TP-The Compact Precision

Transcription

1 S Version Self-Contained Gear Reducer TP-The Compact Precision M Version Motor-Mounted Gear Reducer K Version Angle Gear Reducer TP Low-Backlash Planetary Gear Reducer

2 Introduction 2 Motor-Mounted (M) Version 11 7 Technical Data Dimensions Mass Moments of Inertia and Quick Selection Self-Contained (S) Version 7 Technical Data Dimensions Mass Moments of Inertia and Quick Selection Angle (K ) Version 11 Technical Data Dimensions Mass Moments of Inertia and Quick Selection Dimensioning Contents Mounting Versions 15 Gear Reducer Selection / Cycle Operation S5 16 Gear Reducer Selection / Continuous Operation S1 18 Symbols 19 Bearing Calculation 20 Operating Modes 21 Ordering Code 22 Installation and Application Examples 24

3 page 2 Introduction Compact precision alpha s TP Low-backlash Planetary gear reducers are applied in increasing numbers in robots, automation applications, machine tools, packaging machines and printing presses for highly dynamic positioning operations as well as for continuous operations as a state-of-the-art component of servo systems. The principles of design of the TP gear reducers renders them particularly applicable for drive systems with high standards for precision and reliability: Excellent quality a long service life and extremely constant backlash achieved by optimized, ground gearing and high-duty material for highly dynamic cycle operations (S5) and high failsafety in continuous operations (S1) alpha gear reducers should be your first choice optimized quality assurance: a result of controlling 100% of the manufactured products Unsurpassed concepts high efficiency and low mass moments of inertia of the planetary gear reducers enable highly dynamic drives with minimized energy loss as a consequence alpha gear reducers contribute ticeably to saving our resources and to the protection of our environment alpha offers forward-looking drive concepts to our customers Invative techniques ingeniously simple, patented system of motor mounting with integrated thermal length compensation creative solutions in design and in the production process ensure technical superiority forward-looking manufacturing techlogies guarantee precision and premium quality standard Modular planetary gear reducer program standardized modules are the basis of all alpha reducer series flexible, modular adapter parts enable simple, safe and fast mounting on practically any motor since alpha has standardized the geometry of the output parts, we guarantee the compatibility of our entire gear reducer range Worldwide partnerships sales agencies and service worldwide guarantee competent support wherever you are the market requests minimized maintenance: alpha s gear reducers are maintenance-free and lubricated for life - a perfect service our customers can feel perfectly safe thanks to our excellent reliability, even if extreme demands are to be met Product characteristics Extremely silent thanks to its unique reducer kinematics High torsional rigidity thanks to the flange Extremely compact as a result of integrated design High dynamics thanks to a compact design and, consequently, low moments of inertia Unsurpassed positioning accuracy thanks to low backlash and high torsional rigidity Product details Ingeniously simple, patented motor mounting with integrated thermal length compensation O-Ring groove Adapter plate Motor Input side sealed Bushing for nstandard motor shaft diameters Clamping hub Supported driving pinion Input bearing 2nd possibility for centering C E-Version TP M-Version Strongly recommended for highly dynamic cycle (S5) and a high failsafety for continuous operations (S1) thanks to our advanced design Universal motor mounting with the help of modular adapter parts; Motor tolerance N to DIN can be used Whatever mounting orientation the customer chooses thanks to lubrication with synthetic oil High efficiency, quiet running and high uniformity thanks to optimal gearing geometry and unsurpassed quality in the manufacturing processes Minimum backlash 1arcmin because of compensation of tolerances without distortions Through holes Output side sealed Output bearing TP Angular ball bearing TP 050/110 Tapered roller bearing ISO flange TP TP 110 1st possibility for centering The TP Integrated ( E ) is built into customers own constructions. The drive pinion has to be supported in an input shaft of the customer s construction. Please consult alpha with regard to the mechanical design of the input shaft. C M-Version page

