High-Performance Universal Joint Shafts, Products

High-Performance
Universal Joint Shafts
Products | Engineering | Service
Universal Joint Shafts and
Hirth Couplings
We are the experts for cardanic power transmission components and Hirth couplings within Voith Turbo.
Voith Turbo, the specialist for hydrodynamic drive, coupling
and braking systems for road, rail and industrial applications,
as well as for ship propulsion systems, is a Group Division of
Voith GmbH.
Voith sets standards in the markets energy, oil & gas, paper,
raw materials and transportation & automotive. Founded in
1867, Voith employs almost 40 000 people, generates Euro
5.6 billion in sales, operates in about 50 countries around the
world and is today one of the biggest family-owned companies in Europe.
2
Contents
1
Voith high-performance universal joint
shafts – What makes them unique?
4
2
Range
6
3
Designs
8
3.1
Center sections
8
3.2
Flanges
9
3.3
Type designations
9
4
Applications
8
Selection aids
40
8.1
Definitions of operating variables
41
8.2
Size selection
42
8.3
Operating speeds
45
8.4
Masses
48
8.5
Connection flanges and bolted connections
52
9
Service
57
9.1
Installation and commissioning
58
9.2
Training
59
10
5
Definitions and abbreviations
14
9.3
Genuine Voith spare parts
60
5.1
Lengths
14
9.4
Overhaul, maintenance
61
5.2
Torque loads
15
9.5
Repair and maintenance
62
6
Technical data
16
9.6
Retrofit and modernizations
63
6.1
S Series
16
10
Services and supplementary products
64
6.2
R Series
18
10.1
Engineering
64
6.3
CH Series
24
10.2
6.4
E Series
26
Connecting components
for universal joint shafts
65
10.3
Quick-release coupling GT
66
7
Engineering basics
28
10.4
Voith Hirth serrations
67
7.1
Major components
of a Voith universal joint shaft
28
10.5
Universal joint shaft supports
68
7.2
Telescopic length compensation
30
10.6
Universal joint shafts with carbon fiberreinforced polymer (CFRP) components
69
7.3
Kinematics of the universal joint
32
10.7
7.4
Two universal joints
35
High-performance lubricant
for universal joint shafts
70
7.5
Bearing forces on input and output shafts
36
10.8
Safeset torque-limiting safety couplings
72
7.6
Balancing of universal joint shafts
39
10.9
ACIDA torque monitoring systems
73
11
Integrated management system
74
11.1
Quality
75
11.2
Environment
76
11.3
Occupational health and safety
77
3
1
2
1 Voith High-Performance
Universal Joint Shafts
What makes them unique?
Features
•
Closed bearing eye
Advantages
•
Heavy-duty cross-sections without joints or bolts
Minimal notch stresses
Enclosed seal surfaces
•
•
•
Drop-forged journal crosses
•
Maximum possible torque capacity
•
FEM-optimized geometry
•
•
Optimal design for torque transmission
Minimal notch stresses
•
High strength tempering and case-hardened steels
•
Capability to withstand high static and dynamic loads
•
Load-optimized welded joints
•
Optimal design for torque transmission
•
Length compensation with SAE profile (straight flank
profile) for larger series
•
Lower normal forces and thus lower displacement
forces
Low surface pressure
High wear resistance
•
•
•
Patented balancing procedure
•
Dynamic balancing in two planes
Balancing mass where unbalanced forces act
•
•
Engineering and products from a single source
•
Single contact person when designing the driveline
•
Certifications and classifications for rail vehicles and
marine vessels
•
Officially-approved product
•
Made in Germany
•
Seal of approval for quality, efficiency and precision
•
Voith Engineered Reliability
•
Competent and trustworthy partner
4
3
4
1 Assembly building
for Voith universal joint shafts
2 Welding robot
3 Balancing machine
4 Shipping
Benefits
+ Productivity increase
+ Long service life
+ Ease of movement
+ Long service life
+ Extremely smooth operation
+ Time and cost savings
+ Combined responsibility
+ Time and cost savings
+ Reliability
+ Innovative product and system solutions
5
2 Range
Voith high-performance universal joint shafts offer an ideal combination of
torque capacity, torsional rigidity and deflection resistance. We supply
standard universal joint shafts, customer-specific adaptations, as well as
special designs. Technical consultation, simulation of torsional vibrations
and measurement of operating parameters complete our range of services.
6
Series
Torque range
Mz [kNm]
Flange diameter
a [mm]
S
0.25 to 35
58 to 225
R
32 to 1 000
225 to 550
CH
260 to 19 440
350 to 1 400
E
1 600 to 14 000
590 to 1 220
Features
•
•
•
Standard design of Voith universal joint shafts
Non-split bearing eyes thanks to single-piece forged flange yoke
Length compensation with involute profile
Applications
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Paper machinery
Pumps
General industrial machinery
Marine vessels
Rail vehicles
Test stands
Construction machinery and cranes
High torque capacity
Optimized bearing life
Flange in friction and positive locking design (see page 9)
Length compensation with involute profile up to size 315; from size 350 with
SAE-profile (straight flank profile, see page 30); optional tripod
Optimized torsional rigidity and deflection resistance in a low-weight design
Particularly suitable for use with high-speed drives
Optional: Low-maintenance length compensation through use of plasticcoated (Rilsan®) involute spline profile
•
Very high torque capacity
Optimized bearing life
Flange with Hirth connection for transmitting maximum torque
Length compensation with SAE-profile (straight flank profile, see page 30)
•
•
Rolling mill drives
Construction of heavy machinery
Paper machinery
Maximum torque capacity
Optimized bearings for exceptionally demanding applications
Patented 2-piece flange yoke
Flange with Hirth connection for transmitting maximum torque
Length compensation with SAE profile (straight flank profile, see page 30)
•
Heavy-duty rolling mill drives
•
•
•
•
•
•
Rolling mill drives
Heavy-duty industrial drives
Paper machinery
Pumps
Marine vessels
Rail vehicles
7
3 Designs
3.1 Center sections
Type
Description
…T
Universal joint shaft with
standard length compensation
…TL
Universal joint shaft with
longer length compensation
…TK
Universal joint shaft with
short length compensation
…TR
Universal joint shaft with
tripod length compensation1
…F
Universal joint shaft without
length compensation (fixed-length shaft)
…GK
Joint coupling: short, separable joint
shaft without length compensation
…FZ
Intermediate shaft with
a joint head and bearing
…Z
Intermediate shaft with double bearing
1
8
Technical data:
Please request separate catalog
3.2 Flanges
Type Description
Type Description
S
Friction flange,
torque transmission by a
non-positive connection
K
Flange with split sleeves
for torque transmission
(DIN 15 451)
Q
Flange with face key
for torque transmission
H
Flange with Hirth coupling
for torque transmission
3.3 Type designations
Example
R
T
250.8
S
285 / 315
R
2 560
Series
S, R, CH, E
Center-section design
T, TL, TK, TR, F, GK, FZ, Z
Size
Flange design
S, K, Q, H
Flange size input end / output end, see section 7.1 (Page 28)
Profile coating
S: Steel (Standard)
R: Rilsan®
Length lmin or lz min in mm
9
1
2
10
3
1 Rolling mills (horizontal rolling stand)
2, 3 Rolling mills (edging mill stand)
4 Applications
11
1
2
12
3
4
5
6
1 Rail vehicle drives
2 Paper machines
3 Marine propulsion
4 Pumps
5 Test stands
6 Special drives (mine hoist)
13
5 Definitions and abbreviations
5.1 Lengths
Universal joint shaft without length compensation
Universal joint shaft with length compensation
lB,max
lv
lz
lB : Operating length, which corresponds to the universal
joint shaft length l
(to be specified when ordering)
lB : Operating length
(to be specified when ordering)
lz : Shortest length of the universal joint shaft
(fully collapsed)
lv : Available length compensation
The distance between the driving and the driven
machines, together with any length changes during
operation, determines the operating length:
Optimal operating length:
l
lB,opt ≈ lz + __v
3
Maximum permissible operating length: lB,max = lz + lv
14
lB (=l)
5.2 Torque loads
Designation
Torque definitions
Explanation
Components
M (t)
MDW
This is the reversing fatigue torque
rating. The shaft will have an infinite
fatigue life up to this torque level.
MDS
This is the pulsating, one-way fatigue
torque rating. The shaft will have infinite
fatigue life up to this torque level.
Here: MDS ≈ 1.5 · MDW
MK
Maximum permissible torque. If this level
is exceeded, plastic deformation may
occur.
MDS
MDW
0
t
Bearing
Note
MDW , MDS and MZ are load limits for the universal joint shaft.
In the case of torque values that are close to the load limit,
the transmission capability of the flange connection needs to
be checked, especially when Hirth couplings are not being
used.
MZ
The permissible torque for rarely
occuring peak loads. At torque levels in
excess of MZ, the bearing tracks might
suffer plastic deformation. This can lead
to a reduced bearing life.
