Doppelklicken um Titelbild einzufügen. Rexroth GTE Planetary Gearboxes. Project Planning Manual DOK-GEAR**-GTE********-PR02-EN-P

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1 Doppelklicken um Titelbild einzufügen Rexroth GTE Planetary Gearboxes Project Planning Manual

2 About this Documentation Rexroth GTE Title Type of Documentation Rexroth GTE Planetary Gearboxes Project Planning Manual Document Typecode Internal File Reference B304-02/EN MNR: R Purpose of Documentation This documentation describes the product attributes, applications and conditions for use includes technical data of the available gearboxes gives notes to product selection, handling and operation Record of Revisions Description Release Date Notes 02/2005 First edition Copyright 2005 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. BRC/EDM (mh/ar) Note This document has been printed on chlorine-free bleached paper.

3 Rexroth GTE Content I Content 1 Introduction to the Product GTE Planetary Gearboxes About this Documentation Important Instructions on Use Appropriate Use Fields of Use and Application Inappropriate Use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Improper Use General Information Protection Against Contact with Electrical Parts Protection Against Electric Shock by Protective Low Voltage (PELV) Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Dimensioning and Selection Dimensioning Selection Application Notes Operating Conditions Operating Mode S5 (intermitted operation) Operating Mode S Mechanical Features Combination possibilities of GTE planetary gearboxes with AC-motors Technical Data Technical Data for Intermittent and Continuous Operation Technical Data for Increased Lifetime

4 II Content Rexroth GTE 6.3 Permittable Shaft Loading Specifications GTE GTE GTE GTE GTE Type Codes Type Code GTE Type Code GTE Type Code GTE Type Code GTE Type Code GTE Handling, Transport and Storage Handling Identifying the Goods Name Plates Transport and Storage Assembly Skilled Personnel Mounting on the Motor Mounting Procedure Gearbox Mounting Startup, Operation and Maintenance Startup Preparation Execution Deactivation Dismantling Maintenance Measures Troubleshooting Excess Temperature of Gearbox Housing Gearbox-Motor Unit Generates Vibrations Specified Position Is Not Reached Ordering Designations Service & Support Helpdesk Service-Hotline...1

5 Rexroth GTE Content III 13.3 Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities Appendix List of Standards Index 15-1

6 IV Content Rexroth GTE

7 Rexroth GTE Introduction to the Product Introduction to the Product 1.1 GTE Planetary Gearboxes IndraDyn S mit GTE.tif Fig. 1-1: Mounting example: GTE planetary gearboxes mounted on IndraDyn S motors Fields of application In combination with the drive and control system of BOSCH REXROTH, GTE planetary gearboxes provide a low-cost automation system for various sectors of industry. They are well-suited for use with gear racks or toothed belts in handling systems with high speed and accelerations (e.g.: loader, robots). The low-backlash between the honed planetary gears permits the execution of exact positioning tasks. Furthermore, the gearboxes are suited for S1-operation-typically required for application in the printing sector.

8 1-2 Introduction to the Product Rexroth GTE Gradation 800 Gearbox output rated torque in Nm GTE Gear ratio GTE120 GTE080 GTE060 GTE040 GK000009v01_EN.EPS Fig. 1-2: Nominal torque gradation of the GTE planetary gearboxes for mounting on AC motors Mode of Functioning The GTE series of planetary gearboxes offers a coaxial input and output. The output shaft of the motor is connected to the sun gear with a torsionally-stiff compression coupling. The sun gear drives the planetary gears, which rotate within a ring gear internal gear. The planetary gears, of which there are three or four depending on the ratio, are fixed to the planet carrier, which drives the output shaft. By dividing the load between the planetary gears, a balanced force splitting occurs. This allows for a very compact gearbox with a high power density. High operational reliability Maintenance-free operation through lifetime lubrication Use under adverse environmental conditions is possible due to the completely-enclosed IP54 design. Safe and long-lasting seal guaranteed via sealed bearing. Hermetically-sealed housing Backlash-free torque transmission via the compression coupling High performance data Easy to mount to machine Low backlash combined with high accuracy provided by honed planetary gears High efficiency, low temperature and minimum power loss made possible by using the smallest possible seal diameters. Low running noise by optimized gear profiles. High emergency stop torque made possible by internal-transferred power. Highly dynamic because of low-inertia design Low weight through compact design The high radial-load capability and tilt resistance makes it possible to directly mount a pinion or pulley.