4 page 4 M-Version Technical data The dimensions of the two-stage gear reducers are different between variant 1 and 2. This difference is based on the choice of the motor shaft / clamping hub diameter (D10), which causes a change in dimensions (D11, L11, L14, L15, L18) within the size, shown in figure 1 and 2 on this page. Because of this design difference we offer two variants of gear reducers, variant 1 (figure 1) with very low moment of inertia and variant 2 (figure 2) where a larger motor can be mounted. Figure 1 (Variant I) very low mass moments of inertia Conversion Table: 1 Nm = 8.85 in. lb. 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 N =.225 lb f 1 kg = lb. Size TP 004 TP 010 TP 025 TP 050 TP 110 TP 00 TP 500 max. T 2B Nm i = 5, 7, Acceleration i = 10, 21, 61, Torque 1) i = 5, 7, 10, i = i = 61, Emergency Stop 2) T 2Not Nm Nominal Output T 2N Nm i = 5, 7, Torque i = 10, 21, 61, i = 5, 7, 10, i = i = 61, max. Input n 1Max rpm 1-stage Speed 2-stage Nominal Input n 1N rpm i = 5, Speed ) i = i = 21, i = i = Ratios 4) i 1-stage 5 / 7 / 10-2-stage 21 / 1 / 61 / 91 1 / 61 / 91 Torsional Backlash j t arcmin standard 5 reduced 1 - Torsional Rigidity C t21 Nm/arcmin 1-stage i = stage i = max. Axial Load 5) F 2AMax N max. Tilting Mom. M 2KMax Nm No-load Running T 012 Nm i = Torque 6) i = (n 1 =000 rpm) i = Tilting Rigidity C 2K Nm/arcmin Efficiency with η % 1-stage 96 - full load 2-stage 9 Weight m kg 1-stage stage Lubrication Synthetic oil viscosity ISO VG220 Paint Blue RAL 5002 Mounting Position advised with your order Permissible Gear Reducer Temp. o C - 10 o C to + 90 o C Direction of Rotation Motor and gear reducer same direction Degree of Gearbox Protection IP 64 Noise level L PA db(a) 1-stage (n 1 =000 rpm) 2-stage ) 1000 cycles per hour. 2) 1000 times during the service life. ) at 20 C ambient temperature (if you have higher ambient temperature, please reduce the n 1N speed). 4) Further ratios see operations page 21. 5) applied to the flange centre. 6) at 20 C gear reducer temperature. Figure 2 (Variant II) larger motor can be mounted PVariant I Variant II Dimensions [mm] View A TP 050/TP 110 TP 00/TP 500 1) Motor shaft diameter/length 2) Screw of the 1-stage version are sanked R = 0.4 View A TP 025 TP 004/TP Dimensions of the adapterplate depends on the motor 1) OD for O-Ring deep Flange according to ISO 9409 with additional thread TP TP mm = in. View B Mounting hole closed with plastic plugs Size TP 004 TP 010 TP 025 TP 050 TP 110 TP 00 TP 500 Gear Stages a b C1 - ) xm8x1 xm8x1 xm8x1 xm12x1.5 4xM12x1.5 4xM14x1.5 D1 H D D h D5 h D D D8 7xM5 7xM6 11xM6 11xM8 11xM10 12xM16 12xM20 D9 H D10 4) F7 Variant I max. 14 max. 11 max. 19 max. 11 max. 2 max. 14 max. 8 max. 19 max. 48 max. 28 max. 5 max. 48 Variant II max max max. 2 - max D11 4) Variant I (comp. D10) Variant II D12 h D14 8x4.5 8x5.5 8x5.5 12x6.6 12x9 16x1.5 16x1.5 L L L L L L L L L L11 4) min. Variant I (comp. D10) Variant II L11 4) max. Variant I (comp. D10) Variant II L L14 4) Variant I (comp. D10) Variant II L15 4) Variant I (comp. D10) Variant II L L18 4) +1 Variant I (comp. D10) Variant II OD 66x2 90x 110x 145x 200x5 28x5 270x6 X Y ) without drain plug 4) dimensions depend on the motor M-Version page 5