Flanged connections
Individually designed
15
6 Technical data
6.1 S Series
SF
SGK
l fix
l
General specifications
Mz
MDW
CR
ßmax
[kNm]
[kNm]
[kNm]
[°]
a
k
b ± 0.1
c H7
058.1
0.25
0.08
0.09
30
58
52
47
30
065.1
0.52
0.16
0.16
30
65
60
52
075.1
1.2
0.37
0.23
30
75
70
090.2
2.2
0.68
0.44
20
90
100.2
3.0
0.92
0.62
20
120.2
4.4
1.3
0.88
120.5
5.4
1.6
150.2
7.1
Size
ST
h C12
lm
r
t
z
g
5
30
28 x 1.5
1.5
4
35
6
32
32 x 1.5
1.7
62
42
6
36
40 x 2
86
74.5
47
8
42
100
98
84
57
8
20
120
115
101.5
75
1.4
20
120
125
101.5
2.2
2.0
20
150
138
1
LA
lv
3.5
A, B
25
4
4
A, B
30
2.2
6
5.5
A, B
35
50 x 2
2.5
4
6
A. B, C
40
46
50 x 3
2.5
6
7
A, B, C
40
10
60
60 x 4
2.5
8
8
A, B, C
60
75
10
60
70 x 4
2.5
8
9
A, B, C
60
130
90
12
65
80 x 4
3
8
10
C
110
150.3
11
3.3
2.6
35
150
150
130
90
12
90
90 x 4
3
8
12
C
110
150.5
13
4.3
3.3
24
150
158
130
90
12
86
100 x 5
3
8
12
C
110
180.5
22
6.7
4.6
30
180
178
155.5
110
14
96
110 x 6
3.6
8
14
C
110
225.7
35
6.9
30
225
204
196
140
16
110
120 x 6
5
8
15
C
140
Dimensions in mm
16
11
1
Longer lv on request
ST / STK
lz
lm
45°
45
45
°
øb
øb
ør
øk
øc
øa
øb
øb
22.5°
°
øh
lv
t
g
øh
z=4
SFZ
øh
z=6
z=8
SZ
l
l
ld
ød
ød
ld
ta
ga
ta
ga
LA: Length compensation
A: without profile guard
B: with profile guard
C: Rilsan® coating with profile guard
STK 1
STK 2
STK 3
STK 4
2
SF
SGK
SFZ
SZ
SFZ, SZ
Iz min
LA
lv
Iz fix
LA
lv
Iz fix
LA
lv
Iz fix
LA
lv
Iz fix
Imin
Ifix
Imin
Imin
Id
d
ga
ta
240
B
25
215
B
25
195
B
25
175
B
20
165
160
120
-
-
-
-
-
-
260
B
30
235
B
30
220
B
30
200
B
20
180
165
128
-
-
-
-
-
-
300
B
35
270
B
35
250
B
35
225
B
25
200
200
144
-
-
-
-
-
-
350
B, C
40
310
B, C
40
280
B, C
40
250
B, C
25
225
216
168
-
-
-
-
-
-
375
B, C
40
340
B, C
40
310
B, C
40
280
B, C
30
255
250
184
-
-
-
-
-
-
475
B, C
60
430
B, C
60
400
B, C
50
360
B, C
35
325
301
240
-
-
-
-
-
-
495
B, C
60
450
B, C
60
420
B, C
50
375
B, C
35
345
307
240
-
-
-
-
-
-
550
C
80
490
C
80
460
C
80
400
C
40
360
345
260
-
-
-
-
-
-
745
C
110
680
C
110
640
C
80
585
C
40
545
455
360
-
-
-
-
-
-
660
C
110
600
C
80
555
C
45
495
C
40
400
430
344
-
-
-
-
-
-
740
C
110
650
C
60
600
C
45
560
C
60
500
465
384
-
-
-
-
-
-
830
C
110
720
C
80
650
C
55
600
C
40
550
520
440
533
586
171
80
25
4
2
shorter lZ upon request
17
6.2 R Series
RF
RGK
l fix
l
General specifications
Size
Mz
MDW
CR
ßmax
[kNm]
[kNm]
[kNm]
[°]
RTL1
RT
k
lm
r
LA
lv
Iz min
LA
lv
Iz min
198.8
32
16
8.6
25
198
110
160 x 10
C
110
780
-
-
-
208.8
55
20
11.4
15
208
120
170 x 12.5
B, C
120
815
B, C
370
1 110
250.8
80
35
19.1
15
250
140
200 x 12.5
B, C
120
895
B, C
370
1 280
285.8
115
50
26.4
15
285
160
220 x 12.5
B, C
140
1 060
B, C
370
1 430
315.8
170
71
36.6
15
315
180
240 x 16
B, C
140
1 170
B, C
370
1 470
350.8
225
100
48.3
15
350
194
292 x 22.2
B
140
1 240
B
400
1 640
390.8
325
160
67.1
15
390
215
323.9 x 25
B
170
1 400
B
400
1 800
440.8
500
250
100
15
435
260
368 x 28
B
200
1 540
B
400
2 100
490.8
730
345
130
15
480
270
406.4 x 32
B
220
1 870
B
400
2 300
550.8
1 000
500
185
15
550
305
470 x 32
B
220
1 940
B
400
2 500
Dimensions in mm
18
1
Longer lv on request
RT / RTL / RTK
lz
øk
ør
lm
lv
RFZ
RZ
l
l
ld
ød
ød
ld
ta
ga
ta
ga
LA: Length compensation
B: with profile guard
C: Rilsan® coating with profile guard
RTK 22
RTK 1
RF
RGK
RFZ
RZ
Imin
Ifix
Imin
Imin
LA
lv
Iz fix
LA
lv
Iz fix
-
-
-
-
-
-
480
440
535
568
B, C
100
725
B, C
80
640
520
480
626
B, C
110
800
B, C
70
735
620
560
B, C
120
960
B, C
100
880
720
B, C
120
1 070
B, C
100
980
B
130
1 160
B
110
B
150
1 280
B
B
170
1 380
B
200
1 680
B
170
1 775
2
RFZ, RZ
d
ga
ta
171
80
25
4
732
229
90
32
5
716
812
251
110
34
6
640
804
883
277
130
42
6
805
720
912
1 019
316.5
160
45
7
1 070
855
776
980
1 087
344.5
200
48
7
100
1 200
955
860
1 023
1 091
346.5
200
48
9
B
100
1 300
1 155
1 040
-
-
-
-
-
-
B
170
1 520
1 205
1 080
-
-
-
-
-
-
B
100
1 680
1 355
1 220
-
-
-
-
-
-
Shorter lz on request
ld
Flange dimensions: Pages 20 to 23
19
S flange: friction flange
22.5°
36°
45
36
°
°
øh
t
198
208
250
285
315
350
390
z = 10
a
b ± 0.2
c H7
g
h C12
t
z
Note
225
196
140
15
16
5
8
Standard
250
218
140
18
18
6
8
285
245
175
20
20
7
8
225
196
140
15
16
5
8
Torque MDW = 18 kNm
250
218
140
18
18
6
8
Standard
285
245
175
20
20
7
8
315
280
175
22
22
7
8
250
218
140
18
18
6
8
Torque MDW = 25 kNm
285
245
175
20
20
7
8
Standard
315
280
175
22
22
7
8
350
310
220
25
22
8
10
285
245
175
20
20
7
8
Torque MDW = 36 kNm
315
280
175
22
22
7
8
Standard
350
310
220
25
22
8
10
390
345
250
32
24
8
10
315
280
175
22
22
7
8
350
310
220
25
22
8
10
390
345
250
32
24
8
10
435
385
280
40
27
10
10
350
310
220
25
22
8
10
Torque MDW = 75 kNm
390
345
250
32
24
8
10
Standard
435
385
280
40
27
10
10
390
345
250
32
24
8
10
Torque MDW = 100 kNm
435
385
280
40
27
10
10
Standard
Dimensions in mm.
Additional flanges on request.
1
Rotation diameter of the universal joint shaft.
20
øh
z = 8
g
k1
øb
øk
øc
øa
øb
øb
Torque MDW = 52 kNm
Standard
Q flange: flange with face key
22.5°
10° 2
0°
30°
20
°
30
45
°
°
øb
øk
x
øc
øb
øa
øb
øb
y
t
øh
øh
øh
g
z=8
k1
208
250
285
315
350
390
440
z = 10
z = 16
a
b ± 0.2
c H7
g
h
t
x h9
y
z
Note
225
196
105
20
17
5
32
9
8
Standard
250
218
105
25
19
6
40
12.5
8
285
245
125
27
21
7
40
15
8
250
218
105
25
19
6
40
12.5
8
285
245
125
27
21
7
40
15
8
315
280
130
32
23
8
40
15
10
285
245
125
27
21
7
40
15
8
315
280
130
32
23
8
40
15
10
350
310
155
35
23
8
50
16
10
315
280
130
32
23
8
40
15
10
350
310
155
35
23
8
50
16
10
390
345
170
40
25
8
70
18
10
350
310
155
35
23
8
50
16
10
390
345
170
40
25
8
70
18
10
435
385
190
42
28
10
80
20
16
390
345
170
40
25
8
70
18
10
435
385
190
42
28
10
80
20
16
480
425
205
47
31
12
90
22.5
16
435
385
190
42
28
10
80
20
16
480
425
205
47
31
12
90
22.5
16
550
492
250
50
31
12
100
22.5
16
480
425
205
47
31
12
90
22.5
16
550
492
250
50
31
12
100
22.5
16
550
492
250
50
31
12
100
22.5
16
Standard
Standard
Standard
Standard
Standard
Standard
Standard
490
550
Standard
Dimensions in mm.
Additional flanges on request.
1
Rotation diameter of the universal joint shaft.
21
K flange: flange with split sleeve
48
22.5°
°
36°
54
°
45
°
36
°
øb
øk
øc
øb
øa
øb
øe
øe
ød
ød
øh
t
øh
g
z=8+4
k1
z = 10 + 4
a
b ± 0.2
c H7
g
h C12
t
z
d
e h12
225
196
140
15
16
5
8
192
21
250
218
140
18
18
6
8
214
25
250
218
140
18
18
6
8
214
25
285
245
175
20
20
7
8
240
28
285
245
175
20
20
7
8
240
28
315
280
175
22
22
7
8
270
30
315
280
175
22
22
7
8
270
30
350
310
220
25
22
8
10
300
32
350
310
220
25
22
8
10
300
32
390
345
250
32
24
8
10
340
32
390
345
250
32
24
8
10
340
32
435
385
280
40
27
10
10
378
35
435
385
280
40
27
10
10
378
35
Note
Standard
198
Standard
208
Standard
250
Standard
285
Standard
315
Standard
350
390
Dimensions in mm.
Additional flanges on request.
1
Rotation diameter of the universal joint shaft.
