THE POWER OF [E]MOTION P ol yC h ain® GT Timing Belts Walther Flender Gruppe PolyChain® GT Timing Belts Page 02 Page THE POWER OF [E]MOTION We are in motion for you … … with innovative, new service ideas and individual system solutions which we develop together with you. The Walther Flender Group stands for expertise, experience and commitment. With top class technology and craftsman’s know-how in the areas of drive and conveyor technology, bearing, clamping, and sintering technology, in addition to the automotive sector. We‘re looking forward to do more for you. The Walther Flender Group – we are packaged know-how for drive, conveyor, bearing and clamping technology as well as automotive technology. For more than 70 years as a family company and a market leader for timing belt drives, we have been offering a complete product range: from individually manufactured single parts, to drive assemblies and ready-to-install components, to industryspecific complete solutions. Complete expertise from engineering to implementation A large proportion of our business today is made up of special solutions. Experienced engineers from our development department, but also mechatronic engineers and technicians advise you comprehensively and develop a tailored concept based on your requirements and assisted by powerful 3D CAD programs. The products are tested in our own laboratories for their operational characteristics under various conditions of use, and complete assemblies are tested by means of computer supported simulations. During this process we work closely together with you in order to achieve the optimum result. Comprehensive quality management The entire Walther Flender Group with its four divisions is certified to DIN EN ISO 9001:2000 and therefore fulfils the high quality standards required by all of our customers. But you can expect even more from us. Because individual quality assurance agreements such as special sampling arrangements or companyspecific performance clauses are equally a given for us. We are pleased to make our quality management documentation available to you, in order to ensure the maximum transparency. New requirements bring new solutions Markets are changing ever more quickly today. We help to shape progress with innovations, flexibility and high service consciousness. Our own company development department is involved with new materials, processes and designs in order to optimise quality and efficiency even more. Service – as evident as it is first class Availability is a key for business success. That is what we stand for – with our logistics and project execution on the basis of the most modern ERP systems. Furthermore, our consultants are accessible to support you at all times. In the after-sales area, we support you for example in adjusting the belt tension, checking the running behaviour, or with important installation tips. The Walther Flender Group – core skills Drive technology: Timing belt drives, non-positive belt drives, frequency inverters, gears, assemblies Conveyor technology: Conveyor units, machine covers, system components Clamping and bearing technology: Clamping sets, adjusting rings, sliding bearings Automotive: Steering parts, wheel bearing sets, timing belts, wiper blades, sensors Further important information and news about the Walther Flender Group can also be found on the Internet at www.walther-flender-gruppe.de Walther Flender Gruppe PolyChain® GT Timing Belts Table of contents Page 03 Page Page Introduction General features A glance at practice Design characteristics Timing belts Design & components Models Timing belt pulleys Standard timing belt pulleys Timing belt pulleys – custom models 04 Manufacturing guidelines 11 Assembly & maintenance 14 Technical data Power output values & belt lengths Timing belt pitch 8MGT Timing belt pitch 14MGT Calculation & formulas 17 Standard line of timing belt pulleys Pitch 8 mm Pitch 14 mm Models 28 Clamping sets General features Calculation instructions Hub coefficient K Description of models & tables 33 Causes of malfunctions 43 Product overview 44 Project data sheet 45 Important notice: PolyChain® timing belts are not suitable for use in aircraft drive systems or other drive systems where a defective belt could result in bodily injury. Suitable protective measures must be taken to encapsulate exposed drive systems from unintended access! Note: All information in this catalogue is subject to change. Technical details subject to change. Errors excepted. 05 06 07 07 07 08 10 10 10 17 17 20 23 28 30 32 34 34 36 37 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE Page 04 4 Page Introduction The new PolyChain® timing belt systems present a line of timing belts that ensure up to 8 times higher power transmission as compared with classic drive systems; with the same space requirements, up to 30 % more power can be transmitted than with conventional PolyChain® GT belts. PolyChain® synchronous belts can be used in existing PolyChain® GT drive systems; they use the same pulleys and require no modifications to the drive. In addition to the existing PolyChain® GT2 belts, with tensile fibres made of aramid fiber, Walther Flender Antriebstechnik GmbH has expanded its product portfolio to include the new PolyChain® GT ­Carbon™ belt. The tensile member of this belt is made of carbon fibres, which enables the transmission of very high forces in a compact design. The PolyChain® GT2 belt construction is based on an innovative technological design. The polyurethane mixture used for the body and teeth of the belt is new and unique. PolyChain belts are therefore resistant to many oils, chemicals and fluids, which means that they have clear advantages over rubber timing belts in operating conditions where they are exposed to these substances. Example: Paint stripper drive unit for skid conveyor systems PolyChain® timing belts are available with pitches of 8 mm and 14 mm and, with a reliable power transmission of up to 950 kW, they set completely new standards in many areas of mechanical engineering. The completely maintenance-free and smooth-running PolyChain® belts are especially suitable as a replacement for slowrunning chain drives with high torques. