More Detail about Helical & Bevel Helical Reduction Gear ... · PDF fileGraphs as per DIN 3962...

More Detail about Helical & Bevel Helical Reduction Gear Boxes.

For Inspection & Checking of these Housings we have Brown & Sharpe (USA) CNC CMM with full automatic rotating Renishaw Probe Head with Inspection Accuracy of 3 Microns along with 2012 PC DMIS Software which provided Instant Inspection Reports.

We also have Digital Profile Projector for measuring small dimensions which are difficult to measure with conventional measuring instruments.

PINION SHAFTS, GEARS & BEARINGS

Pinions Shafts & Gears are made from Forged High Alloy Case Hardening Steel. For

Cutting Forged Alloy Steel Round Bars we have Bandsaw Machines, For accurate

Centering & Facing – We have WMW Germany Facing & Centering Machines, For Final

machining we have Latest Model CNC Lathes, VMC machines, Cylindrical Grinding,

Surface Grinding, Vertical Milling Machines, M & TR Machines.

Gears are generated with highest accuracy on our Imported German Hobbing

Machines, Selection of Module, Tooth profile and Helix Angle is made in conformity to

speeds, ratios and load conditions to give maximum tooth contact and overlap, thus

ensuring most favorable meshing and silent running.

For Gear Cutting - We have Gear Hobbing Machines, Gear Shapers, Worm Milling, Rack

Milling, Broaching Machines.

For Gear Finishing & Grinding - We have Gear Tooth Deburring, Gear Shaving, Internal

Grinding, Gear Grinding, Worm Grinding Machines.

For Gear Inspection - We have HOFLER (GERMANY)- EFRS 630 Lead & Profile Tester of DIN 1 Accuracy with Automatic Measurement System of Precision Grounded Gears & Pinions with the help of latest Software which would give Instant Test Reports & Test Graphs as per DIN 3962 Standards of various important parameters - Form Error, Total Form Error, Angular Error, Crowning Error, Tip / Root Relief, Top / Bottom End Relief. To Check & Measure Pitch Error we have HOFLER (GERMANY)- ZW400 Double Flank Gear Roll Tester of DIN 4 Accuracy level.

We use High Quality Precision Roller Ball Bearings in our these Gear Boxes of reputed

Make – SKF/FAG/NBC etc. Taper Roller Bearings are also used as per requirement of Customers in special case for extra rigidity and prolong usage.

The Shaft Extensions are fitted with high quality oil seals to prevent outflow of Oil and entry of dust. In case of highly polluted and dusty atmosphere, labyrinth sealins can also be provided.

Gear & Pinion Assembly - For assembly we have highly trained staff who assemble

these Gear & Pinions with highest accuracy, We use high quality heat treated parallel

keys and after assembly of gears & pinions, we measure the TIR/Run Out on bench

centres with Dial Indicators to ensure accurate fitment.

LUBRICATION

The Gears & Bearings are lubricated by splashing of Oil, Shaft or Motor driven Pumps

can also be provided for forced lubrication at high peripheral speeds or where low input

speeds make Oil Splash Inadequate.

COOLING

Depending upon the application and rating requirements, Our these Gear Units are

cooled by –

Normal Cooling by convection from the external surfaces of the Gear case.

Mechanical Fan fitted to high speed shaft which is effective for either direction of

rotation

Cooling water coil fitted in the bottom half of Gear case, dipped in the lubrication

Oil sump.

Fan and Cooling Coil

Separate Oil Cooler used in conjunction with forced lubrication system.

BASE PLATES & GEAR COUPLINGS

Base Plates & Gear Couplings can be supplied complete fitted with Gear Units along

with foot mounted or flange mounted Electric Motors directly mounted on input shaft

line with the use of adaptor housings.

Motor and Gear Unit Shafts are connected by flexible Gear Couplings. Couplings Guards

can also be provided. Such requirements are supplied on specific request. Please

specify the scope of this type of job along with Inquiry.

HOLD BACK MECHANISMS

Gearboxes for applications where reverse operation of the machine is not permissible

are fitted with back stop device. Enquiries or order should state the required direction

of rotation and holding torque.

Gear Box Final Inspection & Testing - After Splash Lubrication and Lapping operation

of the Gear & Pinion, Each Gear Box goes through Rigorous Inspection and Testing

process before dispatch involving various testing stages in accordance to latest

IS/DIN/AGMA Standards :-

Gear Box Oil Temp. Rise Test (Through LASER Temperature Tester)

Leakage Test (Through Ultrasonic Leakage Tester & Visual Inspection)

Noise Level Test (Through Sound Level Meter at a distance of 10 Mtrs.)

Output RPM/Reduction Ratio Test (Through Photo + Contact type Tachometer)

Gear Box Finishing & Painting - In all our Gear Boxes we provides breather vents, easily accessible drain plugs and a suitable Oil level indicator. After successful Testing, Gear Box Casing is painted with suitable Anti Rust Red Oxide Paint and suitable Anti Rust Putty is applied all over the surface of the Gear Box to fill up any uneven rough surfaces and after that complete Gear Box is painted over the Spray Paint booth with customer selected dry spray paint color or by our standard hammer tone paint.

Gear Box Labelling, Packing & Dispatch :- Our Gear Box Name Plate contains all the required information :- Serial Number, Model, Input KW, Class of Duty, Input Speed, Output Speed, Reduction Ratio, Manufacturing Month & Year, Lubrication Type & Recommended Oil details. Packing is done as per Customer Requirement in Wooden Pallets, Plastic Pallets, Full 4 Side Wooden Box etc. with Pull hooks for easy lifting, loading & Unloading.

