.
Lastly, consider the operating
environment for the actuator. What are
the temperature requirements? Are
there any contaminants such as water,
oil or abrasive chemicals? Contaminants
can affect seals and impact the working
life of the actuator. In such cases,
selecting the appropriate IP rating for
an application can guard against the
effects of contaminants.

16 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

ElectricActuators_PT2016_V3.indd 16 4/29/16 10:41 AM

 MAINTENANCE-
fREE OPERATION.
WORRy-fREE
DESIGN.

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17 World ad_K1 Unit[250314]v1.indd 1 2014-03-25 3:14 AM
PM
NSK 8-15.indd 4/29/16 10:04
 REFERENCE GUIDE LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

MECHANICAL COMPONENTS
AT T H E H E A R T O F M O T I O N D E S I G N

RIGID-CHAIN
actuators work by pairing a drive
(usually an electric motor) with
a length of chain sporting shoulders on each link. The motor
output shaft—fitted with a specialty sprocket or pinion—applies
Power Transmission

tangential force to the chain. Then the chain comes out and
straightens, and its links’ shoulders lock to form a rigid series.
When the motor runs in the opposite direction, the chain
shoulders disengage and allow for coiling.
Inside the actuator body, reaction plates and guides counter
thrust resistance and keep the chain on track. Links travel around
the pinion to exit the actuator body along the stroke path. Here,
the motor’s torque comes to act as forward thrust via the link
shoulder to the rest of the links’ shoulders. The last link in the
chain before the load has geometry that puts the thrust higher
than the articulation axis. This makes a moment that effectively
locks the link shoulders. In reverse, pulling force acts along the
links’ cross axes.
Rigid-chain actuators have the mechanical benefits of
conventional chain but can act in horizontal push setups or
vertically as jacks. Plus they’re compact. In contrast, traditional
chain drives can only pull, so need two drives for bidirectional
motion. Traditional screw jacks for vertical power transmission
need space for retraction that’s as long as the working stroke
itself.
Before specifying a rigid-chain actuator, determine
the application’s total load, including the transported load, This is a custom loading-station scissor lift that
acceleration forces, external environmental forces, and that uses a SERAPID 40 chain actuator. Retractable
due to friction—with a coefficient between 0.05 and 0.5 for to table-top level, the platform can smoothly
typical rigid-chain actuator setups. Next, determine what type lift a heavy load more than 10 ft. A space-
saving chain storage magazine fits compactly
of actuator body and chain-storage magazine the application
at the bottom.
can accommodate. Determine whether the chain will need to
change direction on its way from the magazine to actuator body.
Actuators usually feed chain around 90° or 180° turns.
Note that rigid-chain actuators can work alone or in tandem.
Twin-chain setups deliver high positioning accuracy and stability
where loads are large or bulky.

Common rigid
chain has two rows
of link plates and
shoulders; duplex
chain has three;
other options
abound.
Image courtesy
iwis Drive Systems

18 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

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RigidChainActuators_PTGuide_V3.LE.MD.indd 18 4/29/16 10:43 AM

Here, a pushing bar acts
as a yoke to keep loads steady,
with optional hooks for pulling
as well. Optimized geometry has
the force vector act on the load’s
center for balance. If twin-chain
setups are impossible, consider
adding framework to guide
awkward loads.
Guides on the chain also
help maintain stability—even
over very long strokes—because
they address side and buckling
forces. Such guides come in
different shapes with different
crampons and subcomponents
to engage the chain. Where use
of chain guides is impossible,
most designs run the chain
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QUICK DIE CHANGEപͳപSTAGE AND ORCHESTRA LIFTSപͳപCUSTOM ENGINEERED SYSTEMSപͳപINDUSTRIAL LIFTS
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DW halfRigidChainActuators_PTGuide_V3.LE.MD.indd
page rv.indd 1
19
with link shoulders down for
moderate stability.
Some last design notes:
Standard chain is carbon steel
to withstand heat to 200° C,
but stainless, high-temperature,
and coated chain for long life
are other options. The required
length of chain is total design
stroke plus a few links to engage
the actuator pinions.
As with any power-
transmission setup, consult
the manufacturer for tips and
guidance on determining
necessary drive power and
other details.
LinkLiŌ
liŌ columns
RIGID CHAIN ACTUATORS
Common rigid-chain arrangements
Chain link shoulders
Unguided chain with shoulders up coils downwards ...
... but guided chain is most stable.
Actuator body
Pinion
Input drive shaft
Choose a rigid-chain actuator to satisfy the design geometry.
Unguided chain with shoulders up coils downward, which is useful but
not always stable enough for long strokes. That with shoulders down
(here, bottom) is slightly more stable. Use guided chain wherever space
permits.
RollBeam
Telescopic push-pull
Press-mounted dual
push-pulls
4/12/2016 2:17:33 PMPM
4/29/16 2:58
 REFERENCE GUIDE
BASICS OF

BALLSCREWS
MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION
Power Transmission

BALLSCREWS
are a mainstay of motion actuation. Compared to
similar actuation methods such as leadscrews, they
typically cost a bit more but are generally more accurate. They also boast higher
efficiencies, even though they demand more lubrication because of the use of
recirculating balls.
The basic components of a ballscrew are a nut, a screw with helical grooves, and
balls (often made from steel, ceramic, or hard plastic material) that roll between the
nut, the screw and the grooves when either the screw or nut rotates. Balls are routed
into a ball return system of the nut and travel in a continuous path to the ball nut’s
opposite end. Seals are often used on either side of the nut to prevent debris from
compromising smooth motion.
Recent advances in manufacturing and materials have improved ballscrew
performance so machine designers today can get better linear motion with them
at lower cost. Some improvements include the fact that the latest generation of
ballscrews has more load density than ever, giving designers higher capacity from a
smaller package. There is also a trend toward more miniaturization, but also faster
ballscrews with rolled and ground screw manufacturing methods.
Ballscrews suit applications needing light, smooth motion, applications requiring
precise positioning, and when heavy loads must be moved. Examples include
machine tools, assembly devices, X-Y motion, Z motion, and robots.
Ballscrews are usually classified according to factors such as lead
accuracy, axial play and preload, and life/load relationship.
Lead accuracy refers to the degree to which the shaft’s
rotational movements are translated into linear
movement. With lead accuracy and axial
play determined by the manufacturing
method of the ballscrew shaft
and the assembly of the nut, high
lead accuracy and zero
axial play is generally

This cutaway, courtesy of Nook

Industries, shows the inner workings
of a ballscrew, most notably the
recirculating balls and the deflector,
in relation to the screw assembly.

20 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Ballscrews_PTGuide_V2-mb.indd 20 4/29/16 2:26 PM

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POWER TRANSMISSION
REFERENCE GUIDE
A sample ballscrew assembly, such as the Precision Metric Ball Screws (PMBS) series
from Nook Industries, features a single nut with flange, uses precision thread-rolling
technology and is available in a wide range of leads and diameters.
associated with relatively higher-cost
precision ground ballscrews, while
lower lead accuracy and some axial
play is associated with lower cost rolled
ballscrews. Fabricated by rolling or
other means, ballscrew shafts yield a
less precise but mechanically efficient
and less expensive ballscrew.
Axial play is the degree to which
a ball nut can be moved in the screw
axis direction without any rotation of
either nut or screw. Preload is applied
to eliminate axial play. The process
of preloading removes backlash and
increases stiffness.
Ball recirculation inside the ball nut
can affect precision and repeatability.
Thus, ball nuts are available with a range
of preload options to reduce or remove
the axial play as they rotate around the
screw. Minimal axial play allows better
accuracy, for example, because no
motion is lost from the clearance in the
balls as they reengage.
There are several techniques for
preloading. Some common methods
include oversizing the balls inside
the nut housing; using the so-called
“double-nut” or “tension nut” method;
or by using a manufactured offset in
the raceway spiral to change the angle
of ball engagement (the “lead shift”
method) and deliberately force the balls
into a preload condition. Each method
has its advantages and disadvantages,
but all serve to minimize or eliminate
backlash between the nut and screw.
Perhaps the biggest overall
benefit of a ballscrew is that it has high
efficiencies that can be well over 90%.
By contrast, Acme lead screws average
about 50% efficiency or less. There are
also minimum thermal effects. Backlash
can be eliminated through preloading.
22 DESIGN WORLD 4 • 2016
Ballscrews also offer smooth movement
over the full travel range. The higher
cost of ballscrews can be offset by
decreased power requirements for
similar net performance.
One drawback to ballscrews is that
they require high levels of lubrication.
Ballscrews should always be properly
lubricated, with the correct type of
lubricant, to prevent corrosion, reduce
friction, extend operating life, and
ensure efficient operation.
Because ballscrews are a bearing
system, they’ll need some type of
lubrication to avoid metal-to-metal
contact of the balls in the raceway.
While the lubrication choice can be
either oil or grease, it’s advisable to
avoid solid additives (such as graphite)
as they will clog the recirculation
system. An NLGI no. 2 type grease
is recommended but it should also
depend on the application, whether
food-grade or another special type
of lubrication is required. Ballscrews,
especially those used in machine tools,
generally require lubricants with EP
additives to prevent excessive wear.
The lube amount will be fixed,
but the frequency of lubrication will
vary depending on factors such as
the move cycle characteristics, or
contamination in the environment.
Contaminated lubrication can increase
friction. In addition, ballscrews can fail
if the balls travel over metal chips or
dirt in the ball thread raceway. Using
lubricants recommended by machine
tool manufacturers can help prevent
this effect. Using telescopic covers or
bellows can help keep ballscrews clean
when used in environments with many
contaminants.
www.designworldonline.com
4/29/16 10:47 AM
# Zero-Max_full_pgs_r10_Design World 2/12/10 4:02 PM Page 1

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 3 times

REFERENCE GUIDE
lighter
than

Power Transmission
stainless REVIEW OF

BEARINGS
MIKE SANTORA • ASSOCIATE EDITOR • @DW_MIKESANTORA

IT’S EASY
for bearings to go unnoticed—an out of sight,
out of mind mentality. This attitude is common
among so many because bearings are simple, internal machine
elements. However, that doesn’t make them any less crucial for motion
applications. The purpose of a bearing is to reduce frictional forces
between two moving parts by giving a surface something to roll on,
rather than slide over. There are basic features that all bearings share,
but specific application needs demand many different variations of this
universal motion system component.
A bearing usually consists of smooth rollers or metal balls and
the smooth inner and outer surfaces, known as races, that the rollers
or balls roll against. These rollers or balls act as the load carrier for
the device, allowing it to spin freely. Bearings typically encounter two
kinds of load: radial and axial. Radial loads occur perpendicular to the
shaft, while axial loads occur parallel to the shaft. Depending on the
application the bearing is being used in, some bearings experience
DryLin® aluminum lead both loads simultaneously. There are many different types of bearings,

screws with optimized each suitable for different purposes in varying applications.

geometry for high- BALL BEARINGS

One of the most common forms of bearings is the ball bearing. As
efficiency and long the name implies, ball bearings use balls to provide a low friction
means of motion between two bearing races. Since the contact area
service life. Variety of between the balls and races is so small, ball bearings cannot support
nut types available in 5 as large a load as other bearing types and are best suited for light to
moderate loads. However, their small surface contact also limits the
materials, including FDA heat generated by friction, meaning that ball bearings can be used in
high-speed applications.
and high-temperature
ROLLER BEARINGS
compliant. Possibly the oldest form of bearing, roller bearings can be spherically

Learn more at: or cylindrically shaped and are commonly used in applications like
conveyor belt rollers. Because of their shape, roller bearings have
www.igus.com/DryLin® greater surface contact than ball bearings, and are thus able to handle
larger loads without deforming. Their shape also allows for a moderate
amount of thrust load since the weight is distributed across cylinders
instead of spheres.

Plastics for longer life® 24 DESIGN WORLD — MOTION 4 • 2016

Bearings_PTGuide_V3.indd 24 4/29/16 10:53 AM


NEEDLE
ROLLER BEARINGS
When you need to reduce friction
between two moving parts but have
very limited space to do so, a needle
roller bearing may be just what you’re
looking for. A needle roller bearing is a
roller bearing with rollers whose length
is at least four times their diameter.
Despite their low cross section, the
large surface area of the needle
roller bearing allows them to support
extremely high radial loads.
They usually consist of a cage,
which orients and contains the needle
rollers and an outer race, which is
sometimes the housing itself. The
bearings can often be found in two
different arrangements. The first is a
radial arrangement, in which the rollers
run parallel to the shaft. The second
is a thrust arrangement, in which
the rollers are placed flat in a radial
pattern and run perpendicular to the
shaft.
These bearings are often
used in automotive applications,
such as rocker arm pivots, pumps,
compressors and transmissions. The
drive shaft of a rear-wheel drive vehicle
typically has at least eight needle
bearings (four in each U joint) and
often more if it is particularly long, or
operates on steep slopes.
motioncontroltips.com | designworldonline.com
Bearings_PTGuide_V3.indd 25
 BEARINGS
Tested and
Proven
138 million
cycles
Spherical roller bearings like
Koyo’s RZ Spherical Roller
Bearing have a greater surface
contact than ball bearings, and
are thus able to handle larger
loads without deforming.
THRUST BALL BEARINGS
Thrust ball bearings are designed for
1
62
use in applications with primarily axial
t3
loads and are capable of handling shaft
s
misalignment. These bearings are also
Te
useful in high-speed applications, such
as in the aerospace and automotive
industries.
THRUST ROLLER BEARINGS
Thrust roller bearings are designed so
that the load is transmitted from one
raceway to the other, meaning that
these bearings can accommodate radial
loads. Bearings like these also have a
self-aligning capability that makes them
immune to shaft deflection and alignment
errors.
TAPERED ROLLER BEARINGS
Test 3621: Chainflex®
Tapered roller bearings feature tapered control cable CF98.05.04
inner and outer ring raceways with
tapered rollers arranged between them, Has withstood more than
angled so the surface of the rollers 138 million strokes at a
converge at the axis of the bearing. These
bearings are unique in that, unlike most radius of 3.2 x d
bearings that can handle either axial
or radial loads, they can handle large
amounts of load in both directions. Test information and
A single row taper bearing is limited
in that it can only take high axial loads details available online:
from one direction, but if adjusted against
a second tapered roller bearing, that chainflex.com/test3621
axial load is counteracted. This allows the
bearings to accept high radial and axial
loads from multiple directions.
DESIGN WORLD — MOTION 25
4/29/16 2:33 PM
 REFERENCE GUIDE
Power Transmission

Depending on application requirements, some ball bearing are

made with magnetic, lubricant-free motion plastics like this igus
xiros M180 which uses a lightweight polymer ball bearing.

The ability of a tapered roller bearing to accommodate angular misalignment of the

inner ring in relation to the outer ring is limited to a few minutes of arc. As with other roller
bearings, tapered roller bearings must be given a minimum load, especially in high speed
applications where the inertial forces and friction can have a damaging effect between the
rollers and raceway.

LINEAR MOTION BEARINGS

Linear motion bearings are specifically designed to allow motion in one direction and are
typically used to carry a load on a slide or rail. They can be powered by a motor or by
hand and experience over turning moments of force instead of radial and axial loads.

PLAIN BEARINGS
Plain bearings are the simplest form of bearing available, as they have no moving parts.
They are often cylindrical, though the design of the bearing differs depending on the
intended motion. Plain bearings are available in three designs: journal, linear and thrust.
Journal style bearings are designed to support radial motion where a shaft rotates
within the bearing. Linear bearings are often used in applications requiring slide plates,
as these bearings are designed to permit motion in a linear motion. Finally, a plain thrust
bearing is designed to do the same job as its roller bearing counterpart, but instead of
using cone shaped rolling elements, the bearing uses pads arranged in a circle around
the cylinder. These pads create wedge-shaped regions of oil inside the bearing between
the pads and a rotating disk, which supports applied thrust and eliminates metal-on-metal
contact.
Out of all the bearing types available, plain bearings tend to be the least expensive.
They can be made from a variety of materials including bronze, graphite and plastics, such

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Bearings_PTGuide_V3.indd 26 4/29/16 10:55 AM


as Nylon, PTFE and polyacetal.
Improvements in material
characteristics have made plastic
plain bearings increasingly popular
in recent years. Plain bearings of
all types, however, are lightweight,
compact and can carry a substantial
load.
As far as lubrication is
concerned, some plain bearings
require outside lubrication while
others are self-lubricating. Plain
bearings made of bronze or
polyacetal, for example, contain
lubricant within the walls of
the bearing, but require some
outside lubrication to maximize
performance. For other plain
bearings, the material itself acts
as the lubricant. Such is the case
with bearings made from PTFE or
metalized graphite.
The growing popularity of plain
plastic bearings and increasingly
stringent industry standards
has resulted in more consumers
requiring the bearings to meet FDA
and RoHS standards. There has
even been a call for the bearings to
meet the standards of EU directive
10/2011/EC, which also takes the
material manufacturing process
into account.
motioncontroltips.com | designworldonline.com
Bearings_PTGuide_V3.indd 27
 BEARINGS
The greater surface contact of roller bearings enables them to
handle larger loads without deforming. Demonstrating just a few of
the many types of roller bearings, here we see a needle, spherical,
tapered and cylindrical roller bearing. Image courtesy of AST.
APPLICATIONS
Bearings are all around us in everyday life and most of the time they go unnoticed. But
without them, many of the tasks we undertake would move along much less smoothly.
The ball bearings’ simple design, ability to operate at high speeds and relatively low-
maintenance requirements, makes them one of the most common roller bearings found
in a variety of industrial applications.
For example, deep groove ball bearings are often used in small- to medium-sized
electric motors because of their ability to accommodate both high speeds and radial
and axial loads. Self-aligning ball bearings, on the other hand, are ideal for use in fans.
These bearings have two rows of balls with a common raceway in the outer ring. This
design allows for angular misalignment while maintaining running accuracy. They are,
however, one of the most difficult bearings to install correctly.
Tapered roller bearings are another form of
bearing that just about every industry depends
on one way or another. They are usually found in
applications where support for axial and radial loads
is required, such as in a tire hub where the bearing
must deal with the radial load from the weight of
the vehicle and the axial load experienced while
cornering. These bearings are also commonly found
in gearboxes where they are generally mounted with
a second bearing of the same type in a face-to-face
or back-to-back orientation. They provide rigid shaft
support, keeping deflection to a minimum. This
reduced shaft deflection minimizes gear backlash.
Tapered bearings also have the advantage of
having less mass but high efficiency, however this
Common applications for drawn cup needle
does limit their overall speed.
roller bearings like this from Koyo include:
In applications where bearings are mounted precision gear boxes, machine tool, medical
vertically, they are typically oriented in a face-to- equipment, precision assembly equipment,
face setup, while horizontal applications use a robotics, after-market racing equipment and
back-to-back setup. Some pumps use this design aerospace.
because of shaft deflection concerns.
4 • 2016 DESIGN WORLD — MOTION 27
4/29/16 2:36 PM
 REFERENCE GUIDE

THE BASICS OF

BELTS & PULLEYS

Power Transmission

LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

Belts and pulleys lift loads, use mechanical advantage to apply forces, and transmit
power. They also form the basis of industrial conveyors big and small. Here are the
fundamentals of their operation and how to apply them.