5 page 6 M-Version Mass moments of inertia J1 [kgcm 2 ] applies to the input Gear reducer Shaft-Ø Ratio i single-stage Ratio i two-stage size [mm] TP > TP > > > TP > > > > > TP > > > > > > TP > > > > > > > TP TP Quick Selection Exact gear reducer selection can be found on page 16 to 20 Cycle Operation S5 (for number of cycles 1000) Duty cycle < 60 % Continuous Operation S1 (use FPM-sealings, indicate this in your order) Duty cycle > 60% 1. Determination of the max. motor acceleration torque T 1BMot [Nm] 2. Determination of the actual max. acceleration torque on the reducer output T 2b [Nm] T 2b = T 1BMot x i. Comparison of the actual max. acceleration torque T 2b [Nm] with the max. permissible acceleration torque T 2B [Nm] on the reducer output. T 2b T 2B 1. Determination of the motor minal torque T 1NMot [Nm] 2. Determination of the actual minal torque on the reducer output T 2n [Nm] T 2n = T 1NMot x i. Comparison of the actual minal torque T 2n [Nm] with the permissible minal torque T 2N [Nm] on the reducer output T 2n T 2N 4. Determination of the actual input speed 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 mm = in. 1 Nm = 8.85 in.lb. 4. Comparison of the motor shaft diameter D Mot [mm] with the dimension D10 [mm] D Mot D10 5. Comparison of the motor shaft length L Mot [mm] with the dimension L11 [mm] L11 min L Mot L11 max 5. Comparison of the actual input speed n 1n [rpm] with the permissible minal speed n 1N [rpm] n 1n n 1N 6. Comparison of the motor shaft diameter D Mot [mm] with the dimension D10 [mm] D Mot D10 7. Comparison of the motor shaft length L Mot [mm] with the dimension of L11 [mm] L11 min L Mot L11 max Product characteristics Space-saving motor mounting thanks to parallel arrangements of the components High torsional rigidity thanks to the flange Minimum backlash 1arcmin because of compensation of tolerances without distortions High dynamics thanks to a compact design and, consequently, low moments of inertia Unsurpassed positioning accuracy thanks to low backlash and high torsional rigidity High security in case of an emergency stop thanks to high-duty gearings tough bearings Product details O-Ring groove rd possibility for centering Input side sealed Centering boring internally-threaded Input shaft Input bearing Fastening thread 2nd possibility for centering C Extremely compact as a result of integrated design TP S-Version Extremely silent thanks to its unique reducer kinematics Strongly recommended for highly dynamic cycle (S5) and a high failsafety for continuous operations (S1) thanks to our advanced design Whatever mounting orientation the customer chooses thanks to lubrication with synthetic oil High efficiency, quiet running and high uniformity thanks to optimal gearing geometry and unsurpassed quality in the manufacturing processes Very easy to install owing to input fastening thread for coupling flanges C Through holes Output side sealed Output bearing TP010/025 Angular ball bearing TP050/110 Tapered roller bearing ISO 9409-flange 1st possibiliy for centering page 7 S-Version n 1n [rpm]

6 page 8 S-Version Technical data Conversion Table: 1 Nm = 8.85 in. lb. 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 N =.225 lb f 1 kg = lb. Size TP 010 TP 025 TP 050 TP 110 max. T 2B Nm i = 5, 7, Acceleration i = 10, 21, 61, Torque 1) i = 5, 7, 10, i = i = 61, Emergency Stop 2) T 2Not Nm Nominal Output T 2N Nm i = 5, 7, Torque i = 10, 21, 61, i = 5, 7, 10, i = i = 61, max. Input n 1Max rpm 1-stage Speed 2-stage Nominal Input n 1N rpm i = 5, Speed ) i = i = 21, i = i = Ratios 4) i 1-stage 5 / 7 / 10 2-stage 21 / 1 / 61 / 91 Torsional Backlash j t arcmin standard reduced 1 Torsional Rigidity C t21 Nm/arcmin 1-stage i = stage i = max. Axial Load 5) F 2AMax N (Output) max. Tilting Output M 2KMax Nm Moment 1-stage Input M 1KMax Nm 2-stage max. Axial Load 5) F 1AMax N 1-stage (Input) 2-stage max. Radial Load 5) F 1RMax N 1-stage (Input) 2-stage No-load Running T 012 Nm i = 10 5 Torque 6) i = (n 1 =000 rpm) i = Tilting Rigidity C 2K Nm/arcmin Efficiency η % 1-stage 95 with full load 2-stage 92 Weight m kg Lubrication Synthetic oil viscosity ISO VG220 Paint Blue RAL 5002 Mounting Position advised with your order Permissible Gear Reducer Temp. o C - 10 o C to + 90 o C Direction of Rotation Motor and gear reducer same direction Degree of Gearbox Protection IP 64 Noise level L PA db(a) 1-stage (n 1 =000 rpm) 2-stage ) 1000 cycles per hour. 2) 1000 times during the service life. ) at 20 C ambient temperature (if you have higher ambient temperature, please reduce the n 1N speed). 4) Further ratios see operations. 5) applied to the flange/shaft centre. 6) at 20 C gear reducer temperature. Dimensions [mm] View A TP 050/TP 110 TP 025 TP 010 1) keywayed input shaft available, indicate this in your order 1) OD for O-Ring Flange according to ISO 9409 with additional thread 1 mm = in. View B Size TP 010 TP 025 TP 050 TP 110 Gear Stages 1 / 2 1 / 2 1 / 2 1 / 2 a b C1 xm8x1 xm8x1 xm8x1 xm12x1.5 DR M5 / M M8 / M4 M12 / M5 M16 / M8 D1 H D D h D5 h D D D8 7xM6 11xM6 11xM8 11xM10 D9 H D10 k6 16 / 9 22 / 12 2 / / 22 D11 48 / 8 60 / / / 62 D12 h D14 8x5.5 8x5.5 12x6.6 12x9 D15 0 / 22 8 / / 0 70 / 8 D16 g D17 4xM4 4xM5 6xM6 6xM8 D L L L L L L L L L L / / / 7.5 L L14 28 / 20 6 / / / 6 L / / / / 198 L L L18 2 / 1 2 / 1 2 / 2 OD 90x 110x 145x 200x5 R V X Y Z deep page 9 S-Version