9 Rexroth GTE Introduction to the Product About this Documentation The design of the output shaft with a solid shaft shoulder makes axial tightening of output elements simple. The gearbox can be mounted in any position. Due to the defined bearing position and the pump effect the bearings have on the lubrication, sufficient lubrication supply is always ensured. The output elements can be mounted in two different ways: A press-fit shaft-to-hub connection by means of a plain output shaft, or connection by means of an output shaft with keyway This document contains safety regulations, technical data, and operating instructions for gearboxes. The individual chapters can be subdivided into the following focal points: Chapter Title Content 1 Introduction to the Product General Information 2 Important Instructions on Use 3 Safety Notes 4 Dimensioning and Selection 5 Application Notes 6 Technical Data 7 Specification 8 Type Codes 9 Handling, Transport and Storage 10 Assembly 11 Startup, Operation and Maintenance 12 Ordering Data 13 Appendix 14 Service and Support 15 Index Fig. 1-3: Document Structure Safety Product Description (for planners and machine constructors) In practice (for operating and maintenance personnel) General Information

10 1-4 Introduction to the Product Rexroth GTE Standards This documentation refers to German, European and international technical standards. Documents and sheets on standards underlie the protection by copyright and may not be passed on to third parties by REXROTH. If necessary, please contact your local authorized sales office or, in Germany, contact: BEUTH Verlag GmbH Burggrafenstrasse Berlin Phone +49/ , Fax +49/ Internet: postmaster@beuth.de Feedback Your experiences are an essential part of the process of improving both product and documentation. Please do not hesitate to inform us of any error you detect in this documentation or of any modifications you might desire. We would appreciate your feedback. Please send your remarks to: Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2, Lohr a. Main, Dept. BRC/EDM Fax /

11 Rexroth GTE Important Instructions on Use Important Instructions on Use 2.1 Appropriate Use Introduction Bosch Rexroth products are designed and manufactured using the latest state-of-the-art-technology. Before they are delivered, they are checked for an safety of operation. The products may only be used as intended. If they are inappropriate used, situations may arise resulting in injuries to property and persons. Note: For damage caused by products not being used as intended, Bosch Rexroth gives no warranty, assumes no liability, and will not pay for any damages. Any risks resulting from the products not being used as intended are the sole responsibility of the user. Before using the Bosch Rexroth products, the following condition precedent must be fulfilled so as to ensure that they are used as intended: Anyone handling one of the products in any manner must read and understand the appropriate safety regulations and the intended use. Regarding hardware components, the products concerned must be left in their original state, i.e. it is not permitted to modify it structurally. Software products may not be decompiled; their source codes may not be altered. Damaged or faulty products may not be installed or put into operation. It must be ensured that the products are installed according to the regulations mentioned in the documentation.

12 2-2 Important Instructions on Use Rexroth GTE Fields of Use and Application Typical application ranges of the GTE planetary gearboxes are: Handling and Mounting systems, Packaging and Food-processing machines, Printing and Paper-processing machines and Machine tools Controlling and monitoring of the motor/-gearbox combination may require connection of additional sensors and actuators. Note: The gearboxes may only be used with the accessories specified in the documentation. Components which are not expressly named may neither be mounted nor connected. The same applies to cables. The motors may be operated only in the expressly specified component configurations and combinations and with the software and firmware specified in the appropriate functional description. Any drive controller must be programmed before startup, in order to ensure that the motor executes the functions specific to the particular application. 2.2 Inappropriate Use The gearboxes may only be operated under the assembly, mounting and installation conditions, in the normal position, and under the environmental conditions (temperature, degree of protection, humidity, EMC, and the like) specified in this documentation. Any use of the planetary gearboxes outside of the fields of application mentioned above or under operating conditions and technical data other than those specified in this documentation is considered to be inappropriate use. Planetary gearboxes may not be used if... they are subjected to operating conditions which do not comply with the ambient conditions described above (e.g. operation under water, under extreme temperature fluctuations or extreme maximum temperatures is not permitted), the intended application is not explicitly released by Bosch Rexroth. Please be absolutely sure to also observe the statements made in the general safety notes.