22
Standard
H flange: Flange with Hirth connections
22.5°
45°
60
øb
øh
g
°
øb
øh
z=4
k1
45
øk
øc
øb
øa
øb
°
z=6
a
b ± 0.2
c
g
h C12
u2
z
Note
225
196
180
20
18
48
4
Standard
250
218
200
25
20
48
4
250
218
200
25
20
48
4
285
245
225
27
21
60
4
285
245
225
27
21
60
4
315
280
250
32
23
60
4
315
280
250
32
23
60
4
350
310
280
35
24
72
6
350
310
280
35
24
72
6
390
345
315
40
25
72
6
390
345
315
40
25
72
6
435
385
345
42
28
96
6
435
385
345
42
28
96
6
480
425
370
47
31
96
8
480
425
370
47
31
96
8
550
492
440
50
32
96
8
550
492
440
50
32
96
8
øh
z=8
208
Standard
250
Standard
285
Standard
315
Standard
350
Standard
390
Standard
440
Standard
490
550
Standard
Dimensions in mm.
Bore on internal gear tooth.
Additional flanges on request.
1
Rotation diameter of the universal joint shaft.
2
Number of teeth of Hirth coupling.
23
6.3 CH Series
CHT
lz
22.5°
30°
lm
30
°
°
15° 1
5°
øb
øb
øh
øh
øh
lv
g
z = 12
CHF
z = 16
CHGK
l
24
.5
ør
øk
øa
øb
øb
22
l fix
z = 24
LA: Length compensation
A: without profile guard
CHT2
General specifications
1
Mz
[kNm]
1
MDW
[kNm]
CR
[kNm]
350.8
260
140
390.8
350
190
440.8
560
280
490.8
730
550.8
ßmax
[°]
a
k
48.3
10
350
350
67.1
10
390
100
10
390
130
1 010
560
590.40
1 330
620.40
b ± 0.2
h
lm
r
z
320
17.5
210
292 x 22.2
390
355
20
230
440
440
405
20
10
490
490
450
185
10
550
550
890
212
10
580
1 430
1 030
228
10
650.40
1 800
1 190
284
680.40
1 920
1 360
710.40
2 390
740.40
CHF2
CHGK
Ifix
g
LA
lv
Iz min
Imin
12
45
B
170
1 684
1 050
840
323.9 x 25
12
50
B
170
1 874
1 160
920
260
368 x 28
16
55
B
190
2 104
1 300
1 040
22
290
406.4 x 32
16
60
B
210
2 344
1 460
1 160
510
24
330
470 x 32
16
70
B
250
2 644
1 620
1 320
590
535
26
350
508 x 50
24
75
B
250
2 784
1 740
1 400
610
620
565
26
370
508 x 50
24
75
B
250
2 864
1 820
1 480
10
640
650
590
30
390
558.8 x 55
24
80
B
250
3 034
1 940
1 560
304
10
670
680
620
30
405
558.8 x 55
24
80
B
250
3 094
2 000
1 620
1 550
362
10
700
710
645
33
420
609.6 x 60
24
90
B
250
3 284
2 100
1 680
2 550
1 760
385
10
730
740
675
33
440
609.6 x 60
24
90
B
250
3 364
2 180
1 760
770.40
3 150
1 980
472
10
760
770
700
36
460
660.4 x 65
24
95
B
250
3 554
2 300
1 840
800.40
3 330
2 220
500
10
790
800
730
36
480
762 x 60
24
95
B
250
3 634
2 400
1 920
830.40
4 090
2 480
588
10
820
830
765
39
500
762 x 60
24
105
2 000
860.40
4 310
2 760
620
10
850
860
795
39
510
790 x 85
24
105
2 040
890.40
5 050
3 060
706
10
880
890
805
45
535
790 x 85
24
115
2 140
920.40
5 300
3 380
742
10
910
920
835
45
550
790 x 85
24
120
2 200
950.40
6 070
3 720
847
10
940
950
865
45
570
790 x 85
24
120
2 280
980.40
6 360
4 080
887
10
970
980
895
45
580
865 x 90
24
120
2 320
1 010.40
7 340
4 470
1 015
10
1000
1 010
920
45
590
865 x 90
24
130
2 360
1 040.40
7 660
4 880
1 060
10
1030
1 040
940
52
620
865 x 90
24
135
2 480
1 070.40
7 880
5 170
1 090
10
1060
1 070
975
52
640
915 x 90
24
135
2 560
1 090.40
9 100
5 620
1 275
10
1080
1 090
995
52
660
966 x 90
24
145
2 640
1 120.40
9 480
6 090
1 328
10
1110
1 120
1 025
52
670
1 000 x 90
24
145
2 680
1 170.40
11 620
6 940
1 592
10
1160
1 170
1 065
62
700
1 000 x 90
24
150
2 800
1 200.40
12 070
7 490
1 654
10
1190
1 200
1 095
62
720
1 100 x 90
24
150
2 880
1 250.40
14 010
8 480
1 889
10
1240
1 250
1 145
62
740
1 100 x 90
24
160
2 960
1 280.40
14 510
9 100
1 957
10
1270
1 280
1 175
62
760
1 200 x 90
24
160
3 040
1 320.40
16 570
9 980
2 215
10
1310
1 320
1 215
62
790
1 200 x 90
24
170
3 160
1 360.40
17 330
10 920
2 316
10
1350
1 360
1 255
62
815
1 300 x 90
24
170
3 260
1 400.40
19 440
11 910
2 583
10
1390
1 400
1 285
70
840
1 300 x 90
24
180
3 360
Size
Dimensions in mm.
From size 350.8 to 550.8 without internal bearing ring.
1
2
Values for forged components.
From size 830.40 to customer specification.
25
6.4 E Series
•
•
•
ET, EF and EGK designs
Sizes up to 1 220
Torque capacities upon request
E Series
high-performance
universal joint shaft
Features
Joints
•
•
•
•
•
Storage
Connection technology
Flange geometry with optimal design for torque transmission
Reinforced journal crosses
Optimized cross-sections and transition radii on all torque-transmitting components
Patented 2-piece flange yoke, with serrations alignment on the symmetry axis
One-piece bearing eye
•
Maximum utilization of available space for installation with largest possible bearings
and journal crosses
•
•
Optimized incorporation of bearings
Best leverage ratios at journal cross
•
Roller bearings with outer and inner rings
•
Optimized rolling element design
•
Improved rolling element lubrication
•
Flange with Hirth coupling
•
Full flange design
E Series high-performance universal joint shafts with size comparison
26
Advantages
•
Significantly higher torque capacity than with previous
universal joint shaft designs
Optimized to withstand torque peaks
•
Heavy-duty cross-sections without joints or bolts
•
•
•
•
Individually replaceable cartridge style roller bearings
•
Optimized to withstand torque peaks
•
Improved hydrodynamic lubrication
•
•
•
•
•
+
+
+
+
Productivity increase
Long service life
Reduced maintenance costs
Capability to roll higher strength steels
Increased bearing life and capability to withstand high static
and dynamic loads
Long bearing life
Uniformed load distribution throughout bearing
Capability to withstand high static and dynamic loads
•
Benefits
Reliable transmission of the highest torques
Optimal centering
Easy to assemble
+ Low assembly and maintenance costs
+ Productivity increase
No weakening of components as a result of necking or
reduced cross-sections
+ Capability to roll higher strength steels
+ Able to withstand overloads
Three-dimensional, sectioned model of an E Series joint
27
7 Engineering basics
7.1 Major components of a Voith universal joint shaft
Design
Hub yoke, output end
Splined
hub
Welded yoke
Tube
Flange yoke
Journal cross
28
Irrespective of their series, all versions and sizes of Voith universal joint shafts share many of the same common attributes that contribute to ensuring reliable operation:
• Yokes and flange yokes with optimized geometry
• Drop-forged journal crosses
• Low maintenance roller bearings with maximum load
capacity
• Use of high-strength tempering and hardened steels
• Optimal welded joints
Journal cross set
Flange yoke
Splined
journal
Dirt scraper
Welded yoke
Profile guard
Shaft yoke, input end
29
1
2
1 SAE profile (straight flank profile)
2 Involute profile
7.2 Telescopic length compensation
For many applications, length compensation of the universal
joint shaft is required. In comparison with other driveline
products, in the case of universal joint shafts, length compensation is achieved by the center section and offset by the
universal joints.
Two types of length compensation are used in Voith universal
joint shafts: the SAE profile (straight flank profile) and the
involute profile. The universal joint shaft series and size
determine the type of length compensation.
30
For smaller universal joint shafts, which typically experience
lower loads, the involute profile is a suitable solution with a
good cost-benefit ratio. The SAE profile (straight flank profile)
is a better solution for large, high-performance universal joint
shafts.
Force introduced during torque transmission
Torque transmission and centering
Torque transmission
Centering function
FN ≈ FU
FN > FU
FU
SAE‑profile
(straight flank profile)
Involute profile
SAE‑profile
(straight flank profile)
Involute profile
Length compensation with SAE profile (straight flank profile)
Features
•
•
•
Straight flank, diameter-centered
profile
Almost orthogonal introduction of
force
Large contact surfaces
Favorable pairing of materials for
hub and spline shaft
• Spline shaft nitrated as standard
•
•
Patented lubrication mechanism in
the grease distribution groove for
uniform distribution of grease
across the full diameter of the
profile
Advantages
Benefits
Separation of torque transmission
and centering functions
++ Long service life
Lower normal forces and thus
lower displacement forces
++ Ease of movement
•
Low surface pressure
++ Long service life
•
High wear resistance
++ Long service life
Tooth shape incorporates lubri­ca­
tion reservoir for reliable supply of
lubricant to sliding surfaces
++ Extended maintenance intervals
•
•
•
31
7.3 Kinematics of the universal joint
•
•
•
When the input shaft W1 rotates at a constant angular velocity (1 = const.), the output shaft W2 rotates at a varying
angular velocity (2 ≠ const.).
The angular velocity of the output shaft 2 and the differential angle = (1 – 2) vary in a sinusoidal manner, their
values depending upon the deflection angle .
This characteristic of universal joints is called the gimbal
error and must be taken into consideration when selecting
a universal joint shaft.
Universal joint
1
G1
W1
2
M 1, 1
M 2, 2
32
W2
G1
Standard universal joint
W1
Input shaft
W2
Output shaft
1, 2
Angle of rotation
Deflection angle
M 1, M 2
Torques
1, 2
Angular velocities
Movement relation
0.8°
= 12°
0.4°
= 6°
0°
lmaxl
for = 12°
-0.4°
-0.8°
1.02
= 12°
1.01
= 6°
1.00
0.99
1 – cos 12°
0.98
0°
90°
180°
270°
360°
1
•
•
•
With one rotation of the shaft W1, the differential angle changes four times, as does the angular velocity 2.