7 Product characteristics Universal motor mounting with the help of modular adapter parts;motor tolerance N to DIN can be used Whatever mounting orientation the customer chooses thanks to lubrication with synthetic oil High efficiency, quiet running and high uniformity thanks to optimal gearing geometry and unsurpassed quality in the manufacturing processes High dynamics thanks to a compact design and, consequently, low moments of inertia High security in case of an emergency stop thanks to high-duty gearings and tough bearings Ingeniously simple, patented motor mounting with integrated thermal length compensation Product details Input side supported and sealed Adapter plate Motor Clamping hub Bushing TP K-Version Extremely silent thanks to its unique reducer kinematics High torsional rigidity thanks to the flange Extremely compact as a result of integrated design Compact and space-saving design thanks to right-angled arrangement of the components Strongly recommended for highly dynamic cycle (S5) and a high failsafety for continuous operations (S1) thanks to high quality helical gear Unsurpassed positioning accuracy thanks to low backlash and high torsional rigidity Low backlash because of compensation of tolerances without distortions Through holes Output side sealed Output bearing TP 10/25 Angular ball bearing TP 50/110 Tapered roller bearing ISO 9409-flange 1st possibility for centering 2nd possibility for centering page 11 K-Version page 10 S-Version S-Version Mass moments of inertia J1 [kgcm 2 ] applies to the input Gear reducer Ratio i single-stage Ratio i two-stage size TP TP TP TP Quick Selection Exact gear reducer selection can be found on page 16 to 20 Cycle Operation S5 (for number of cycles 1000) Duty cycle < 60% Continuous Operation S1 (use FPM-sealings, indicate this in your order) Duty cycle > 60% 1. Determination of the max. motor acceleration torque T 1BMot [Nm] 2. Determination of the actual max. acceleration torque on the reducer output T 2b [Nm] T 2b = T 1BMot x i 1. Determination of the motor minal torque T 1NMot [Nm] 2. Determination of the actual minal torque on the reducer output T 2n [Nm] T 2n = T 1NMot x i. Comparison of the actual minal torque T 2n [Nm] with the permissible minal torque T 2N [Nm] on the reducer output T 2n T 2N 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 Nm = 8.85 in.lb.. Comparison of the actual max. acceleration torque T 2b [Nm] with the max. permissible acceleration torque T 2B [Nm] on the reducer output T 2b T 2B 4. Determination of the actual input speed n 1n [rpm] 5. Comparison of the actual input speed n 1n [rpm] with the permissible minal speed n 1N [rpm] n 1n n 1N Seite 00 Version-X Titel

8 page 12 K-Version Technical data Size TPK 010 TPK 025 TPK 050 TPK 110 TPK 00 6) max. T 2B Nm i = 5, 7, 10, 14, Acceleration i = 20, 42, 122, Torque 1) i = 5, 7, 10, 14, 20, i = i = 122, Emergency Stop 2) T 2Not Nm Nominal Output T 2N Nm i = 5, 7, 10, 14, Torque i = 20, 42, 122, i = 5, 7, 10, 14, 20, i = i = 122, max. Input n 1Max rpm 2-stage Speed -stage Nominal Input n 1N rpm i = 5, Speed ) i = 10, 14, i Ratios 6) i 2-stage 5 / 7 / 10 / 14 / 20 -stage 42 / 62 / 122 / 182 Torsional Backlash j t arcmin standard 4 reduced 2 Torsional Rigidity C t21 Nm/arcmin 2-stage i = stage i = max. Axial Load 4) F 2AMax N max. Tilting Moment M 2KMax Nm No-load Running T 012 Nm i = 5.2 Torque 5) i = (n 1 =000 rpm) i = i = Tilting Rigidity C 2K Nm/arcmin Efficiency with η % 2-stage 9 full load -stage 90 Weight m kg 2-stage stage Lubrication Synthetic oil viscosity ISO VG220 Paint Blue RAL 5002 Mounting Position advised with your order Permissible Gear Reducer Temp. o C - 10 o C to + 90 o C Direction of Rotation Motor and gear reducer same direction Degree of Gearbox Protection IP 64 Noise level L PA db(a) (n 1 =000 rpm) 1) 1000 cycles per hour. 2) 1000 times during the service life. ) If you require higher n 1N speed, please contact alpha. ) At 20 C ambient temperature (if you have higher ambient temperature, please reduce the n 1N speed). 4) applied to the flange centre. 5) at 20 C gear reducer temperature. 6) i = 42 t available for TPK 00 Conversion Table: 1 Nm = 8.85 in. lb. 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 N =.225 lb f 1 kg = lb. Dimensions [mm] Flange boring pictures see page 5 Mounting hole closed with plastic plugs for View A 1) Dimensions of the adapterplate depends on the motor deep Flange according to ISO 9409 with additional thread 1) Motor shaft diameter / lenght 1 mm = in. Size TPK 010 TPK 025 TPK 050 TPK 110 TPK 00 Gear Stages 2 / 2 / 2 / 2 / a b C xm8x1 xm12x1.5 / xm8x1 xm12x1.5 / xm8x1 xm12x1.5 4xM12x1.5 D1 H D D h D4 42/40 54/40 70/42 100/54 70 D5 h D D D8 7xM6 11xM6 11xM8 11xM10 12xM16 D9 H D10 2) F7 19 / / 14 5 / / 28 5 D12 h D14 8x5.5 8x5.5 12x6.6 12x9 16x1.5 L L L L L L L L L11 2) min. 2 / 15 0 / 15 2 / 2 45 / 0 2 max. 40 / 0 50 / 0 60 / / L L1 12 / / / 20.5 / L14 2) 22 / / / / L / 2 51 / / / L16 4 / / / 4 8 / L / 7.5 / / / 5.5 L18 2) 6.2 / / / / L / / / / L20 2) 144 / / / / R ) dimensions depend on the motor page 1 K-Version