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE Page 05 5 Page General features Positive power transmission The positive meshing of the PolyChain® belt teeth in the teeth of the drive pulleys ensures the positive synchronous transmission of power. Slippage and related deviations in speed are eliminated. No maintenance While chain drives generally have to be lubricated and require complex lubricating systems even for relatively low peripheral speeds, the PolyChain® timing belt drive unit operates entirely without lubrication. This minimizes the design and equipment requirements, in addition to eliminating contamination from the area around the drive unit. Constant angular velocity The PolyChain® timing belt wraps around the timing belt pulley in a circular pattern and not in the form of a polygon, preventing periodic fluctuations and vibrations. Noise level The PolyChain® timing belt drive satisfies requirements for low noise levels, as confirmed by extensive tests in cooperation with technical universities. The noise level is reduced by the special profile of the PolyChain® timing belt and by the c­ apability of Cost effectiveness Due to the high transmission capacity of PolyChain® timing belt drive systems, the pulley diameter and width can be reduced substantially as compared with other drive elements, saving additional installation space within the machine constructions. Constant belt tension Since PolyChain® timing belts do not elongate due to permanent plastic deformation when used within the permissible power range, the belt tension remains constant once the belt has been adjusted. Due to minimal stretching during the wear-in ­period, the belt tension can decrease slightly; one-time re-tightening is necessary only in exceptional cases, eliminating expensive and time-consuming maintenance at regular intervals. Drehzahl dersmallest kleinsten Scheibe (1/min) Speed of the pulley (1/min) . Power and speed range The power range of PolyChain® timing belts extends from slow-running drive units with extremely high torques, such as those that are typical for heavy chain drives, to high-performance drive units with several hundred kW. Belt speeds of more than 30 m/s are possible, in which case it may be necessary to provide suitable sound insulation. 10000 5000 1000 PC-8MGT2 100 PC-14MGT2 10 0,1 1 10 100 1000 10000 Berechnungsleistung (kW) Calculated power output (kW) . Diagram 1: Selection diagram: belt pitch PolyChain® GT2 . Drehzahl dersmallest kleinsten Scheibe (1/min) Speed of the pulley (1/min) With efficiency ratings as high as 98 %, PolyChain® timing belts are modern drive train elements that fully meet the trend for energy-saving drive units. maintaining the same power transmission with a narrower belt than those used in other systems. At high belt speeds, various options are available for reducing noise; please ask our application engineers. 10000 5000 1000 PCC-8MGTC 100 PCC-14MGTC 10 0,1 1 10 100 1000 10000 Berechnungsleistung (kW) Calculated power output (kW) Diagram 2: Selection diagram: belt pitch PolyChain® GT CarbonTM . Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 06 Page A glance at practice From a belt width of 125 mm to 68 mm: Efficient and costeffective drive technology due to innovative carbon tensile member CarbonTM By using the new PolyChain® timing belt in a heavyduty metal saw, the drive technology engineers at Walther Flender ­Antriebstechnik achieved cost reductions of up to 25 % and therefore more than satisfied the customer‘s requirement for a highperformance and economical timing belt drive system. With a maximum saw blade diameter of 2.2 meters, the metal saw of a well-known Austrian component manufacturer is certainly one of the largest saws on the market. The customer designed the saw with a time-tested PolyChain® timing belt drive unit. The belt width was 125 mm. Due to the maximum transferable power of 517.4 kW, the PolyChain® timing belt used for the system achieved a safety factor of 3.27. Based on the product presentation of the new PolyChain® GT Carbon™ belt and extensive technical advice from the Walther Flender Antriebstechnik sales engineers, the customer decided to rethink the existing drive unit and to have it checked by the WF drive technology engineers. An analysis of the existing design showed that the drive unit was overrated with the aforementioned safety factor. A safety factor of 2.0 is fully adequate for this type of drive unit. As a result, one of two alternative designs with the new PolyChain® GT Carbon™ timing belt was chosen. The design of the belt drive unit made optimal use of the advantages of the new PolyChain® GT CarbonTM timing belt. The WF drive technology engineers designed a drive with identical technology to the existing drive unit with a safety factor of 3.06, optimizing the system with an adequate safety factor of 2.3. In the first case, the use of the Carbon timing belt made it possible to reduce the original belt width from 125 mm to 90 mm, which reduces costs by about 14 % due to the smaller belt pulleys. In the optimized design, a timing belt with a width of 68 mm already achieves the required drive power. This even made it possible to reduce the costs by 25 %. The timing belt is driven via the corresponding PolyChain timing belt pulleys. The belt pulleys are equipped with special teeth that are precision-cut in the gear hobbing process. Only original timing belt pulley hobbing cutters are used. Only these original tools ensure a reliable and long-lasting timing belt drive unit. The modified timing belt drive unit has passed all test runs so far and the customer is already convinced of the high performance of the carbon belt and the advanced technological expertise of the Walther Flender drive technology engineers. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 07 Page Design characteristics Timing belts Design & components 1 2 1. The tensile member of the PolyChain® GT CarbonTM belt is made of carbon fibres, as opposed to the PolyChain® GT2 belt, which has a tensile member consisting of aramid fibres. Both fibre types give the belts their outstanding performance properties. In addition to exceptional bending fatigue strength, the tensile members feature high notch impact strength so they also resist impacts and vibrations. Unlike polyester, aramid and carbon fibres are thermally stable and can be used at extreme temperatures. They are chemically neutral and therefore resistant to oils, chemicals, dirt and corrosion. Both aramid and carbon fibres have a higher E-module than steel cord, with minimal stretching. 3 2. The elastic mixture from which the back and the cogs of the belt are made is a polyurethane specially developed and optimized for good adhesion to the cord and fabric. It is: • highly resistant to chemicals, oils and dirt • highly resistant to abrasion and therefore extremely durable • fully serviceable even at extreme temperatures (–54 °C to + 85 °C) 3. The surface of the PolyChain® belt is a specially woven and impregnated nylon fabric, which reduces friction on the timing belt pulleys and prevents heat build-up. This highly abrasion-resistant fabric makes the PolyChain® belt absolutely maintenance-free and smooth-running. During the wear-in period, the nylon fabric, which is specially impregnated in the production process, can show minimal signs of abrasion, especially at very high belt speeds. This abrasion is wholly acceptable and usually stops after only a few hours of operation. Note: With the PolyChain® GT Carbon™ belt, idler pulleys can be used as reverse idlers. However, PolyChain® GT2 belts are sensitive to the use of reverse idlers. Please observe the handling instructions especially with respect to storage and assembly. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 08 Page Models Endless design Weights per metre in kg for PolyChain® GT2 Pitches PolyChain® endless timing belts are manufactured with 8 mm and 14 mm pitches and are available in a large assortment of lengths and widths. The main dimensions of the timing belt are: Pitch (mm) 8 14 Belt width (mm) 12 20 21 36 37 62 68 90 125 0.057 0.099 0.170 0.293 0.158 0.292 0.536 0.709 0.985 Pitch – Pitch length – Width The timing belt pitch is the distance in millimeters between two adjacent tooth centres, measured on the timing belt pitch line. The pitch length is the total circumference of the timing belt in millimeters, measured on the belt pitch line. The theoretical pitch line of a PolyChain® timing belt is in the centre of the tensile member. The available timing belt lengths and standard widths are listed on pages 19 and 22. Dimensions Pitch (mm) t (mm) ht (mm) hS (mm) 8 14 8 14 3.4 6.0 5.9 10.2 Weights per metre in kg for PolyChain® CarbonTM Pitch (mm) 8 14 Belt width (mm) 12 21 36 37 62 68 90 The ordering designation includes the pitch, pitch length and belt width: PolyChain® GT2 PC-8MGT 640 - 12 Example: PC-14MGT 1190 - 37 ht PolyChain® GT CarbonTM Example: t Length tolerances (in relation to the centre distance of axes; specified in mm) Belt length Tolerance up to 762 above 762 to 1016 above 1,016 to 1,270 above 1,270 to 1,524 above 1,524 to 1,778 above 1,778 +/- 0,30 +/- 0,33 +/- 0,38 +/- 0,41 +/- 0,43 +/– 0.43 mm ± 0.03 mm for every 254 mm level for 1778 mm and above To use PolyChain® timing belts with fixed centre distances of axes, please consult our application engineers. PC-8MGT 640 - 12 Carbon PC-14MGT 1190 - 37 Carbon or Width tolerances For both 8 mm and 14 mm pitches, the tolerance is ±3 % of the belt width. 125 The weights per metre can vary slightly depending on the belt construction and the tolerance positions. or hs 20 0.056 0.099 0.169 0.291 0.158 0.292 0.537 0.711 0.987 Pitch (mm) Pitch length (mm) Width (mm) 8M 14 M 640 1190 12 37 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 09 Page Open-ended model (LongLength) Pitches PolyChain® GT2 Long Length (LL) timing belts are available with 8 mm and 14 mm pitches. Dimensions and weights Designation Standard widths (mm) PC-LL-8M PC-LL-14M 12 21 36 20 37 Weight per Maximetre in g mum (10 mm roll belt width) length 47.0 37 t ht hS (mm) (mm) (mm) 30 m 30 m 8 14 3.4 6.0 5.9 10.2 For information about dimensioning for special applications requiring other dimensions, please consult our application ­engineers. Technical information Permissible tangential loads in newtons (8M: 21 mm belt width, 14M: 37 mm belt width) Pitch 8M 14M 22 26 3097* 3151 Number of pulley teeth 28 30 34 38 40 ≥ 44 ≥ 52 3206 3237 3269 3278 9900* 10 204 10400 10599 * Minimum number of teeth 22 (8M) or 28 (14M) Minimum tensile strength in newtons Pitch 8M 14M Belt width in mm 20 21 11 254 20568 12 5787 36 19291 37 38054 Ordering designation The ordering designation includes the belt width, pitch length and roll length: PC-21-LL-8M 30M Example: Width (mm) Pitch (mm) Roll length (mm) 21 8M 30M Technical data of the PolyChain® CarbonTM Long Length timing belt is available on request. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 10 Timing belt pulleys PolyChain® timing belt pulleys are equipped with special precision-cut teeth in the gear hobbing process. Only original timing belt pulley hobbing cutters are used. Only these original tools ensure a reliable and long-lasting timing belt drive unit. Only ­PolyChain® timing belts and PolyChain® timing belt pulleys with the same pitch can be used together. The main features of the timing belt pulley are: Standard timing belt pulleys The information on pages 23 to 26 describes our extensive line of standard timing belt pulleys with and without taper lock clamping bushes. Standard pulleys are available for the following belt widths: Pitch designation Number of teeth, pitch, width, design The pitch of the timing belt pulley is measured on the pitch diameter and is the distance between the centres of two adjacent hollows. The pulley pitch diameter is always outside the outer diameter of the timing belt pulley and is congruent with the timing belt pitch line. Pitch line 8M 12 21 36 62 Nominal belt width in mm 14M 37 68 90 125 Standard timing belt pulleys are statically balanced; for drive systems with v > 30 m/s, please ask. Pitch diameter Ordering designation O r ute The ordering designation for PolyChain® timing belt pulleys includes the following: r ete m dia 8M - 48S - 36 3F Pitc h Pitch Number of teeth Pulley width designation (mm) Design 8M 48 36 3F Timing belt pulleys – standard and custom models Timing belt pulleys – custom models Standard timing belt pulleys are adequate for the requirements of many drive systems with respect to functionality and space conditions and are available on a short-term basis. Although the PolyChain® standard timing belt pulleys are available with different numbers of teeth and pulley designs for a broad range of applications, many applications require custom solutions with specially designed pulleys. For heavy-duty, precise drives requiring exact positioning, however, we recommend custom timing belt pulleys that we manufacture according to your drawings. Numerous custom teeth are available, for example for essentially backlash-free or quiet drive systems. In addition to the standard cast, aluminum and steel timing belt pulleys, pulleys made of numerous other materials, also with surface treatment, are available. Please ask our application engineers. Due to the high specific bearing percentage, standard aluminum (e.g. AlZn5,5MgCu) should generally be surface treated, for example hard coated, to ensure high wear resistance. For shaft and hub connections, we offer an extensive line of self-centring clamping sets: an overview of models can be found starting on page 37. We have adapted our production facilities to accommodate such solutions. We can deliver any timing belt pulley you require, based on your drawings; special processing, such as grinding, balancing or surface treatment, is also available. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 11 Manufacturing guidelines Due to the high belt loads and speeds that can occur, the use of non-wearing materials is preferable. We offer an extensive selection of pulleys made of steel, sintered metal and polymer, in addition to high-strength aluminum. The specified minimum pulley diameters should always be ­observed: 60 mm for 8 mm pitch and 130 mm for 14 mm pitch. Recommended pulley widths Tooth code ­designation 8M 14M Pulley width ­ designation * Smallest tooth width G mm Smallest pulley width with rim flanges** E mm 12 21 36 62 20 37 68 90 125 14 23 38 65 23 40 71 95 130 18 27 42 70 27 46 77 101 136 * Corresponds to the nominal belt width in mm. ** The specified pulley widths include a material allowance for producing the rim flanges and should always be taken into account. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 12 Position & shape tolerances The tooth surface quality, dimensional accuracy and pitch accuracy and the position and shape tolerances of the timing belt pulley have a significant influence on how smooth the drive system operates. Since the outer diameter of the pulleys is also surface milled during the hobbing process, turning produces blanks that are larger than the finished product. In finished state, the outer diameter has an especially close tolerance. – Tolerances of standard timing belt pulleys Outer diameter (mm) above to 50 100 101 175 176 300 301 500 501 800 Permissible deviation (mm) + 0.10 + 0.13 + 0.15 + 0.18 + 0.20 – Tolerances for custom timing belt pulleys all dimensions in mm – Bore dimensions of standard pulleys We recommend a tolerance in the range of IT 7 for the final bore. – Temperature expansion coefficient a of the timing belt pulley materials Thermal effects of the drive system can cause thermal ex­ pansion of the pulley diameters, which can affect the belt tension. ­Therefore, you should take into account the following thermal e­ xpansion coefficients in case of extreme tempera­ture fluctuations: Steel: 12,0 · 10–6 1/K Aluminum: 23,5 · 10–6 1/K – Balancing Rotationally symmetric timing belt pulleys machined on all sides for standard drive systems do not need to be balanced. High-speed timing belt pulleys for precise drive systems are ­balanced according to DIN/ISO 1940 (previously VDZ 2060). In case of a quality grade of less than 6.3, please contact our ­application engineers. Permissible Rough Outer diameter (mm) Permissible above to tolerance c­ oncentricity tolerance ­allowance da+ 50 100 + 0.08 0.05 101 150 + 0.10 0.07 151 200 + 0.12 0.1 201 