INDUSTRIAL
belt drives consist of rubber belts that wrap around drive
pulleys, in turn driven by electric motors. In a typical setup, the
belt also wraps around one or more idler pulleys that keep the belt taut and on track. The
main reasons that engineers pick belt drives over other options is that modern varieties
require little if no maintenance; they’re less expensive than chain drives; and they’re quiet
and efficient, even up to 95% or more. In addition, the tensile members of today’s belts—
cords embedded into the belt rubber that carry the majority of the belt load—are stronger
than ever. Made of polyester, aramid, fiberglass or carbon fiber, these tensile cords make
today’s belt drives thoroughly modern power-transmission devices.
Manufacturers generally describe belts and pulleys with five main geometries. Pitch
diameter is the drive pulley’s diameter. Center distance is the distance between the two
pulleys’ centers. Minimum wrap angle is a measure of how much the belt wraps around
the smallest pulley. Belt length is how long the belt would be if cut and laid flat. Finally, in
the case of toothed belts (also called synchronous belts) the pitch is the number of teeth
per some length—so a 3-mm pitch means that the belt has one tooth every 3 mm, for
example.

APPLYING SYNCHRONOUS BELTS

Some general guidelines are applicable to all timing belts, including miniature and
double-sided belts. First of all, engineers should always design these belt drives
with a sufficient safety factor—in other words, with ample reserve horsepower
capacity. Tip: Take note of overload service factors. Belt ratings are
generally only 1/15 of the belt’s ultimate strength. These ratings are set
so the belt will deliver at least 3,000 hours of useful life if the end user
properly installs and maintains it. The pulley diameter should never
be smaller than the width of the belt.

Shown here is a Gates Carbon Drive CDN system—designed

to be lower in cost for new bike applications. It leverages
new materials and geometries, with nine carbon cords
embedded within engineered polymer belt and a patented
11-millimeter tooth pitch profile for lower tension. Like
many new belt applications, it replaces chain drives.

28 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

BeltsPulleys_PTGuide_V1.LE.indd 28 4/29/16 4:10 PM

 BELTS & PULLEYS
As mentioned, belts are
quieter than other power-
transmission drive options
… but they’re not silent.
Noise frequency increases
proportionally with belt speed,
and noise amplitude increases
with belt tension. Most belt
noise arises from the way
in which belt teeth entering
the pulleys at high speed
repeatedly compresses the
trapped pockets of air. Other
noise arises from belt rubbing
against the flange; in some
cases, this happens when the
shafts aren’t parallel.
Pulleys are metal or
plastic, and the most suitable
depends on required
precision, price, inertia, color,
magnetic properties and the
engineer’s preference based
on experience. Plastic pulleys
with metal inserts or metal
hubs are a good compromise.
Tip: Make at least one pulley
in the belt drive adjustable to
allow for belt installation and
tensioning. Also note that in a
properly designed belt drive,
there should be a minimum of
six teeth in mesh and at least
60° of belt wrap around the
drive pulley.
DESIGN WORLD — MOTION
BeltsPulleys_PTGuide_V1.LE.indd 29
Manufacturers of Power Transmission and
Motion Control Components
These PowerGrip TruMotion timing belts from Stock
Drive Products have nylon tooth facing for longer and
quieter running and less dust. Fiberglass tensile cords
resist elongation and have a high flex life.
Concentric Maxi Torque
Stock and Custom Keyless Hub-to-Shaft
Connection System
Other tips:
• Pretension belts with the proper Email or call to get your
recommended tension. This extends life CMT Stock Products Catalog
and prevents belt ratcheting or tooth Order today. Ships today!
jumping.
• Align shafts and pulleys to prevent
belt-tracking forces and belt edge wear.
Don’t crimp belts beyond the smallest
recommended pulley radius for that
belt section.
• Select the appropriate belt for the
design torque.
• Select the appropriate belt material
for the environment (temperature,
chemical, cleaning agents, oils and
weather). Belt-and-pulley systems
Custom Synchronous Drives
Precise. Reliable. Cost Effective.
are suitable for myriad environments,
but some applications need special
consideration. Topping this list are
environmental factors.
Dusty environments do not generally
present serious problems as long as the
particles are fine and dry. In contrast,
particulate matter can act as an abrasive
and accelerates belt and pulley wear. Debris
should be prevented from falling into belt
drives. Debris caught in the drive is generally
either forced through the belt or makes
Timing Pulley Stock
Guaranteed When You Need It.
the system stall. In either case, serious
damage occurs to the belt and related drive
hardware. Custom Machine & Tool Co., Inc.
Light and occasional contact with (800)355-5949 • sales@cmtco.com
water—during occasional washdowns, for www.cmtco.com
example—has little serious effect. However,
Precise. Reliable. Trusted.
American Engineering • American Made
© 2016 Custom Machine & Tool Co., Inc.
4 • 2016 29
5/3/16 9:22 AM
 REFERENCE GUIDE
Power Transmission

prolonged contact with constant spray or

This setup has an electronic warning system from ContiTech
to alert operators when a conveyor is elongating or at risk of
ripping. Called CONTI PROTECT and most useful on industrial
and mining conveyors, the system uses magnetic markings
on the belts to track irregularities in the splice length and
detects longitudinal rips before they grow. Such monitoring
systems are just one example of how belt-drive technologies
have kept pace with 21st-centrury design concepts.
Shown here are Baldor-Maska
sheaves for V-belt drives,also
called friction drives for the way
they operate. Minimum allowable
sheave diameter depends on the
belt shape and material, whether
that’s synthetic, neoprene,
urethane, or rubber.
submersion can significantly reduce tensile
strength in fiberglass belts and make aramid
belts break down and stretch out. In the same
way, occasional contact with oils doesn’t
damage synchronous belts. But prolonged
contact with oil or lubricants, either directly
or airborne, significantly reduces belt service
life. Lubricants cause the rubber compound to
swell, break down internal adhesion systems
and reduce felt tensile strength. While alternate
rubber compounds may provide some marginal
improvement in durability, it’s best to prevent oil
from contacting synchronous belts.
The presence of ozone can be detrimental
to the compounds used in rubber synchronous
belts. Ozone degrades belt materials in much
the same way as excessive temperatures.
Although the bumper materials used in belts
are compounded to resist the effects of ozone,
eventually chemical breakdown occurs and
they become hard and brittle and begin
cracking. The amount of degradation depends
on the ozone concentration and generation of
exposure.
Rubber belts aren’t suitable for cleanrooms,
as they risk shedding particles. Instead, use
urethane timing belts here … keeping in mind
that while urethane belts make significantly less
debris, most can carry only light loads. Also,
none have static conductive construction to
dissipate electrical charges.

30 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

BeltsPulleys_PTGuide_V1.LE.indd 30 4/29/16 2:59 PM


BRAKES & CLUTCHES
MORE INDISPENSABLE THAN EVER
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
Shaft-mounted electric clutches
from New Torque have a static
torque rating from 15 to 202 Nm,
voltage of 24 to95 Vdc, and power
of 16 to 50 W.
Shown here is an ac solenoid
shoe Brake from Ametek. Gemco
industrial brakes stop industrial
machines in steel mills, gantries,
cranes, and commercial laundry
equipment. They are tough and
long-lasting.
www.designworldonline.com 4 • 2016 DESIGN WORLD 31
BrakesClutches_PTGuide_V3.indd 31
BRAKES & CLUTCHES
BRAKES
and clutches are a mainstay in motion designs
that need to stop, hold or index loads.
Especially over the last five years, a technology trend toward
application-specific designs has quickened as several industries
are pushing the performance envelope of stock components.
Brakes are used to stop a load, typically a rotating load,
while clutches are used to transfer torque. There are many
different types of brakes and clutches. This is a Force Control
A brake would be used in applications where accurate Industries coupler brake. In
fact, the company’s Posistop and
stopping of the load is needed and the motor will stop as well.
MagnaShear coupler brakes mount
A clutch would be used in applications where it’s desirable between motors and reducers, so
to engage or disengage a load and motor while leaving the engineers can eliminate separate
motor to run all the time. When a clutch is used, the load will be brake motors.
allowed to coast to a stop.
A clutch and brake combination would be used where the
load will be started and stopped while the motor continues to
rotate. Both clutches and clutch brakes can mount to a motor
shaft or be base-mounted and have input through a belt drive,
chain drive or coupling.
The motor horsepower and motor frame size play a key
role in determining which specific brake or clutch to select. In Some clutches and brakes — as
the case of base-mounted units, it may be necessary to define the ones from Carlyle Johnson
Machine Company shown here
the RPM at that location. Manufacturers provide quick selection
— can last 15 years on average,
charts where unit size is determined by finding the intersection with some products lasting 50
of motor horsepower and speed at the clutch shaft. The charts years or more.
are commonly created using the dynamic torque capacity for the
product and the torque capacity for the motor plus an overload
factor of some value. Using this method presumes that you’ve
selected a motor that’s sized appropriately to the application. In
applications where cycle rates are considered aggressive for the
inertia of the load, it’s a good idea to consult with the application
support staff of the manufacturer regarding the heat dissipation
capacity.
Coil voltage is another consideration. The most common
options are 6, 24 and 90 Vdc with 90 V being widely preferred in
North American markets, while 24 V is more common in Europe.
In both cases, brake and clutch manufacturers can offer power
supplies to convert ac to dc if required.
4/29/16 11:14 AM
 POWER TRANSMISSION
REFERENCE GUIDE

THE BASICS OF

INDUSTRIAL POWER
TRANSMISSION CABLES
MARY GANNON • SENIOR EDITOR • @DW_MARYGANNON

ENGINEERS
can use a multitude of
cables (including data,
coaxial, and instrumentation cables) in industrial
settings for control networking, low and medium-
voltage power transmission and distribution,
and more. Most cables that distribute power to
motors are low-voltage designs rated for 2,000
V and below. That said, some facilities with
partial responsibility over the utility power they
consume use medium-voltage cables rated for
2,000 to 35,000 V.
Available as both single and multi-conductor
designs, these power cables must be able to
withstand high mechanical loads, speeds and
accelerations. Common applications include
machine tools, cranes, conveyors, portable
designs and stationary heavy-duty equipment.
Such cables can supply temporary ac or dc
power to motors and generators, and can
operate indoors and outdoors, depending on
their temperature rating.
The proper cable for an application depends
on its function and environment. For instance,
only use an unshielded cable when it will
operate in an enclosed space only accessible by
trained professionals. Such enclosures prevent
electromagnetic interference and keep plant
personnel safely away from potentially live
electrical charges.
Manufacturers usually construct low-voltage
cables with aluminum or copper conductors,
insulation and jacketing. Conductors can range
anywhere from finely stranded bare copper wires
to bunched strands of tinned annealed copper.
They come in both shielded and unshielded
versions and usually must be flame retardant and
oil resistant.
Power cables feature conductors that are
either stranded in layers inside or bundled
or braided. The stranded design is easier to
manufacture so costs less. It features long,
layered cores and firm strands wrapped with
an extruded jacket. In the bundled or braided
design, the conductors are braided around a
tension-proof center. By eliminating the layers, a
uniform bend radius is ensured.
To accommodate the complex and
sometimes cramped spaces where they operate,
industrial power cables must also have tight
bending radii, ranging anywhere from 5 to 15
times the overall cable diameter. Jacketing is also
crucial to meet these bending radii requirements.
Therefore, the use of flexible materials such as
PVC, TPE and CPE not only helps these cables
bend and flex but also protects them from
environmental damage.
Because their materials, shielding and
jacketing all vary, so do industrial power cables’
installation techniques. Installers can put cables
into fixed duct, shafts, and conduit; direct-bury or
even immerse the cables in water in water; or lay
cables into open-air applications.
Depending on where a cable is
manufactured and used, it must meet a variety of
approvals, including UL, CSA, TC, AWM, RoHS,
CE and more. In the U.S., the National Electrical
Code (NEC) sets the standards that designers
must usually follow. These codes ensure that the
cables have key performance features to satisfy
machine requirements—for example, to stop the
propagation of flames, satisfy the application’s
maximum voltage draw, withstand extreme
temperatures, and maintain integrity even when
exposed to oil.

Control cables, like this Chainflex continuous flex control design from igus, must be able to withstand high mechanical
loads, speeds and accelerations. These Chainflex cables are intended for use in Energy Chain cable carriers and conform to
key standards; are capable of torsion—depending on the cable; and can be used in high speeds and accelerations. They are
UV resistant, flame retardant, halogen free, and can withstand very high or extremely low temperatures. They are available
shielded or unshielded, with a choice of PVC, PUR and TPE outer jackets.

32 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Cabling_PTGuide_V2 MG.indd 32 4/29/16 11:15 AM

 C

CM

MY

• Flexible
CY

CMY

Bus Cables •
Control Cables
K

Data Cables •
• Continous Flex
Tray Cables •
Cables
Silicone Cables •
• Torsion Cables
Cable Accessories •
• Halogen-Free Cables
Specialty Cables •
• European Cables
• Servo Motor Cables Stock Available
for Immediate Delivery

SAB NORTH AMERICA

344 Kaplan Drive, Fairfield NJ 07004
Phone: 866-722-2974 • Fax: 973-276-1515
info@sabcable.com • www.sabcable.com

SAB_PTGuide4-16.indd 33 4/29/16 10:06 AM

 REFERENCE GUIDE

THE BASICS OF

SPROCKETS &
CHAIN DRIVES
Power Transmission

LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

ENGINEERS
have used chains in motion systems for
more than a century. They are versatile
and reliable components to drive machinery and convey products.
Now, advances in precision and technology let designers use
chains in more applications than ever. Remote installations benefit
from long-life chain that requires no lubrication, for example.
Chain-based machinery abounds, but the most common
industrial designs use roller chain. This type of chain consists of
five basic components: pin, bushing, roller, pin link plate and
roller link plate. Manufacturers make and assemble each of these
subcomponents to precise tolerances and heat treat them to
optimize performance. More specifically, modern roller chains
exhibit high wear resistance, fatigue strength and tensile strength.
Roller-chain applications generally fall into two categories: drives
and conveyors.

CHAIN-DRIVE APPLICATIONS
Most typical drive applications use an ASME/ANSI roller chain
wrapped around a driver sprocket (connected directly to the
motor or reducer) and the driven sprocket (often connected to a
machine’s conveyor head-shaft). This portion of the drive lets the
designer build a system that’s either faster or slower by simply
changing the ratio of teeth between the drive and driven sprocket. Shown here is an MPC sprocket from
The ratio of the teeth determines the reduction in rpm … so to Martin Sprocket and Gear Inc. for use
with a curvilinear timing belt. As a side
reduce rpm, the driven sprocket must be larger than the driver
note, synchronous belt drives work as a
sprocket. For example, if the driver sprocket has 15 teeth and the replacement for roller-chain drive systems
driven sprocket has 30 teeth, the ratio is 2:1, so the rpm is halved where lubrication is unacceptable.
at the driven sprocket.

This Morse leaf chain from Power Transmission Solutions of

Regal-Beloit America is made of roller-chain-type links and riveted
pins for maximum strength for a given width. It works as tension
linkage or a lifting device at slow speeds.