During the course of one rotation, the shaft W2 twice
passes through the points of maximum acceleration and
deceleration.
At larger deflection angles and higher velocities, considerable forces can be generated.
This gives the ratio of the angular velocities between
the two shafts W1 and W2:
2
__
cos _______________
1 = 1 – sin2 · sin2 1
change to maximum:
2
___
|
1
The following equations apply:
(4)
1
at 1 = 90° and 1 = 270°
= _____
cos max
(4a)
change to minimum:
= 1 – 2
(1)
1
tan 1
______
= cos (2)
tan 1 · (cos – 1)
tan = _________________
1 + cos · tan2 1
(3)
tan 2
2
___
|
min
= cos at 1 = 0° and 1 = 180°
(4b)
As regards the torque ratio, the following equation applies:
M2 ___
___
= 1
2
M1
(5)
change to maximum:
M2
___
M1
|
max
1
= ______
cos at 1 = 90° and 1 = 270°
(5a)
change to minimum:
M2
___
M1
|
min
= cos at 1 = 0° and 1 = 180°
(5b)
33
Conclusions
Variation factor, differential angle
max
4.4°
0.44
4.0°
0.40
3.6°
0.36
3.2°
0.32
2.8°
0.28
2.4°
0.24
0.20
2.0°
max
1.6°
0.12
0.8°
0.08
0.4°
0.04
0°
3°
6°
U
0.16
U
1.2°
A single universal joint should only be used if the following
requirements are met:
• The variation in the rotational speed of the output shaft
is of secondary importance
• The deflection angle is very small ( < 1°)
• The forces transmitted are low
9° 12° 15° 18° 21° 24° 27° 30°
One indicator of the variation is the variation factor U:
|
|
2
2
1
_____
___
U = ___
1 max – 1 min = cos – cos = tan · sin (6)
Finally, as regards to the maximum differential angle max
the following equation applies:
1 – cos _________
_____
tan max = ±
2 · √ cos (7)
All of the components of the universal joint shaft should
lie in one plane
G1
A
G2
34
7.4 Double universal joints
Section 7.3 shows that the output shaft W2 always rotates at
the varying angular velocity 2 when connected via a single
universal joint at a given deflection angle .
If, however, two universal joints G1 and G2 are connected together correctly in the form of a universal joint shaft in a Z- or
W-arrangement, the variations in the speeds of the input and
output shaft fully cancel each other out.
Universal joint shaft in Z-arrangement, the input and
output shafts lie parallel to each other in one plane
Universal joint shaft in W-arrangement, the input and
output shafts lie parallel to each other in one plane
1
1
2
2
Conditions for the synchronous rotation of the input and
output shafts:
The three conditions A, B and C ensure that joint G2 operates
with a phase shift of 90° and fully compensates for the gimbal
error of joint G1. This universal joint shaft arrangement is
known as the ideal universal joint shaft arrangement with
complete motion compensation.
This is the arrangement to be aiming for. If just one of the
three conditions is not satisfied, then the universal joint shaft
no longer operates at constant input and output speeds, i.e.
it no longer operates homo-kinetically. In such cases, please
contact your Voith Turbo representative.
Both yokes of the center section of the shaft lie in one plane
The deflection angles 1 and 2
of the two joints are identical
G1
G1
1
2
B
C
G2
G2
35
7.5 Bearing forces on input and output shafts
7.5.1 Radial bearing forces
Due to the deflection of the universal joint shaft, the connection
bearings are also subjected to radial loads. The radial forces
on the bearings vary from no forces to their maximum, twice
per revolution.
Maximum values for radial bearing forces on universal joint shafts in a Z-arrangement
a
b
L
Md
A
1
2
B
e
G1
G2
B1
F1
1 = 0°
A1
E1
A2
F2
B2
E2
1 = 90°
36
f
E
1 ≠ 2
1 = 2
b · cos A1 = Md · _________1 · (tan 1 – tan 2)
L·a
A1 = 0
(a + b) · cos B1 = Md · _____________1 · (tan 1 – tan 2)
L·a
B1 = 0
(e + f) · cos E1 = Md · ____________1 · (tan 1 – tan 2)
L·f
E1 = 0
e · cos F1 = Md · _________1 · (tan 1 – tan 2)
L·f
F1 = 0
F
tan 1
A2 = Md · ______
a
tan 1
A2 = Md · ______
a
tan 1
B2 = Md · ______
a
tan 1
B2 = Md · ______
a
sin 2
E2 = Md · ________
f · cos 1
tan E2 = Md · ______1
f
sin 2
F2 = Md · ________
f · cos 1
tan F2 = Md · ______1
f
Designations and formulas
G 1, G 2
Universal joints
A, B, E, F
Connection bearing
Md
Input torque
A1/2, B1/2, E1/2, F1/2 Bearing forces
1
Angle of rotation
1, 2
Deflection angle
Maximum values for radial bearing forces on universal joint shafts in a W-arrangement
L
1
b
2
e
f
a
Md
A
G1
E
B
1 ≠ 2
b · cos A1 = Md · _________1 · (tan 1 – tan 2)
L·a
B1
F1
A1
E1
1 = 0°
E2
B2
F2
1 = 90°
F
1 = 2
b · sin L·a
A1 = 2 · Md · ________1
(a + b) · cos (a + b) · sin B1 = Md · _____________1 · (tan 1 – tan 2) B1 = 2 · Md · ____________1
L·a
L·a
(e + f) · cos E1 = Md · ____________1 · (tan 1 – tan 2)
L·f
e · cos F1 = Md · _________1 · (tan 1 – tan 1)
L·f
A2
G2
(e + f) · sin E1 = 2 · Md · ____________1
F1 = 2 · Md ·
L·f
e · sin 1
________
L·f
tan 1
A2 = Md · ______
a
tan 1
A2 = Md · ______
a
tan 1
B2 = Md · ______
a
tan 1
B2 = Md · ______
a
sin 2
E2 = Md · ________
f · cos 1
tan E2 = Md · ______1
f
sin 2
F2 = Md · ________
f · cos 1
tan F2 = Md · ______1
f
37
7.5.2 Axial bearing forces
In principle, the kinematics of a universal joint shaft do not
generate any axial forces. However, axial forces that need to
be absorbed by adjacent bearings occur in universal joint
shafts with length compensation for two reasons:
1. Force Fax, 1 as a result of friction in the length compensation assembly
As the length changes during the transmission of torque, friction is generated between the flanks of the spline profiles in
the length compensation assembly. The frictional force Fax,1,
which acts in an axial direction, can be calculated using the
following equation:
2. Force Fax, 2 as a result of the pressure build-up in the
length compensation assembly during lubrication
During the lubrication of the length compensation assembly,
an axial force Fax, 2 , occurs which depends on the force applied while lubricating. Please note that information on this
subject is available in the installation and operating instructions.
2 · cos Fax,1 = · Md · ___
dm
where:
Coefficient of friction;
≈ 0.11 to 0.14 for steel against steel (lubricated)
≈ 0.07 for Rilsan® plastic coating against steel
Md Input torque
dm Pitch circle diameter of the spline profile
Deflection angle
1 Balancing machine
2 Balancing of universal joint shafts
1
38
2
7.6 Balancing of universal joint shafts
As with any other torque transmitting shaft, a universal joint
shaft also has a non-uniform distribution of mass around the
axis of rotation. This leads to unbalanced forces during operation wich has to be compensated depending on the case of
application. Depending on the operating speed and the specific application, Voith universal joint shafts are dynamically
balanced in two planes.
The benefits of balancing:
+ Prevention of vibrations and oscillations, resulting in
smoother operation
+ Longer service life of the universal joint shaft
The balancing procedure employed by Voith for universal joint
shafts is based on that prescribed in DIN ISO 1 940-1 ("Mechanical vibration – Balance quality requirements for rotors in a
constant (rigid) state – Part 1: Specification and verification of
balance tolerances"). An extract from this Standard lists the
following approximate values for balance quality levels:
Type of machine – general examples
Balance
quality level G
Complete piston engines for cars, trucks and locomotives
G 100
Cars: wheels, rims, wheel sets, universal joint shafts; crank drives with mass balancing on elastic
mounts
G 40
Agricultural machinery; crank drives with mass balancing on rigid mounts; size reduction machinery;
input shafts (cardan shafts, propeller shafts)
G 16
Jet engines; centrifuges; electric motors and generators with a shaft height of at least 80 mm and
a maximum rated speed of up to 950 rpm; electric motors with a shaft height of less than 80 mm; fans;
gearboxes; general industrial machinery; machine tools; paper machinery; process engineering
equipment; pumps; turbochargers; hydro-power turbines
G 6.3
Compressors; computer drives; electric motors and generators with a shaft height of at least 80 mm
and a maximum rated speed of over 950 rpm; gas turbines, steam turbines; machine tool drives;
textile machinery
G 2.5
Depending on the application and maximum operating speed,
the balance quality levels for universal joint shafts lie in the
range between G 40 and G 6.3. The reproduction of the measurements can be subject to wider tolerances due to the
influence of various physical factors. Such factors include:
• Design characteristics of the balancing machine
• Accuracy of the measuring method
• Tolerances in the connections to the universal joint shaft
• Radial and axial clearances in the universal joint bearings
• Deflection clearance in length compensation
39
8 Selection aids
The design of a universal joint shaft depends on a number of factors.
Reliable, verified calculations and tests prevent any danger to the
surrounding area. Consideration of the costs that arise over the entire
product lifecycle also comes into play.
The design procedures described in this chapter are only
intended to provide approximate guidelines. When making
a final decision about a universal joint shaft, you can rely on
our sales engineers for their technical knowledge and many
years of experience. We will be happy to advise you.