300 + 0.15 1.0 mm 0.12 + 301 500 + 0.18 0.03 pro 501 ... + 0.20 100 mm Concentricity Runout – Run-out tolerance Outer diameter range (mm) Permissible deviations (mm) to 101.60 0.10 above to 101.60 250.00 above 251.00 0.1 + 0.1 mm per 100 mm outer diameter 0.25 + 0.05 mm per 100 mm outer diameter Ou ter dia me ter Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 13 Rim flanges 8°min 25°max x min. Dmin = 0.5 It should be noted, however, that the driven timing belt pulley should always be equipped with double flanges, since this makes it easier to guide the slack side. For very large centre distances of axes (> 8 · d) and transmission ratios of 1 : 3 or higher and for ­vertical shaft positions, both timing belt pulleys should have double flanges. Poly Chain® 8M Number of teeth 22 23 24 25 26 – 27 28 – 29 30 31 – 32 33 34 – 35 36 37 – 38 39 – 40 41 – 42 43 44 – 45 46 – 48 49 – 51 52 – 53 54 – 55 56 – 57 58 – 61 62 – 64 65 – 67 68 – 70 71 – 73 74 – 77 78 – 83 84 – 92 93 94 – 99 100 – 107 xmin = 6.0 mm S Ø A ± 0.15 Ø B ± 0.5 The rim flanges are bevelled for better guidance of the timing belt when it runs onto the pulley. Straight rim flanges sometimes have the disadvantage that, if the shaft is not aligned precisely, the belt tooth can run onto the inside edge of the flange, resulting in premature wear. Therefore, we do not recommend using straight rim flanges without a bevel. Ø C ± 0.5 We offer an extensive standard line of galvanized steel flanges; please use the rim flange dimensions in the following tables for your design. D Outer Ø Rim flanges for belt guidance Poly Chain® timing belt pulley drive systems are designed with a double flanged pulley for guiding the timing belt. To reduce costs, the smaller timing belt pulley is frequently provided for this purpose. Dmin: Minimum material overlap for functional rolling of rim flange Note: depending on the angle, the outer edge of the rim flange may not be flush with the front face of the timing belt pulley! Poly Chain® 14M Code 18 L 14 H 15 H 16 H 17 H 18 H 19 H 20 H 21 H 22 H 23 H 24 H 25 H 26 H 27 H 28 H 30 H 32 H 33 H 34 H 36 H 38 H 40 H 42 H 44 H 46 H 48 H L216 L238 L260 L260 S L280 A (mm) 48 47 51 53 57 60 64 68 73 76 79 82.5 87 91 97 99 107 116 120 126 132 140 148 156 164 172 180 190 200 210 230 230 B (mm) 54 57 60.5 64 68 72 76 79 84 88 91 96 100 105 109 114 121 129 134 139 145 154 161 170 177 186 195 – – – – – C (mm) 60 63 66.5 71 75 79 83 87 91 93 97 103 106 111 115 119 127 135 140 146 152 160 168 176 184 192 200 216 238 260 260 280 s (mm) 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2.5 2 2.5 Number of teeth Code A (mm) B (mm) 28 L138 105 – 29 – 30 L142 90 – 31 – 32 L156 105 – 33 – 34 L172 115 – 35 – 38 L186 130 – 39 – 43 L200 144 – 44 – 46 L215 160 – 47 – 49 L230 190 – 50 – 52 L242 185 – 53 – 55 L260 210 – 56 – 59 L280 230 – 60 – 64 L300 250 – 65 – 68 L320 260 – 69 – 73 L340 280 – 74 – 79 L372 300 – 80 – 84 L385 330 – 85 – 92 L420 360 – > 92 no standard flange, flange has to be adapted. xmin = 6.0 mm C (mm) 138 142 156 172 186 200 215 230 242 260 280 300 320 340 372 385 420 s (mm) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 14 Assembly & maintenance Installation Proper handling during installation of the timing belt is very important. Avoid bending, twisting, winding or kinking the belts. Under no circumstances should force be applied to put the timing belt on the pulleys. max. 0.25° max. 5 min. / 1 m Installation guidelines For the belt to run straight, it is essential to carefully align the shafts and timing belt pulleys so they are parallel. Impermissible deviations from parallel cause different edge tensions in the belt, causing the belt to run off toward the side with the highest tension or to run up against the flange. At high speeds, the latter can cause excessive noise and excessive wear of the belt. In the case of larger centre distances of axes, it is more difficult to align the shafts precisely, increasing the tendency for the timing belt to run off to one side. Therefore, take measures to ensure that the belt does not run off the face of the timing belt pulleys. It may be necessary to move the driven pulley slightly. Electrical conductivity Tests have shown that PolyChain® timing belts do not conduct electricity under dynamic operating conditions. This can result in static electricity with uncontrolled malfunctions. If PolyChain® ­timing belts are used in potentially explosive areas, we recommend taking measures to ensure that no electrical charge can ­occur before operating the system. This means that the entire system has to be properly earthed. Ambient influences Temperatures PolyChain® timing belts can generally be used in a temperature range between –54 °C and +85 °C. For operating conditions outside of this temperature range, please contact us. Chemical resistance Field and lab tests guarantee resistance against many acids, caustic solutions, grease and oil. Of course, the service life and durability of the timing belt also depend on the concentration of the substance to which it is exposed (e.g. droplets, spray or constant immersion). For special applications, please ask our application engineers. Adjustment tolerances Since fixed (non-adjustable) centre distances of axes can be ­recommended only for slow-running drive systems, the use of a PolyChain® timing belt drive system requires that the timing belt can easily be installed and that the belt tension can be precisely adjusted. The mounting dimension must allow for easy mounting of the belt on a timing belt pulley with rim flanges. The minimum dimensions for the respective centre distances of axes are listed in the tables below. The travel of