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ChainRollerSprockets_PTGuide_V3.indd 34 4/29/16 11:18 AM

 CHAIN, ROLLER & SPROCKET

The easiest way to select a roller chain is using

horsepower charts. First, obtain the motor horsepower and
rpm of the small driver sprocket. From this, determine the
chain size and number of teeth for the driver sprocket. Where CHAINS ENDURE SUBOPTIMAL
roller chain must drive applications that need long life without ENVIRONMENTS
contamination, pick chain with self-lubricating subcomponents. The environments of many chain applications
Where roller chain must drive applications that need high are less than ideal. Some require clean
precision, pick chain with precision roller bearings at each link operation without the lubrication that can
connection. contaminate products. Others expose
Morse inverted-tooth
chain-driven machinery to weather, water
chain drives from Power
CONVEYOR APPLICATIONS or chemicals. So, chain manufacturers offer Transmission Solutions
Conveyor chains come in myriad versions to move product several products to meet these challenges. of Regal-Beloit America
horizontally, vertically or even around curved radii. The Consider roller chain: One critical area come in HV versions for
most common conveyor chains are ASME-style (ANSI-style) where roller chains need lubrication is the high capacity at high
speed. Silent chain is
attachment chains. These chains include extended pins or pin-bushing contact zone. Self-lubricating
another option to make
plates with tabs onto which parts or product-holding shoes chains stay cleaner because the exterior of smooth, silent drives at
can bolt. Common versions are single-pitch attachment chain, the chain is free of excess lube. These chains slower speeds.
double-pitch attachment chain, hollow-pin chain, curved-
attachment chain and plastic-sleeve chain. The attachments let
engineers put special fixtures or blocks onto the chain to serve
specific conveyor functions. Roller-chain selection chart
One subtype of conveyor chain is the accumulating Chain strands
conveyor. These stop discrete products even while the chain 4 3 2 1

is still moving, and they do so with minimal friction and wear. 900
500
1,000 700
Accumulating conveyors are suitable for 400
1,000 800 500 300
applications (such as assembly lines) that have products ride 800 600 400

20 40
200

2
through several stations. Tip: Select chain with top rollers or 600

0
400 300

5T
T 2

T
25

16 80
side rollers to let discrete products idle while the conveyor

1
400 300 200

0
Roller-chain drive capacity (horsepower)

22

T
23
100

T
continues to run. Also pick custom attachments or work with

0
22
300

14
9T
T
200
19

80

25 T 1

0
23 T

12
25
manufacturers that make custom fixtures to handle specific
T
200 60
19

100
25 21T

0
parts. Many industries (including the automotive, food and
T

80

10
100 40
60 21 7T
T

1
beverage, and consumer-products industries) use custom
19

100 80 30 T
25 T
21

80 60 40
attachments on their chain-based accumulator conveyors to
80
T
T

25

20
60 30
7T

economically and consistently move. 40

1

60
17

40 30 20
T
21

10
25 1T

50
2

30
20
T

8
T
25

20 10 6
T
17
21 7T

40
1

10 8 4
T

T
19

35

10 8 6 3
T

This is a Zone Touch case conveyor from Container Handling Systems

23

8 6
T
23

4 2
T

Corp. (CHSC), which uses chain drives that function as accumulating 6

15

4 3
15

5
sections. It has longer life than conventional machines with rollers
T
19

4 3
and fabric belts. It’s also quieter than roller 2 1
3
conveyors because its tabletop chain rides low- 2 0.8
friction UHMW wear strips and return ways. 2 1 0.6
0.8
1 0.4
0.8 0.6
1 0.3
0.8 0.6 0.4
0.2
0.6 0.4 0.3
0.4 0.3 0.2

10 30 50 80 200 500 1,000 3,000 7,000

20 40 60 100 300 700 2,000 5,000 10,000

Speed of roller chain’s small sprocket (rpm)

motioncontroltips.com | designworldonline.com 4 • 2016 DESIGN WORLD — MOTION 35

ChainRollerSprockets_PTGuide_V3.indd 35 4/29/16 11:19 AM

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SYNCHRONOUS
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MartinSprockett_PTGuide4-16.indd 36 4/29/16 10:11 AM


Power-transmission and conveyor chain attachment options
A1 chain (sometimes called B1 one-hole chain) has links
with one hole and a bent attachment. A2 is similar
but always double pitch with two attachment holes per link.
Single-pitch WA1 (WCB1 one hole) chain and wide-contour
WA2 (WCB1 two holes) chain both have bent attachments
on one side and one or two holes per link.
SK1 chain (sometimes called S2 one-hole or M1 chain) has straight attachments
on both sides. SK2 (S2 two holes or M2) is the same but with two holes per link.
Roller-chain sprockets come in myriad versions,
but most are shaft-ready designs. The sprocket
here is from the Power Transmission Solutions
division of Regal-Beloit America.
motioncontroltips.com | designworldonline.com
ChainRollerSprockets_PTGuide_V3.indd 37
CHAIN, ROLLER & SPROCKET
K1 (B2 one-hole) and K2 (B2 two-hole) chains
both have bent attachments on both sides.
D1 (E1) and D3 (E2) chains have extended pins.
WSK1 (WCS2 one-hole or WM1) and WSK2
(WCS2 two holes or WM2) is wide-contour chain
with straight attachments on both sides.
WK1 (WCB2 one-hole) and WK2
(WCB2 two holes) is wide-contour
chain with bent attachments.
SA1 (S1 one-hole or M35) chain and SA2 (S1 two holes or M35-2) chain
both have straight attachments on one side, but the latter has two holes per link.
also attract less dust and particulates than regular chains. Such
roller chains are useful where oil contamination is a concern,
including paper-product or wood-processing industries.
SPECIALTY COATINGS AND STAINLESS STEEL CAN DELAY
OR PREVENT CORROSION
Nickel-plated chains offer another alternative for chain coatings,
providing some protection for mildly corrosive environments.
Stainless-steel chains offer superior corrosion resistance; however,
designers must be aware that regular stainless steels cannot be
hardened in the same manner as carbon steel. Therefore, the load
carrying capacity of stainless steel is lower than carbon steel.
Proper chain maintenance requires periodic inspection. All
chains must be checked for damage, wear and chemical attack
on a regular basis.
Another issue is wear elongation. Eventually
roller chains wear so much that they necessitate
replacement—typically at 1.5 to 2% (12.180
in./ft to 12.240 in./ft) elongation.
Chains may work until they reach
3% elongation, but are at
increased risk for suboptimal
performance.
4 • 2016 DESIGN WORLD — MOTION 37
4/29/16 11:19 AM
 REFERENCE GUIDE
Power Transmission
THE BASICS OF
COMPRESSION SPRINGS
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
ENGINEERS incorporate compression
springs in designs that need
linear compressive forces and mechanical energy storage—
designs such as pneumatic cylinders and push-button
controls, for example. The most conventional compression
spring is a round metallic wire coiled into a helical form.
The most common compression spring, the straight
metal coil spring, bends at the same diameter for its entire
length, so has a cylindrical shape. Cone-shaped metal
springs are distinct in that diameter changes gradually from
a large end to a small end; in other words, they bend at a
tighter radius at one end. Cone-shaped springs generally
go into applications that need low solid height (the total
height when compressed) and higher resistance to surging.
Whether cylindrical or cone shaped, helical compression
springs often go over a rod or fit inside a hole that controls
the spring’s movement. Other configuration types include
hourglass (concave), barrel (convex), and magazine (in
which the wire coils into a rectangular helix).
Most compression springs have squared and ground
ends. Ground ends provide flat planes and stability under
load travel. Squareness is a characteristic that influences
how the axis force produced by the spring can be
transferred to adjacent parts.
Although open ends may be suitable in some
applications, closed ends afford a greater degree of
squareness. Squared and ground end compression springs
38 DESIGN WORLD 4 • 2016
CompressionSprings_PTGuide_V2.indd 38
When hit by an object, oil inside this Zimmer shock
absorber floods a spiraling channel from its fat opening
to its narrow end. Sold by Intercon Automation Parts, the
shock absorber relies on compression springs to return to
its extended position after each cycle.
are useful for applications that specify high-duty springs;
unusually close tolerances on load or rate; minimized solid
height; accurate seating and uniform bearing pressures;
and minimized buckling.
The key physical dimensions and operating
characteristics of these springs include their outside
diameter (OD), inside diameter, wire diameter, free length,
solid height, and spring rate or stiffness.
• Free length is the overall length of a spring in the
unloaded position.
• Solid height is the length of a compression spring
under sufficient load to bring all coils into contact with
adjacent coils.

• Spring rate is the change in load per unit deflection in
pounds per inch (lb/in.) or Newtons per millimeter (N/
mm).
The dimensions, along with the load and deflection
requirements, determine the mechanical stresses in the
spring.
When the design loads a compression spring, the
coiled wire is stressed in torsion and the stress is greatest at
the wire surface. As the spring is deflected, the load varies,
causing a range of operating stress. Stress and stress range
affect the life of the spring. The higher the stress range, the
lower the maximum stress must be to obtain comparable
www.designworldonline.com
4/29/16 11:21 AM
RotorClip_PTGuide4-16.indd 39 4/29/16 10:12 AM
 REFERENCE GUIDE
life. Relatively high stresses may be used when the stress range
is low or if the spring is subjected to static loads only. The stress
at solid height must be low enough to avoid permanent damage
because springs are often compressed solid during installation.

HOW TO SELECT COMPRESSION SPRINGS

Here are the most important factors to consider when selecting
This concave (hourglass-shaped)
helical compression springs. compression spring can stay centered,
The OD of a spring expands under compression. Be sure even in large-diameter bores.
Power Transmission

to consider this if the spring goes into a tube or a bore during

assembly. Also remember that the OD of a spring is subject to
manufacturing tolerances, just as any mechanical part. If the
tolerance range is positive, the spring’s dimensions may be slighter
larger and can add to the overall assembly’s envelope size. Most
spring suppliers specify work-in-hole diameters for their springs
to factor in manufacturing tolerances and the OD’s expected
expansion. Look for this information to quickly select from stock
spring catalogs, or use this information to better communicate
product needs when ordering custom-made springs.
Consider loading or travel requirements on the compression
spring. The spring rate (also called the spring constant) is the
This compression spring has
relationship of the force to compress a spring by a unit of length,
a barrel shape for lateral
typically pounds per inch. So with a given load, the product designer stability.
can calculate expected spring travel. The further the spring travels,
the more stress it endures. So at a critical point, stress can yield
the wire material … causing a phenomenon called spring set. After
spring set, the spring can’t expand back to its original unloaded
length. Even so, in some assemblies, such springs can still function.
Stress formulas and online calculators predict spring set.
Otherwise, a starting rule of thumb is to avoid solid height by at
least 20% (so that there’s always 20% of the spring’s total travel left
during the normal range of operation).
Compression spring-end types are standard or special. Standard This compression spring has reduced ends.
ends are either plain open or closed. Either can be ground or not
ground. The ends actually affect the spring rate. So, springs with
dissimilar ends that are otherwise identical (with the same total coils,
wire size, and OD) have different spring rates. Ground ends require
more manufacturing effort. However, combined with closed ends,
round ends improve the squareness of the loading force and reduce
spring-buckling tendencies.
Some manufacturers include closed and ground ends in
standard catalog stock design, while some don’t. Be sure to know
the difference. Special end examples include reduced coil for screw
mounting, offset legs to work as alignment pins, and enlarged coils
to snap into ring grooves.
Spring materials abound and include everything from carbon
steel to exotic alloys. Music wire is a high-carbon spring steel and is Surging is when a spring builds compression-wave
the most widely used material. Stainless steel 302 has less strength motion when subject to vibrations close to its
than music wire, but adds general corrosion resistance. Nickel alloys natural frequency. This cone-shaped compression
spring resists surging. The larger outer coils
make a lot of springs branded under various trademarks and are
collapse before the smaller inner coils, so forces
chosen for extreme high or low operating temperatures, specific on the spring also increase the spring rate for a
corrosive environments, and non-magnetic qualities. Springs made natural damping effect. Photo courtesy Lee Spring.
of phosphor bronze and beryllium copper are copper alloys for
good corrosion resistance and electrical conductivity.

40 DESIGN WORLD 4 • 2016 www.designworldonline.com

CompressionSprings_PTGuide_V2.indd 40 4/29/16 11:21 AM


COUPLINGS:
TAC K L I N G T O R Q U E , M I S A L I G N M E N T A N D M O R E
MIKE SANTORA • ASSOCIATE EDITOR • @DW_MIKE SANTORA
FOUND
in countless applications, couplings are simple devices that
connect two shafts together. Couplings are usually found
on rotating equipment such as motors to transmit a number of motion
parameters. These parameters include the precise transmission of velocity,
angular positioning and torque. However, the simplicity of these devices often
serves to obscure their importance.
Couplings should be designed to allow for some end movement. Two
types are available: rigid and flexible. Flexible couplings compensate for
misalignment, while rigid designs are used when shafts are already
in alignment.
Within these two types exists a variety of coupling styles. Rigid couplings
include sleeve-style and clamped, or compression style, and require precise
alignment. Flexible couplings include bellows, jaw, Oldham, disc and beam
styles.
RIGID COUPLINGS
Rigid couplings are torsionally stiff and best used when shafts are already in
proper alignment; parallel shaft misalignment ideally should be well below one
thousandth of an inch. One drawback is that they are susceptible
to vibration and cannot be run at high speeds.
Sleeve-style rigid couplings are suitable for light- to
medium-duty applications. The one-piece sleeve—
essentially a tube with an inner diameter that is the same
as the shafts it is joining together—has two set-screws to
fasten it to the shaft. They are easy to use and offer high
torque capacity, stiffness and zero backlash.
Clamped, or compression style, couplings come in
two parts that completely wrap around the shaft. Like most
motioncontroltips.com | designworldonline.com 4 • 2016
Couplings_PTGuide_V3.indd 41
COUPLINGS
In these images we see an exploded and fully
assembled view of GAM’s KHS metal bellows coupling.
The conical hubs, and rotationally symmetric
construction allow for speeds up to 30,000RPM and
are commonly used for test stands, spindle drives and
other high speed applications.
coupling designs, this protects the shaft from
damage while providing high torsional holding
power. Their advantage comes from their two-
piece design, which allows them to be removed
for easy maintenance.
FLEXIBLE COUPLINGS
Flexible couplings can be used where there
is a slight amount of misalignment between
shafts. They accommodate misalignment while
still transmitting torque. Misalignments can be
one of several fundamental types, including
lateral, axial, angular or skewed. The greater
the misalignment, the less efficient the motor is
in generating speed and torque. Misalignment
also contributes to premature wear including
broken shafts, failed bearings and excessive
vibration.
Flexible couplings are typically the most
compliant of components in mechanical
motion systems, making torsional stiffness a
critical factor in terms of maintaining positional
control over a load. Many users of servomotors
require the shaft to start and stop multiple
times per second, which requires a torsionally
stiff coupling to help diminish the settling time
between cycles. However, torsionally flexible
couplings frequently win out in terms of their
DESIGN WORLD — MOTION 41
4/29/16 11:23 AM
 REFERENCE GUIDE
Power Transmission
Internal leaf springs, like those on this R+W BK-LK
serve the purpose of making the coupling axially rigid
for rotary / linear applications.
torque capacity in a given body size. Torsionally flexible
couplings are naturally better for vibration damping,
which is needed just as frequently in continuous motion
applications as in cyclic duty applications.
Types of motion differ in applications as well. For
instance, in manufacturing lines, motion may be either
continuous or start and stop. With the latter type, couplings
can help dampen all-too-common vibration, diminish
the settling time of the system and improve throughput.
In contrast, continuous motion applications give greater
weight to torsional strength over damping capabilities.
Motion applications that require precise motion control,
such as in packaging and scanning and inspection, call for
zero-backlash couplings.
Bellows couplings are commonly used in motion
control applications that require precision control and
where shaft misalignment is present. If your application
requires precision, then it is important to understand
the performance factors that are critical for selecting the
optimum bellows coupling for the task.
There is a difference between backlash—which is a
true mechanical clearance, such as that which is found
between gear teeth—and torsional deflection, or wind-
up, which everything on earth will exhibit to some degree.
Most couplings are preloaded to eliminate backlash or
are inherently backlash free, like the bellows coupling. But
they all have different levels of torsional stiffness, which is
often traded off for lateral flexibility during the coupling
selection process. Bellows couplings tend to have the
highest torsional stiffness of any servomotor coupling, do
not handle quite as much misalignment as others, but also
do not impose heavy reaction loads onto the shafts and
bearings as they flex.
42 DESIGN WORLD — MOTION 4 • 2016
Couplings_PTGuide_V3.indd 42
Key benefits of bellows couplings include
misalignment compensation and precise transmission
of velocity, positioning and torque. Bellows couplings
are known for their exceptional torsional rigidity, and
flexibility in dealing with axial, angular and parallel shaft
misalignment.
Bellows couplings are typically made from a
stainless-steel tube hydroformed to create deep
corrugations that make them flexible across axial,
angular and parallel shaft misalignments. When
coupling shafts, bellows couplings absorb slight
misalignments from perpendicularity and concentricity
tolerances between the mounting surfaces of the two
connected components.
Jaw couplings feature two metal hubs and a spider
insert, usually made of elastomer, which are fitted
together to absorb vibration and shock. The elastomer
is available in a variety of hardness and temperature
ratings, so the spiders can be chosen for specific
applications. Because they are not as torsionally stiff
as other couplings, they are better suited to constant
motion applications.
Jaw couplings are available in two types: straight
jaw and curved jaw with zero backlash. Because
accuracy of torque transmission can be an issue,
straight jaw couplings are not used in most servo
applications. Curved jaw couplings, on the other hand,
reduce deformation on the spider and the effects of
centrifugal forces during high-speed (up to 40,000+
In this image we see R+W’s new SP6 series
backlash free precision elastomer couplings.
Elastomer couplings like this are often used for
high speed spindle applications.
motioncontroltips.com | designworldonline.com
4/29/16 11:24 AM
 Metal Bellows
Transfer Pressure or Temperature
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ServometerBellows_PTGuide4-16.indd 43 4/29/16 1:21 PM

