\ srl High Technology Gear Reducers and Cardan Shafts CERTIFIED QUALITY SYSTEM: UNI ISO EN 9001:2008 ICIM 2779/2; IQNET N. IT UNIVERSAL SHAFT

Transcription

1 UNIVERSAL SHAFT

2 CAT CERTIFICATION

3

4 CARDAN SHAFTS - COUPLINGS Alongside with the production of special gearboxes, our company has developed the production of Universal shafts, with the same high quality and accuracy. The production range covers the medium-heavy duty sector, up to a torque of Nm. Our technology also allows us to manufacture special universal shafts, for those application not included in the normal commercial products. Starting from the design and until the painting, each production step is controlled and verified in order to guarantee an excellent, top quality product. All the universal shafts produced must meet a series of strict controls, starting from the quality of the raw material up to the dynamic balancing (also for the big shafts), where the application requires it. Our company offers its customers the know-how and the experience in the field of the industrial design, to optimise and integrate its products, so as to increase the efficiency of the plants. We offer our technical support during the design, the installation, the maintenance and the evaluation of the performance. The main characteristics of a universal joint are: -its capacity of compensating high angles, thus allowing the transmission of the torque between two shafts not in line -In its version with double extensible joint, a universal joint will allow both radial and axial displacements. -It can transmit very high torques -it requires a very reduced maintenance -it is easy to install

5 DESIGN AMBIENT TEMPERATURE C REVERSAL TIME POWER OF MOTOR (S1) KW SEC 5 SPEED RATED RPM 700 SPEED RANGE RPM GEARS BOX RATIO 1:15 OVERLOAD 2.3 (10 sec.) MAX ROLLING TORQUE KNm 1700 MEAN ^(1/3) ROLLING TORQUE KNm 1050 MAX ROLLING SPEED m/s 4 WORKING CYCLES OPERATION TIME 1% OF THE MAX LOAD 10% OF THE 80% MAX LOAD 60% OF THE MEAN ROLLING TORQUE 10% OF THE 40% MAX LOAD 19% OF THE 30% MAX LOAD SPEED 90 RPM (4 m/s) time 50% 45 RPM (1.5 m/s) time 20% 60 RPM (3 m/s) time 30% Sample of cardan shaft design parameter

6 Cross Sketch with shrinking bearing and bush Sketch of cardan shaft and companion flanges assembled

7 QUALITY CONTROL PLAN ORDER date CUSTOMER SIEMENS VAI M. T. S.r.l. JOB NUMBER TYPE UNIVERSAL JOINT HH S001FF SERIAL NUMBER A7.1QCP REV B

8 CONTROLS LIST 0 APPROVAL OF GRAPHS 33 DEPTH OF CASEHARDENING 1 CHEMICAL ANALYSIS (Steel mill) 34 DISMANTLING AFTER TEST/RE-ASSEMBLY 2 TENSILE TEST (Steel mill) 35 FINAL INSPECTION 3 IMPACT TEST(Steel mill) 36 VIBRATION PHASE PLOTS 4 HARDNESS TEST 37 SOUND LEVEL TEST 5 MAGNETIC TEST 38 MATERIAL CERTIFICATION 6 ULTRASOUND TEST 39 WIRING INSPECTION 7 PENETRATING LIQUIDS TEST 40 GEAR ACCURACY CHECK 8 RADIOGRAPHIC TEST 41 HOMOLOGATION BY CLASSIFICATION AUTHORITY 9 HYDROSTATIC TEST 42 SEISMIC VIBRATION DATA 10 ANNEALING 43 DOUBLE HELICAL AXIAL STABILITY 11 STATIC BALANCING 44 (TAPE) RECORDED VIBRATION DATA 12 ELECTRIC AND MECHANICAL RUN OUT 45 NAME PLATE VERIFICATION 13 STATIC AND DYNAMIC BALANCING 46 INSPECTION RELEASE NOTE CHECK 14 WELDING PROCEDURE 47 FINAL DOCUMENTATION CHECK 15 THERMAL TREATMENT AFTER WELDING 48 NITHRITED SURFACE HARDNESS CHECK 16 MAGNETIC TEST ON WELDING 49 HEAT TREATMENT(s) CERTIFICATES 17 ULTRASOUND TEST ON WELDING 50 MATERIAL PROTECTION 18 PENETRATING LIQUIDS TEST ON WELDING 51 SUITABLE PACKAGING 19 RADIOGRAPHIC TEST ON WELDING 52 PACKING LIST VERIFICATION 20 DIMENSION CONTROL (SHOP INSPECTION) 53 MICROGRAPHIC CONTROL 21 VISUAL CONTROL (SHOP INSPECTION) 54 MACROGRAPHIC CONTROL 22 PAINTING 23 CLEANLINESS INSPECTION 24 FLUSHING 25 CONFORMITY CERTIFICATE 26 FINAL ASSEMBLY, MAINTENANCE AND RUNNING CLEARANCES 27 FUNCTION TEST 28 MARKING 29 CONTROL OF CERTIFICATIONS 30 ULTRASOUND CONTROL ON CRITICAL THICKNESSES 31 SETTING CONTROL 32 CONTACT CHECK CONTACT CHECK TAPE LIFT Our control list is extensive and completely customizable for each particular need, critical application or request

9 DATE APPROVED CONTROLS PLANNING PROCEDURES AND CRITERIA OF ACCEPTABILIY DESCRIPTION OF MACHINE: UNIVERSAL JOINT HH S001FF ITEM POSITION DRAWING QTY. MATERIAL TESTS TO PERFORM NOTES ASSEMBLY FLANGE HH S001FF 2-20,21,22,25,47 HH S00Z4 8 34CrMo4 1,2,4,6,21,21,29,49 CROSS ASSEMBLY HH S00Z0 4 42CrMo 1,2,4,6,21,21,29,49 CROSS BUSH HH S00ZA 16 20CrMnMo 1,2,4,6,21,21,29,33,49,53,54 CONNECTION PIPES HH S00Z6 4 tbd 1,2,4,6,21,21,29,49 PIPE FLANGE CONNECTION HH S00ZB 2 40Cr 1,2,4,6,18,17,21,21,29,49 CENTRAL PIPE UNIT HH S00Z9 2 40Cr 1,2,4,6,18,17,21,21,29,49 SLEEVE (ROLL SIDE) HH S00ZC 2 42CrMo 1,2,4,6,21,21,29,49 09 SLEEVE (GEARBOX SIDE) HH S00ZD 2 42CrMo 1,2,4,6,21,21,29,49 10 ELONGATION UNIT HH S00ZE 2 40Cr 1,2,4,6,18,17,21,21,29,49 11 PACKAGING AND SHIPPING Attachment B 2-50,51,52 Each item and operation has a customized quality control procedure, to be checked either by documentation, witnessing or reports. Controls are redundant and extensive to assure top quality results.

10 An example of an individual position QCP, exploded and explained in the single steps with the relevant acceptation parameters and/or standards clearly explained.

11 MANUFACTURE AND TEST

12 Turning and grinding operation are made on CAM machines. Each Items have to pass all test required in QCP and witnessed by our personnel: Chemical analysis, mechanical tests, ut test, magnetic test, hardness test

13 Each item is assembled by our qualified personnel, and double checked before delivery

14 Final cardan shaft assembled are painted with our standard or by clients request.