13 Rexroth GTE Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. Do not attempt to install or start up this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment, contact your local Bosch Rexroth representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the equipment is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the equipment. WARNING Improper use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! 3.2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535. The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions. Warning symbol with signal word Degree of hazard seriousness according to ANSI Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or material damage may occur. CAUTION Fig. 3-1: Hazard classification (according to ANSI Z535)

14 3-2 Safety Instructions for Electric Drives and Controls Rexroth GTE 3.3 Hazards by Improper Use DANGER High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life or bodily harm by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to improper handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock or incorrect handling of pressurized systems! Risk of injury due to incorrect handling of batteries! CAUTION

15 Rexroth GTE Safety Instructions for Electric Drives and Controls General Information Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Only persons who are trained and qualified for the use and operation of the equipment may work on this equipment or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and equipment on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Use only safety features and applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. The following areas of use and application, for example, include safety features and applications: construction cranes, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, transport of hazardous goods, nuclear applications, applications in which electrical devices with vital functions can be electromagnetically disturbed, mining, food processing, control of protection equipment (also in a machine). The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Startup of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.

16 3-4 Safety Instructions for Electric Drives and Controls Rexroth GTE Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems". The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

17 Rexroth GTE Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. In order to operate electrical equipment, certain parts must unavoidably have dangerous voltages applied to them. DANGER High electrical voltage! Danger to life, severe bodily harm by electric shock! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on high voltage installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the ground wire is not permanently connected to the points of the components provided for this purpose. Before working with electrical parts with voltage higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. Make sure the equipment cannot be switched on again unintended. The following should be observed with electrical drive and filter components: Wait thirty (30) minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Electrical components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example, in a control cabinet.

18 3-6 Safety Instructions for Electric Drives and Controls Rexroth GTE To be observed with electrical drive and filter components: DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. 3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth products are protective low voltages designed in accordance with international standards on electrical safety. WARNING High electrical voltage due to wrong connections! Danger to life, bodily harm by electric shock! Only connect equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) to all terminals and clamps with voltages of 0 to 50 Volts. Only electrical circuits may be connected which are safely isolated against high voltage circuits. Safe isolation is achieved, for example, with an isolating transformer, an opto-electronic coupler or when battery-operated.

19 Rexroth GTE Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily injury and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

20 3-8 Safety Instructions for Electric Drives and Controls Rexroth GTE DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated. Pay attention to unintended machine motion or other malfunction in any mode of operation. Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum, especially if there is a possibility of loose parts flying off. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts. Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes - adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety!

21 Rexroth GTE Safety Instructions for Electric Drives and Controls 3-9 Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such equipment cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation. 3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated near current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers, hearing aids and metal implants are not permitted to enter the following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a heart pacemaker to enter such an area, then a doctor must be consulted prior to doing so. Heart pacemakers that are already implanted or will be implanted in the future, have a considerable variation in their electrical noise immunity. Therefore there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise, health hazards will occur.

22 3-10 Safety Instructions for Electric Drives and Controls Rexroth GTE 3.9 Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch housing surfaces near sources of heat! Danger of burns! After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Do not touch hot parts of the equipment, such as housings with integrated heat sinks and resistors. Danger of burns! 3.10 Protection During Handling and Mounting Under certain conditions, incorrect handling and mounting of parts and components may cause injuries. CAUTION Risk of injury by incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general installation and safety instructions with regard to handling and mounting. Use appropriate mounting and transport equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stand under suspended loads. Clean up liquids from the floor immediately to prevent slipping.