9 page 14 K-Version Mass moments of inertia J1 [kgcm 2 ] applies to the input J1 isn t dependent on the motor shaft diameter Quick selection Exact gear reducer selection can be found on page 16 to 20 Cycle Operation S5 (for number of cycles 1000) Duty cycle < 60% Continuous Operation S1 (use FPM-sealings, indicate this in your order) Duty cycle > 60% 1. Determination of the max. motor acceleration torque T 1BMot [Nm] 2. Determination of the actual max. acceleration torque on the reducer output T 2b [Nm] T 2b = T 1BMot x i. Comparison of the actual max. acceleration torque T 2b [Nm] with the max. permissible acceleration torque T 2B [Nm] on the reducer output T 2b T 2B 1. Determination of the motor minal torque T 1NMot [Nm] 2. Determination of the actual minal torque on the reducer output T 2n [Nm] T 2n = T 1NMot x i. Comparison of the actual minal torque T 2n [Nm] with the permissible minal torque T 2N [Nm] of the reducer output T 2n T 2N 4. Determination of the actual input speed n 1n [rpm] 1 kgcm 2 = 8.85 x 10-4 in. lb.s 2 1 mm = in. 1 Nm = 8.85 in. lb. Gear reducer Ratio i 2-stage Ratio i -stage Size TPK TPK TPK TPK TPK Comparison of the motor shaft diameter D Mot [mm] with the dimension D10 [mm] D Mot D10 5. Comparison of the motor shaft length L Mot [mm] with the dimension L11 [mm] L11 min L Mot L11 max 5. Comparison of the actual input speed n 1n [rpm] with the permissible minal speed n 1N [rpm] n 1n n 1N 6. Comparison of the motor shaft diameter D Mot [mm] with the dimension D10 [mm] D Mot D10 7. Comparison of the motor shaft length L Mot [mm] with the dimension of L11 [mm] L11 min L Mot L11 max Mounting versions Mounting versions of the housing The centering features of the gearbox housing yield two possibilities for mounting (see Fig. beside). An O-ring can be fitted to seal the gearbox housing if version a) is chosen. a) b) Installation example: TP 010 and TP 025 Integrated in an robot hand a) b) Mounting versions of the output flange The ISO-output flange has two possibilities for centering as well as an Index bore. a) External centering b) Internal centering ISO Output flange page 15 Dimensioning Mounting versions