the centre distance of axes for mounting and adjustment of the belt tension is shown in the right column. Adjustment tolerances without rim flange Belt length (mm) to 1000 from 1000 up to 1780 from 1780 up to 2540 from 2540 up to 3300 from 3300 up to 4600 Travel (mm) for mounting the timing belt Travel (mm) for adjusting the timing belt tension 1.8 0.8 2.8 0.8 3.3 1.0 4.1 1.0 5.3 1.3 Adjustment tolerances with rim flange Pitch Rim flanges on one timing belt pulley (mm) Rim flanges on both timing belt pulleys (mm) 8 mm 14 mm 21.8 31.2 33.3 50.0 Fixed centre distance of axes Belts with a pitch of 8M can be used up to a pitch length of ca. 1,600 mm for slow running drives (n ≤ 100 rpm) with fixed centre distances of axes; the tolerance for the centre distance of axes should be within the calculated range of 0 to –0.2 mm. Since the pulley diameter should also be within close tolerances, please ask our application engineers. Idlers Idlers should only be used on drive systems with a fixed centre distance of axes and should be mounted on the inside of the slack side. We recommend using idlers with up to 40 teeth. For larger diameters, smooth idlers without teeth can also be used. An idler exerting force on the back should not be used with aramid belts, since they have a negative effect on the service life due to the special construction of the timing belts. For carbon belts, the minimum diameter for outer idlers is 70 mm for a pitch of 8 mm and 150 mm for a pitch of 14 mm. Inner idlers should not be smaller than the smallest power transmitting timing belt pulley. To maximize the number of meshing teeth on the small timing belt pulley, it is recommended to position the idler near the large pulley on the slack side. If the belt touches the idler with only one tooth, this can result in high noise levels. It is better to have several belt teeth mesh with the pulley. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 15 Belt tension The Poly Chain® timing belt needs a certain tension during operation to maintain reliable engagement of the teeth also under intermittent loads and temporary overloads. Unnecessarily high initial tension reduces the service life of the drive system, increases wear on the bearings and the teeth, and also increases the noise level. Insufficient tension can prevent the belt teeth from meshing properly in the pulley teeth, which can even cause the belt to skip in case of an overload. Depending on the application and the particular dynamic peak loads, the belt tension can deviate from the calculated initial tension, so that the calculation provided here should be used only as a recommendation for standard applications. This applies especially to drive systems with extreme impact and pulse loads; in this case, please contact us. 1. Frequency measurement A precise method for pre-setting the correct belt tension is to measure the frequency with the WF Tension Meter (Figure 1) or the Gates-Sonic Tension Meter (Figure 2). With a sensing head that is held above the installed belt it is possible to measure the ­frequency at the pre-tensioned belt in order to achieve the optimum belt tension. The calculated oscillation frequency f [Hz] depends on the freely oscillating span length L [m], the static initial tension load FSt [N] and the weight per meter m [kg/m] of the belt and corresponds to the relationship f= 1 2·L · √ Fm St Calculation of the static initial load FSt = K · Pv+ m · v2 FSt [N] = Static initial tension P [kW] = Installed motor power output v [m/s] = Belt speed K = 600 m = Factor for weight per metre, see table K = Constant for compensating for impact loads max. initial tension for compensating for pulse loads Figure 1: WF Tension Meter Figure 2: Gates Sonic Tension Meter 507C For a detailed description of the instruments and detailed calculation documentation, please contact our application engineers. 2. Test load method Pitch Belt width (mm) 12 21 36 62 20 14 mm 37 68 90 125 Table: Calculation factors for belt tension 8 mm m Y 0.057 0.098 0.167 0.290 0.158 0.291 0.536 0.711 0.986 80 140 240 413 245 454 834 1103 1530 Belt width (mm) 12 21 36 62 20 37 14 mm 68 90 125 Table: Minimum initial tension of PolyChain® timing belts 8 mm S d FP S= If the transmission capacity is significantly higher than the calculated capacity of the belt, the calculations can result in incorrect belt tensions. In this case, please use the minimum initial tensions specified in the following table: Pitch Calculation of deflection Min. Fst Values (N) 125 220 375 645 530 980 1800 2380 3310 Checking the belt tension Two methods can be used for checking the belt tension: 1. Frequency measurement and 2. Test load method √A – [ d 2 wG – dwk 2 ] 2 S : d : dwk : dwG : FP : A : Span length for test force measurement (mm) Deflection (mm) Pitch diameter of the small pulley (mm) Pitch diameter of the large pulley (mm) Test force (N) Centre distance of axes (mm); separate tables are available for the calculation and will be provided on request. If the span tension is set correctly, the deflection is d ~ 1/100 · S Calculation of test force FP = S ·Y lw 25 FSt + FP : Test force (N) FSt : Static initial tension lw : Pitch length (mm) Y : Constant (see table) Adjusting the initial tension For the calculated test force, the deflection should be ca. 1/100 of the span length [mm] of the test force measurement. It may be necessary to correct the belt tension. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 16 Storage & maintenance PolyChain® timing belts require no special maintenance. During the wear-in period of heavy-duty drive systems there may be some reduction in the belt tension; in this case, it is necessary to retighten the belts only once with 50 % of the original initial tension. When storing belts, they should never be kinked or folded tightly, because this can damage the tensile members. Therefore, we recommend that timing belts be stored in the original package until needed; during storage, belts should be protected from extreme temperatures, humidity and UV radiation. Clamping elements For secure fastening of the timing belt pulley to the shaft, you can use the conventional feather key connection or any number of frictionally engaged, removable clamping elements for all standard bore dimensions. In addition to the TL (TaperLock®) bushes used primarily for standard pulleys, we offer an extensive line of cylindrical inner and outer clamping sets, which are especially suitable to fulfil requirements for optimal true running properties. Please note the required minimum hub and minimum wall thicknesses to ensure reliable use of the clamping sets; please contact us before using aluminum pulleys. Further information on our clamping sets can be found starting on page 33. Advantages of the positive locking cylindrical clamping ­elements: – Easy mounting and removal Mounting and removal by tightening or loosening the clamping screws using conventional tools. A precise torque can be achieved by using a torque wrench. Oil the clamping set lightly when mounting it. Do not use oil containing molybdenum disulfide and do not use grease. – Backlash-free connection The clamping sets provide a positive-locking, backlash-free connection that can be released at any time. – Large machining tolerances The following fitting combinations are recommended: Tolerances in the shaft diameter: h 7/h 9 Tolerances in the hub bore diameter: H 7/H 9 Surface roughness ≤ RZ 16 The runout error is between 0.02 and 0.04 mm, depending on the model; all clamping elements listed here are self-centring. – High fatigue strength No weakening of the shaft and pulley bore by keyways. – Easy adjustment Since no profile end mating is necessary, the components can be fastened at a precise angle in any required position. – Overload protection If the maximum torque is exceeded, slippage of the clamping set prevents damage to the connected parts. Repeated slipping should be avoided. – Economical connection An economical shaft/hub connection, due to ease of manufacturing the smooth cylindrical shaft and bore fit. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 17 Technical data Power output values & belt lengths Timing belt pitch PC - 8MGT and PC - 8MGT Carbon Calculation of the dimensions and design of belt drive units can be based on the motor side (motor power output) and on the load side (load collectives). Both calculations – depending on the existing safety factors, desired service life or any load-­side efficiency losses – can result in designs for drive systems with ­ ifferent overall widths. In addition to the load value calculation, d therefore, we also recommend that you use the following power output table to compare the actual tangential loads with the ­maximum permissible loads. Maximum permissible tangential loads The values listed in the following tables represent the operationally useable tangential loads. The listed values apply to quasistatic loads, i.e. for low speed ranges (n ≤ 100 rpm) with the use of timing belt pulleys with at least 34 teeth. The initial tensions for mounting of the belts are already included in the power output values and do not have to be subtracted from the listed values. PolyChain® GT2 PolyChain® GT Carbon™ Belt width Fzul (mm) (N) 12 2012 21 3521 36 6037 62 10397 Belt width Fzul (mm) (N) 12 2404 21 4208 36 7213 62 12431 Power output in kW / 12 mm belt width Note: The following power output data was obtained in extensive series of tests on the basis of defined service life values and includes safety factors that were defined internally beforehand to achieve the corresponding service life. Therefore, the power ­ utput data cannot be compared directly with data of other o manufacturers; if you have any questions, please contact our ­application engineers. PolyChain® GT2 Power output of the small timing belt pulley Speed of the small pulley 10 20 40 60 100 200 300 400 500 600 700 730 800 900 1,000 1,200 1,400 1,460 1,600 1,800 2,000 2,400 2,800 2,880 3,200 3,500 4,000 4,500 5,000 5,500 22 25 28 30 32 34 36 38 40 56.02 63.66 71.30 76.39 81.49 86.58 91.67 96.77 101.86 114.59 122.23 127.32 142.60 152.79 162.97 190.99 203.72 0.10 0.16 0.25 0.34 0.51 0.90 1.26 1.61 1.94 2.26 2.58 2.67 2.89 3.19 3.49 4.07 4.64 4.81 5.19 5.73 6.27 7.30 8.29 8.49 9.26 9.97 11.11 12.22 13.30 14.34 0.12 0.18 0.30 0.40 0.60 1.07 1.51 1.92 2.33 2.72 3.11 3.22 3.48 3.85 4.22 4.93 5.62 5.82 6.30 6.96 7.61 8.88 10.11 10.35 11.30 12.18 13.59 14.97 16.30 17.58 0.14 0.21 0.34 0.46 0.70 1.24 1.75 2.24 2.71 3.17 3.63 3.76 4.07 4.50 4.93 5.77 6.59 6.83 7.39 8.17 8.94 10.44 11.90 12.19 13.31 14.35 16.03 17.66 19.23 20.76 0.15 0.23 0.37 0.50 0.76 1.35 1.91 2.45 2.97 3.47 3.97 4.12 4.46 4.93 5.41 6.33 7.23 7.49 8.11 8.97 9.82 11.48 13.08 13.40 14.64 15.78 17.63 19.43 21.16 22.83 0.16 0.24 0.40 0.54 0.82 1.47 2.07 2.66 3.22 3.77 4.31 4.47 4.84 5.36 5.88 6.88 7.86 8.15 8.83 9.77 10.69 12.50 14.25 14.60 15.95 17.20 19.22 21.17 23.06 24.88 0.17 0.26 0.43 0.58 0.88 1.58 2.23 2.86 3.47 4.07 4.65 4.83 5.23 5.79 6.34 7.43 8.50 8.81 9.54 10.56 11.56 13.52 15.41 15.79 17.26 18.60 20.79 22.90 24.93 26.89 0.18 0.28 0.46 0.62 0.94 1.69 2.39 3.07 3.72 4.36 4.99 5.18 5.61 6.21 6.81 7.98 9.12 9.46 10.24 11.34 12.42 14.53 16.57 16.97 18.55 20.00 22.34 24.60 26.78 28.87 0.19 0.29 0.48 0.66 1.00 1.80 2.55 3.27 3.97 4.66 5.33 5.53 5.99 6.63 7.27 