23 Rexroth GTE Safety Instructions for Electric Drives and Controls Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. CAUTION Risk of injury by incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). Never charge non-chargeable batteries (danger of leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Do not damage electrical components installed in the equipment. Note: Be aware of environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other waste. Observe the legal requirements in the country of installation Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems. Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents. In these cases, improper handling of external supply systems, supply lines or connections can cause injuries or material damage. CAUTION Danger of injury by incorrect handling of pressurized systems! Do not attempt to disassemble, to open or to cut a pressurized system (danger of explosion). Observe the operation instructions of the respective manufacturer. Before disassembling pressurized systems, release pressure and drain off the fluid or gas. Use suitable protective clothing (for example safety glasses, safety shoes and safety gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The media used in the operation of the pressurized system equipment may not be environmentally compatible. Media that are damaging the environment must be disposed separately from normal waste. Observe the legal requirements in the country of installation.

24 3-12 Safety Instructions for Electric Drives and Controls Rexroth GTE Notes:

25 Rexroth GTE Dimensioning and Selection Dimensioning and Selection 4.1 Dimensioning Applications for GTE planetary gearboxes are characterized by the following curves. Triangular speed curve with pause interval Operation with constant speed and pause interval Operation with trapezoidal speed curve and pause interval Continuous operation without pause interval (S1) The speed-time curves define the dimension criteria. Triangle operation with pause interval This operating mode is characteristic for all highly-dynamic feeds. These are often found in roll-feed mechanisms in the sheet-metal, paper, plastic and packaging industries. Speed v Time t GK000011v01_en Fig. 4-1: Speed-time curve for triangle operation Constant speed with pause interval The dimensioning of this operation is mainly made according to the necessary maximum torque M max and the average velocity V mittel resp. mean speed n mittel. This operation is characteristic for all highly-dynamic feeds. These are often found in winding machines, drive rolls and in portioning devices in the sheet-metal, paper, plastic and packaging industry. Speed v resp. rotation speed n Time t GK000012v01_EN Fig. 4-2: Speed-time diagram for operation with constant speed The dimensioning of this operation is mainly made according to the necessary maximum torque M max and the average velocity V mittel resp. mean speed n mittel.

26 4-2 Dimensioning and Selection Rexroth GTE Trapezoidal operation with pause interval This mode of operation is characteristic for the most highly-dynamic feeds. They can be found in loaders and handling systems in nearly all industry sectors. Speed v resp. rotation speed n Time t GK000013v01_EN Fig. 4-3: Speed-time-graph for trapezoidal operation The dimensioning of this operation is mainly made according to the necessary maximum torque M max and the average velocity V mittel resp. mean speed n mittel. Constant speed without pause interval (S1) This mode of operation is characteristic for drives in printing machines. Power loss curve over time Speed curve over time Power loss Pv Speed n T A T B T s Time t n PV TA TB Ts = Speed = Power loss = Starting time = Operation time = Duty cycle time GK000014v01_EN Fig. 4-4: Speed-time graph for constant speed The dimensioning is made according to the necessary continuous torque M dn and the velocity or the speed n.

27 Rexroth GTE Dimensioning and Selection Selection Drive-determined sizes The selection of the suitable motor/-gearbox combination, operating with a drive control device, has to be done via the following drive-determined sizes: Frictional torque Starting torque Processing torque Accelerating torque Effective speed Necessary speed ON time Dimensioning criteria The motor-gearbox combination must fulfill the following conditions: The necessary speed must be reached. The continuous torque rating of the motor-gearbox combination has to be higher than the effective load torque. The intermittent torque has to be higher than the sum of the frictional, starting and processing torque. The maximum torque has to be higher than the sum of frictional, weight and processing torque. The required acceleration time has to be within the limit of the relevant drive selection lists. The thermal use-limit of the motor-gearbox combination must be adhered. The cycles of the operation modes S4 and S5 should not exceed 1,000 cycles per hour. If higher cycle rates are necessary, the GTE gearbox must be derated accordingly (see Fig. 5-3). Note: It must be ensured that the maximum load torque is smaller than the maximum input torque of the gearbox. the maximum load speed does not require the motor to operate above the maximum permissible input speed of the gearbox.