10 page 16 Dimensioning Accurate Selection of Reducer for Cycle Operation S5 Cycle Operation S5 Select a larger gear reducer Select a smaller ratio i and possibly a larger motor Select a larger gear reducer Calculation on page 20 Determination of the duty cycle ED ED < 60% and ED < 20 min Determination of the number of cycles Z h [1/h] Determination of the shock factor f s Determination of the maximum motor acceleration torque T 1BMot [Nm] Determination of the ratio i Determination of the maximum acceleration torque on the output T 2b [Nm] T 2b < T 2B Determination of the maximum output speed n 2c [rpm] n 2c < n 2Max Determination of the emergency stop torque T 2t [Nm] T 2t < T 2Not Calculation of the bearing service life L h necessary? End of reducer selection ( t b + t c + t d ) ED = (tb + t c + t d + t e ) Selection according to the criteria for continuous operation S1 (page 18) Z h = 600 [s/h] cycle time [s] 100 [%] ED = t b + t c + t d [min] i from - maximum possible input speed - ratio of the mass moments of inertia - needed output speed T 2b = T 1BMot i f s η n 2c depends on the application T 2t depends on the application ED = [%] ED = Z h = Z h = f s = T 1BMot = i= T 2b = T 2b = n 2c = T 2t = 600 n 2Max = n 1Max i [min] Rapid reversals in combination with short acceleration times may cause vibration within the drive assembly. The resulting overloads should be calculated using the shock factor f s. Shock Stoßfaktor factor fs [ - ] 2,1 2,0 1,9 1,8 1,7 1,6 1,5 1,4 1, 1,2 1,1 1,0 0, Version η [%] M 1-stage 96 2-stage 9 S 1-stage 95 2-stage 92 K 2-stage 9 -stage 90 Number Zyklenzahl of cycles pro per Stunde hour Z h [1/h] On request we carry out calculations at our company for you to select a gear reducer. Drehzahl speed Drehmoment torque T 2Break T 2B T 2b T 2c T 2e T 2d n 2c n 2b n 2e All usual loads at the output 4 x T 2B T 2Not T 2t t b t c t d t e Zeit time cycle Zykluszeit time (Start/Stop/Ereignis) (start/stop/event) Version TP004 1) TP010 TP025 TP050 TP110 TP00 1) TP500 1) T 2B M/S i=5/7/ i=10/21/61/ [Nm] i=5/7/10/ i= i=61/ K i=5/7/10/14/ i=20/42/122/ i=5/7/10/14/20/ i= ) - i=122/ ) - 1) only available as M-Version. 2) K-Version only -stage Version TP004 1) TP010 TP025 TP050 TP110 TP00 1) TP500 1) n 1Max M/S 1-stage stage [rpm] K 2-stage stage ) only available as M-Version. T 2Not [Nm] Version TP004 1) TP010 TP025 TP050 TP110 TP00 1) TP500 1) M/S/K 1) only available as M-Version. 1 Nm = 8.85 in. lb n 2d Zeit time n 2b = n 2d = 1 n2c 2 page 17 Dimensioning Accurate Selection of Reducer for Cycle Operation S5 Designation and index see page 19

11 page 18 Dimensioning Accurate Selection of Reducer for Continuous Operation S1 Continuous Operation S1 Selection according to the criteria of cycle operation S5 (see page 16) Select a larger reducer Select a smaller ratio i and possibly a larger motor See calculation on page 20 Determination of the duty cycle ED ED 60% or ED 20 min Further determination of the area of the cycle operation S5 that is marked with colors (see page 16) Determination of the mean output torque T 2m [Nm] T 2m < T 2N Determination of the mean output speed n 2m [rpm] n 2m < n 2N Calculation of the bearing service life L h necessary? End of reducer selection ( t b + t c + t d ) ED = (tb + t c + t d + t e ) ED = t b + t c + t d [min] T 2m = T 2m = T 2m = n 2m = n 2m = n 2m = n 2b t b T 2b +...+n 2n t n T 2n n 2b t b +...+n 2n t n n 2b t b +...+n 2n t n t b +...+t n On request we carry out calculations at our company for you to select a gear reducer. 100 [%] ED = [%] n 2N = n 1N i ED = [min] Drehzahl speed torque Drehmoment T 2Break T 2B T 2b T 2c T 2e T 2d n 2c n 2b n 2e All usual loads at the output 4 x T 2B T 2Not T 2t t b t c t d t time e Zeit cycle Zykluszeit time (Start/Stop/Ereignis) (start/stop/event) n 2d Symbol Unit Designation C Nm/arcmin Rigidity ED % Duty cycle F N Force f s - Shock factor i - Ratio j arcmin Backlash K1 Nm Bearing calculation factor L h Service Life M Nm Moment n rpm Speed p - Bearing calculation exponent η % Efficiency t s Time T Nm Torque x mm Distance of the radial load to the shaft collar y mm Distance of the axial load to the centre of the gear reducer z mm Bearing calculation factor Z 1/h Number of cycles time Zeit n 2b = n 2d = 1 n 2c 2 Index Capital letters Permissible values Small letters Actual values 1 Input 2 Output A/a Axial B/b Acceleration Break Break c Constant d Delay e Pause h Hours K/k Tilt m Mean Max/max Maximum Mot Motor N Nominal Not/t Emergency stop 0 No-load running R/r Radial t Torsional If in continuous operations S1 the gear reducer is loaded below or equal the minal torque T 2N, the gearing s fatigue strength will be sufficient. If the input speeds are lower than or equal to the minal speed n 1N and the ambient conditions are rmal, the gear reducer temperature will t exceed 90 C. 1 Nm = 8.85 in. lb. Version TP004 1) TP010 TP025 TP050 TP110 TP00 1) TP500 1) T 2N M/S i=5/7/ i=10/21/61/ [Nm] i=5/7/10/ i= i=61/ K i=5/7/10/14/ i=20/42/122/ i=5/7/10/14/20/ i= ) - i=122/ ) - 1) only available as M-Version. 2) K-Version inly -stage. n 1N Version TP004 1) TP010 TP025 TP050 TP110 TP00 1) TP500 1) M i=5/ i= i=21/ i= i= S i=5/ i= [rpm] i=21/ i= i= K i=5/ i=10/14/ i ) only available as M-Version. page 19 Dimensioning Accurate Selection of Reducer for Continuous Operation S1