The following factors have a major influence upon
any decision regarding universal joint shafts:
•
•
•
•
Operating variables
Main selection criteria: Bearing lifetime or durability
Installation space
Adjacent bearings
Three-dimensional bending
v1
v2
h1 h2
40
8.1 Definitions of operating variables
Designation
Usual
unit
Explanation
PN
[kW]
Rated power of the drive motor
nN
[rpm]
Rated speed of the drive motor
MN
[kNm]
Rated torque of the drive motor, where:
PN
60 · P ≈ 9.55 · ___
MN = _______
N
nN with MN in kNm, nN in rpm and PN in kW
2 · nN
ME
[kNm]
Equivalent torque
This torque is an important operating variable if bearing lifetime is the main criterion in the selection
of a universal joint shaft. It takes operating conditions into account and can be calculated for situations involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently
known, the rated torque can be used as an initial estimate.
nE
[rpm]
Equivalent speed
This speed is an important operating variable if bearing lifetime is the main criteria in the selection
of a universal joint shaft. It takes operating conditions into account and can be calculated for situations involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently
known, the rated speed can be used as an initial estimate.
Mmax
[kNm]
Peak torque
This is the maximum torque that occurs during normal operation.
nmax
[rpm]
Maximum speed
This is the maximum speed that occurs during normal operation.
nz1
[rpm]
Maximum permissible speed as a function of the deflection angle during operation
The center section of a universal joint shaft in a Z- or W-arrangement ( ≠ 0°) rotates at a varying
speed. It experiences a mass acceleration torque that depends upon the speed and the deflection
angle. To ensure smooth operation and prevent excessive wear, the mass acceleration torque
is limited by avoiding the exceeding of the maximum speed of the universal joint shaft nz1. For additional information see section 8.3.1.
nz2
[rpm]
Maximum permissible speed taking bending vibrations into account
A universal joint shaft is an elastic body when bent. At a critical bending speed (whirling speed), the
frequency of the bending vibrations equals the natural frequency of the universal joint shaft. The
result is a high load on all of the universal joint shaft components. The maximum speed of the
universal joint shaft must be significantly lower than this critical speed. For additional information,
see section 8.3.2.
[°]
Deflection angle during operation
Deflection angle of the two joints in a Z or W-arrangement, where:
= 1 = 2
If the situation involves three-dimensional deflection, the resulting deflection to angle R can be
determined thus:
_______________
tan R = √ tan2 h + tan2 V und es gilt: = R
max
[°]
Maximum possible deflection angle
This is the deflection angle that occurs during normal operation.
41
8.2 Size selection
There are essentially two selection criteria when
choosing the size of a universal joint shaft:
1. The lifetime of the roller bearings in the joints
2. The fatigue-free operating range, and thus the
torque capacity and / or load limits
As a rule, the application determines the primary selection criteria. A selection based upon bearing lifetime is usually made
if the drives need to have a long service life and pronounced
torque spikes never occur or happen only briefly (for instance,
during start-up). Typical examples include drives in paper machinery, pumps and fans. In all other applications, the selection
is made on the basis of the fatigue-free operating range.
8.2.1 Selection based upon bearing lifetime
The procedure used for calculating the bearing lifetime is
based upon that prescribed in DIN ISO 281 ("Rolling bearings – Dynamic load ratings and rating service life").
However, when applying this standard to universal joint shafts,
several different factors are not taken into account; for
instance, the support of the bearing, i.e. deformation of the
bore under load. So far, these factors could only be assessed
qualitatively.
The theoretical lifetime of a bearing in a universal joint shaft
can be calculated using the following equation:
10
1.5 · 107
CR ___
3
Lh = ________ · ___
nE · · KB ME
( )
where:
Lh is the theoretical lifetime of the bearing in hours [h]
CR Load rating of the universal joint in kNm
(see the tables in Chapter 6)
Deflection angle in degrees [°]; in the case of threedimensional bending, the resulting deflection angle R
is to be used; in any case, however, using a minimum
angle of 2°
KB Operational factor
nE Equivalent speed in rpm
ME Equivalent torque in kNm
Operational factor
In drives with diesel engines, torque spikes occur that are
taken into account by the operational factor KB :
42
Prime mover
(driving machine)
Operational factor KB
Electric motor
1
Diesel engine
1.2
Equivalent operating values
The equation for the theoretical lifetime of the bearing assumes
a constant load and speed. If the load changes in increments,
the equivalent operating values can be determined that
produce the same fatigue as the actual loads. The equivalent
operating values are ultimately the equivalent speed nE and
the equivalent torque ME.
If a universal joint shaft transmits the torque Mi for a time
period T i at a speed of ni, a time segment qi that normalizes
the time period T i with respect to the overall duration of
operation Ttot is first defined:
Ti
qi = ____
with
Ttot
Conclusions
•
•
The bearing's calculated lifetime is a theoretical value
that is usually significantly exceeded.
The following additional factors affect the lifetime of the
bearings, sometimes to a significant degree:
− Quality of the bearings
− Quality (hardness) of the journals
− Lubrication
− Plastic deformation as a result of overloading
− Quality of the seals
u
∑qi = q1 + q2 + … + qu = 1
i=1
In this way, the equivalent operating values can be determined:
u
nE =
∑ qi · ni =
q1 · n1 + q2 · n2 + … + qu · nu
i=1
ME =
(
10
___
u
∑ qi · ni · Mi 3
3
___
10
)
i=1
___________
nE
(
10
___
10
___
10
___
q1 · n1 · M13 + q2 · n2 · M23 + … + qu · nu · Mu 3
= _____________________________________
nE
3
___
)
10
Incremental variation of the load on a universal joint shaft
M, n
M1
Mu
M2
n1
0
q1
n2
q2
nu
qu
1
q
43
8.2.2 Selection on the basis of fatigue-free operating
range
Calculations regarding the fatigue-free operating range can
be made using a load spectrum. In practice though, sufficiently accurate load spectra are seldom available. In this case,
one needs to rely on the quasi-static dimensioning procedure. In this procedure, the expected peak torque Mmax is
compared with the torques MDW , MDS and MZ (see section
5.2).
Shock
load
Shock
factor K3
Typical driven machinery
Minimal
1.1…1.3
•
The following estimate is made for the peak torque:
Moderate
•
•
•
•
1.3…1.8
•
•
•
Mmax ≈ K3 · MN
•
K3 is called the shock factor. These are empirical values based
upon decades of experience in designing universal joint
shafts.
•
Severe
2…3
•
•
•
The peak torque determined in this manner must meet the
following requirements:
•
•
•
1. Mmax ≤ MDW for alternating load
•
•
2. Mmax ≤ MDS for pulsating load
•
•
3. Individual and rarely occurring torque peaks must not
exceed the value MZ. The permissible duration and frequency
of these torque spikes depends upon the application; please
contact Voith Turbo for more information.
•
•
•
Very
severe
3…5
•
•
•
•
Extremely
severe
6…15
•
•
•
44
Generators
(under a uniform load)
Centrifugal pumps
Conveying equipment (under a
uniform load)
Machine tools
Woodworking machinery
Multi-cylinder compressors
Multi-cylinder piston pumps
Light-section rolling mills
Continuous wire rolling mills
Primary drives in locomotives
and other rail vehicles
Transport roller tables
Continuous pipe mills
Continuously operating main
roller tables
Medium-section rolling mills
Single-cylinder compressors
Single-cylinder piston pumps
Fans
Mixers
Excavators
Bending machines
Presses
Rotary drilling and boring
equipment
Secondary drives in
locomotives and other rail
vehicles
Reversing main roller tables
Coiler drives
Scale breakers
Cogging/roughing stands
Roll stand drives
Plate shears
Coiler pressure rolls
8.3 Operating speeds
8.3.1 Maximum permissible speed nz1 as a function of
the deflection angle
Section 7.3 shows that a universal joint exhibits a varying
output motion. A universal joint shaft is a connection of two
universal joints in series with one another. Under the conditions described in section 7.4, a universal joint shaft in a Z or
W-arrangement exhibits homokinetic motion between the
input and output. However, the center section of the universal joint shaft still rotates at the periodically varying angular
velocity 2 .
Since the center section of the universal joint shaft still exhibits
a mass moment of inertia, it creates a moment of resistance
to the angular acceleration d2 / dt. On universal joint shafts
with length compensation, this alternating mass acceleration
moment can cause clattering sounds in the profile. The consequences include less smooth operation and increased wear.
In addition, the mass acceleration torque can affect the entire
drive chain on universal joint shafts with length compensation,
as well as universal joint shafts without length compensation.
Torsional vibrations should be mentioned here by way of
example.
In order to prevent these adverse effects, please ensure the
following conditions:
nmax ≤ nz1
Approximate values of nz1 as a function of R 208.8
R 198.8
S 120.2
S 120.5
S 090.2
S 100.2
S 058.1
S 065.1
S 075.1
R 390.8 R 350.8 R 315.8
CH 390.8 CH 350.8
R 285.8
R 250.8
S 180.5
S 225.7
S 150.2
S 150.3
S 150.5
6 000
nz1 [rpm]
4 000
2 000
1 000
800
600
500
R 550.8
CH 550.8
2
4
6
8
R 490.8
R 440.8
CH 440.8 CH 440.8
10
12
14
16
18
20
22
24
26
28
30
[°]
45
8.3.2 Maximum permissible speed nz2 as a function of
operating length
Every universal joint shaft has a critical bending speed (whirling speed) at which the rotational bending speed (bending
frequency) matches the natural frequency of the shaft. The
result: high loads on all components of the universal joint
shaft. Damage to or destruction of the universal joint shaft is
possible in unfavorable situations.
The calculation of this critical bending speed for a real
universal joint shaft in a driveline is a complex task that Voith
Turbo performs using numerical computing programs.
The critical bending speed depends essentially upon three
factors:
• Operating length l
B
• Deflection resistance of the universal joint shaft
• Connecting conditions at the input and output ends
The maximum permissible speed nz2 is determined in such
a way that it provides a safety allowance with respect to the
critical bending speed that is suitable for the particular
application.