28 4-4 Dimensioning and Selection Rexroth GTE

29 Rexroth GTE Application Notes Application Notes 5.1 Operating Conditions Maximum ambient temperature, maximum setup elevation The power conductors as stated in the selection data will be reached at the following conditions: Ambient temperature Setup elevation: 0...1,000 m above sea level The power data is reduced according to the diagram below at deviating conditions. If ambient temperatures are above 40 C and installation elevations above 1,000m occur simultaneously, the power data has to be multiplied by both factors. f T f H t A [ C] 1,000 3,000 5,000 h [m] 1: Utilization at ambient temperatures of above 40 C. 2: Utilization at installation elevations above 1,000 m over sea level. Fig. 5-1: Utilization at higher ambient temperature and higher installation elevations Degree of protection According to DIN EN : , the AC motor with mounted planetary gearbox GTE is protected by the housing against contact of parts under load or moving parts penetration of firm foreign bodies and water When GTE gearboxes are mounted to Bosch Rexroth AC servo motors, IP 54 is valid. for the housing of motor and gearbox for the output shaft of the gearbox for the power and encoder connection on the motor at professional mounting. The first reference number defines the degree of protection against contact and penetration of foreign bodies. The reference number 5 means Complete contact protection Protection against interior injurious dust deposits Surface protection The second reference number defines the degree of protection against water. The reference number 4 means Protection against splashed water from all directions The gearboxes are surface-protected by the Citrox-method. The Citroxmethod is an environmentally-sound, thermo-chemically diffusion-method, whereby wear behavior, corrosion-resistance and fatigue resistance of the gearbox housing are improved.

30 5-2 Application Notes Rexroth GTE Operating Mode S5 (intermitted operation) Planetary gearboxes of series GTE are suitable for S5 operating (intermitted operation with braking) according to EN The duty cycle should not surpass 60%. T ED = A + T T B S + T Br 100% 60% A procedure during intermittent duty, which consists of an acceleration and a braking, is defined as a cycle. The specified data of the gearboxes in the chapter Technical data are valid up to 1,000 cycles per hour. If more than 1,000 cycles per hour are necessry during operation of the gearbox, the technical data have to be reduced - see Fig n Power loss curve over time Speed curve over time P V T A T B T Br T s Time t n = Speed P V = Power loss T A = Starting time T B = Operation time T Br = Braking time T s = Duty cycle time GK000016v01_EN.EPS Fig. 5-2: S5 operating (intermittent duty with electronical braking)

31 Rexroth GTE Application Notes 5-3 Reduction at higher cycle rates If a cycle rate of more than 1,000 cycles per hour is needed, the gearbox` torque and power must be derated according to the following curve. Reduction factor k Duty cycles in 1/h GK000017v01_EN.EPS Fig. 5-3: Reduction factor at higher cycle rates Operating Mode S1 Planetary gearboxes GTE are suited for the operating mode S1 according to EN