 REFERENCE GUIDE
Power Transmission
rpm) operation. Both types can easily
handle axial motion. If a spider breaks,
the driving jaws can still contact the
driven jaws directly, maintaining
operation, making jaw couplings fail-
safe designs.
Oldham couplings can be
preloaded to eliminate backlash and
can handle misalignment of all types
depending on the disc material. They
are being used more often as an
alternative to straight jaw couplings
on general industrial equipment
such as pumps, valves, gearboxes
and conveyor systems. They are
versatile and offer long lives when
misalignment is an issue. Their three-
piece design—two hubs and a torque-
transmitting center—makes them easy
to install and disassemble.
Oldham couplings can be
specified in a variety of materials
to meet the needs of different
applications, for example, if zero
backlash is required versus vibration
reduction. They are best suited when
parallel misalignment may be high.
And because of their three-piece
design, axial motion is limited.
Disc couplings are a logical choice
for servomotor and other demanding
applications because of their ability
to transmit high torque, operate at
high or changing speeds, and handle
misalignment and system loads.
While a coupling’s torque,
misalignment and speed capacities
44 DESIGN WORLD — MOTION 4 • 2016
Couplings_PTGuide_V3.indd 44
Ringfeder Power Transmission’s Gerwah brand AKN series metal bellows
coupling has zero backlash and compensates for angular, axial and radial
misalignments. It uses clamping hubs on both sides for shaft connection.
need to be evaluated against a system’s requirements, the disc-pack
usually is the most important aspect of the coupling’s construction
because it will affect all critical performance aspects of the coupling and
the system in which it is used.
The most common type of disc-pack is made of metal and can be
found in different shapes (straight-sided, scalloped edges, square, and
so on). In the case of metal disc couplings, double-flex designs need to
be used if there is to be any parallel shaft misalignment. The single-flex
variety of metal disc coupling is good for angular misalignment but not
parallel. This can be quite advantageous in case a user needs to suspend
a load between two single-flex couplings, because their lateral stiffness
can support the weight of the intermediate component.
Beam, or helical couplings are almost always manufactured of
aluminum, but stainless-steel versions are also available for use in
corrosive environments and increased torque and stiffness. Their one-
piece design makes them easy to maintain. Offering zero backlash,
they feature spiral cuts that transmit torque and can handle all types of
misalignment and angular, parallel or axial motion. Parallel motion is
more of a challenge for the single beam design because it must bend in
two directions, which causes stress and possible failure.
Two designs exist under this style—single and multiple beams.
Single beams are best suited to low-torque applications where no
parallel misalignment is present, while multiple-beam designs are stiffer,
for higher maximum torque capabilities.
SPECIAL COUPLINGS
Most disc couplings feature a metal disc-pack. However, some have
composite disc-packs that are constructed of a special composite
material rather than metal. This composite material provides an
alternative to metal disc couplings. The advantages include its ability to
absorb shock and vibration, its misalignment capacity, electrical isolation
and elimination of fatigue and fretting. Whereas metal disc couplings
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4/29/16 11:24 AM
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Keubler_PTGuide4-16---2.indd 45 5/2/16 11:39 AM
 REFERENCE GUIDE
may be less expensive initially, overall cost of composite
disc couplings usually will be lower because they are
maintenance free and are rated for long life.
The ability to accommodate misalignment is a critical
aspect of a flexible disc coupling. Misalignment between
coupled shafts often exists due to manufacturing tolerances,
improper installation or from loads on the system.
Parallel, angular and axial misalignment
between coupled shafts should all be
Power Transmission

examined to see if the coupling selected

is up to the task. It is important to know
a coupling’s misalignment rating as
well as the stiffness rating. The stiffer
a coupling, the higher the reaction
load misalignment will transmit to the
coupled items. These reaction loads
will have a negative effect on the life
of the system. To limit these reaction
loads, composite disc couplings are less
radially stiff than metal disc couplings.
Therefore, they transmit lower reaction
loads on the coupled equipment, thereby
increasing the life of connected (and often
expensive) components.
The amount of misalignment that a system
Jaw couplings like the GWE 5104 from Ringfeder have
can experience will typically determine the selection
two metal hubs and a spider insert, usually made of
between a single-flex (one flexible disc-pack) and a double- elastomer. This particular coupling is available with
flex (two flexible disc-pack) coupling. While more compact elastomeric spiders of different degrees of shore
in size than the double-flex variety, a single-flex coupling will hardness for varying damping levels.
have lower misalignment capacity and higher reaction loads.
A common misconception is that single-flex disc couplings
cannot accommodate parallel misalignment. Although this is
true for metal disc couplings, the design of some disc-pack
couplings allow single-flex CD couplings to accommodate
limited parallel misalignment. This permits designers to
implement a single-flex disc coupling into designs that may
not have space for a double-flex coupling.
Gear couplings are a type of mechanical device
designed to transmit torque between two shafts that are not
collinear. The coupling typically consists of two flexible joints,
one fixed to each shaft. These joints are often connected by
a third shaft called the spindle.
Each joint generally consists of a 1:1 gear ratio internal/
external gear pair. The tooth flanks and outer diameter of the
external gear are crowned to allow for angular displacement
between the two gears. Mechanically, the gears are
equivalent to rotating splines with modified profiles. They
are called gears because of the relatively large size of the
teeth. Gear couplings are generally limited to angular
misalignments of 4 to 5°.
Gear couplings ordinarily come in two variations:
flanged sleeve and continuous sleeve. Flanged gear
couplings consist of short sleeves surrounded by a

46 DESIGN WORLD — MOTION 4 • 2016

motioncontroltips.com | designworldonline.com

Couplings_PTGuide_V3.indd 46 4/29/16 11:25 AM

 Linear Mount Products

PMK
Parallel
mounting
kit
EPL-H
Inline gearbox, with
hollow output design
for easy mounting to
linear actuators

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Bellows style DL-DC
distance coupling Right angle Dyna Lite gearbox with
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mounting to linear actuators. Includes
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For Everything Between the Motor and Actuator

Linear Mount Products include gear reducers, couplings, and mounting kits
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GAM_PTGuide4-16.indd 47
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3/24/15 10:14 AM
9:53 AM
 POWER TRANSMISSION
REFERENCE GUIDE

perpendicular flange. One sleeve is placed on

each shaft so the two flanges line up face to face.
A series of screws or bolts in the flanges hold
them together. Continuous-sleeve gear couplings
feature shaft ends coupled together and abutted
against each other, which are then enveloped by
a sleeve. Generally, these sleeves are made of
metal, but they can also be made of Nylon.
Single-joint gear couplings are used
to connect two nominally coaxial shafts. In
this application, the device is called a gear-
type flexible, or flexible coupling. The single
joint allows for minor misalignments, such as
installation errors and changes in shaft alignment
due to operating conditions. These types of
gear couplings are generally limited to angular
misalignments of 1⁄4 to 1⁄2°.
Magnetic couplings are designed to transfer
torque from one shaft to another, but they do
so without a physical mechanical connection.

"GEAR COUPLINGS ARE A TYPE OF

MECHANICAL DEVICE DESIGNED
TO TRANSMIT TORQUE BETWEEN
SHAFTS THAT ARE NOT COLINEAR."

This makes them suitable for fluid pumping

applications since the connection can be made
through thin barriers, which help maintain a
hermetically sealed rotary feed through.
Since there are no contacting parts in the
coupling, wear is virtually nonexistent and the use
of permanent magnets means no external power
source is needed. Magnetic couplings also have

THE PROTECTOR
a built-in safety feature where, in the event of an
overload on the coupling, it will shift to the next
position and keep going.
Magnetic couplings can typically only handle
FOR THE SAFETY OF YOUR DRIVE LINE: light torque loads and applications with either
gradual starts, or low rotational inertia of the
OUR PRELOADED BALL-DETENT SAFETY COUPLINGS. driven side of the system. They are also rather
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RW-AMERICA.COM THE COUPLING. 48 DESIGN WORLD — MOTION 4 • 2016

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 REFERENCE GUIDE
BASICS OF
MOTOR DRIVES
MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION
Power Transmission
ELECTRIC
motors that drive industrial machines
need some way to control motor speed.
And at its most basic level, a motor
drive controls the speed of the motor.
Some manufacturers refer to a controller and motor
together as a drive system. However, from the electrical
side of things, the drive is often specifically the electrical
components that make up the variable frequency inverter
itself. So drives are the interface between the control signals
and the motor and include power electronic devices such as
SCRs (silicon controlled rectifiers), transistors and thyristors.
Matching the correct drive to the type of motor in an
application is critical for getting the best fit. A wide range
Drives continue to offer more performance in smaller packages. For instance, a new
line of drives from Yaskawa, the Sigma-7 family, features a smaller footprint, increased
bandwidth, and 24-bit encoding that boosts precision. A package of algorithms corrects
machine imperfections, including ripple compensation, anti-resonance and friction model
compensation.
50 DESIGN WORLD — MOTION 4 • 2016
Drives_PTGuide_V2-mb.indd 50
of drives is available depending on the needs of the
specific application and motor type. In general though,
drive types typically fall into two categories: dc and ac.
DC DRIVES
Dc drives control dc motors. A basic dc drive is similar
in operation to an ac drive in that the drive controls the
speed of the motor. For dc motor control, a common
method is a thyristor-based control circuit. These circuits
consist of a thyristor bridge circuit that rectifies ac into dc
for the motor armature. And varying the voltage to the
armature controls the motor’s speed.
AC DRIVES
Ac drives control ac motors, such as induction motors
and synchronous motors. These drives are sometimes
known as variable frequency drives (VFDs) or inverters.
Ac drives convert ac to dc, then, using a range of
different switching techniques, generate variable voltage
and frequency outputs to drive the motor.
An adjustable speed drive is a general term used
sometimes interchangeably with variable speed drive or
variable frequency drive. It controls the motor by varying
the frequency of the output power. Again, from an
electrical perspective, all of these ultimately refer to the
frequency converter circuitry.
An ac motor’s speed is determined by the number
of poles and the frequency. Thus, as frequency is
adjusted, the motor’s speed can be controlled as well. A
common way to control frequency is by the use of pulse
width modulation (PWM). A PWM drive outputs a train of
dc pulses to a motor and by modulating the pulse width,
makes it either narrower or wider, which delivers an ac
current waveform to the motor.
Another drive feature, the ability to slow down
or stop a motor, is known as regenerative braking or
regen braking. It provides a way of stopping a motor’s
rotation by using the same solid-state components that
control the motor’s voltage. The energy generated from
braking can be channeled back into the ac mains or into
a braking resistor. One advantage of regenerative drives
include their ability to stop a motor faster than it would
normally coast to a stop.
motioncontroltips.com | designworldonline.com
4/29/16 4:27 PM
 Size matters.
Especially with gearmotors...

Too small = premature failure

Too large = high cost & low efficiency

Unsure of your drive size? Then go

online to PT Pilot®. Simply enter the
parameters of your hoist, conveyor, or
travel car. PT Pilot® will automatically
calculate the optimal horsepower, speed,
and gear unit – with or without a VFD.

PT Pilot® also provides documentation,

pricing, and a 3D CAD drawing for every
selection. Visit ptpilot.com.

ptpilot.com | 864-439-7537

SEW_MCTrends_3-16.indd 51 4/29/16 1:26 PM

 REFERENCE GUIDE
Power Transmission
The Altivar 320 series of drives from
Schneider Electric boast connectivity options
including Ethernet (Modbus TCP, Ethernet/
IP, Profinet, EtherCAT) or serial (Modbus RTU,
CANopen, Profibus DP, DeviceNet) based
networks. They also feature embedded safety
solutions for simple application requirements
to comply with Machinery Directive 2006/42/
EC and simplify certification.
52 DESIGN WORLD — MOTION
Drives_PTGuide_V2-mb.indd 52
VFDs
VFDs operate by switching their output devices­­—which can be transistors,
IGBTs (insulated gate bipolar transistors), or thyristors—on and off. VFDs can
be either constant voltage or constant current. Constant voltage types are the
most common type of VFD. They use PWM to control both the frequency and
the voltage applied to the motor.
Why use VFDs? They are a powerful way to control the speed of ac
induction motors and are fairly simple and easy to use. Among the benefits of
using a VFD for motor speed control is the actual energy savings. Controlling
the amount of current drawn by the motor can save a lot on energy costs
because the motor will not run at full load all of the time.
Especially since Congress passed the Energy Independence and Security
Act of 2007 (EISA), motor efficiency has become a top design priority. For
instance, single-phase induction machines (specifically, permanent split-
capacitor motors) and universal motors, widely used in industrial washers, are
managed with simple voltage-control techniques. Contrast this with high-end,
high-performance machines where three-phase motors are more common and
which use VFDs.
Switch reluctance motors (SRMs) are not yet an appropriate alternative
because their control schemes are still evolving, but three-phase motors
are readily available and may be a smart choice because their VFD control
techniques have improved significantly. More importantly, VFD electronics
costs have been dropping as well, making them more cost-effective.
In the same way, an OEM using a universal motor with simple triac control
may now find that a three-phase VFD control will provide better energy
efficiency, while OEMs using three-phase/VFD configurations may make the
move to technologies like brushless dc motors.
Another advantage of VFDs is seen on motor start-up. Without a VFD, an
induction motor on start-up has to handle a high initial in-rush current. As the
motor speeds up and approaches a constant speed, the current levels off from
the peak in-rush values. So with a VFD, the motor’s input starts off with low
voltage and a low frequency, avoiding the problem of high in-rush currents.
Of course, the main reason any kind of speed control is used on motors
is to gain greater and more precise control over motor speed and therefore
adjust the motor speed to meet the requirements of the load and reduce
energy costs.
Another benefit of using a VFD for motor speed control is the reduction
of mechanical wear on the motor components. Eliminating the in-rush
currents upon start-up gets rid of the excessive torque on the components,
and thus increases the life of the motor and reduces maintenance costs and
the need for repair. In addition, mechanical stresses on the entire system are
greatly reduced. In many cases, mechanical controls such as throttles, valves,
dampers and louvers can be removed, thereby reducing mechanical wear and
maintenance costs. Further, with reduced mechanical wear, the system output
quality may be improved and production times reduced.
There are some drawbacks to using VFDs, however. The main one is
the possibility of harmonic distortion which can effect the power quality as
well as the operation of other machinery. However, VFD manufacturers have
developed solutions that mostly eliminate this problem.
4 • 2016 motioncontroltips.com | designworldonline.com
4/29/16 11:31 AM
 Power Transmission and Motion Control Solutions
for Industrial Applications

The Power Brands in Power Transmission

Ameridrives Couplings Delroyd Worm Gear Kilian Manufacturing Svendborg Brakes
Ameridrives Formsprag Clutch Lamiflex Couplings TB Wood’s
Power Tranmission Guardian Couplings Marland Clutch Twiflex Limited
Bauer Gear Motor Huco Dynatork Matrix International Warner Electric
Bibby Turboflex Industrial Clutch Nuttall Gear Warner Linear
Boston Gear Inertia Dynamics Stieber Clutch Wichita Clutch
www.AltraMotion.com

Altra_PTGuide4-16.indd 53 4/29/16 1:29 PM

 REFERENCE GUIDE
GEARING &
GENERAL GEAR DESIGN
THE BASICS
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
Power Transmission
THE PRIMARY
function of a gear is to mesh
with other gears to transmit
altered torque and rotation. In fact, gearing can change
the speed, torque and direction of motion from a drive
source.
When two gears with an une qual number of teeth
engage, the mechanical advantage makes their rotational
speeds and torques different.
In the simplest setups, gears are flat with spur teeth
(with edges parallel to the shaft) and the input gear’s shaft
is parallel to that of the output. Spur gears mostly roll
through meshing, so can be 98% or more efficient per
reduction stage. However, there is some sliding between
tooth surfaces, and initial tooth-to-tooth contact occurs
along the whole tooth width at once, causing small shock
loads that induce noise and wear. Sometimes lubrication
helps mitigate these issues.
In slightly more complex setups, parallel-axis
gearsets have helical gears that engage at an angle
between 90° and 180° for more tooth contact and higher
torque capacity. Helical reducers are suitable for higher-
horsepower applications where long-term operational
efficiency is more important than initial cost. Helical gear
teeth engage gradually over the tooth faces for quieter
and smoother operation than spur gearsets. They also tend
Worm gear Spiroid gear
®
Spiroid® or Helicon® gear
Helicon® gear
Hypoid gear
Spiral bevel gear
54 DESIGN WORLD — MOTION 4 • 2016
Gearing_PTGuide_V4.LE.indd 54
to have higher load capacities. One caveat: Angled tooth
contact generates thrust that the machine frame must
resolve.
No matter the subtype, most parallel-axis gearsets
have gear teeth with tailored involute profiles—customized
versions of the rolled trace off a circle with an imaginary
string. Here, mating gears have tangent pitch circles for
smooth rolling engagement that minimizes slipping. A
related value, the pitch point, is where one gear initially
contacts its mate’s pitch point. Involute gearsets also have
an action path that passes through the pitch point tangent
to a base circle.
Besides parallel-axis gearsets, there are non-parallel
and right-angle gearsets. These have input and output
shafts that protrude in different directions to give
engineers more mounting and design options. The gear
teeth of such gearsets are either bevel (straight, spiral or
zerol), worm, hypoid, skew or crossed-axis helical gears.
The most common are bevel gearsets with teeth cut on
an angular or conical shape. Hypoid gears are much like
spiral-bevel gearsets, but the input and output shaft axes
don’t intersect, so it’s easier to integrate supports. In
contrast, zerol gearsets have curved teeth that align with
the shaft to minimize thrust loads.
Shown here are Spiroid and Helicon brand
gearing. Suitable for right-angle power
transmission in applications with high power
density requirements, these skew-axis gear
forms operate on non-intersecting and
non-parallel axes. Compared to traditional
right-angel bevel and worm gearing, the
gear-centerline offset of Spiroid and Helicon
branded gearing allows for more tooth-surface
contact and results in higher contact ratios.
This boosts torque capacity and smooths
motion transmission. Spiroid brand gears use
advanced software and tooling to make the
proprietary gearing fit specific application
requirements. The gearsets are quiet, stiff, and
compact, delivering ratios from 3:1 to 300:1
and beyond.
motioncontroltips.com | designworldonline.com
4/29/16 11:34 AM
 GEARS
Now available factory direct

259 Elm Place, Mineola, NY 11501

Phone: 516.248.3850 | Fax: 516.248.4385
Email: info@khkgears.us

KHK-USA_9x10.875.indd 1 55
KHK_3-16_MCTrends.indd 2/25/16
4/29/16 11:48
1:30 PM
 Common gear options
Spur gearsets are simple ...
Pitch circle
Reaction force
... but helical gearsets are
more efficient. Cross-axis
sets are another option.
Planetary gearsets
are compact and
run to 10,000 rpm.
Here, a lightweight
Schaeffler differential
for a hybrid vehicle has an
axial spline to boost efficiency.
Zerol bevel gearsets are
a special veriation of
straight right-angle
bevel sets.
Worm gearsets are rugged
and don’t let designs backdrive ...
which can eliminate the need for brakes.
Note there’s some overlap between bevel
and worm applications. Case in point: The
MS-Graessner DynaGear below is a
single-stage bevel gear with a 30:1 ratio.
56 DESIGN WORLD — MOTION
Gearing_PTGuide_V4.LE.indd 56
POWER TRANSMISSION
REFERENCE GUIDE
THE BASICS OF GEARING:
GENERAL SPEED
REDUCERS, SHAFT-MOUNT
SETS, WORM DRIVES
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
GEAR
reducers, also known as speed
reducers, are a component of
many mechanical, electrical, and hydraulic
motors. Essentially it is a gear or series of
gears combined in such a manner as to
alter the torque of a motor. Typically, the
torque increases in direct proportion to the
reduction of rotations per unit of time.
Speed reducers come in two varieties;
base mounted and shaft mounted. Shaft-
mounted types come in two versions. One is
truly shaft mounted in that the input shaft of
the drive motor supports it … with a special
coupling to address torque reactions. The
other mounts to the machine housing so
the input shaft doesn’t support the reducer’s
weight or address torque reactions.
By the American Gear Manufacturers
Association (AGMA) definition, engineers
apply the term “speed reducer” to units
operating at pinion speeds below 3,600 rpm
or pitch-line velocities below 5,000 fpm.
(The AGMA is an international group of gear
manufacturers, gear consultants, academics,
and gear users and suppliers.) Reducers
operating at speeds higher than these are
called high-speed units. Manufacturers
base catalog ratings and engineering
specifications for speed reducers on these
AGMA standards.
There are as many types of speed
reducers as there are gear types. Consider
reducers in which the input and output shafts
are at different angles. The most common of
these are worm-gear reducers.
Worm gear reducers are used in low to
moderate-horsepower applications. They
offer low initial cost, high ratios, and high
output torque in a small package, along
The ratio of a helical or bevel gearset is simply the number of teeth in the larger gear divided by the number of teeth
in the smaller gear. Other gear types such as planetary gears have more complex ratio relationships.
4 • 2016
with a higher tolerance for shock loading
then helical gear reducers. In a traditional
setup, a cylindrical toothed worm engages
a disk-shaped wheel gear with teeth on its
circumference or face.
Most worm gears are cylindrical with
teeth of consistent size (for one pitch
diameter for the length). Some worm-gear
reducers use a double-enveloping tooth
geometry, though—with a pitch diameter
that goes from deep into short and back to
deep—so more teeth engage. No matter the
version, most wheel gears in worm-based
reducers sport cupped teeth edges that wrap
around the worm shaft during engagement.
In many cases, the sliding engagement
lowers efficiency but extends life, as worm-
gear mating holds a film of lubricant during
operation. The ratio of a worm-gear ratio is
the number of wheel teeth to the number of
threads (starts or leads) on the worm.
A FEW WORDS ON GEARHEADS
A gearhead is similar to a gear reducer;
however, a gearhead doesn’t just reduce
speed. Engineers use them wherever an
application calls for high torque at low
speed. It reduces a load’s reflected mass
inertia, which makes accelerating heavy
loads easier, enabling designs to run off
smaller motors. Gearheads come in a
variety of styles from basic spur gearheads
to more complex planetary gearheads and
harmonic type gearheads, each with their
own characteristics and suitable applications.
One caveat: In some applications, gearhead
backlash may become an issue. In this case,
consider using a gearhead with low or zero
backlash.
motioncontroltips.com | designworldonline.com
4/29/16 11:34 AM
Neugart 8-15.indd 57 4/29/16 1:32 PM
 REFERENCE GUIDE
Power Transmission

Interoll conveyors for material

handling use power rollers that
incorporate precision gearing.