For safety reasons and to prevent the failure of the universal
joint shaft, please ensure the following conditions:
nmax ≤ nz2
46
For normal connecting and operating conditions, it is possible to specify approximate values for the maximum permissible speeds nz2 as a function of the operating length lB:
Approximate values of nz2 as a function of lB for the S Series
S 150.5
6 000
S 180.5
S 225.7
4 000
2 000
nz2 [rpm]
1 000
800
600
400
200
100
S 058.1
1 000
S 065.1
2 000
S 075.1
S 100.2
S 090.2
3 000
S 120.2
S 120.5
4 000
S 150.2
S 150.3
5 000
6 000
IB [mm]
Approximate values of nz2 as a function of lB for the R and CH Series
R 198.8
R 208.8
R 250.8
R 285.8
R 315.8
R 350.8
R 390.8
CH 350.8 CH 390.8
R 440.8 R 490.8
R 550.8
CH 440.8 CH 490.8 CH 550.8
nz2 [rpm]
4 000
2 000
1 000
800
600
500
2 000
3 000
4 000
5 000
6 000
IB [mm]
47
8.4 Masses
Size
Values for the tube
based on length
Universal joint shafts with length compensation
m'R
[kg / m]
mL min
[kg]
mL min
[kg]
mL min
[kg]
mL min
[kg]
mL min
[kg]
ST / STL / SF
ST
STL
STK1
STK2
STK3
058.1
1.0
1.1
1.1
1.0
1.0
065.1
1.1
1.7
1.7
1.6
1.5
075.1
2.0
2.7
2.5
2.4
2.3
090.2
2.4
4.8
4.3
4.1
4.0
100.2
3.5
6.1
5.8
5.5
5.3
120.2
5.5
10.8
10.2
9.8
9.2
Values upon request
120.5
6.5
14.4
13.7
13.2
12.3
150.2
7.5
20.7
20.7
20.1
17.1
150.3
8.5
32.0
27.0
25.9
27.4
150.5
11.7
36.4
36.5
34.9
32.4
180.5
15.4
51.7
48.5
46.7
43.1
225.7
16.9
65
66
64
60
RT / RTL / RF
RT
RTL
RTK1
RTK2
198.8
37.0
92
-
-
-
208.8
49
135
165
126
110
250.8
58
199
222
179
165
285.8
64
291
323
334
246
315.8
89
400
599
387
356
350.8
148
561
624
546
488
390.8
185
738
817
684
655
440.8
235
1 190
1 312
1 050
1 025
490.8
296
1 452
1 554
1 350
1 300
550.8
346
2 380
2 585
2 170
2 120
Continued on pages 50 and 51
48
Universal joint shafts
without length
compensation
Joint coupling
mL min
[kg]
mL min
[kg]
mL fix
[kg]
STK4
SF
SGK
0.9
0.9
0.8
1.4
1.2
1.0
2.1
2.0
1.0
3.8
3.6
3.2
5.1
4.5
4.2
8.6
7.7
7.4
11.5
10.5
9.2
15.8
15.2
13.8
26.0
22.1
16.6
29.4
25.3
21.6
40.9
32.4
30.6
56
36
36
RWF
RGK
56
59
78
85
115
127
182
191
250
270
377
370
506
524
790
798
1 014
1 055
1 526
1 524
49
Size
Values for the tube
based on length
Universal joint shafts with length compensation
m'R
[kg / m]
mL min
[kg]
CHT / CHF
CHT
350.8
134.2
685
390.8
149.9
1 018
440.8
189.3
1 415
490.8
261.3
1 979
550.8
305.2
2 807
590.40
564.7
3 887
620.40
564.7
4 232
650.40
683.3
4 949
680.40
683.3
5 364
710.40
813.2
6 523
740.40
813.2
7 020
770.40
954.4
8 186
800.40
1 040
8 884
Values for dimensions and series not listed are available on request
Designation
Explanation
m'R
Mass of the tube per 1 m of length
Universal joint shafts
with length compensation
mL min
Mass of the universal joint shaft for a length of…
lz min
Calculations for the entire universal joint shaft:
mtot
50
Total mass
mges = mL min + (lz – lz min) · m'R
Universal joint shafts
without length
compensation
Joint coupling
mL min
[kg]
mL fix
[kg]
CHF
CHG
508
453
708
626
1 001
895
1 379
1 228
1 918
1 730
2 442
2 154
2 787
2 466
3 243
2 856
3 657
3 232
4 286
3 758
4 783
4 207
5 461
4 759
6 085
5 282
Universal joint shafts
without length compensation
lmin
mges = mL min + (l – lmin) · m'R
51
8.5 Connection flanges and bolted connections
When installing the Voith universal joint shaft in a driveline,
the connection flanges and bolted connections must satisfy
a number of requirements:
1. Design
• When using a universal joint shaft without length compensation, a connection flange ("coupling") that is moveable in
a longitudinal direction is required so that the universal joint
shaft can slide over the spigot. The connection flange also
absorbs additional length changes arising, for instance,
from thermal expansion or changes in the deflection angle.
2. Material
The material used for the connection flanges has been
selected to permit the use of bolts of property class 10.9
(according to ISO 4 014 / 4 017 and/or DIN 931 - 10.9).
• Special case for the S and R Series:
If the material used for the connection flanges does not
permit the use of bolts of property class 10.9, the torques
that can be transmitted by the flange connection are
reduced. The specified tightening torques for the bolts
must be reduced accordingly.
•
52
3. Dimensions, bolted connections
• On universal joint shafts from the S and R Series, the
dimensions of the connection flanges match those of the
universal joint shaft, apart from the locating diameter c.
The locating diameter provides a clearance (fit H7 / h6).
• On universal joint shafts with an H flange, the dimensions
of the connection flanges are identical to those of the universal joint shaft. The Hirth couplings are self-centering.
• On universal joint shafts from the S and R Series, the relief
diameter fg on the universal joint shaft flange is not suitable
for locking hexagon head bolts or -nuts. A relief diameter fa
on the connection flange is suitable for this purpose.
Flange connection for universal joint shafts of the S and R Series
A
B
mmin
Z1
mmin
m
g
Z2
A
g
n
v
o
Z1
p
m
g
g
v
t
øb
øfg
øa
øfa
øb
øfg
x
øc
øa
øfa
ya
S flange / Q flange
K flange
H flange
Fastener hole pattern for flange connections on the S and R Series of universal joint shafts
A+B
A
A
22.5°
22.5°
A
A
30°
A
A
B
A
A
A
8xA
4xB
8xA
12 x A
A
10 x A
4xB
10 x A
16 x A
A
A
A
B
A
A
A
A
A
A
36°
36°
A
22.5°
53
Dimensions of the connection flanges
Bolted connection (A)
Comments
Size
a
b ± 0.1
c H7
fa -0.3
fg
g
t
v
x P9
ya +0.5
1
2
3
4
5
Z 1, Z 2
z
z
z
m
Bolt
S flange / K flange
058.1
58
47
30
38.5
3.5
1.2 -0.15
9
0.05
4
M5 x 16
065.1
65
52
35
41.5
4
1.5 -0.25
12
0.05
4
M6 x 20
075.1
75
62
42
51.5
5.5
2.3 -0.2
14
0.05
6
M6 x 25
090.2
90
74.5
47
61
6
2.3 -0.2
13
0.05
4
M8 x 25
100.2
100
84
57
70.5
7
2.3 -0.2
11
0.05
6
M8 x 25
120.2
120
101.5
75
84
8
2.3 -0.2
14
0.05
8
M10 x 30
120.5
120
101.5
75
84
9
2.3 -0.2
13
0.05
8
M10 x 30
150.2
150
130
90
110.3
10
2.3 -0.2
20
0.05
8
M12 x 40
150.3
150
130
90
110.3
12
2.3 -0.2
18
0.05
8
M12 x 40
150.5
150
130
90
110.3
12
2.3 -0.2
18
0.05
8
M12 x 40
180.5
180
155.5
110
132.5
14
2.3 -0.2
21
0.05
8
M14 x 45
225.7
225
196
140
171
159
15
4 -0.2
25
0.06
8
M16 x 55
225.8
225
196
140
171
159
15
4 -0.2
15
0.06
8
M16 x 55
250.8
250
218
140
190
176
18
5 -0.2
24
0.06
8
M18 x 60
285.8
285
245
175
214
199
20
6 -0.5
30
0.06
8
M20 x 70
315.8
315
280
175
247
231
22
6 -0.5
31
0.06
8
M22 x 75
350.8
350
310
220
277
261
25
7 -0.5
30
0.06
10
M22 x 80
390.8
390
345
250
308
290
32
7 -0.5
36
0.06
10
M24 x 100
435.8
435
385
280
342
320
40
8 -0.5
40
0.06
10
M27 x 120
Q flange
225.8
225
196
105
171
159
20
4 -0.2
25
32
250.8
250
218
105
190
176
25
5 -0.2
25
40
285.8
285
245
125
214
199
27
6 -0.5
26
315.8
315
280
130
247
231
32
7 -0.5
350.8
350
310
155
277
261
35
390.8
390
345
170
308
290
440.8
435
385
190
342
320
490.8
490
425
205
377
550.8
550
492
250
9.5
0.06
8
4
M16 x 65
13
0.06
8
4
M18 x 75
40
15.5
0.06
8
4
M20 x 80
31
40
15.5
0.06
10
4
M22 x 95
7 -0.5
30
50
16.5
0.06
10
6
M22 x 100
40
7 -0.5
40
70
18.5
0.06
10
6
M24 x 120
42
9 -0.5
38
80
20.5
0.1
10
6
M27 x 120
350
47
11 -0.5
46
90
23
0.1
10
8
M30 x 140
444
420
50
11 -0.5
40
100
23
0.1
10
8
M30 x 140
H flange
208
225
196
180
171
159
20
25
18
4
M16 x 65
250
250
218
200
190
175
25
25
20
4
M18 x 75
285
285
245
225
214
199
27
26
21
4
M20 x 80
315
315
280
250
247
230
32
31
23
4
M22 x 95
350
350
310
280
277
261
35
30
24
6
M22 x 100
390
390
345
315
308
290
40
40
25
6
M24 x 120
440
435
385
345
342
322
42
36
28
6
M27 x 120
490
480
425
370
377
350
47
36
31
8
M30 x 130
550
550
492
440
444
420
50
40
32
8
M30 x 140
Dimensions in mm
54
Bolted connection with split sleeve (B)
6
7
8
9
10
11
12
MA
[Nm]
EB
z
n
Bolt
o
Sleeve
p
Washer
MA
[Nm]
Designation
Explanation
a
Flange diameter
b
Bolt circle diameter
c
Locating diameter
fa
Flange diameter, bolt
side
fg
Flange diameter, nut
side
Comments
Additional information
7
No
13
No
13
No
32
No
g
Flange thickness
32
No
t
64
No
Locating depth in
connection flange
64
No
v
111
No
111
No
Length from the
contact surface of the
nut to the end of the
hexagon head bolt
111
No
x
Width of face key
in universal joint shaft connection flanges with a face key
177
No
ya
Depth of face key
270
No
4
M12 x 60
21 x 28
13
82
in universal joint shaft connection flanges with a face key
270
Yes
4
M12 x 60
21 x 28
13
82
z1
Axial run-out
372
No
4
M14 x 70
25 x 32
15
130
z2
Concentricity
526
No
4
M16 x 75
28 x 36
17
200
710
Yes
4
M16 x 80
30 x 40
17
200
710
Yes
4
M18 x 90
32 x 45
19
274
m
906
No
4
M18 x 110
32 x 60
19
274
1 340
No
4
M20 x 110
35 x 60
21
386
Hexagon head bolt to
ISO 4 014 / 4 017-10.9
or DIN 931-10.9 with
hexagon nuts to
ISO 7 040-10 or
DIN 982-10
270
No
372
No
526
No
710
No
710
No
906
No
1 340
No
1 820
No
1 820
No
270
No
372
No
526
No
710
No
710
No
906
No
1 340
No
1 820
No
1 820
No
1
Permissible values for deviation in axial runout Z1 and
concentricity Z2 at operating
speeds below 1 500 rpm.