32 5-4 Application Notes Rexroth GTE 5.2 Mechanical Features Construction, installation position Rexroth planetary gearboxes GTE are produced in B05 construction for flange mounting (acc. to EN : ). The constructions as shown in Fig. 5-4 can be used for installation of motor-gearbox combination. Gearbox Construction B05 Permissible installation positions according to EN : IN B5 IN V1 IN V3!!!!!! Important Installation Note!!! Vertical mounting position IM V3 When installing in position IM V3 (vertically, output shaft upwards) avoid the collection of liquid on the gearbox, as liquid can penetrate into the gearbox over time. Fig. 5-4: Permissible installation positions for motor-gearbox combinations Output Shaft The output shaft of the planetary gearboxes is available in the following variants: Smooth output shaft For a plain non-positive shaft-hub connection. This type of output assures a smoother operation and a backlash-free connection between shaft and hub. Note: We recommend to use output shafts with non-positive shafthub connections. or Output shaft with keyway according to DIN : For a keyed shaft-hub connection. A keyed shaft is suitable for non-demanding, constant-direction applications. This mode necessitates an additional axial connection. Therefore, the end of the gearbox output shaft is provided with a threaded centering hole (see dimension sheet). Shaft Load When checking the shaft load, the axial and radial shaft loads have to be calculated separately: Calculate the radial shaft load with regards to the point of application of force and the average speed from the diagrams of chapter 6.3 Permittable shaft load. An L10 life of 30,000 hours was used as a basis for the bearing life (bearing calculation according to DIN ISO 281: ). The axial shaft load is also described in the chapter 6.3 Permittable shaft load. Assembly of output elements The output shaft of the GTE-gearboxes is fitted with a solid shaft shoulder, which is well-suited for the support of axial forces, especially when using keyed connections.

33 Rexroth GTE Application Notes 5-5 The appropriate tightening torque (T A ), resp. preliminary-tension forces (F V ), for mounting the output unit have to be taken from the following table. Size (one-stage & two-stage) GTE040 GTE060 GTE080 GTE120 GTE160 Thread M3 M5 M6 M10 M16 T A [Nm] F V* [kn] Fig. 5-5: Tightening torque, resp. preload at mounting the drive units T A F V T A: F V: Fig. 5-6: Tightening torque Preload Output Shaft GG000018v01_NN.EPS

34 5-6 Application Notes Rexroth GTE 5.3 Combination possibilities of GTE planetary gearboxes with AC-motors The following table shows the combination possibilities of GTE planetary gearboxes with AC-motors. Planetary gearbox Motor type MKD MSM MSK GTE040 Not possible MSM020B Not possible GTE060 MKD025 MSM030B MSK030 GTE080 MKD041 MSM030C MSM040B GTE120 GTE160 Fig. 5-7: MKD041 MKD071 MKD071 MKD090 MKD112 MSM040B Not possible MSK030 MSK040 MSK040 MSK050 MSK060 MSK050 MSK060 MSK070 MSK071 Possible motor/gearbox combination with GTE planetary gearboxes Note: To mount the GTE planetary gearboxes on the AC-motors, the AC-motors must have a smooth drive shaft.

35 Rexroth GTE Technical Data Technical Data 6.1 Technical Data for Intermittent and Continuous Operation Ratio-dependent data Description Symbol Transmission GTE040 GTE060 GTE080 GTE120 GTE160 ratio i=3 18,000 13,000 7,000 6,500 6,500 n, max in n, max out one-stage i=4 18,000 13,000 7,000 6,500 6,500 i=5 18,000 13,000 7,000 6,500 6,500 i=8 18,000 13,000 7,000 6,500 6,500 min -1 i=12 18,000 13,000 7,000 6,500 6,500 two-stage i=20 18,000 13,000 7,000 6,500 6,500 i=40 18,000 13,000 7,000 6,500 6,500 i= one-stage i= i= M in, max i= Nm i= two-stage i= i= , i=3 6,000 4,333 2,333 2,167 2,167 one-stage i=4 4,500 3,250 1,750 1,625 1,625 i=5 3,600 2,600 1,400 1,300 1,300 i=8 2,250 1, min -1 i=12 1,500 1, two-stage i= i= i= one-stage i= i= M out, max i= Nm i= two-stage i= i= For more technical data - see next page Max. input speed 3) Max. input torque 1) Max. output speed Max. output torque 1) 1) at max. 1,000 cycles/h 3) permitted operating temperatures may not be exeeded!