12 Input ( S - Version ) F Max Output ( M/S/K - Version ) page 20 Dimensioning Calculation of the Service Life of the Bearing L h F 1am = F 1rm = n 1b t b F 1ab +...+n 1n t n F 1an M 1km = F 1am 0.7 F 1rm TP10 F 1am 2-stage 1.14 TP25 F 1rm F 1am y 1 + F 1rm (x 1 +z 1 ) 1000 S-Version TP010 TP025 TP050 TP110 z 1 [mm] 1-stage stage F 1amax y 1 + F 1rmax (x 1 +z 1 ) M 1kmax = 1000 L h1 = n 1b t b +...+n 1n t n n 1b t b F 1rb +...+n 1n t n F 1rn n 1b t b +...+n 1n t n Select a larger reducer (Gear reducer selection) S-Version TP010 TP025 TP050 TP110 M 1KMax [Nm] 1-stage stage F 1AMax [N] 1-stage stage n 1b t b n 1n t n n 1m = t b t n n 1m K1 1 M 1km S-Version TP010 TP025 TP050 TP110 p 1 1-stage stage.. K1 1 1-stage [Nm] 2-stage Select a larger reducer (Gear reducer selection) Designations and index see page 19 p 1 Drehzahl speed force Kraft F b F c F e F d n c n b n e t b t c t d t e time Zeit cycle Zykluszeit time (start/stop/event) Start/Stop/Ereignis Determination of the mean axial and radial force F am, F rm [N] Consult alpha! Determination of the mean tilting moment M km [Nm] Determination of the maximum tilting moment M kmax [Nm] M kmax M KMax F amax F AMax Determination of the mean speed n m [rpm] Determination of the service life L h [h] Eugh life time L h? Calculation of the tilting angle necessary? Determination of the tilting angle ϕ kmax n 2d time Zeit n 2b = n 2d = 1 n2c 2 F 2am y 2 + F 2rm (x 2 +z 2 ) M 2km = 1000 F 2amax y 2 + F 2rmax (x 2 +z 2 ) M 2kmax = 1000 L h2 = F 2am = F 2rm = n 2m n 2b t b F 2ab +...+n 2n t n F 2an TP04 F 2am -TP25 F 2rm 1.14 TP50 F 2am -TP500 F 2rm 0.7 x 1 >0 x 2 >0 n 2b t b n 2n t n n 2m = t b t n K1 2 End of the calculation of the service life of the bearing L h M 2kmax ϕ2kmax = C 2K n 2b t b +...+n 2n t n n 2b t b F 2rb +...+n 2n t n F 2rn n 2b t b +...+n 2n t n M 2km p 2 1 Nm = 8.85 in. lb. 1 N =.225 lb f 1 mm = in. Version TP004 TP010 TP025 TP050 TP110 TP00 TP500 [mm] M/S/K 51,8 71,1 88,2 76,6 99,4 14,1 152,8 z 2 Version TP004 TP010 TP025 TP050 TP110 TP00 TP500 M 2KMax M/S/K [Nm] F 2AMax M/S/K [N] Version TP004 TP010 TP025 TP050 TP110 TP00 TP500 p 2 M/S/K,,,, K1 2 [Nm] M/S/K Version TP004 TP010 TP025 TP050 TP110 TP00 TP500 C 2K [Nm M/S/K /arcmin] Possible Operation Modes: The drive pinion, output flange or gear reducer housing can be used as the input or output or fixed in an TP-gear reducer. The following diagram illustrates the resulting seven different modes of operation and the corresponding formulae for determining the transmission ratios. Please observe that depending on the mounting version the permissible speeds and torques will change. Please contact alpha! 1. Pinion Gearbox 4. Input: Output: Fixed: Input: Output: Fixed: i 4 = Pinion Flange Gearbox Flange Pinion Gearbox 7. Differential and Variable- speed gear A C B Input: Output: Fixed: Input: Output: Fixed: Pinion Gearbox Flange i 1 = i i 2 = - (i - 1) All versions rotate n A - i n B - (1 - i) n C = 0 1 n A : Pinion speed n B : Flange speed n C : Gearbox speed i Flange i 5 =- Gearbox Pinion Flange 1 i - 1 Input: Output: Fixed: Input Output Fixed i : Ratio i 1-6 : Ratio for the particular application. 6. i = Input: Output: Fixed: i 6 = Gearbox Flange Pinion i i - 1 Flange Gearbox Pinion i - 1 i page 21 Dimensioning Possible Operation Modes