At operating speeds of
1 500 rpm to 3 000 rpm, the
values should be halved!
2
z each per standard connection flange
3
z each per connection flange
with face key
4
z each per connection flange
with Hirth coupling
5
Dimension of hexagon head
bolt with nut
6
Tightening torque for a coefficient of friction µ = 0.12 and
90 % utilization of the bolt
yield point
mmin
Minimum length for the
installation of bolts
EB
Insertion options
7
Insertion of bolts from the
joint side
n
Hexagon head bolt to
ISO 4 014 / 4 017-10.9
or DIN 931-10.9 with
hexagon nuts to
ISO 7 040-10 or
DIN 982-10
8
z each per connection flange
9
Dimension of hexagon head
bolt with nut
12
Tightening torque for a
coefficient of friction µ = 0.12
and 90 % utilization of the bolt
yield point
Length of the hexagon head
bolt m including the height of
the bolt head
o
Split sleeve
10
Outer diameter x length of the
split sleeve [mm x mm]
p
Washer
11
Interior diameter of the
washer [mm]
55
Success needs
reliable partners.
That’s what moves us.
56
9 Service
For us, service means quality and dependability that exceeds the expectations of our customers. We will support you anywhere in the world
throughout the entire lifetime of your Voith equipment. You can count on
us from the planning and commissioning phase through to maintenance.
With the Universal Joint Shaft capabilities from Voith Turbo, you will increase the reliability, availability and lifetime of your equipment.
Voith Turbo Universal Joint Shaft Service
Consulting and engineering
Pre-sales
After-sales
Installation
Commissioning
Original spare parts' supply
Overhaul
Repairs
Modernizations, retrofits
Training
Torque measurements (ACIDA)
57
9.1 Installation and commissioning
The correct installation of a universal joint shaft provides the
basis for trouble-free commissioning. A systematic commissioning procedure with extensive operational testing is an
important factor in achieving the maximum reliability and long
operational life of the universal joint shaft and the system as a
whole.
Our services
•
•
Installation and commissioning by our service experts
Training of operation and maintenance personnel
Your benefits
+ Immediate access to expert know-how throughout the
start-up phase
+ Assurance of problem-free and professional
commissioning of your universal joint shaft
58
9.2 Training
Efficiency, reliability and availability are essential factors in
ensuring your system is successful. One requirement in this
regard is having the best-trained employees in technology and
servicing. Initial and ongoing training are worthwhile investments in ensuring the efficient operation of your universal joint
shafts. Our training programs provide specific technical
knowledge about your Voith equipment, as well as other
potential products to enhance your system. We bring your
personnel up to speed with the latest Voith technology – in
theory and in practice.
Our services
•
•
Product training at Voith or on-site at your premises
Theoretical and practical maintenance and repair training
Your benefits
+ Safe handling of Voith products
+ Avoidance of operating and maintenance errors
+ Better understanding of Voith technology in the driveline
59
9.3 Genuine Voith spare parts
Avoid risk, use Voith orginal spares and wear parts. These are
the only parts manufactured with Voith's know-how, and
guarentee the reliable and safe operation of your Voith equipment. Ensuring the highest availability, in combination with
efficient logistics, to ensure rapid deployment of parts globally.
Our services
•
•
•
•
•
Inventory of most original and wearing parts located
at local service branches
Same day shipment of in-stock parts (orders received
by 11 a.m.)
Consultation with your spare parts' management staff
Preparation of spares kits for specific project maintenance
Spares for older and obsolete series of Voith universal joint
shafts still available
Your benefits
+
+
+
+
+
+
Journal cross
60
Safe and reliable operation of all components
Parts of the highest quality that fit precisely first time
Maximum lifetime of driveline components
Manufacturer's warranty
Maximum system availabilty
Efficient and speedy delivery of spare parts
Flange yoke
9.4 Overhaul, maintenance
Constant operation subjects universal joint shafts to natural
wear, which is also influenced by the surroundings. Professional and regular overhauls of your universal joint shaft
prevent damage and minimize the risk of expensive production
downtimes. You gain operational reliability and save money in
the long term.
Our services
•
•
•
Maintenance or complete overhaul by our service experts
with all the necessary tools and special fixtures
Use of original spare and wearing parts
Consultation regarding your maintenance strategy
Your benefits
+ Safety due to professional maintenance
+ Manufacturer's warranty
+ Increased system availability
61
9.5 Repair and maintenance
Even with the best preventive maintenance, unplanned downtime due to equipment failures cannot be ruled out. The
priority then is to repair the components and equipment as
quickly as possible. As the manufacturer we not only have the
wealth of knowledge about universal joint shafts, but we also
possess the necessary technical competence, experience and
tools to ensure the most professional of rapid repairs. Our
service technicians can assess the damage in the minimum
amount of time, in order to provide suggestions for the rapid
rectification of the situation to enable operation of equipment
as soon and as safely possible.
Our services
•
•
•
Rapid and professional repairs that comply with the latest
safety standards on-site, or at one of our head officecertified Voith Service Centers located strategically around
the globe
Experience damage assessment, with analysis of the
weaknesses
Immediate delivery of replacement original spare parts
Your benefits
+
+
+
+
62
Maximum safety due to the best practice repairs
Manufacturer's warranty
Shortest possible outage and downtime of your equipment
Avoidance of repeat outages, or malfunction
9.6 Retrofit and modernizations
Technology is advancing all the time and sometimes the
original requirements upon which the design of a system was
based can change. Voith Turbo helps you achieve significant
improvements in the efficiency and reliability of your equipment, through a modernization or retrofit program of old
driveline equipment, e.g. slipper spindles. We will analyze, and
provide advise as to the latest and most economical technology for your particular driveline application.
Our services
•
•
Modernization of existing, or new replacement designs for
your universal joint shafts and connection components
Even with the best preventative maintenance schedule,
unplanned downtime due to equipment failure can never
be ruled out
Your benefits
+ Improved reliability, availability and affordability of your
driveline
+ Reduction of operating costs
+ Universal joint shafts that feature the latest technology
63
10 Services and
Supplementary products
10.1 Engineering
We not only supply products, but ideas too! You too can
benefit from our many years of engineering expertise in allround project planning of complete drive systems: from
design calculations, installation and commissioning, to questions about cost-optimized operating as well as maintenance
concepts.
Engineering services
•
•
•
•
•
•
•
•
Specification preparation
Preparation of project-specific drawings
Torsional and bending vibration calculations
Design and sizing of universal joint shafts and connecting components
Clarification of special requirements from the operator
and its employees
Preparation of installation and maintenance instructions
Documentation and certification
Special acceptance tests conducted by classifying
and certifying agencies
Project planning of a driveline using CAD
64
Special universal joint shafts
Designing special universal joint shafts to match your drive
system and your operating conditions is just one of the everyday engineering services we offer. These include:
• All necessary design work
• Integrity checks and optimization of design through
the application of FEM analysis
• Reliability trials based on dynamic load testing
FEM analysis of a work roll, with a split connection coupling
10.2 Connecting components for universal joint shafts
To ensure maximum reliability of the driveline, the input and
output connecting parts of the universal joint shaft, should
equally be analyzed for suitability, e.g.:
• All couplings
• All connecting fl anges bolted or otherwise
• All Adapters
Applications
•
•
•
•
•
•
Rolling mills
Paper machinery
Pumps
General industrial machinery
Test stands
Construction equipment and cranes
Features
•
•
•
•
Individual adaptation to all adjoining components
Precision manufacturing through the use of state-of-the-art
machining centers
Maximum torque transmission capability through the use of
the highest quality materials.
Hardened contact surfaces to ensure maximim levels of
wear resistance.
Connection hubs (wobblers/couplings) to attach universal joint shafts to the work rolls
65
10.3 Quick-release GT coupling
The quick-release GT coupling is designed to be an efficient
and effective quick release connection device. The GT coupling allows you to assemble and disassemble a wide range of
shaft connections, which in turn significantly reduces the
amount of required downtime associated with maintenance
and repair. which in turn significantly reduces downtimes for
maintenance and repair.