36 6-2 Technical Data Rexroth GTE Description Symbol Transmission ratio GTE040 GTE060 GTE080 GTE120 GTE160 i=3 4,500 4,000 4,000 3,500 3,000 Nominal initial speed 3) one-stage min -1 n in, nenn two-stage Nominal input torque Nm Nominal output speed min -1 Nominal output torque Nm Mass moment of inertia 2) kg cm² M in, nenn n out, nenn M out, nenn J one-stage two-stage one-stage two-stage one-stage two-stage one-stage two-stage i=4 4,500 4,000 4,000 3,500 3,000 i=5 4,500 4,000 4,000 3,500 3,000 i=8 4,500 4,000 4,000 3,500 3,000 i=12 4,500 4,000 4,000 3,500 3,000 i=20 4,500 4,000 4,000 3,500 3,000 i=40 4,500 4,000 4,000 3,500 3,000 i= i= i= i= i= i= i= i=3 1,500 1,333 1,333 1,167 1,000 i=4 1,500 1,333 1,333 1,167 1,000 i=5 1,500 1,333 1,333 1,167 1,000 i=8 1,500 1,333 1,333 1,167 1,000 i=12 1,500 1,333 1,333 1,167 1,000 i=20 1,500 1,333 1,333 1,167 1,000 i=40 1,500 1,333 1,333 1,167 1,000 i= i= i= i= i= i= i= i= i= i= i= i= i= i= ) Mass moment of inertia of the gearbox referred to the input of the gearbox 3) Permitted operating temperatures may not be exceeded! Fig. 6-1: Ratio-dependent data

37 Rexroth GTE Technical Data 6-3 General Data Description Symbol Unit GTE040 GTE060 GTE080 GTE120 GTE160 Backlash 4) ϕ arcmin Torsional rigidity 5) Efficiency η % Lifetime L h H Lubrication Permittable ambient temperature D T Um C Permittable gearbox housing temperature 6) T G C Noise level 7) Lp db (A) International Protection Class Weight M kg one-stage <30 <20 <12 <8 <6 two-stage <35 <25 <17 <12 <10 Nm/ one-stage arcmin two-stage one-stage 96 two-stage 94 one-stage two-stage one-stage two-stage one-stage two-stage one-stage two-stage one-stage two-stage one-stage two-stage 30,000 Filled for life, closed system C -25 C C IP54 one-stage two-stage ) with regard to the gearbox output at 3% nominal output torque of the gearbox and locked gearbox input side 5) torsional rigidity of the gearbox with regard to the gearbox output side at locked gearbox input side 6) related on center of housing surface 7) at an input speed of 3,000 min -1 Fig. 6-2: General Data Note: The GTE planetary gearboxes are designed for the indicated specified permitted technical data. With regard to the operating safety it is only allowed to use the gearboxes in this case under view of all operating factors. Any sort of overload of the gearbox is classified as inappropriate use. Any changes on the gearbox voids all liability on the part of Bosch-Rexroth for any damages.

38 6-4 Technical Data Rexroth GTE 6.2 Technical Data for Increased Lifetime The technical data is based on a calculated gearbox-lifetime of L h = 30,000 h If a gearbox-lifetime of more than 20,000h is required, the technical data, regarding torque and speed have to be reduced by the following diagram. Lifetime dependent on speed and torque 2 1,75 1,5 Factor 1,25 1 n2 / nnenn M2 / Mnenn 0,75 0, calculated lifetime [h] GK000010v01_EN.EPS Fig. 6-3: Reduction of the technical data for increased lifetime Note: The permitted technical operating data may not be exceeded!