THE BASICS OF GEARING:

GEARBOXES, SPECIALTY
GEARHEADS & SERVOGEARSETS
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

SERVO SYSTEMS
move heavy objects. Speed specifications for gearmotors are
normal speed and stall-speed torque.
are precision-motion setups with Gearbox: This is a contained gear train … a mechanical
feedback and (in most cases) fairly unit or component consisting of a series of integrated gears.
stringent accuracy demands. So for Planetary gears are common in integrated gearboxes.
these designs, engineers should pick Planetary gears: Particularly common in servo systems,
servogear reducers with good torsional these gearsets consist of one or more outer planet gears that
stiffness, reliable output torque and revolve about a central, or sun, gear. Typically, the planet
minimal backlash. OEMs tasked with gears mount on a movable arm or carrier that rotates relative
integrating servo systems should look for to the sun gear. The sets often use an outer ring gear, or
quiet reducers that easily mount to the annulus, that meshes with the planet gears.
motor and require little or (if possible) no The gear ratio of a planetary set requires calculation,
maintenance. because there are several ways they can convert an input
In fact, a lot of advanced machinery rotation to an output rotation. Typically, one of these three
integrates servogears into application- gear wheels stays stationary; another is an input that provides
specific electromechanical arrangements, power to the system, and the last acts as an output that
and several of these arrangements are receives power from the driving motor. The ratio of input
common enough to have specific labels. rotation to output rotation depends on the number of teeth in
Here is a look at some of the most each gear and on which component is held stationary.
widespread. Planetary gearsets offer several advantages over other
Gearmotor: This complete motion gearsets. These include high power density, the ability to
component is a gear reducer integrated get large reductions from a small volume, multiple kinematic
with an ac or dc electric motor. Usually combinations, pure torsional reactions and coaxial shafting.
the motor includes the gears on its Another advantage to planetary gearbox arrangements is
output (typically in the form of an power-transmission efficiency. Losses are typically less than
assembled gearbox) to reduce speed and 3% per stage, so rather than waste energy on mechanical
boost available output torque. Engineers losses inside the gearbox, these gearboxes transmit a high
use gearmotors in machines that must proportion of the energy for productive motion output.

58 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Gearing_PTGuide_V4.LE.indd 58 4/29/16 11:35 AM

 GEARING

Planetary gearbox arrangements distribute load

efficiently, too. Multiple planets share transmitted
load between them, which greatly increases torque
density.
The more planets in the system, the greater
load ability and the higher the torque density.
This arrangement is also very stable due to the
even distribution of mass and increased rotational
stiffness. Disadvantages include high bearing loads,
inaccessibility and design complexity.
In servo systems, besides boosting output
torque, gearboxes impart another benefit—reducing
settling time. Settling time is a problem when motor
inertia is low compared to load inertia … an issue
that’s the source of constant debate (and regular
improvement) in the industry. Gearboxes reduce the
reflected inertia at the controls by a factor equal to
the gear reduction squared.

These are self-lubricating metal-core gears from Intech for

applications with frequent start-and-stop stop cycles and
high torque that need power-transmission components to
resist shock.

DieQua offers more gearboxes

Are You Selecting
For Power Transmission

The Right Technology?

Whether your application is for precise motion control or
for general power transmission, there are several gear
technologies that can do the job. But which one does it best?

Only DieQua offers the widest range of gearmotors, speed Worm Reducers Helical Gearmotors Spiral Bevel Gearboxes
reducers and servo gearheads along with the experience and
expertise to help you select the optimal solution to satisfy
your needs. For Motion Control

If you are using gearboxes,

you should be talking to DieQua!

Planetary Gearheads Servo Worm Gearheads Precision Cycloidals

www.diequa.com 630-980-1133
half page horizontal ad.indd 1 1/19/16 3:00 PM

motioncontroltips.com | designworldonline.com 4 • 2016 DESIGN WORLD — MOTION 59

Gearing_PTGuide_V4.LE.indd 59 4/29/16 11:35 AM

 REFERENCE GUIDE
Power Transmission
Circular spline
60
Gearing_PTGuide_V4.LE.indd 60
THE BASICS OF GEARING:
STRAIN-WAVE GEARING
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
STRAIN-WAVE
gearing is a special gear design
for speed reduction. It uses the
metal elasticity (deflection) of a
gear to reduce speed. (Strain-
wave gearing sets are also known
as Harmonic Drives, a registered
trademark term of Harmonic Drive
Systems Inc.) Benefits of using
strain-wave gearing include zero
backlash, high torque, compact
size and positional accuracy.
A strain-wave gearset consists
of three components: wave
generator, flexspline and circular
spline. The wave generator is an
assembly of a bearing and steel
disk called a wave generator plug.
The outer surface of the wave
generator plug has an elliptical
shape machined to a precise
specification. A specialty ball
bearing goes around this plug
to conform to the same elliptical
shape of the wave generator plug.
Designers typically use the wave
generator as the input (attached
to a servomotor).
The flexspline— usually
acting as the output—is a thin-
walled steel cup. Its geometry
makes the cup walls radially
compliant but torsionally stiff
(because the cup has a large
diameter). Manufacturers machine
the gear teeth into the outer
surface near the open end of the
cup (near the brim).
The cup has a rigid boss
at one end for mounting. The
wave generator goes inside the
Flexspline
This is a progression of flex-spline tooth engagement with circular-spline teeth. The profile of Harmonic Drive gear
teeth lets up to 30% of the teeth engage ... for higher stiffness and torque than gearsets with involute teeth.
DESIGN WORLD — MOTION
flexspline so the bearing is at the same axial location as the flexspline teeth.
The flexspline wall near the brim of the cup conforms to the same elliptical
shape of the bearing. This conforms the teeth on the outer surface of the
flexspline to the elliptical shape. That way, the flexspline effectively has an
elliptical gear-pitch diameter on its outer surface.
The circular spline is a rigid circular steel ring with teeth on the inside
diameter. It is usually attached to the housing and does not rotate. Its teeth
mesh with those of the flexspline. The tooth pattern of the flexspline engages
the tooth profile of the circular spline along the major axis of the ellipse.
This engagement is like an ellipse inscribed concentrically within a circle.
Mathematically, an inscribed ellipse contacts a circle at two points. However,
gear teeth have a finite height, so two regions (instead of two points) engage.
The pressure angle of the gear teeth transforms the output torque’s
tangential force into a radial force acting on the wave-generator bearing. The
teeth of the flexspline and circular spline engage near the ellipse’s major axis
and disengage at the ellipse’s minor axis. The flexspline has two less teeth than
the circular spline, so every time the wave generator rotates one revolution,
the flexspline and circular spline shift by two teeth. The gear ratio is:
number of flexspline teeth
÷ (number of flexspline teeth - number of circular spline teeth)
The tooth engagement motion (kinematics) of the strain wave gear is different
than that of planetary or spur gearing. The teeth engage in a manner that lets
up to 30% of the teeth (60 for a 100:1 gear ratio) engage at all times. This
contrasts with maybe six teeth for a planetary gear, and one or two teeth for a
spur gear. In addition, the kinematics enable the gear teeth to engage on both
sides of the tooth flank. Backlash is the difference between the tooth space
and tooth width, and this difference is zero in strain-wave gearing.
As part of the design, the manufacturer preloads the gear teeth of the
flexspline against those of the circular spline at the ellipse’s major axis. The
preload is such that the stresses are well below the material’s endurance limit.
As the gear teeth wear, this elastic radial deformation acts like a stiff spring
to compensate for space between teeth that would otherwise increase in
backlash. This lets the performance remain constant over the life of the gear.
Strain-wave gearing offers high torque-to-weight and torque-to-volume
ratios. Lightweight construction and single-stage gear ratios (to 160:1) let
engineers use the gears in applications requiring minimum weight or volume ...
especially useful for designs with small motors.
Another tooth profile for strain-wave gearing is the S tooth design. This
design lets more gear teeth engage for a doubling of torsional stiffness and
peak torque rating, as well as longer life. The S tooth form doesn’t use the
involute tooth curve of a tooth. Instead, it uses a series of pure convex and
concave circular arcs that match the loci of engagement points dictated by
theoretical and CAD analysis. The increased root filet radius makes the S tooth
much stronger than an involute curve gear tooth. It resists higher bending
(tension) loads while maintaining a safe stress margin.
4 • 2016 motioncontroltips.com | designworldonline.com
4/29/16 11:36 AM
 247 Lynnfield Street, Peabody, MA 01960 • 800.921.3332 • www.HarmonicDrive.net
Harmonic Drive is a registered trademark of Harmonic Drive LLC. Robonaut image courtesy of NASA/JPL-Caltech.

DW Robotics Ad.indd 1 9/15/15 2:04 PM

Harmonic Drives 10-15_Robotic Supp.indd 61 4/29/16 1:33 PM
 REFERENCE GUIDE
Power Transmission

Most of the time, design engineers pair gearsets with electric motors. These setups get a roman-nu-
meral service class number (I, II, or III, for example) that equates to the standalone gear-set service
factor (in this case, 1.0, 1.41, or 2.0).

This chart provides values for C-face motor input (flanged) or directly coupled (non-flanged)
motors. It lets the design engineer verify that with 15:1 reduction, a 726 flanged gearbox outputs
116.7 rpm … and when used with a 2 hp motor, outputs 994 in.-lb of torque.

62 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Gearing_PTGuide_V4.LE.indd 62 4/29/16 11:36 AM

 GEARING

THE BASICS OF GEARING:

CONSULTATION, CUSTOM
GEAR DESIGN & GEAR ANALYSIS
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

CUSTOM
gearboxes are increasingly common, mainly because they’re
easier than ever to manufacture to specification. That’s not to
say that the design work isn’t challenging. However, modern manufacturing lets
some suppliers make gearboxes and components to meet specific application
requirements. New supplier approaches to giving engineering support as well as
new machine tools, automation and design software now let OEMs and end users
get reasonably priced gearing even in modest volumes.
When enlisting help from a consultant or manufacturer, an engineer is more
likely to get gearing that mounts properly and performs to specification after
reviewing the following and answering as many of these questions as possible:

• What’s the input speed and horsepower?

• What’s the gearbox target output speed or output torque? This partially
defines the required gear ratio.
• What are the characteristics of use? How many hours per day will the gearbox
run? Will it need to withstand shock and vibration?
• How overhung is the load? Is there internal overhung load? Remember that
bevel gears usually can’t accommodate multiple supports, as their shafts
intersect … so one or more gears often overhang. This load can deflect the
shaft which misaligns the gears, in turn degrading tooth contact and life. One
potential fix here is straddle bearings on each side of the gear.
• Does the machine need a shaft or hollow-bore input ... or a shaft or hollow-
bore output?
• How will the gearing be oriented? For instance, if specifying a right-angle
worm gearbox, does the machine need the worm over or under the wheel?
Will the shafts protrude from the machine horizontally or vertically?
• Does the environment necessitate corrosion-resistant paints or stainless-steel
housing and shafts?

Service factor: The starting point for most gearbox manufacturers is to

define a service factor. This adjusts for such concerns as type of input, hours
of use per day, and any shock or vibration associated with the application. An
application with an irregular shock (a grinding application, for example) needs a
higher service factor than one that’s uniformly loaded. Likewise, a gearbox that
runs intermittently needs a lower factor than one used 24
hours a day.
Class of service: Once the engineer
determines the service factor, the next step is to
define a class of service. A gearbox paired to

Shown here is a MS-Graessner

PowerGearHS, a high-speed bevel
gearbox for dynamic servo drivetrains.
Efficiency reaches 98% and torque
reaches 45 to 360 Nm (with emergency-
stop torques of 90 to 720 Nm)
depending on the version.

4 • 2016 DESIGN WORLD — MOTION 63

Gearing_PTGuide_V4.LE.indd 63 4/29/16 11:37 AM

 REFERENCE GUIDE as mounting feet for either above or below the body
of the gearbox, hollow outputs, and input and output
configuration are all possible. All gearbox manufacturers
list their mounting options as well as dimensional
information in catalogs and websites.
Lubricant, seals and motor integration: Most
manufacturers can ship gearboxes filled with lubrication.
However, most default to shipping units empty to let users
fill them on site. For applications where there is a vertical
shaft down, some manufacturers recommend a second set
of seals. Because many gearboxes eventually mount to a
Power Transmission

C-frame motor, many manufacturers also offer to integrate

motors onto gearboxes and ship assemblies as single units.
Trained machinists run this machine shop to let gear Work with consultants and even use custom gear
manufacturer NORD Gear Corp. accommodate customer- designs if the application needs a unique motor-gearbox
specific requirements. The Waunakee, Wis. shop processes 20 combination. Some combinations are more efficient.
to 30 specially designed and machined components each day.
Getting a pre-engineered geamotor ensures that the
motor-gearbox combination will perform to specification.
a plain ac motor driving an evenly loaded, constant-speed Also remember that today’s custom and standard
conveyor 20 hours per day may have a service class 2, for gearing aren’t mutually exclusive. Where fully custom
example. This information comes from charts from gearbox gearboxes aren’t feasible (if quantities aren’t high enough,
manufacturers that list classes of service. To use these for example) consider working with manufacturers that sell
charts, the design engineer must know input horsepower, gearboxes built to order from modular subcomponents.
application type and target ratio. For instance, suppose that Otherwise, look for manufacturers that leverage the latest
an application needs a 2-hp motor with a 15:1 ratio. To use CAD and CAM software and machine tools to streamline
the chart, find the point where 2 hp and 15:1 ratio intersect. post-processing work and reduce the cost of one-offs.
In this case, that indicates a size 726 gearbox. According One final tip: Once the gearmotor has been chosen
to one manufacturer’s product-number system, size 726 and installed in the application, perform several test runs
defines a gearbox that has a 2.62 center distance. Such in sample environments that replicate typical operating
charts also work in reverse, to let engineers confirm the scenarios. If the design exhibits unusually high heat, noise
torque or speed of a given gearbox size. or stress, repeat the gear-selection process or contact the
Overhung load: After the designer picks a size, the manufacturer.
gearbox manufacturer’s catalog or website lists values for
the maximum overhung load
that is permissible for that
sized unit. Tip: If the load in
an application exceeds the
allowed value, increase the
gearbox size to withstand the
overhung load.
Mounting: At this point,
the designer or manufacturer
has defined the gearbox
size and capability. So, the
next step is to pick the
mounting. Common mounting
configurations abound, and
gearbox manufacturers offer
myriad options for each unit
size. A flanged input with
hollow bore for a C-frame
motor combined with an
output shaft projecting to the
left may be the most common
mounting, but there are many
KHK USA Inc. manufactures gearing to operate in ratchets and pawls, which is mechanical
other choices. Options such
gearing that transmits intermittent rotary motion. They only let shafts rotate in one direction.

64 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Gearing_PTGuide_V4.LE.indd 64 4/29/16 11:39 AM

 ®
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From design to delivery, you can count on us to give you the best gearmotor solution for your
application. When your product demands perfect performance every time, call Bodine.

