Servo planetary gearbox
Flexible, durable and precise
SEW-Eurodrive presents a new modular system for precision planetary servo gear units. Its drives are variably selected to meet demanding customer requirements in terms of installation space, capacity utilization and configurability. Integrated project planning, assembly and testing options as well as the latest machining processes and innovative components ensure quality and performance.
SEW-Eurodrive presents the modular system for compact precision planetary servo gear units of the Px.G product family. In terms of dynamics and precision, it is positioned between the existing series of PS.F planetary servo gear units and ZN precision servo gearmotors and is characterized by short delivery times. The P5.G performance level is the dynamic all-rounder, P6.G focuses on efficiency and P7.G is characterized by increased overload capacity. The series consists of six sizes each with gear ratios from 3 to 1,000, covering a torque range from 20 to 6,500 Nm and available with backlash up to less than 1'. The special feature is the flexible interchangeability of the gearbox components. The universal interfaces in the gearbox make it possible to select individual components for specific applications. For example, in addition to all standard input and output geometries, individual customer connections are also available.
SEW has invested heavily in infrastructure and manufacturing processes to ensure consistently high product quality of the planetary servo gear units. Thanks to the further development of the latest machining processes, tribologically optimized surfaces can be produced on gear parts and in the rolling contacts. The improvement of the sliding contacts ensures high wear protection with high efficiency. Washing processes with ultra-fine filters prepare the components for confirmation of the quality specifications using nanometer-precise 3D measurement technology. Optimum conditions such as air-conditioned gearbox assembly with cleanroom-compatible ventilation technology enable the reliable assembly of gearboxes with a backlash of less than 1' and a long product service life.
Prior to physical quality assurance in production and assembly, virtual quality assurance was already implemented during the development phase. Multi-body simulations were used to map the dynamic effects of production-related deviations from the nominal dimensions and determine the necessary tolerances. The finite element method was used to optimize the calculation accuracy, assembly methodology and stiffness prediction of rolling bearings in order to enable application-specific output bearing adjustment. Calculation models for the physical description of the relationships between heat generation and heat transfer form the basis for efficiency and temperature predictions.
After project-dependent assembly, a gearbox characterization is carried out to ensure that the drive meets the customer's requirements exactly. Extended gearbox characterization is possible on request. For this purpose, the gearbox performance characteristics are determined on different test benches and linked to a digital twin. The results - for example synchronization, backlash and efficiency, torsional and tilting rigidity as well as running noise - are thus available at any time.
CAD models for simple project planning
SEW has implemented the modular concept in a modular and fully parametric gearbox model. The designer does not so much design the gearbox himself, he controls the development process. The modular system was automatically calculated and evaluated during the design phase. This approach enables the automated creation of 3D CAD models, drawings, parts lists and calculation models. This also makes project planning even more individual for the customer. The starting point for gearbox selection can be a given motion task or existing drive technology such as a servomotor. Various methods are available for determining the load data. In the simplest case, the drive is selected using catalog values or gearbox maps. In addition, the drives can be configured with software support on the basis of a travel diagram. To precisely determine the application loads and their effect on the drivetrain, the application can be mapped using an elastic multi-body simulation. Depending on the user's requirements, the direction of view and the depth of the selection process can be varied.
Up to twice the service life
Components that have been specially developed with renowned partners ensure the longevity of the gear units. A new type of lubricant, SEW GearOil, is used. This is characterized by high-quality base oils and the latest additive technologies. The Premium Sine Seal (PSS) sealing system has also been newly developed. The sinusoidal sealing lip prevents shaft run-in. Depending on the application, this combination of lubricant and sealing system can achieve up to twice the service life of conventional solutions. While drives with standard radial shaft seals can exhibit significant shaft run-in and large running track widths on the sealing ring after more than 20,000 operating hours, the PSS sealing system effectively counteracts these mechanisms. The new shaft seal can therefore be fitted in the original position during repair. This avoids the need to replace expensive drive shafts or rotors.
In addition, tribologically effective coatings just a few micrometres thick can be applied as required as standard, for example to gear parts. This means that the wear resistance of torque-carrying components can be increased many times over. SEW was able to confirm these properties in its own test field in continuous and short-term operation over many millions of load cycles.
Typical applications for the Px.G planetary servo gear units include packaging machines in the food and beverage industry, intralogistics systems and applications in robotics and handling. At the start of the market launch, the precision planetary servo gear units will be available exclusively in Germany and Europe with the usual SEW delivery times. At SPS IPC Drives 2018, the Bruchsal-based company will be demonstrating the wide range of possible combinations within the Px.G product family. A portal application with a complete SEW drive train will illustrate the possible applications of the new gear units. The company will also be presenting the options for connecting to the digital twin.
Philipp Abele, M. Sc., Development Engineer in the "Precision Gear Unit Design" development group, Dipl.-Ing. Markus Lutz, Development Engineer in the "Technical Acoustics" technology group, Dr.-Ing. Markus Wöppermann, Head of the "Precision Gear Units" development group at SEW-Eurodrive / am
SPS IPC Drives, Hall 3 A, Stand 411
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