Reliable Planetary Gearboxes for Stationary Equipment

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1 Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service Reliable Planetary Gearboxes for Stationary Equipment The Drive & Control Company

2 2 Rexroth Planetary Gearboxes Overview Rexroth A Good Partner for Optimum Gearbox Components "Planetary gearboxes are ideal drive components for industrial applications. No matter whether I need a two-, three- or four-stage planetary gearbox or a combined unit featuring a primary spur or bevel gear stage the experts from Rexroth are always at my disposal as experienced and competent partners for high-quality gearbox components with attractive price-performance ratios." Professionals know: Rexroth offers a uniquely wide range of mechanical drive components. Whether you are in the market for a standard gearbox for a continuous casting plant or a special gearbox design for an offshore platform we have the right solution for almost any industrial drive system.

3 3 Rexroth Planetary Gearboxes Fields of Application It's the Application that Matters Due to our long years of experience, our wide spectrum of products and our vast applications know-how, we know what specific requirements planetary gearboxes for industrial applications must meet. We know what is really necessary for the economic operation of your equipment, be it an offshore platform, an apron feeder, a sugar mill, a ropeway system, a shredder, a tunnel boring machine, a seed press, a continuous casting plant, a high-pressure grinding roll, a flood barrage, an amusement park ride, a forging manipulator, or any other type of equipment.

4 Rexroth Planetary Gearboxes Fields of Application 4 Photo: Doppelmayr

5 A versatile range of products Rexroth's REDULUS gearbox range offers a wide choice of model versions. REDULUS gearboxes come with two, three or four planetary stages. If desired, we supply gearboxes with primary spur or bevel gear stages. The planetary gearboxes are suitable for mounting in horizontal or vertical position. Foot- and flange-mounted configurations as well as shaft-mounted versions with shrink disc and torque arm are available. At the output end, the gearboxes can be equipped with a hollow shaft for a shrink disc or a solid keyed shaft or an involute spline shaft. The REDULUS GMH planetary gearboxes can be supplied with a wide variety of hydraulic motors. The REDULUS GME type can be used in combination with an electric motor. Our technology guarantees low-noise operation, high power density and compact design. Rexroth drive components ensure long gearbox service life and low maintenance requirements. Components and systems Rexroth offers a unique variety of hydraulic and electronic components and has solid system and industry competence that is unrivaled worldwide. The company not only provides intelligent engineering solutions, but also intelligent drive and control concepts. In such concepts, gearbox technology is a major factor. For many years, we have developed and produced mechanical drive components for a wide spectrum of applications. We offer our customers optimally designed industrial drives, i.e. perfect combinations of planetary gearboxes and hydraulic motors. This makes us unique at an international level. Competence in marketing and design The importance of industry-specific system solutions is steadily growing. Rexroth meets this trend with internationally operating, market-oriented application centers for example for the wood and paper industry, for steel-making plants and rolling mills, and for mining equipment. Each of these centers is manned with product experts, who are not only specialized in drive technology, but are also familiar with the specifics of your application. Rexroth industrial gearboxes are designed for safety and reliability. Our experienced engineers are assisted in their design and development work by modern computer software for gearing design and component optimization.

6 6 Rexroth Planetary Gearboxes Processes Top Performance from Start to End Rexroth has full control over the entire gearbox manufacturing operations. Our process chain extends from machining to heat treatment and assembly, including testing, painting and shipment. For us, perfect quality management consists not only in systematically planning and controlling quality characteristics, but also in striving for continuous improvement in every step of the value added chain. Purchasing The metals and materials we use must meet the same quality standards that we have set for ourselves. For torque-transmitting parts we use highly annealed, die-forged steel from approved suppliers. Our forged spindles, planet carriers and ring gears have excellent strength which enables compact gearbox designs with small space requirements. Heat treatment Modern heat-treatment methods have a significant impact on the quality of gearings and components. The external teeth of sun wheels and planetary gears are case-hardened and the internal teeth of ring gears are nitrided. Our vast experience in hardening technology is a decisive quality factor, which makes sure that our gearboxes meet maximum standards in terms of strength, load-carrying capacity, compactness and service life. Machining The know-how we have accumulated over several decades in the various turning, milling and grinding operations involved in the manufacture of gearbox components and gearings is continually being further developed and forms the basis of the highest possible manufacturing quality. Rexroth invests systematically in advanced production machinery to ensure maximum quality and economic efficiency.