All the wear & tear parts assembled in our Gear Box have our S.No. Identification mark on them so that you can order these parts individually for post guarantee maintenance within your premises even after 10 years of purchase. We guarantee trouble free performance of our Gear Box for a period of 18 months from the date of dispatch or 12 months from the date of commissioning, whichever is earlier. On Customer’s complaint we undertake to repair or replace any defective part/parts at our option for defective material or bad workmanship provided the product supplied by us has been used strictly within the limits of our recommended working conditions. Our Lead time for dispatch is also very short as per the general industry standards.

We have very wide range in our ZURR HELICAN Series :-

a) HELICAL SINGLE REDUCTION GEAR BOX [HSRA]

In this series our Size range of Gear Units is from 80 to 560mm.

Reduction ratio from 1.25:1 to 6.30

Standard Reduction ratios - 1.25, 1.40, 1.60, 1.80, 2.00, 2.24, 2.50, 2.80, 3.15, 3.55, 4.00, 4.50, 5.00, 5.60, 6.30.

Efficiency – Upto 99.0 %

Average Weight of Gear Box – 18 to 2550 Kgs.

Centre Height as per DIN 747 Standard

Shaft Tolerances as per DIN 748 Standard

Keys according to DIN 6885, Part – 1, Shape - A Standard.

Shaft End Centres according to DIN 322 Standards.

Nominal Power Rating (Pn) from 6 to 5000 KW.

b) HELICAL DOUBLE REDUCTION GEAR BOX [HDRA]


Reduction ratio from 6.30 to 22.40

Standard Reduction ratios - 6.30, 7.10, 8.00, 9.00, 10.00, 11.20, 12.50, 14.00, 16.00, 18.00, 20.00, 22.40.




c) HOLLOW SHAFT MOUNTED HELICAL DOUBLE REDUCTION GEAR BOX [HDRH]







These Gear Boxes are supplied in two types as per customer requirement –

1) Hollow Shaft with Key. 2) Hollow Shaft with Shrink Disc.

d) HOLLOW SHAFT – SHAFT MOUNTED HELICAL DOUBLE REDUCTION GEAR BOX [HDRS]









e) HELICAL TRIPLE REDUCTION GEAR BOX [HTRA]



Standard Reduction ratios - 22.40, 25.00, 28.00, 31.50, 35.50, 40.00, 45.00, 50.00, 56.00, 63.00, 71.00, 80.00, 90.00, 100.00, 112.00



Nominal Power Rating (Pn) from 3.80 to 4200 KW.

f) HOLLOW SHAFT FOOT MOUNTED HELICAL TRIPLE REDUCTION GEAR BOX [HTRH]









g) HOLLOW SHAFT – SHAFT MOUNTED HELICAL TRIPLE REDUCTION GEAR BOX [HTRS]









h) HELICAL QUADRUPLE REDUCTION GEAR BOX [HQRA]



Standard Reduction ratios - 112.00, 125.00, 140.00, 160.00, 180.00, 200.00,224.00, 250.00, 280.00, 315.00, 355.00, 400.00, 450.00, 500.00, 560.00, 630.00




i) HOLLOW SHAFT FOOT MOUNTED HELICAL QUADRUPLE REDUCTION GEAR BOX [HQRH]









j) HOLLOW SHAFT – SHAFT MOUNTED HELICAL QUADRUPLE REDUCTION GEAR BOX [HQRS]









k) BEVEL HELICAL DOUBLE REDUCTION GEAR BOX [BDRA]



Standard Reduction ratios - 5.00, 5.60, 6.30, 7.10, 8.00, 9.00, 10.00, 11.20, 12.50, 14.00, 16.00, 18.00




l) HOLLOW SHAFT FOOT MOUNTED BEVEL HELICAL DOUBLE REDUCTION GEAR BOX [BDRH]









m) HOLLOW SHAFT – SHAFT MOUNTED BEVEL HELICAL DOUBLE REDUCTION GEAR

BOX [BDRS]









n) BEVEL HELICAL TRIPLE REDUCTION GEAR BOX [BTRA]



Standard Reduction ratios - 16.00, 18.00, 20.00, 22.40, 25.00, 28.00, 31.50, 35.50, 40.00, 45.00, 50.00, 56.00, 63.00, 71.00, 80.00, 90.00, 100.00




o) HOLLOW SHAFT FOOT MOUNTED BEVEL HELICAL TRIPLE REDUCTION GEAR BOX

[BTRH]

In this series our Size range of Gear Units is from 112 TO 630mm.





Nominal Power Rating (Pn) from 3.50 to 3400 KW



p) HOLLOW SHAFT – SHAFT MOUNTED BEVEL HELICAL TRIPLE REDUCTION GEAR BOX [BTRS]









q) BEVEL HELICAL QUADRUPLE REDUCTION GEAR BOX [BQRA]







r) HOLLOW SHAFT FOOT MOUNTED BEVEL HELICAL QUADRUPLE REDUCTION GEAR BOX [BQRH]









s) HOLLOW SHAFT – SHAFT MOUNTED BEVEL HELICAL QUADRUPLE REDUCTION GEAR BOX [BQRS]









More Detail about Helical & Bevel Helical Reduction Gear ... · PDF fileGraphs as per DIN 3962...

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