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BOD designWorld-swoosh-full page.indd 1 3/21/16 9:58 AM

Bodine_PTGuide4-16.indd 65 4/29/16 1:33 PM
 REFERENCE GUIDE
T E CHN ICAL R E V I E W OF
GEARMOTORS
MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION
GEARMOTORS
Power Transmission
are a fairly well-established
technology. And recently,
there is renewed interest in gearmotors, following a trend
in integrated systems in general. More specifically, rising
energy costs are driving demand for improved process
efficiencies. This presents an opening for gearmotors that
can be used in a variety of applications and represents a
tremendous opportunity for global
energy savings.
Essentially, a gearmotor is a type of gear reducer
based around an ac or dc electric motor. In fact, in a
gearmotor, the gear and the motors are combined into
one unit. It delivers high torque at low horsepower or
low speed. The speed specifications for these motors are
normal speed and stall-speed torque. These motors use
gears, typically assembled as a gearbox, to reduce speed,
which makes more torque available. Gearmotors are most
often used in applications that need a lot of force to move
heavy objects.
By and large, most industrial gearmotors use ac
motors, typically fixed-speed motors. However, dc motors
can also be used as gearmotors, a lot of which are used in
automotive applications.
Gearmotors have a number of advantages over
other types of motor/gear combinations. Perhaps
most importantly, gearmotors can simplify design and
implementation by eliminating the step of separately
designing and integrating the motors with the gears, thus
reducing engineering costs.
Another benefit of gearmotors, if sized properly, is that
having the right combination
of motor and gearing can
prolong gearmotor life and
allow for optimum power
management and use.
Also, because
gearmotors are integrated
units, they eliminate the
need for couplings and
also eliminate any potential
alignment problems. Such
problems are common
Gearmotors can be simply a motor with a
simple gear attached or as complex as this when a separate motor and
unit from Nord Gear incorporating bevel gear reducer are connected
gears with a 90-degree hollow-shaft output. together and result in more
66 DESIGN WORLD — MOTION 4 • 2016
Gearmotors_PTGuide_V3.indd 66
An in-line gearmotor design
featuring a helical gearset
from Nord Gear is one common
type of gearmotor.
engineering time and cost as well as the potential for
misalignment causing bearing failure and ultimately
reduced useful life.
Gear reducers, also known as speed reducers, are a
component of many mechanical, electrical and hydraulic
motors. Essentially, it is a gear or series of gears combined
in such a manner as to alter the torque of a motor. Typically,
the torque increases in direct proportion to the reduction of
rotations per unit of time.
A gearbox, or gear train, is a mechanical unit or
component consisting of a series of integrated gears.
Planetary gears are a common type of integrated gearing
in a gearbox.
Advances in gearmotor technology include the use of
new specialty materials, coatings and bearings, and also
improved gear tooth designs that are optimized for noise
reduction, increase in strength and improved life, all of
which allows for improved performance in smaller packages.
Conceptually, motors and gearboxes can be mixed
and matched as needed to best fit the application, but
in the end, the complete gearmotor is the driving factor.
There are a number of motors and gearbox types that
can be combined; for example, a right angle wormgear,
planetary and parallel shaft gearbox can be combined with
permanent magnet dc, ac induction, or brushless dc motors.
Though there are a number of different motor and
gearbox combinations available, not just any one will work
for a specific application. There will be certain combinations
that will be more efficient and cost-effective than others.
Knowing the application and having accurate ratings for
the motor and gearbox is the foundation for successfully
integrating a gearmotor into a system.
motioncontroltips.com | designworldonline.com
4/29/16 11:40 AM
 YOUR NEEDS.
OUR EXPERTISE.

Groschopp Inc. Phone: 712.722.4135

420 15th St. NE Toll-free: 800.829.4135
Sioux Center, IA 51250 Fax: 712.722.1445
© 2016 Groschopp Inc.
www.groschopp.com Email: sales@groschopp.com

Groschopp_PTGuide4-16.indd 67 4/29/16 1:34 PM

 REFERENCE GUIDE

Anti-backlash leadscrew assemblies,

such as the CMP Series from Haydon
Kerk, use a general purpose self-
compensating nut in a small compact
package. The standard CMP Series
assembly uses a self-lubricating
acetal nut, axially preloaded, on
a 303 stainless steel screw.
Power Transmission

BASICS OF

LEADSCREWS
MILES BUDIMIR
SENIOR EDITOR LEADSCREWS are one of many linear actuator components that also
include ballscrews as well as belt and pulley systems, linear
motors and belt-drive systems. A leadscrew, also known as a power screw, is a threaded
@DW_MOTION
rod or bar that translates rotational motion into linear motion. Leadscrews generate sliding
rather than rolling friction between a nut and the screw. Consequently, higher friction
means a lower overall efficiency. And efficiency, when talking about leadscrews, is simply
the ability to convert torque to thrust while minimizing mechanical losses.
Leadscrews are a staple of motion designs, driving axes on machines big and small
alike. They usually sport higher ratings than comparable ballscrews thanks to more contact
between the nut and screw load surfaces. Now, innovations in materials and helix geometry
address old issues associated with leadscrew friction, bringing it down to better than 0.10
in some cases—good for fast and dynamic applications. In fact, there’s also been an uptick
in leadscrew use because of proliferating machines for 3D printing, manufacturing and
medical applications.

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Industries across the board are
adopting new leadscrew components
and linear systems. Designers of kiosks
and automated retail applications, for
instance, are looking for ways to simplify
machines, reduce design weight and
simplify assembly and maintenance. In a
similar way, both additive manufacturing
(3D printing) and traditional subtractive
processes—plasma cutter, laser and
waterjet manufacturing—are driving new
leadscrew uses. The same holds true for
factory automation.
Leadscrew manufacturing processes
can determine the performance and cost of
the leadscrew. For instance, there are three
ways leadscrews can be manufactured; by
machining, rolling, or grinding. Ground
leadscrews are the most expensive and
are generally considered to be the highest
performing as well.
Another determinant of efficiency
is the thread type. Acme threads are the
simplest to produce, the most inexpensive,
but also among the least efficient. Other
types include buttress threads and square
threads, which generally have the least
amount of friction and higher efficiencies.
Smaller leadscrews have been
finding their way into many
applications, from vending
machines to medical equipment.
Miniature leadscrews such as
the MINI Series from Haydon
Kerk, are designed to minimize
backlash with drag torque of
less than 1 oz.-in. and in some
sizes as low as 0.1 oz.-in.
motioncontroltips.com | designworldonline.com
Leadscrews_PTGuide_V3.indd 69
LEADSCREWS
Leadscrews have a number of advantages including a relatively high
load carrying capacity. They are also compact and simple to design into a
system with a minimal number of parts. The motion is also generally smooth
and quiet and requires little maintenance. Leadscrews also work well in
wash-down environments because the materials used and the lubricant-free
operation allows total immersion in water or other fluids.
On the other hand, leadscrews do not have high efficiencies. Because of
lower efficiency ratings they’re not used in applications requiring continuous
power transmission. There’s also a high degree of friction on the threads
meaning that the threads can wear quickly. Because a leadscrew nut and
screw mate with rubbing surfaces they have relatively higher friction and
stiction compared to mechanical parts that mate with rolling surfaces and
bearings.
There are several parameters that help determine leadscrew
performance. These include thrust, speed, accuracy and repeatability.
The two most important factors in determining the performance of
a leadscrew are the screw pitch and lead. The pitch is the linear distance
between the threads while the lead is the linear distance the nut travels.
Speed is another critical parameter. Leadscrews have a critical velocity,
which is the rotational velocity limit of the screw. Reaching this limit induces
vibrations in the leadscrew.
Accuracy and repeatability are also important factors. The accuracy of a
leadscrew is a measure of how close to a desired end point the assembly can
move a load to within a given tolerance. The accuracy of the leadscrew will
mostly determine the system’s accuracy. On the other hand, repeatability is a
measure of how well a leadscrew assembly can repeatedly move a load to the
same position.
4 • 2016 DESIGN WORLD — MOTION 69
4/29/16 11:44 AM
 REFERENCE GUIDE
Power Transmission
This Schaeffler INA assembly has a linear
recirculating-ball bearing and guideway. Called
the KUVE-B-HS, it has conventional steel rolling
elements for speeds to 10 m/sec. Plastic in the
recirculation mechanism prevents rolling-
element tilting and pulse loads. The guides run
on standard guideways.
70 DESIGN WORLD — MOTION
LinearMotion_PTGuide_V3.indd 70
TECHNICAL SUMMARY OF
LINEAR-MOTION GUIDES,
RAILS & SYSTEMS
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL
LINEAR-MOTION
systems are
essential in
all sorts of applications, including everything
from manually operated industrial drawers to
advanced Cartesian robots. Mechanisms that
include the former operate without power,
using inertia or manual power to move loads.
Components to complete the latter include
ready-to-install drive and guidance designs
… in the form of self-contained actuators or
linear-motion machinery subsections. Some
designs simply rely on the rotary-to-linear
mechanism or actuator structure for total load
support. However, most industrial linear designs
have pneumatics, linear motors or motor-
driven, rotary-to-linear mechanisms to advance
attached loads, as well as rails that guide and
support the loads.
Here, linear rails, rotary rails, guide rails,
linear slides and linear ways are just a few
options to facilitate single-axis motion. Their
main function is to support and guide load with
minimal friction along the way. Typical linear-
4 • 2016
Heavy Duty Slides from HepcoMotion work
for long-length transport applications such
as pick-and-place or robot-translation stages.
V slide rails are made from bearing-grade
steel in sections to four meters long. The V
slides typically bolt to aluminum extrusions or
supporting back plates. A guide wheel bearing
with matching V geometry rolls on the V slide
raceway. Image courtesy Bishop-Wisecarver
motion arrangements consist of rails or shafts,
carriages and runner blocks, and some type
of moving element. Engineers differentiate
these systems by the type of surface interaction
(sliding or rolling), the type of contact points,
and (if applicable) how the design’s rolling-
element recirculation works. In fact, slides
and rails are more advanced than ever, with
advances in materials and lubrication setups (to
help designs last longer in harsh applications),
innovative rail geometries (to help designs
withstand more misalignment and load than
ever), and modular guide mounts (to boost
load capacity and minimize deflection).
No matter the ultimate installation, linear-
motion rails, guides, and ways enable motion
along an axis or rail either through sliding or
rolling contact. Myriad moving elements can
produce either sliding or rolling support: ball
bearings, cam roller sliders, dovetail bearings,
linear roller bearings, magnetic bearings, fluid
bearings, X-Y tables, linear stages and machine
slides.
motioncontroltips.com | designworldonline.com
4/29/16 11:48 AM
Dunkermotoren_PTGuide4-26_LOWRES.indd 71 4/29/16 1:35 PM
 REFERENCE GUIDE
One classic rail with sliding contact is
a dovetail slide, and one classic rail with
rolling contact is a ball rail with a recirculating
system. Sliding-contact bearings are the more
straightforward type of linear-motion component.
These consist of a carriage or slide that rides over
a surface known as a rail, way or guide. Sliding
contact occurs when the moving part directly
contacts the rail section. Older versions of these
Power Transmission
sliding-contact rails generated considerable friction
during movement, so were only suitable for basic
applications. However, newer versions have self-
lubricating sleeves and other features to boost
positioning accuracy and repeatability.
In contrast, rolling-element linear-motion
systems are either recirculating or non-recirculating.
Non-recirculating types use rolling elements such
as bearing balls, rollers and cam followers for
movement. Recirculating types use some type
of moving platform that houses a bearing block.
This bearing block contains raceways with rolling
elements that let the platform move along the rail
with little friction. Recirculating types include linear
guides and ball-bushing bearings.
More specifically, rolling-element linear guides
come in two basic versions—those with circular arc
grooves and those with Gothic arc grooves. These
groove choices are a result of industry evolution
that’s enabled new geometries for better load
handling. Circular arc grooves contact bearing balls
at two points. The Gothic arch contacts the balls at
four points for bidirectional load capacity.
Another option for rolling-element linear
motion is ball bushings that have a bushing nut
72 DESIGN WORLD — MOTION 4 • 2016
LinearMotion_PTGuide_V3.indd 72
lined with recirculating bearing balls. This nut rides along a
round shaft to allow axial movement. History lesson: In 1946,
the manufacturer Thomson introduced ball bushings, and
the technology established the basic mechanism of rolling-
element linear-motion bearings. In today’s designs, the
bushings may also have integral flanges to support axial loads.
SLIDING-CONTACT RAIL GEOMETRIES
A distinguishing feature of sliding carriage-and-rail setups is
that manufacturers typically incorporate a ground groove in a
rectangular track’s geometry (to serve as a working surface).
Manufacturers typically build these rails in one of three shapes:
• Rails with a boxway shape or square shape are simplest.
Square rails excel at carrying large loads without a lot of
deflection. Manufacturers often preload square rails, and
most linear systems based on square rails do not self-
align. Square rails often have a smaller envelope size; the
boxway rails handle the highest loads in all directions.
• Rails with a dovetail shape (or twin rail) have male
geometry that securely engages female saddle geometry.
That boosts stability and load capacity, even in unusual
orientations or applications with unsteady loads.
• Round rails deflect less under load. In addition, systems
based on round rails are inherently self-aligning, so are
easier to install than the other options.
No matter the type, rails are available in a wide range of sizes
and lengths.
ROLLING-CONTACT FUNCTIONS AND OPTIONS
Rolling-element linear systems need little force to initiate
motion. In addition, friction-force variations due to speed
are minimal, so these systems can position loads with small
and precise steps. The low friction also lets these systems
move at high speeds without generating too much heat. That
minimizes wear to help machinery maintain a level accuracy for
much of the linear system’s operating life.
Manufacturers produce rolling-contact guides in several
variations. The differences are in rolling element shape (ball or
roller); rolling element size; whether the rolling contact is two
or four-point; conformity of ball contact; whether the design
has two, four, six or some other number of rolling-element
rows; contact angle; and how the rolling-element rows are
arranged—in an X or O configuration. All these design factors
determine load capacity, rigidity and friction. For example,
O-shaped arrangements can withstand higher torque than X
arrangements. In general, the number of load-bearing rolling-
element rows influences the load capacity … so more rail rows
means more load capacity and rigidity. However, more rows
makes systems more complex and costly.
This linear plain bearing is PBC Linear Uni-Guide with a Frelon
self-lubricating liner to lower the coefficient of friction, reduce
wear, and boost load capacity.
motioncontroltips.com | designworldonline.com
4/29/16 11:49 AM
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1-800-962-8979 | www.pbclinear.com | 6402 Rockton Road, Roscoe, IL 61073 | USA

PBC Linear 3-16.indd 73 4/29/16 1:36 PM

 REFERENCE GUIDE
Here are more details on these rolling-contact options:
• Rolling elements are either linear rollers or balls.
Because the rolling elements recirculate in recirculating
rolling-element guides, they have a nearly infinite stroke
length. They are available on flat guide ways and guide
way rails. Flat guide ways are available in single or
double row rolling elements. Guide way rails are often
square rails.
Power Transmission
• Non-recirculating roller type units have limited stroke
length. Flat guide ways are dominant here and have
either a grooved race compatible with crossed rollers,
or non-grooved race, which uses cage and roller-type
rolling elements.
• Recirculating elements (ball or roller bearings) between
the rail and the bearing block enable precise linear
motion. The coefficient of friction with roller-element-
based systems is much less than with slide based linear
motion guides … about 1/50th that of non-recirculating
systems.
Ball-type rolling element units are also subdivided into
recirculating and non-recirculating types. The flat guide
ways here typically use double row recirculating rolling
elements. The guide way rail can be either round or square.
If the raceway is not grooved, the rolling element is typically
a linear ball bushing. If the raceway is grooved, the unit
usually uses a ball spline. For square rails, the raceway is
usually grooved. For ball-type rolling element units that are
non-recirculating, the flat guide ways are grooved and use
linear ball guides. The guide ways are round rail, without a
grooved raceway, and use stroke bearings.
QUICK NOTE ON FLUID-FLOATED BEARINGS
Less common types of linear systems include hydrostatic
or aerostatic linear-motion bearings. Because these
systems have no mechanical contact, they are suitable
for applications that need extremely accurate or quiet
operation. Here’s how they work: A pressure regulator
sends pressurized fluid between the rail and carriage.
That lifts the carriage off the guideway by about
0.01 mm or so. Aerostatic versions use air as the
fluid; hydrostatic linear bearings use specially
formulated hydraulic oil. This type of guide
is difficult to manufacture and expensive, but
damps vibrations and allows for moves to
120 m/min and 10 g—useful for
ultra-precision machines.
74 DESIGN WORLD — MOTION 4 • 2016
LinearMotion_PTGuide_V3.indd 74
LINEAR-RAIL LUBRICATION
Some linear-motion systems need periodic
application of lubricant, but many are available
pre-lubricated. In addition, a number of systems use
self-lubricated moving elements, eliminating the
need for lubrication during the useful life. Note that
the rails, ways and guides of linear motion systems
tend to pick up dirt and debris from their application
environment. For this reason, use carriages and slides
with some kind of wiper system to keep the systems
clean.
When selecting linear systems, engineers should
consider space limitations, accuracy needs, stiffness,
travel length, magnitude and direction of loads,
moving speed and acceleration, duty cycle, and the
application’s environment. Note that an excessively
large load or an impact load can permanently deform
the raceway surface whether the linear guideway is
at rest or in motion. Most manufacturers offer tables
on the basic dynamic load rating, which can help
engineers determine the proper load ratings for a
system.
Another caveat about friction: Friction
measurements are carried out on all profiled rail
systems. The friction values are given in tables in the
manufacturers’ respective product catalogs. The level
of friction depends on load, preload and sealing,
taking into account travel speed, lubricant and runner
block temperature. The total friction of a runner block
includes the associated rolling or sliding friction,
lubricant friction, and the friction of any seals.
This Rexroth CKL Compact Module incorporates a linear
motor to deliver high force density with a compact
package … for travel velocities up to 5 m/sec. A ball
rail with central relubrication helps the module deliver
precise positioning and zero backlash.
motioncontroltips.com | designworldonline.com
4/29/16 11:49 AM
 LOCKING DEVICES

E S S E N T I A L I N F O R M AT I O N F O R

SHAFT COLLARS
& LOCKING DEVICES
LISA EITEL • SENIOR EDITOR • @DW_LISAEITEL

IN THE
context of motion and machine design, locking
devices are mechanical connections that attach power-
transmission parts, such as gears, timing-belt pulleys and sprockets, to
drive shafts. Locking devices keep rotary drive components secure and
machines running.