7 Assembly of planetary gearboxes Our industrial customers expect not only compact and economic gearbox and drive solutions, but wish to receive application specific variants in small and medium lots. Rexroth meets these demands with an intelligent modular system and a flexible assembly concept. Test benches Prior to shipment, all planetary gear units are tested to the most stringent quality standards on our test benches. Test runs are performed under no-load or partial-load conditions. In addition to the actual functional test, the gearboxes are subjected to a leakage test. Modern test programs are used to record temperature conditions and noise levels. Environment and quality management Our quality management system to DIN EN ISO 9001:2000 is the base and guarantor of a consistently high quality level. Another area of major concern to Rexroth is environmental protection. At our Witten production plant, for example, we have implemented also an environment management system to DIN EN ISO

8 8 Rexroth Planetary Gearboxes REDULUS GMH / GME Planetary Gearboxes Pulling the Strand: REDULUS GMH / GME Gearboxes All is flowing. The strand with its barely solidified skin exits from the mold. Thick slabs are produced by continuous casting in volumes of millions of tons per year. Planetary gearboxes drive the guide rolls that serve to transfer the strand. Here robustness and reliability are an absolute must. No problem for REDULUS GME gearboxes. Photo: SMS Demag

9 9 The REDULUS GMH / GME coaxial type two-, three- or four-stage planetary gearboxes are reliable drive components that have proven their worth in industry under widely varied conditions. No matter if you require an electro-mechanical drive or a hydraulic motor drive, we offer a wide range of gearboxes of different sizes for various applications requiring output torques of between 7 and 3,300 knm. The compact drives are characterized by high performance and low weight. Case-hardened and ground planetary gears as well as highly annealed and nitrided ring gears ensure high gearing quality and low-noise operation. Photo: SMS Demag Technical characteristics REDULUS GMH / GME planetary gearboxes for output torques of between 7 and 3,300 knm Gear ratios from 17 to 2,334 Compact, space-saving two-, three- or four-stage planetary design Can be mounted in horizontal and vertical position Several configurations are available for the input and output ends REDULUS GMH with Rexroth fixed or variable motors of space-saving, plug-in design or standard flange-mounted design REDULUS GME for direct attachment of electric motor The torque arm / shrink disc type is especially easy to mount Optional brake Noise-optimized

10 10 Rexroth Planetary Gearboxes REDULUS GMH / GME Planetary Gearboxes A Versatile Multi-talent: REDULUS GMH / GME Special Gearbox Rush hour at the ski lift. Skiers hate to wait; they want to get back to the top fast, comfortably and safely. The ski lift operator knows that and expects his lift to give high performance and availability throughout the season. This puts great demands on the ski lift gearbox: a REDULUS planetary-bevel gearbox from Rexroth. Photo: Doppelmayr

11 11 Different industries, particular requirements. Rexroth's customers expect specific solutions. Special variants of the REDULUS GMH / GME gearboxes are used for a wide variety of applications. They have proven their worth on offshore platforms, ropeway systems, apron feeders and in other fields of application. Unlike the coaxial standard versions, this type of drive consists of a combination of planetary gear stages including spur or bevel gear stages. The externally toothed spur gears are case-hardened and ground. The internally toothed ring gears are highly annealed and nitrided. The bevel gears are case-hardened and HPG-geared or ground. In combination with optimized housing parts and selected shaft bearings, the high-quality gearing ensures low-noise operation. Photo: Doppelmayr

12 12 Rexroth Planetary Gearboxes Consulting and Service We are at your Disposal Always and Everywhere Once your equipment featuring an industrial REDULUS gearbox has been put into operation, you expect it to give you maximum availability. Nobody can afford costly downtimes. Our service people are available to you around the clock in more than 80 countries to provide competent advice on all drive and control problems. Use our unique consulting competence and our comprehensive support services. From consultancy to training, from product selection to start-up, from quality optimization to documentation. No matter what industrial gearbox is concerned our qualified experts and dependable service people will be pleased to help you. To find a Rexroth expert near you, go to:

13 13 Gearbox inspection and early damage detection Preventive maintenance can help you increase your equipment availability and improve your operating economics. Our qualified service engineers have vast experience in early damage detection. They have proven test programs at their disposal and use the most advanced equipment for all measuring and test operations. Repair Our expert knowledge of gearbox design and manufacture guarantees you perfect, cost-optimized repair. In our workshop, components are overhauled or re-manufactured and toothings are re-ground to the original drawings. Before shipping the repaired gearboxes to our customers, we test them on our test benches to the most stringent quality standards and document the results in a test report. Spare parts This Rexroth service is characterized by speed, competence and worldwide efficient logistics. You receive from us original manufacturers' spare parts even after series production has been discontinued as well as spare part kits and upgrade kits for existing equipment. Documentation and support We can provide all required facts and figures in the form of comprehensive product documentation. Your contact at Rexroth will be pleased to furnish detailed information. Alternatively, you may visit our website, from which you can download any technical information you may require about our products and services. Should you require still further details, just contact your Rexroth partner. He knows our experts in engineering, consulting and service around the world.

14 Bosch Rexroth AG Hydraulics Mannesmannstraße Witten, Germany Tel Fax Printed in Germany RE 76002/04.07