39 F R A Rexroth GTE Technical Data Permittable Shaft Loading F A L GG000019v01_NN.EPS F A : permittable axial force F R: permittable radial force A: distance between shaft shoulder on the output shaft and point of application of the radial force n 2m : average output speed of the cycle Fig. 6-4: permittable shaft load of the GTE n 2m n = 2 * t a a + n2b * tb n2n t a + t b t n * t n Basis of design The GTE gearboxes are designed for a L 10h bearing life of 30,000 hours. For radial forces F Rerf, which lie over the value of the diagram, decreases the nominal bearing lifetime as follows: L 30,000 F R 10h = FRerf 3 F R : permittable radial force F Rerf : necessary radial force

40 6-6 Technical Data Rexroth GTE Permittable radial force F R : GTE GTE40 permitted radial forces relating to L h =30, Radial forces [N] n2=100 n2=200 n2=300 n2=500 n2=1000 n2=1500 n2= Distance A [mm] valid for F <160N A GK000018v01_EN.EPS Fig. 6-5: Permitted radial force F R, GTE 040 Permitted axial force F A < 160N F A : permittable axial force F R : permittable radial force Do occur higher axial forces, the bearing lifetime for this use has to be calculated individually.

41 Rexroth GTE Technical Data 6-7 Permitted radial force F R : GTE GTE 60 permitted radial forces relating to L h =30.000h Radial forces [N] n2=100 n2=200 n2=300 n2=500 n2=1000 n2=1500 n2= Distance A [mm] valid for F < 450N A GK000019v01_EN.EPS Fig. 6-6: Permitted radial force F R, GTE 060 Permitted axial force F A < 450N F A : permittable axial force F R : permittable radial force Do occur higher axial forces, the bearing lifetime for this use has to be calculated individually.

42 6-8 Technical Data Rexroth GTE Permitted radial force F R : GTE GTE 80 permitted radial forces relating to L h =30.000h 1200 Radial forces[n] n2=100 n2=200 n2=300 n2=500 n2=1000 n2=1500 n2= Distance A [mm] valid for F < 900N A GK000020v01_EN.EPS Fig. 6-7: Permitted radial force F R, GTE 080. Permitted axial force F A < 900N F A : permittable axial force F R : permittable radial force Do occur higher axial forces, the bearing lifetime for this use has to be calculated individually.

43 Rexroth GTE Technical Data 6-9 Permitted radial force F R : GTE GTE 120 permitted radial forces relating to L h =30.000h 2500 Radial forces[n] n2=100 n2=200 n2=300 n2=500 n2=1000 n2=1500 n2= Distance A [mm] valid for F < 2100N A GK000021v01_EN.EPS Abb. 6-8: Permitted radial force F R, GTE 120 Permitted axial force F A < 2,100N F A : permittable axial force F R : permittable radial force Do occur higher axial forces, the bearing lifetime for this use has to be calculated individually.

44 6-10 Technical Data Rexroth GTE Permitted radial force F R : GTE GTE 160 permitted radial forces relating to L h =30.000h Radial forcesn] n2=100 n2=200 n2=300 n2=500 n2=1000 n2=1500 n2= Distance A [mm] valid for F < 6000N A GK000022v01_EN.EPS Abb. 6-9: Permitted radial force F R, GTE 160 Permitted axial force F A < 6,000N F A : permittable axial force F R : permittable radial force Do occur higher axial forces, the bearing lifetime for this use has to be calculated individually.

45 Rexroth GTE Specifications Specifications 7.1 GTE040 GG000021v01 EN.tif Fig. 7-1: Dimensional details of the one and two-stage GTE040 gearboxes Flanged motor type One-stage Two-stage K1) L B L B [mm] [mm] [mm] [mm] [mm] MSM020B 93,5 28,5 106,5 28,5 40 1) biggest flange size (motor/gearbox) Fig. 7-2: GTE040 dimensions, one and two-stage

46 7-2 Specifications Rexroth GTE 7.2 GTE060 GG000020v01 EN.tif Fig. 7-3: Dimensional details of the one and two-stage GTE060 gearboxes Flanged motor type One-stage Two-stage K1) L B L B [mm] [mm] [mm] [mm] [mm] MSK ,5 118,5 24,5 60 MSM030B , ,2 60 MKD ,5 118,5 24,5 60 1) biggest flange size (motor/gearbox) Fig. 7-4: GTE060 dimensions, one and two-stage