To put locking devices in context, here are common approaches to

mount and lock drive components on shafts.
• Keyways are notched geometry in a rotary component’s inner
diameter to mate with notched geometry in the shaft. In many cases,
a key or metal slug plugs into the notches to set the component’s
radial orientation. Though prone to backlash and eventual failure,
this locking method is still common in industrial applications and
some drivetrains in consumer products.
• Setscrews mount through the face of a rotary component to tension
via threads through the component and shaft surface. These can
mount rotary components that output unidirectional rotation in
lightweight designs that aren’t subject to any shock.
• Shaft collars clamp or screw-set onto shafts to act as mechanical
stops and axially locate components and bearings on shafts. Solid
versions that use setscrews can gouge shafts unless the engineer
This flange coupling from Ringfeder Power
specifies flat-machined shaft sections. In contrast, collars with screw- Transmission is for heavy-duty applications. It has
tightened tapers that clamp onto shafts are more reliable. One shrink discs to integrate into machines without
caveat: In applications subject to shock, taper-based collars need an making the installer cool or heat the connections.
undercut on the shaft to have a positive stop so they don’t turn free.
Two-piece designs simplify installation.
• Taper-locking devices are any components that use a wedge action
from tightening a screw or screws to induce radial locking pressure
at a hub and shaft bore. For example, QD bushings (short for quick
detachable) are split rings with a screw that bridges the flange and
taper opening. Typically (though not always) a few inches in diameter
or smaller, screw tensioning clamps the bushing to the shaft and
replicates a shrink fit.

As a side note, traditional shrink fits are when a mounted component’s

inner diameter comes to an interference fit with the shaft on which it
mounts. The installer heats the component so it expands; when it cools to
room temperature, the ID contracts and locks to the shaft.

This BLC Bearlok Shrink Disc from Whittet-Higgins Co. locks power-transmission components
such as gears, conveyor rolls, sheaves, cam shafts, pulleys and sprockets to keyless shafts more
securely than conventional collars. It’s balanced for high-speed applications and comes in alloy
steel and black-oxide coated versions.

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 POWER TRANSMISSION
RETAINING DEVICES & Shown here are just some of
3,600 standard shaft collars,

maintenance & assembly tools

couplings, and mounts from Stafford
Manufacturing Corp. for packaging
machinery. Options include Staff-
BEARLOK SHOELOK BEARLOK Shrink Disc Lok hinged collars that simplify
opening, closing, and clamping
connections by hand, as well as Grip
& Go handles that convert standard
shaft collars into adjustable locators.
The components come in aluminum,
steel, stainless steel, and plastic in
ODs from 1/4 to 6 in. Options and
finishes abound.

BEARHUG CLAMPNUT TANGENTLOK

LOCKING DEVICE OPERATION AND CAVEATS

For applications of medium torque and above, double-taper
locking devices—more commonly called keyless locking
devices or power locks, friction locks or shaft locks—connect
radial power-transmission components to shafts by interference
fit. These have inner and outer rings held together by bolts
PRECISION NUTS & WASHERS ADAPTER SLEEVE ASSEMBLIES
INCH and METRIC THREADS or capscrews. Internal inclined planes make the rings come
LEFT HANDED as well as
RIGHT -HANDED together and expand inward (into the shaft) and outward (to
Materials of: the radial component’s hub-bore inner diameter). That makes a
CARBON, ALLOY and two-way gripping force to hold components to shafts in a way
HARDENED ALLOY
STEELS that’s rigid and free of backlash.
Materials of: There are some caveats. Locking devices expand to
ALLUMINUM and
CORROSION RESISTANT
accommodate a range of shaft ODs and component-bore IDs,
STEEL but design engineers should respect published ranges and
pick a locking device that’s sized to the machine application
NUTS & WASHERS HARDENED TONGUE WASHERS SPLIT COLLAR
(or change the latter to match a standard locking device). In
addition, locking devices only deliver top performance when
they’re installed correctly, with a torque wrench in a diametrical
pattern … just as one lugs a tire to a vehicle. When selecting a
mounting approach in conjunction with a coupling, match it to
the application while remembering that locking devices work
well with couplings in high-speed or reversing applications—
RETHREADING DIES ADJUSTABLE SPANNER WRENCH BEARING ASSEMBLY SOCKET engineered disc couplings, for example. (In contrast, locking
devices are over-engineered for applications of below-average
precision and basic couplings.) In addition, design engineers
should specify a shaft finish that’s not overly smooth—say,
W
HI
TT
ET
between 40 and 120 Ra—so the locking device can hold fast,
-H
IG
GI
NS even under maximum load.
US
A

WHITTET-HIGGINS manufactures quality oriented, stocks

abundantly and delivers quickly the best quality and largest array of These clamp-style shaft collars
adjustable, heavy thrust bearing, and torque load carrying retaining are designed and manufactured
devices for bearing, power transmission and other industrial assemblies; by Ruland Manufacturing to have
and specialized tools for their careful assembly. high holding power. Suitable
for medical equipment, they are
Visit our website–whittet-higgins.com–to peruse the many possibilities
often used to guide, space, stop,
to improve your assemblies. Much technical detail delineated as well as
and align. Precise face to bore
2D and 3D CAD models for engineering assistance. Call your local
perpendicularity is maintained by
   



 

 

 
  

  

having TIR of less than or equal to
or a good distributor.
0.002”, which is critical when the
collar is used as a load-bearing face
33 Higginson Avenue, Central Falls, Rhode Island 02863 or for aligning gears or bearings.
Telephone: (401) 728-0700 • FAX: (401) 728-0703
E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com
76 DESIGN WORLD — MOTION 4 • 2016

LockingDevices_PTGuide_V1.indd 76 4/29/16 11:53 AM

 Single Source
Widest range of shaft
collars including over 2,500
standard parts to simplify

2,500
the design process and
ensure the collar you need

Over
is available from stock.

carefully Made

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3.21.16_R1_RU_Design World
Ruland_PTGuide4-16.indd 77 Ad_9x10.875.indd 2 3/21/16
4/29/16 12:16
1:43 PM
PM
 REFERENCE GUIDE
The MINIRAIL carriage for this SCHNEEBERGER
miniature guideway has a lubricant reservoir
carrying LUBE S lubricant. It uses a capillary effect
to apply tangential lubrication of the circulating
bearings, no matter the installation orientation. So
under normal conditions and appropriate
loads, the reservoir works to 20,000
km of carriage travel.
Power Transmission

REVIEW OF
LUBRICATION BASICS
MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION

IN ANY
system with moving parts, no
matter how small or large,
lubrication is essential. It performs a number of
important functions including reducing friction,
dissipating heat, and protecting components from
corrosion and wear.
Lubricants can be classified in a number
of different ways, but usually are identified as
either one of two kinds; oils or greases. Oil-based
lubricants can be made from petroleum sources or
newer synthetic oils. Greases have an oil base to
which various thickening agents are added.
The most important parameters for evaluating lubricants include
operating temperature, load, speed, viscosity, and application rate.
Lubricants are available to accommodate a wide range of application
needs. For instance, there are general-purpose greases that handle lubrication
needs for general industrial uses as well as greases for special requirements
and special applications. For example, there are greases for high temperatures
and for low temperatures, as well as greases for high-load applications. There
are also greases designed to be biodegradable as well as food-grade greases
for use in food and beverage production facilities.
Potential problems with lubrication can include two extremes of either
using too little lubrication or using too much. Using too little lubrication can
increase friction and heat, leading to premature component damage. On the

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Lubrication_PTGuide_V2-mb.indd 78 4/29/16 11:58 AM


other hand, using too much lubrication can
also generate additional heat, which can
cause lubrication to break down thermally,
ultimately leading to more component
damage. Sticking to a maintenance
schedule can help avoid damage due to
improper or inadequate lubrication and
ensure against premature equipment failure.
LUBRICATION FOR MOTION CONTROL
In motion control applications, lubrication
plays a critical role, even though sometimes
it can be an afterthought or taken for
granted. All kinds of components need
lubrication; from ballscrews and leadscrews
to bearings, gears and motors. Lubrication
is used to lubricate bearings in motors,
linear motion components such as
leadscrews and ballscrews as well as rails,
ways and guides.
“LUBRICANTS CAN BE CLASSIFIED IN A NUMBER OF DIFFERENT WAYS,
BUT USUALLY ARE IDENTIFIED AS EITHER ONE OF TWO KINDS; OILS
OR GREASES.“
Because ballscrews are a bearing
system, they’ll need some type of
lubrication to avoid metal-to-metal contact
of the balls in the raceway. While the
lubrication choice can be either oil or
grease, it’s advisable to avoid solid additives
(such as graphite) as they will clog the
recirculation system. An NLGI no. 2 type
grease is recommended but it should also
depend on the application, whether food-
grade or another special type of lubrication
is required. Ballscrews, especially those
used in machine tools, generally require
lubricants with EP additives to prevent
excessive wear. The frequency of lubrication
will vary depending on factors such as the
move cycle characteristics, or contamination
in the environment.
motioncontroltips.com | designworldonline.com 4 • 2016
Lubrication_PTGuide_V2-mb.indd 79
LUBRICATION
Leadscrew mechanisms using bronze
nuts also need a lubricant, usually a thick
damping grease. Leadscrew assemblies
with plastic nuts can run well without
lubricant due to the internal lubricants
in the nut materials, but the use of a gel
type lubricant will help increase allowable
loading and extend life by reducing friction.
If particulates are present, the screw should
be cleaned before reapplying lubricant.
Scheduled preventative maintenance
should occur when there is no visible film
remaining on the flanks of the screw thread.
Grease should not be used in
environments with significant particulate or
debris that can load the grease and cause
it to become an abrasive slurry. In this type
of application, dry film lubricant should be
used instead. PTFE coating is a dry film
that creates a lubrication barrier between
a metal substrate and a polymer bushing
or lead nut. It is well suited for use with
plastic nuts and stainless-steel leadscrews.
Lubrication maintenance intervals can be
eliminated and the coating does not attract
particulate like a gel lubricant.
There are linear motion systems that
require periodic application of a lubricant,
but most are available pre-lubricated. In
addition, a number of systems use self-
lubricated moving elements, eliminating the
need for lubrication during the useful life.
The rails, ways and guides of linear
motion systems tend to pick up dirt and
debris from their application environment.
For this reason, it’s good to use carriages
and slides with some kind of wiper system
to keep the systems clean.
DESIGN WORLD — MOTION 79
4/29/16 11:58 AM
 REFERENCE GUIDE
BASICS OF
ELECTRIC MOTORS
MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION
Power Transmission
AC MOTORS
All electric motors convert electrical energy to mechanical
energy. Motors are typically divided into either ac—
alternating current, or dc—direct current. The main
difference is that ac motors take an input of ac current,
while dc motors use dc current.
For ac motors, speed control is done by varying
the voltage and frequency (along with the number of
magnetic poles) while on dc motors control is achieved by
varying voltage and current.
There is another common way to break down ac
motors that is based on the magnetic
principle that produces rotation. So
there are two fundamental types of
ac motors; induction motors and
synchronous motors.
80 DESIGN WORLD — MOTION 4 • 2016
Motors_PTGuide_V4.indd 80
In induction motors, the key idea is the rotating
magnetic field. The most common source of this in ac
motors is the squirrel cage configuration. This is essentially
two rings, one at each end of the motor, with bars of
aluminum or copper connecting the two ends.
Induction motors have properties that make them
especially well suited to a number of industrial as well
as home appliance applications. For starters, they are
simple and rugged motors that are easy to maintain. They
also run at constant speed across a wide range of load
settings, from zero to full-load. The only drawback is that
induction motors are generally not amenable to speed
control, although the availability of sophisticated variable-
frequency drives means that even induction motors,
usually three-phase induction motors, can now be speed
controlled as well.
The other type of ac motor is a synchronous
motor. Synchronous motors are so named
because they run synchronously with whatever
the frequency of the source is. The motor
speed is fixed and doesn’t change with
changes to the load or voltage. These
motors are primarily used where the
requirement is precise and constant speed.
Most synchronous motors are used in heavy
industrial applications, with horsepower
ratings ranging from the low hundreds up
to thousands of hp.
Synchronous motors can
be used in motion control
applications, but there are
some down sides to using
these motors. Because of
the rotor size, the motor’s
response in incrementing
applications is typically not good.
ClearPath brushless servomotors from Teknic include a DSP-based
vector servodrive, high-resolution encoder, and controller. The
compact motors are low cost to let machine builders replace ac
induction, stepper, dc brush, and other servomotors without
sacrificing performance.
motioncontroltips.com | designworldonline.com
4/29/16 12:03 PM
 MOTORS

Also, because acceleration of inertial loads may not be as high as other

motor types, these motors may operate at irregular speeds and produce
undesirable noise. And generally, synchronous motors are larger and more
costly than other motors with the same horsepower rating.

DC MOTORS
Motors characterized as dc generate a magnetic field via electromagnetic
windings or permanent magnets. According to most common industry
naming conventions, there are three dc motor subtypes: brush motors,
permanent-magnet (PM) motors, and universal motors.
Many larger dc motors still employ brushes and wound fields, but PM
motors dominate fractional and integral-horsepower applications below 18
hp. That being said, PM motors are increasingly common in many designs.
In a brushed dc motor, the magnet acts as the stator. The armature is
integrated onto the rotor and a commutator switches the current flow. The
commutator’s function is to transfer current from a fixed point to the rotating
shaft. Brushed dc motors generate torque straight from the dc power
supplied to the motor by using internal commutation, fixed permanent
magnets, and rotating electromagnets.
Brushless dc (BLDC) motors, on the other hand, do away with
mechanical commutation in favor of electronic commutation, which
eliminates the mechanical wear and tear involved with brushed dc motors.
In BLDC motors, the permanent magnet is housed in the rotor and the coils
are placed in the stator. The coil windings produce a rotating magnetic field
because they’re separated from each other electrically, which enables them
to be turned on and off. The BLDC’s commutator does not bring the current
to the rotor. Instead, the rotor’s permanent magnet field trails the rotating
stator field, producing the rotor field.

STEPPER MOTORS
Stepper motors are one of the most common motors used in motion control
applications. They’re used mostly in positioning applications and have the
advantage of being able to be accurately controlled for the most precise
positioning applications, down to fractions of a degree without the use
of feedback devices such as encoders or resolvers. They are operated in
open-loop (not closed-loop), without the need for tuning parameters as in
closed-loop servo systems.
Steppers are generally classified by the number of allowable steps
they can be commanded to move. For instance, a 1.8 degree step motor
is capable of 200 steps/revolution (1.8 x 200 = 360 degrees, or one full
revolution) in full-step mode. If operated in half-step mode, each step
becomes 0.9 degrees and the motor can then turn 400 steps/revolution.
Another mode called microstepping subdivides the degrees per step even
further, allowing for extremely precise movements.
There are several different stepper motor technologies including
permanent magnet motors, variable reluctance, and hybrid types. The
principle of operation for stepper motors is fairly straightforward. Traditional
variable reluctance stepper motors have a large number of electromagnets
arranged around a central gear-shaped piece of iron. When any individual
electromagnet is energized, the geared iron tooth closest to that
electromagnet will align with it. This makes them slightly offset from the next
electromagnet so when it is turned on and the other switched off, the gear

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 REFERENCE GUIDE
moves slightly to realign. This continues
with the energizing and de-energizing of
individual electromagnets, thus creating
the individual steps of motion.
Stepper motors are relatively
inexpensive and can be run open loop,
requiring no feedback devices. Also,
because the speed is proportional to the
Power Transmission
frequency of the input pulses, a wide range
of speeds is attainable. However, while
stepper motors are capable of producing
high torque at low speeds, they generally
are well suited for lower power applications
not for applications requiring lots of torque
to move heavier loads. They are best
for applications requiring the control of
rotation angle, speed, and position.
A few drawbacks are that not properly
controlling the motor can produce
undesired resonance in the system. Also,
stepper motors are generally not easy to
operate at extremely high speeds. And
as the motor speed increases, torque
decreases.
A stepper motor’s low-speed torque
varies directly with current. How quickly the
torque falls off at higher speeds depends
on a number of factors such as the winding
inductance and drive circuitry including
the drive voltage. Steppers are generally
sized according to torque curves, which are
typically specified by the manufacturer.
SERVOMOTORS
The hallmark of any servomotor is the
presence of feedback and closed-loop
control. Servomotors provide precise
control of torque, speed or position using
closed-loop feedback. They can also
operate at zero speed while maintaining
enough torque to maintain a load in a
given position.
Servomotors have several distinct
advantages over other types of motors. For
starters, they offer more precise control of
motion. This means they can accommodate
complex motion patterns and profiles more
readily. Also, because the level of precision
offered is high, the position error is greatly
reduced.
The electric motor itself can be either
an ac or a dc motor. Under the dc heading,
82 DESIGN WORLD — MOTION 4 • 2016
Motors_PTGuide_V4.indd 82
brushed dc servomotors are generally less expensive than brushless
servos, but do require more maintenance due to the brushes needed for
motor commutation.
Brushless servomotors are more expensive than brushed dc motors.
Generally, these are used in applications requiring higher torque. Brushless
dc servomotors are highly reliable and virtually maintenance free.
However, the drives for brushless dc servomotors are more complex
because the commutation is done electronically rather than mechanically
as in the brushed dc motor.
Another way to classify servomotors can be as either single-phase or
three-phase motors. Motors of the single-phase variety can range from the
simple and inexpensive brushed dc motors to voice coils for small micro-
and nano-positioning applications.
Servomotors also require a form of feedback, often with the feedback
device, such as an encoder, built right into the motor frame. The feedback
signal is needed by the control circuitry to close the control loop. It is
this closed-loop control that gives servomotors their precise positioning
ability. Lastly, the control circuitry typically involves a motion controller,
which generates the motion profile for the motor, and a motor drive which
supplies power to the motor based on the
commands from the motion controller.
Servomotors are used in many different
industrial applications from machine tools, The MCM series of synchronous
packaging machinery, communications servomotors from Lenze are
and robotics applications to newer optimized for a range of
positioning tasks, including
applications such as solar panel control
robotics, packaging
and a broad range of automation control equipment and handling
applications. The diversity of applications systems. Featuring IP65-rated
means that servomotors are designed for protection class housings, the
general-purpose indoor environments but motors come in power ratings
up to 3.35 hp and torque
also for specialized situations requiring
ratings to 233.66 in-lb.
them to withstand extreme temperatures
and pressures outdoors as well as
the special demands of food
processing industries in
washdown environments.
motioncontroltips.com | designworldonline.com
4/29/16 12:05 PM
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Baldor_PTGuide4-16.indd 83 4/29/16 1:43 PM

 REFERENCE GUIDE
Power Transmission

MILES BUDIMIR • SENIOR EDITOR • @DW_MOTION

BASICS OF
POSITIONING
stages and tables are a part of many

POSITIONING
motion systems. Stages or tables, whether
linear or rotary, are complete motion sub-systems themselves. That
is, they’re comprised of components such as linear motion elements,

STAGES
Linear stages for extremely fine positioning, such as the
V-52x series from Physik Instrumente, feature a voice coil
linear motor direct drive with 0.1-micrometer resolution.
An integrated optical linear encoder and precision crossed
roller bearings with anti-creep cage assist provide high
positioning resolution and guiding accuracy.
motors or actuators, encoders, sensors and controllers.
Stages have continued to evolve as their components improve.
Some key developments include better mechanical components and
innovations in feedback and control that are improving metrology,
particularly in high-end stages.
As a result, today’s positioning stages can do many things
including making moves with incredible accuracy, synchronizing
complicated axis commands, and optimizing travel from coarse and
fine drives in tandem, closing the loop on one common position
feedback.
Stages and tables are used in a wide range of high-performance
applications such as industrial robots, fiber optics and photonics,
vision systems, machine tools, semiconductor equipment, medical
component laser machining, micromachining, electronic manufacturing,
and other industrial automation applications.
Stages can provide one of several different types of motion.
They can be linear, rotary, or even lift types (Z-axis positioning stages).
Among these, they can be configured in many different ways including
movement in one direction (or axis) only, in multiple directions (X-Y
positioning), or for extremely small and precise movements, as in
nanopositioning applications where moves are in the micro- or nano
meter range.