13 page 22 Dimensioning Ordering Code TP Ordering Code Code Number - Clamping hub bore diameter (TP) 1 mm = in. Gear stages Motor shaft-ø [mm]* TP 004 TP 010 TP 025 TP 050 TP 110 TP 00 TP x x x 1 x x x x x x x x x 2 x 1 x x x x x 2 x 1 x x x 2 x x x x x x - x 4 x x x x x x 6 1 x x * If your motor shaft diameter is t listed, add 2 mm to diameter and select next higher size. - = choose next larger gear reducer x = choose next larger code number Bushing If the motor shaft- and the clamping hub diameter do t fit together... Mounting Position M = Motor G = Gear reducer Gear Reducer type TP 004 / 010 / 025 / 050 / 110 / 00 / 500 Reducer Design M = Motor-mounted M E = Integrated E S = Self-contained S TP 004 / TP 00 / TP 500 only M Reducer Execution F = Standard FPM seals (Viton ) X = Customized Number of Stages 1 = 1-stage 2 = 2-stage B5-horizontal TP MF /Motor - V Ratio i TP TP 110: 1-stage = 5 / 7 / 10 2-stage = 21 / 1 / 61 / 91 TP 00 + TP 500: 2-stage = 1 / 61 / 91 Clamping hub Motor shaft Bushing V1-vertical, with output flange facing downwards V-vertical, with output flange facing upwards Mounting Position (see below) Motor Designation (manufacturer type) isn t necessary E- and S-versions Backlash 1 = Standard 0 = Reduced Clamping hub bore Diameter M-version: Code numbers - see table below E-version: 0 = only input pinion S-version: 0 = smooth input shaft 1 = keyed input shaft Type of Output flange 0 = Standard 4 = Customized... a bushing is used. S-can be pivoted ± 90 from the horizontal Ordering Code Bushing Gear Reducer Type TPK 010 / 025 / 050 / 110 / 00 Reducer Design M = Motor-mounted M Reducer Execution F = Standard FPM seals (Viton ) X = Customized Stages * 2 = 2-stage = -stage * TPK 00 only -stage If the motor shaft- and the clamping hub diameter do t fit together... Ratio i 2-stage = 5 / 7 / 10 / 14 / 20 -stage = 42* / 62 / 122 / 182 * t available for TPK 00 Code Number - Clamping hub bore diameter (TPK) Mounting Position M = Motor G = Gear reducer B5/V-Output flange horizontal, Motor shaft facing upwards TPK MF /Motor - V/B5 V/B5-Output flange vertical facing upwards, Motor shaft horizontal Clamping hub Motor shaft Bushing B5/V1-Output flange horizontal, Motor shaft facing downwards B5/B5-Output flange and motor shaft horizontal Mounting Position (see below) Motor Designation (Manufacturer-Type) Backlash 1 = Standard 4 arcmin 0 = Reduced 2 arcmin Clamping hub bore Diameter Code numbers - see table below Type of Output flange 0 = Standard 4 = Customized - = choose next larger gear reducer x = choose next larger code number... a bushing is used. V1/B5-Output flange vertical facing downwards, Motor shaft horizontal S-can be pivoted 60 1 mm = in. Gear stages Motor shaft-ø [mm]* TPK 010 TPK 025 TPK 050 TPK 110 TPK x x x x x x x x - x x x x x - x 4 x x * If your motor shaft diameter is t listed, add 2 mm to diameter and select next higher size. page 2 Dimensioning Ordering Code TPK

14 page 24 Dimensioning Installation- and Application Examples Installation- and Application Examples KUKA Industrial Robot IR 6/6.0 TP - Motor-mounted gear reducer as belt pulley/wheel drive TP - Motor-mounted gear reducer with pinion-rack TP - Motor-mounted gear reducer as robot axe 2 TP - Self-contained Gear Reducer as differential gear axe 1 axe 2 TP - Motor-mounted gear reducer as turnable