Applications
•
•
Drivelines that require a quick release while retaining
accurate radial alignment, e.g. universal joint shafts and
disc couplings
Roll connections, e.g. on paper machines
Features
•
•
•
•
•
Schematic diagram of the quick-release GT coupling
66
Positive transmission of torque through radial drive dog
design
Quick and easy assembly / disassembly
Compact design
Only two major components
Stainless steel versions available
Universal joint shaft with a ring from a quick-release GT coupling
10.4 Voith Hirth couplings
Voith Hirth couplings transmit maximum torque at the specified diameters.
Applications
•
•
•
•
•
•
•
•
•
High performance universal joint shafts, for high torque
applications
Connection flange for universal joint shafts (also when
provided by the customer)
Machine tools
Turbo compressors
Measuring equipment
Robotic equipment
Nuclear technology
Medical equipment
General industrial machinery
Features
•
•
•
•
Highest torque transmission capability, as the angular
surfaces provide positive locking of most of the peripheral
forces. The bolts only need to accomodate a small amount
of axial force.
Self-centering by means of optimized tooth geometry
A high load bearing on the tooth profile, significantly
inreases wear resistance of the hirth serration.
Repeatability accuracy maximized as a result of the
multiple tooth design.
Positive locking
Accurate indexing
Self-centering
Fa
Fu
Universal joint shaft flanges with Hirth coupling
Primary functions of the Hirth serration
67
10.5 Universal joint shaft supports
To position and support a universal joint shaft and its connection coupling and flanges, a support mechanism is required.
Applications
•
•
Rolling mills
Customer-specific drives
Features
•
•
•
Universal joint shaft support (red) and coupling support (yellow)
68
Increased productivity and system availability as a result
of shorter downtime for maintenance
Reduction of energy and lubrication costs, together with
higher transmission efficiency through the use of roller
bearings
Reduced wear as a result of uniform power transmission
10.6 Universal joint shafts with
carbon fiber-reinforced polymer (CFRP) components
Universal joint shafts with CFRP components increase the
efficiency and performance of machines and plants. CFRP
use in universal joint shaft construction, reduces masses,
vibrations, deformations and power consuption of the machines. We offer not only the characteristic know-how, but
also the production know-how of CFRP components – all
from a single source.
Applications
•
•
•
•
•
•
•
Long drivelines without the need for intermediate bearing
supports
Drivelines with low masses
Drivelines that require optimized vibration behaviour
Pumps
Marine vessels
Rail vehicles
General industrial machinery
Features
•
•
•
•
Depending on the requirements of the specific application,
universal joint shafts can incorporate CFRP tube, or solid
shafts
Reduced dynamic loads, due to lower masses
Extremely smooth operation and low vibration induced
wear, as a result of the higher rigidity of CFRP
Lower acceleration / deceleration torques as a result of the
lower mass of intertia of CFRP
Universal joint shaft with CFRP tube
69
1
1 Voith WearCare 500 in 45 kg and 180 kg
drums
10.7 High-performance lubricant
for universal joint shafts
Voith development engineers have combined their universal
joint shaft know-how with the tribological knowledge and
experience of renowned bearing and lubricant manufacturers.
The result of this cooperation is an innovative and exclusive
lubricant with properties that far exceed those of conventional
lubricants. This lubricant gives bearings in universal joint shafts
operating at low speeds and under high loads an even longer
life. In addition, lubrication intervals can be extended and
emergency dry-running characteristics are improved significantly.
70
Characteristics of the Voith WearCare 500
high-performance lubricant
Advantages
•
Optimum adhesion and surface wetting
+ Lubricating film even in the event of poor lubrication
+ Formulated for oscillating bearing motion
•
Exceptional corrosion protection
+ Ideal for rolling mills
•
Maximum ability to withstand pressure
+ Hydrodynamic lubricating film even under maximum torque
conditions
•
Optimal and long-lasting lubricating action
+ Minimal abrasive wear in the bearing
+ Extended lubrication intervals
+ Reduced maintenance costs
•
Can be mixed with lithium-based greases
+ Simple changeover to Voith's high-performance lubricant
•
High resistance to aging
+ Long shelf life
•
Excellent compatibility with all bearing components
+ No softening of bearing seals
+ Does not corrode non-ferrous metals
•
Free of silicone and copper-based ingredients
+ Suitable for aluminum rolling mills
FE8 test stand trial
Metal particles in the bearing lubricant of a high-performance
universal joint shaft used in a rolling mill drive
Bearing wear in an axial cylindrical roller bearing
1.5
15
Reference
wear condition
Relative bearing wear
Relative metal particles in the lubricant
Field trial
1
Standard lubricant
0.5
Extended
operating time
Voith
WearCare 500
0
3
6
9
12
15
18
21
Standard
lubricant
10
5
1
Voith
WearCare
500
24
Operating time in months
71
10.8 Safeset torque-limiting safety couplings
The Safeset coupling is a torque-limiting safety coupling that
instantaneously disengages the power transmission of the
driveline in the event of a potentially catastrophic torque overload event. Thus it protects all of the drive components in the
driveline such as motors, gearboxes, universal joint shafts etc.
against costly and time consuming damage.
By integrating the Safeset safety coupling into the universal
joint shaft, which is known as the Voith 'integral design',
reduces the deflection angle of the universal joints, and thus
increases the lifetime of driveline components.
Applications
•
•
•
•
•
•
Protects drivelines from potentially catastrophic overload
damage
Rolling mills
Shredders
Cement mills
Sugar mills
Rail vehicle drives
3D cut away section through a Safeset safety coupling (type SR-C)
72
Features
•
•
•
•
•
•
Adjustable release torque
The Safeset coupling reacts instantaneously to a torque
overload event
Backlash-free power transmission
Compact, lightweight design
Low mass moment of inertia
Minimal maintenance required
Safeset torque limiting safety couplings (blue) 'integral design'
in a Voith high performance universal joint shaft
10.9 ACIDA torque monitoring systems
ACIDA torque monitoring systems have proven their worth in
accurately measuring dynamics in universal joint shafts.
The direct measuring of the actual, mechanical drive load
provides important information for process observation and
plant optimization. Analysis modules, for instance load spectra
or lifetime observation, have been developed especially for
extremely heavy-duty drives and unusually severe load conditions. Additional options include online vibration diagnosis for
gearboxes and roller bearings.
Applications
•
•
•
•
•
Features
Torque monitoring
Vibration monitoring
Process optimization
Condition-based maintenance
Reference systems: Rolling mills, cement mills, briquetting
plants, agitators, conveying equipment, marine propulsion
systems, locomotives, paper machines, mining, etc.
Non-contact torque monitoring system
•
•
•
•
Permanent or temporary torque sensors
Complete monitoring systems, incl. hardware and software
Report generator with automatic analysis, alarm signaling
and reporting
Tele-service with expert support
The ACIDA monitoring system in comparison
3
2
550
Torque [Nm]
401
253
103
-46
62.84 63.90 64.95 66.00 67.06 68.11 69.16 70.22
1
1 Rotor: Strain gauges and telemetry (requires no drive modifications)
2 Air gap: No contact between rotor and stator
3 Stator: Signal reception and inductive power supply
Time [s]
Light blue: ACIDA monitoring systems measure torques and dynamics
with extreme accuracy.
Dark blue: Conventional systems measure, for example, the motor
current or hydraulic pressure with insufficient signal dynamics.
73
1
11 Integrated management system
At Voith, our top priority is to ensure the affordability, reliability, environmental compatibility and safety of our products and services. In order to
maintain these principles in the future just as we do today, Voith Turbo has
a firmly established integrated management system focused on quality,
the environment, and health and safety at work. For our customers, this
means that they are purchasing high-quality capital goods that are
manufactured and can be used in safe surroundings and with minimal
environmental impact.
74
2
1 Certificates for management systems according to ISO 9 001: 2 000
(Quality), ISO 14 001: 2 000 (Environment) and OHSAS 18 001: 1 999
(Occupational Health and Safety)
2 Flange for a high-performance universal joint shaft on a
3-D-coordinate measuring machine
11.1 Quality
•
•
•
We employ state-of-the-art 3-D-coordinate measuring
machines for quality assurance.
To ensure perfectly welded joints, we conduct X-ray
inspections in-house.
We offer our customers a variety of product and
application-specific certifications and classifications.
•
•
•
•
Production and assembly fixtures are inspected on
a regular basis.
Quality-relevant measuring and testing instruments are
subject to systematic monitoring.
In the case of the welding methods employed, process
controls according to ISO 3834-2 are used. Welding
technicians are qualified to EN287 and our welding
equipment is constantly monitored.
Employees performing non-destructive testing are qualified
to ASNT-C-1A and / or EN 473.
75
1
11.2 Environment
•
Voith universal joint shafts are fitted with sealed roller
bearings. These offer two major advantages over slipper
and gear type spindles:
1. Lubricant consumption is considerably lower because
of the seals.
2. Efficiency is enhanced, as rolling friction is significantly
less than sliding friction. This translates into reduced
CO2-emissions and helps to protect the environment.
Comparison of efficiency and power loss in the main drive of a rolling mill
71.1 kW
99.996 %
Efficiency
Power loss
41.1 kW
99.49 %
99.10 %
0.32 kW
Voith universal joint shaft
76
Gear spindle
Input power 8 000 kW,
deflection angle 2°
Slipper spindle
2
1 An employee coats the roller bearing of a universal joint shaft with
Voith WearCare 500 high-performance lubricant
2 Voith universal joint shafts receive their final finish in a modern paint
booth
11.3 Occupational health and safety
•
•
When painting a Voith universal joint shaft, Voith paint
technicians use a modern paint system that meets all of
the requirements for health and safety at work, and environmetal protection.
The paint is electrostatically applied to reduce overspray
and waste.
•
•
An exhaust system extracts any residual mist that is created
as part of the paint process.
An exhaust air treatment system with combined heat recovery reduces the impact on our employees, as well as the
environment.
77
G830 en, S&F-nlg / CM, 04.2012, 1 000. Dimensions and illustrations without obligation. Subject to modifications.
Voith Turbo GmbH & Co. KG
Universal Joint Shafts and Hirth Couplings
Alexanderstr. 2
89522 Heidenheim, Germany
Tel. +49 7321 37-8283
Fax +49 7321 37-7106
[email protected]
www.voithturbo.com/universal-joint-shafts