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PositioningStages_PTGuide_V2-mb.indd 84 4/29/16 12:22 PM


  POSITIONING STAGES
The drive mechanisms
for positioning stages
and tables can also vary
significantly, depending on a
number of factors including
cost and desired accuracy.
For instance, stages can be
direct-drive types driven by
linear servomotors or by a
combination of motors and
gearing and couplings, and
can be linear or rotary actuator
driven (either using electric
actuators, or even pneumatic
of hydraulic actuation). Other
methods can include belt and
pulley systems, ballscrews or
leadscrews.
Precision and accuracy
requirements can also dictate
design decisions such as
the components used in
assembling a positioning
stage. One kind of component
used in stages where reliability
and high accuracy are desired
4 • 2016
PositioningStages_PTGuide_V2-mb.indd 85
PERFORMANCE
MATTERS
At Primatics, when we tell you that our precision
motion products will perform to specification, you
are air bearings. Air bearings can be certain they will do just that. And, we have
support a load with a thin film the data to back it up.
of pressurized air between the
fixed and moving elements.
We build high performance motion solutions that
They are typically referred integrate easily and function seamlessly with
to as aerostatic bearings, complex automated systems.
because a source of pressure
Our clients experience a high correlation between
rather than relative motion
supplies the film of air.
the test data we provide and the performance they
Unlike ordinary bearings, are measuring in the field.
the surfaces of an air bearing
do not make mechanical When performance matters,
contact, so these systems do
not need to be lubricated.
Primatics delivers!
Because the surfaces do
not wear, the systems don’t
generate particulates, which The PXL33B is small form factor linear stage,
optimized for higher accuracy, repeatability, and
makes them suitable for nanometer level minimum incremental motion.
clean-room applications.
When supplied with clean,
filtered air, the bearings can
operate without failure for
many years.
primatics.com • 541-791-9678
DESIGN WORLD — MOTION 85
4/29/16 12:54 PM
 REFERENCE GUIDE
Power Transmission
These all-rubber HSS seals are
specially developed to protect
large size bearings under the
tough operating conditions in
heavy industrial applications
such as metal rolling mills,
mining equipment or wind
turbines. A well-proven sealing
lip design and a new concept
of reinforcement provides high
stability. Image courtesy of SKF
86 DESIGN WORLD — MOTION
Seals_PTGuide_V4.indd 86
REVIEW OF
SEALS
MARY GANNON • SENIOR EDITOR • @DW_MARYGANNON
SEALS
perform a vital
job in any power
transmission system—they keep dirt
and other ingress materials from
entering and damaging critical,
internal components. They also
have the equally important job of
preventing leakage of necessary
lubricants, such as oil, grease or
hydraulic fluid.
Molded seals and v-shaped
seals are two of the most common
seals found in power transmission
applications. V-shaped seals, such
as wipers, are used most commonly
in fluid power systems to prevent
contaminants from entering a
system while allowing lubricating
oils to return to a system on inward
stroke of the hydraulic piston.
Molded seals, which are more
common in power transmission
applications, can be further
divided into O-rings, radial lip
seals and shaft seals. O-rings are
one of the most common types
of seals because of their simple
and inexpensive construction.
They are designed to create a seal
4 • 2016
Image courtesy of Trelleborg Sealing Solutions
between the interfaces of two or
more components. They generally
consist of an elastomer ring with a
circular cross section and are usually
placed in a groove. They are used
frequently in hydraulic components,
particularly on cylinder pistons and
rotating pump shafts.
Mechanical face seals, or
heavy-duty seals, are used in
extreme applications, such as
bearings, gearboxes, turbines and
machinery that is used in extremely
tough and dirty environments,
such as mining and agriculture.
They feature two metal seal rings
identical in nature that mount
separately on a lapped face seal. A
flexible, elastomer element centers
the metal rings, allowing one half to
rotate while the other remains still.
While many seals are designed
Some seals — such as this Centritec Seal from
primarily to keep debris from
the Carlyle Johnson Machine Co. — work even
entering a machine, radial lip seals in vertical shafts for rotating machinery. This
are designed to keep lubricants particular design uses centrifugal pressure
within a machine that has rotating and includes a sump to collect lubrication
or oscillating parts. These seals are when equipment stops (so there’s no
weepage). They’re appropriate for conveyors,
available as one of two types—
gearboxes and heavy equipment.
spring loaded and non-spring
motioncontroltips.com | designworldonline.com
4/29/16 12:31 PM
 SEALS

loaded. Each is suited to a particular type of lubricant,

grease or oil. Non-spring loaded seals are suited for
applications that use a highly viscous lubricant and
operate at slower shaft speeds. Spring-loaded seals are
best paired with lubricants with low viscosity and higher
speeds. The spring helps the seal lip maintain its contact
with the shaft even as the seal material itself breaks down.
In addition to keeping contaminants out and fluids in,
rotary and shaft seals have the extra benefit of providing
low friction and resistance to wear, thus extending
component life.
When selecting a seal, fluid or lubricant type,
material compatibility is critical. The four most commonly
used materials for sealing applications are polyurethane
(PU), acrylonitrile-butadiene-rubber (NBR), fluoro rubber
(FKM), and polytetrafluoroethylene (PTFE). For example, PTFE is one of the most commonly used materials in O-ring seals,
particularly in hydraulic systems. They offer resistance to high
PTFE is common in hydraulic systems for its resistance
temperatures and corrosive fluids and chemicals. Image courtesy of
to high temperatures and corrosive chemicals and fluids. Trelleborg Sealing Solutions
Nitrile rubber provides wear and aging resistance for
lower temperature applications. FKM is best in higher
temperature applications, or where extremely aggressive
fluids are present.

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motioncontroltips.com | designworldonline.com 4 • 2016 DESIGN WORLD — MOTION 87

Seals_PTGuide_V4.indd 87 4/29/16 12:31 PM

 REFERENCE GUIDE
THE BASICS OF
SHOCK &
VIBRATION
Power Transmission
ABSORBERS
MARY GANNON • SENIOR EDITOR • @DW_MARYGANNON
MOTION
is present in almost all industrial automation
systems. Stopping or changing the direction
of that motion releases kinetic energy, which can cause shock
and vibration to occur. Any sudden shock in a system can cause
immediate damage to the overall machine and the components
it may be manufacturing or processing. And consistent vibration
inputs can cause damaging fatigue over time. This is why it’s
necessary to decelerate a system smoothly through the use of
shock and vibration attenuation components.
Based on the type of inputs present in the application,
vibration and shock attenuation components can be comprised
of shock absorbers, linear dampers, wire rope or spring
isolators, elastomeric isolators, air springs, or structural damping
treatments. These devices help manufacturers reduce equipment
downtime and costly cycle time limitations.
These products can be used in a broad range of applications,
from the rate control mechanisms that slow the motion of the
overhead luggage bin or seat recline on commercial aircraft,
to the isolators which keep GPS systems from losing signal or
becoming damaged on farm and construction equipment as they
harvest crops or pave roadways.
Most shock absorbers achieve their damping characteristics
through the use of hydraulic fluids. The fluid is pushed by a piston
and rod through small orifice holes to create damping, and this
action compresses some type of gas. This in turn creates a spring
force to return the rod back to its
starting position when the load is
removed.
RIGHT: Material pads such as these custom Sorbothane components
can isolate vibrations. The manufacturer designs and manufactures
them in a variety of shapes, sizes and durometers. Each part is
specific to the design and function requirements of end products
and set client parameters.
88 DESIGN WORLD — MOTION 4 • 2016
Shocks_PTGuide_V3.indd 88
SLABS OF MATERIAL
ALSO DAMP VIBRATION
Besides mechanical devices, elastomer and other
synthetic and rubber pads can also damp vibration
and isolate shock loads. These material blocks,
tubes, bushings and washers dissipate energy in
a variety of applications. Manufacturers usually
tailor the geometry, thickness and durometer
of the material pieces to meet specific design
requirements. Common uses are in lab and testing
equipment, aerospace, foundations for presses,
plants and machines, under cranes, as impact
plates, for pipelines and bridges, and in other
heavy-duty applications.
In some cases, the manufacturer assembles
the material in layers to create strong cushioning
plates that protect machinery subsystems against
impacts and isolate vibration and structure-borne
noise. For example, PAD plates from ACE Controls
withstand compressive loads to 10,000 psi (69 N/
mm2) depending on plate form and size.
Another custom product called Sorbothane
(from a company with the same name) is a
thermoset that attenuates shock with near-faultless
memory. That means its deformation is elastic and
not plastic, so pads of the material reliably return to
their original shape. Custom pieces of the material
work for vibration damping, acoustic damping and
isolation. Sorbothane works by turning mechanical
energy into heat as the material is deformed.
Molecular friction generates heat energy that
translates perpendicularly away from the axis of
incidence.
Designed to meet specific requirements
such as load, area, and natural frequency, many
of these padding materials come in soft, rubber-
like consistencies that are forgiving in most
environments.
Predicting the natural frequency of an
application lets material manufacturers target
known disturbance frequencies to dissipate energy.
The lower the ratio of natural system frequency to
disturbance frequency, the more it’s possible to
isolate problem vibrations.
TOP: SLAB damping pads from ACE Controls are made of a
viscoelastic PUR and adapt to myriad applications. A calculating
tool helps users configure pieces with product engineers.
motioncontroltips.com | designworldonline.com
4/29/16 12:51 PM
ITT_4-16.indd 89 4/29/16 1:44 PM
 Deceleration & Vibration

REFERENCE GUIDE
Technology:

Expect more
than Automation
Control!

Power Transmission
Motion Control
Custom control
of hand forces

Vibration Control
Isolate unwanted
vibrations

Industrial shock absorbers are available in a

variety of sizes and styles to help prevent the
sudden release of kinetic energy in a system,
reducing potential and catastrophic machine
damage. Photo courtesy ACE Controls

Shock absorbers and dampers are generally made of high-

Safety strength steel to handle the pressures from the internal hydraulic
Products forces. Elastomeric seals prevent the fluid from leaking out of the
Protection cylinder, and special plating and coatings keep the units protected
for all Automation from harsh operating environments.
Control Recent and ongoing developments in sealing technologies
machine
and in the internal designs of shock absorbers and dampers
designs under Optimum tuning
have allowed for longer service life and more compact designs.
any condition for any design
Ongoing research in the field of noise attenuation (high frequency,
low amplitude vibration) has led to an increased effectiveness in
noise reduction technologies.
A unique application for these types of hydraulic damping
devices has come with the increased awareness for seismic
and environmental protection of our infrastructure (buildings
and bridges, for example). By adding damping to these critical
structures, energy is absorbed by the hydraulic devices instead of
damaging the structure.
Vibration isolation products rely generally on mechanical
designs to achieve their isolation characteristics. A spring function
provides support for the mounted equipment, while decoupling
by ACE it from the vibration source. Friction and elastomeric material
properties give the isolators their damping characteristics.
Isolators can be made from a variety of materials. Wire rope
and spring isolators can be made from carbon steel, stainless
More Info?
Tel. 800-521-3320
steel or aluminum. Elastomeric isolators generally have metallic
Email: shocks@acecontrols.com

90
Download a CAD fileWORLD
DESIGN or our—product
MOTION 4 • 2016 motioncontroltips.com | designworldonline.com
sizing software at: www.acecontrols.com

Shocks_PTGuide_V3.indd 90 4/29/16 12:52 PM


components that function as
mounting brackets, separated
by an elastomeric material
that provides the stiffness and
damping desired. Common
elastomeric compounds
include natural rubber,
neoprene and silicone;
however, a vast selection of
compounds and compound
blends can be used to achieve
different characteristics
specific to the application.
Air springs are comprised
of metallic end fittings
coupled by a composite
elastomeric-based bladder
that contains the compressed
air used to provide isolation.
These single-acting designs
are comprised of a pressurized
bladder and two end plates.
As air is directed into the air
bladders, they are expanded
linearly.
motioncontroltips.com | designworldonline.com
Shocks_PTGuide_V3.indd 91
SHOCK & VIBRATION ABSORBERS
All of these reusable designs are self-
contained, offering a number of advantages
over any other technology that may
require outside componentry. For example,
hydraulic systems may require plumbing
while electrical systems may require wiring
and power.
Energy or power dissipation
is key when selecting a damper or
shock-absorbing device. The size and
characteristics of the device are based
on these inputs, so it is generally the first
consideration to make.
Dynamic spring rate and damping
are the two biggest considerations when
selecting an isolator. These characteristics Wire rope isolators reduce system vibration,
will define the natural frequency (sometimes which can cause damaging fatigue over time.
referred to as resonant frequency) of the Photo courtesy ITT Enidine
isolation system and are important in
achieving the desired performance.
4 • 2016 DESIGN WORLD — MOTION 91
4/29/16 12:55 PM
 REFERENCE GUIDE
Ad Index
ACE Controls Inc. ..................................................... 90
All Motion ................................................................. 81
Altra Industrial Motion Corp. .................................... 53
AMETEK PMC ............................................................ 1
AMETEK/DFS (Windjammer) .................................... 21
AutomationDirect ....................................................... 9
Power Transmission
KHK USA Inc. ............................................................ 55
Kuebler Inc. .............................................................. 45
Martin Sprocket ........................................................ 36
Master Bond ............................................................. 87
Neugart USA Corp. .................................................. 57
NSK Precision ........................................................... 17

Baldor Electric ....................................................83, BC PBC Linear ................................................................ 73

BellowsTech. LLC ...................................................... 43 PITTMAN .................................................................... 7
Bison Gear & Engineering Corp. .............................IBC Primatics, Inc. ........................................................... 85
Follow the whole team on twitter @DesignWorld

Bodine Electric Company ......................................... 65 Promess Inc. ............................................................... 2

Carlyle Johnson ........................................................ 22
Centa Corporation ................................................... 87
CGI, Inc. ............................................................. 12, 13
Custom Machine and Tool Co. Inc. .......................... 29
DIEQUA Corporation ............................................... 59
Dunkermotoren, part of AMETEK ............................ 71
GAM Gear ................................................................ 47
Groschopp. Inc ......................................................... 67
Harmonic Drive ......................................................... 61
Haydon/Kerk .............................................................. 3
igus, inc. ............................................................. 24, 25
Intech ........................................................................ 63
ITT Enidine ............................................................... 89
CONNECT
WITH US!
Power Transmission Distributors Association ........... 49
R+W America ........................................................... 48
Rotor Clip Company, Inc. ......................................... 39
Ruland Manufacturing .............................................. 77
SAB North America .................................................. 33
Serapid Inc. .............................................................. 19
Servometer ............................................................... 43
SEW Eurodrive .......................................................... 51
Teledyne LeCroy ......................................................... 5
THK America, Inc. .................................................... IFC
Whittet-Higgins Co. .................................................. 76
Zero-Max, Inc. ........................................................... 23

SALES LEADERSHIP TEAM

Mike Caruso Michelle Flando Tom Lazar Publisher

mcaruso@wtwhmedia.com mflando@wtwhmedia.com tlazar@wtwhmedia.com Mike Emich
469.855.7344 440.670.4772 408.701.7944 memich@wtwhmedia.com
@mflando @wtwh_Tom 508.446.1823
Todd Christenson @wtwh_memich
tchristenson@wtwhmedia.com Mike Francesconi Jim Powers
440.381.9048 mfrancesconi@wtwhmedia.com jpowers@wtwhmedia.com Managing Director
@wtwh_todd 630.488.9029 312.925.7793 Scott McCafferty
@jpowers_media smccafferty@wtwhmedia.com
Jessica East David Geltman 310.279.3844
jeast@wtwhmedia.com dgeltman@wtwhmedia.com Courtney Seel @SMMcCafferty
330-319-1253 516.510.6514 cseel@wtwhmedia.com
@wtwh_MsMedia @wtwh_david 440.523.1685 EVP
@wtwh_CSeel Marshall Matheson
Michael Ference Neel Gleason mmatheson@wtwhmedia.com
mference@wtwhmedia.com ngleason@wtwhmedia.com 805.895.3609
408.769.1188 312.882.9867 @mmatheson
@mrference @wtwh_ngleason

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92 DESIGN WORLD — MOTION 4 • 2016 motioncontroltips.com | designworldonline.com

Index_PTGuide_V1.indd 92 5/2/16 9:34 AM

 THE BEST JUST GOT BETTER...

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To learn more about PowerSTAR® right-angle gearmotors, please visit Bison’s
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©2014 Bison Gear and Engineering Corp.

Bison Gear 7-15.indd 1 4/29/16 1:45 PM

 The Only Coupling
To Earn Its Wings

The NEW patented Baldor•Dodge® Raptor takes

coupling innovation to greater heights. Utilizing a
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• Drop-in interchangeability

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baldor.com 479-646-4711
Raptor’s slotted clamp rings offer more clearance
at the bolt holes for an easier installation than
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Download a QR reader app

and scan this code for
more information.
©2016 Baldor Electric Company www.baldor.com/dodgeraptor

Baldor_PTGuide4-16.indd 83 4/29/16 1:46 PM