8.53 9.75 10.11 10.95 12.12 13.28 15.53 17.71 18.14 19.83 21.38 23.88 26.29 28.60 30.83 0.20 0.31 0.51 0.70 1.07 1.91 2.71 3.48 4.22 4.95 5.66 5.87 6.36 7.05 7.73 9.07 10.37 10.76 11.65 12.90 14.13 16.52 18.85 19.30 21.10 22.74 25.40 27.95 30.40 32.74 45 0.23 0.35 0.58 0.80 1.22 2.19 3.10 3.98 4.84 5.68 6.50 6.74 7.30 8.09 8.88 10.41 11.91 12.35 13.38 14.82 16.23 18.98 21.65 22.17 24.22 26.10 29.12 32.02 34.78 37.40 Max. power output = (Table output + additional output) x length factor x width factor 48 0.24 0.38 0.63 0.86 1.31 2.35 3.33 4.28 5.21 6.11 6.99 7.25 7.86 8.71 9.56 11.21 12.82 13.30 14.41 15.96 17.48 20.44 23.30 23.86 26.07 28.08 31.31 34.39 37.32 50 0.25 0.40 0.66 0.90 1.37 2.46 3.49 4.48 5.45 6.39 7.32 7.59 8.23 9.12 10.01 11.74 13.43 13.93 15.09 16.71 18.30 21.40 24.39 24.98 27.28 29.38 32.75 35.95 38.98 56 0.29 0.45 0.74 1.02 1.54 2.78 3.95 5.08 6.18 7.25 8.30 8.61 9.33 10.35 11.35 13.31 15.23 15.80 17.11 18.95 20.75 24.25 27.63 28.28 30.87 33.21 36.96 60 0.31 0.48 0.80 1.09 1.66 3.00 4.26 5.47 6.66 7.81 8.94 9.28 10.06 11.15 12.23 14.35 16.42 17.03 18.44 20.42 22.36 26.13 29.74 30.44 33.20 35.70 39.68 64 0.33 0.51 0.85 1.17 1.78 3.21 4.56 5.87 7.13 8.37 9.59 9.95 10.78 11.96 13.11 15.38 17.60 18.25 19.76 21.88 23.96 27.97 31.82 32.57 35.50 38.14 75 0.39 0.60 1.00 1.38 2.10 3.79 5.39 6.93 8.43 9.90 11.33 11.76 12.75 14.13 15.50 18.18 20.79 21.56 23.34 25.83 28.25 32.93 37.38 38.24 41.58 80 0.41 0.64 1.07 1.48 2.25 4.05 5.76 7.41 9.02 10.58 12.12 12.58 13.63 15.11 16.58 19.44 22.22 23.04 24.94 27.58 30.16 35.13 39.82 40.73 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 18 PolyChain® GT Carbon™ Power output of the small timing belt pulley Speed of the small pulley 10 20 40 60 100 200 300 400 500 600 700 800 900 1,000 1,200 1,400 1,600 1,800 2,000 2,400 2,800 3,200 3,500 4,000 4,500 5,000 5,500 Number of teeth 38 40 45 Pitch diameter 56.02 63.66 71.30 76.39 81.49 86.58 91.67 96.77 101.86 114.59 0.11 0.13 0.15 0.17 0.18 0.19 0.21 0.22 0.23 0.26 0.17 0.21 0.24 0.26 0.28 0.31 0.33 0.35 0.37 0.42 0.29 0.34 0.40 0.44 0.48 0.51 0.55 0.59 0.63 0.72 0.39 0.47 0.55 0.61 0.66 0.71 0.76 0.82 0.87 1.00 0.59 0.72 0.84 0.93 1.01 1.09 1.17 1.26 1.34 1.54 1.06 1.29 1.53 1.68 1.83 1.99 2.14 2.29 2.44 2.82 1.50 1.84 2.17 2.40 2.62 2.84 3.06 3.28 3.50 4.05 1.92 2.36 2.80 3.09 3.38 3.67 3.95 4.24 4.53 5.24 2.33 2.87 3.41 3.77 4.12 4.47 4.83 5.18 5.53 6.40 2.73 3.37 4.01 4.43 4.85 5.27 5.68 6.10 6.51 7.54 3.12 3.86 4.59 5.08 5.56 6.05 6.53 7.01 7.48 8.67 3.50 4.34 5.17 5.72 6.27 6.81 7.36 7.90 8.44 9.78 3.88 4.81 5.74 6.35 6.96 7.57 8.18 8.78 9.38 10.88 4.25 5.28 6.30 6.98 7.65 8.32 8.99 9.65 10.32 11.96 4.98 6.20 7.41 8.21 9.00 9.80 10.59 11.37 12.16 14.10 5.69 7.10 8.49 9.41 10.33 11.25 12.16 13.06 13.97 16.21 6.39 7.98 9.56 10.60 11.64 12.67 13.70 14.73 15.75 18.28 7.08 8.85 10.61 11.77 12.93 14.08 15.22 16.37 17.50 20.32 7.75 9.71 11.64 12.92 14.20 15.46 16.73 17.98 19.23 22.34 9.07 11.38 13.67 15.18 16.69 18.19 19.68 21.16 22.63 26.29 10.36 13.02 15.65 17.39 19.12 20.84 22.56 24.26 25.95 30.15 11.61 14.61 17.59 19.55 21.51 23.45 25.38 27.29 29.20 33.92 12.53 15.79 19.01 21.14 23.26 25.36 27.45 29.53 31.59 36.69 14.03 17.71 21.34 23.74 26.13 28.49 30.84 33.17 35.48 41.19 15.49 19.58 23.62 26.28 28.92 31.54 34.14 36.71 39.27 45.56 16.92 21.41 25.84 28.76 31.65 34.51 37.35 40.16 42.95 49.79 18.31 23.19 28.00 31.17 34.31 37.41 40.48 43.51 46.52 53.87 22 25 28 30 32 34 36 48 122.23 0.28 0.45 0.77 1.08 1.66 3.05 4.37 5.66 6.92 8.16 9.38 10.58 11.77 12.95 15.27 17.55 19.79 22.00 24.18 28.46 32.64 36.71 39.70 44.56 49.27 53.81 50 127.32 0.30 0.48 0.81 1.13 1.74 3.20 4.59 5.94 7.27 8.57 9.85 11.11 12.36 13.60 16.04 18.43 20.79 23.12 25.41 29.91 34.29 38.56 41.70 46.79 51.71 56.45 56 142.60 0.34 0.54 0.92 1.28 1.98 3.64 5.23 6.78 8.30 9.78 11.25 12.70 14.13 15.54 18.33 21.08 23.78 26.44 29.06 34.19 39.19 44.05 47.61 53.36 60 152.79 0.36 0.58 0.99 1.39 2.14 3.94 5.66 7.34 8.98 10.59 12.18 13.75 15.30 16.83 19.86 22.83 25.75 28.63 31.47 37.02 42.41 47.65 51.48 57.66 64 162.97 0.39 0.62 1.07 1.49 2.30 4.24 6.09 7.89 9.66 11.39 13.11 14.79 16.46 18.11 21.37 24.57 27.71 30.81 33.86 39.82 45.60 51.21 55.30 75 190.99 0.46 0.74 1.27 1.77 2.74 5.04 7.25 9.41 11.51 13.59 15.63 17.65 19.64 21.61 25.49 29.30 33.04 36.72 40.34 47.39 54.20 60.76 80 203.72 0.49 0.79 1.36 1.89 2.93 5.41 7.78 10.09 12.35 14.58 16.77 18.93 21.07 23.18 27.34 31.43 35.44 39.38 43.24 50.77 58.02 Max. power output = (Table output + additional output) x length factor x width factor Design information on page 23 Additional power output [kW] for step-down ratio PolyChain® GT2: Speed of the small pulley 200 300 400 500 600 700 730 800 900 1,000 1,200 1,400 1,460 1,600 1,800 2,000 2,400 2,800 2,880 3,200 3,500 4,000 4,500 5,000 5,500 1 to 1.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.05 to 1.11 0.01 0.02 0.03 0.03 0.04 0.05 0.05 0.05 0.06 0.06 0.08 0.09 0.09 0.10 0.12 0.13 0.16 0.18 0.19 0.21 0.23 0.26 0.29 0.32 0.36 1.12 to 1.19 0.03 0.04 0.05 0.07 0.08 0.09 0.09 0.10 0.12 0.13 0.16 0.18 0.19 0.21 0.23 0.26 0.31 0.36 0.37 0.42 0.46 0.52 0.59 0.65 0.72 1.2 to 1.3 0.04 0.06 0.08 0.10 0.12 0.14 0.14 0.16 0.18 0.20 0.23 0.27 0.28 0.31 0.35 0.39 0.47 0.55 0.56 0.62 0.68 0.78 0.88 0.98 1.07 1.31 to 1.45 0.05 0.08 0.10 0.13 0.16 0.18 0.19 0.21 0.23 0.26 0.31 0.36 0.38 0.42 0.47 0.52 0.62 0.73 0.75 0.83 0.91 1.04 1.17 1.30 1.43 1.46 to 1.65 0.07 0.10 0.13 0.16 0.20 0.23 0.24 0.26 0.29 0.33 0.39 0.46 0.47 0.52 0.59 0.65 0.78 0.91 0.94 1.04 1.14 1.30 1.46 1.63 1.79 Additional power output [kW] for step-down ratio PolyChain® CarbonTM: 1.66 to 1.99 0.08 0.12 0.16 0.20 0.23 0.27 0.28 0.31 0.35 0.39 0.47 0.55 0.57 0.62 0.70 0.78 0.94 1.09 1.12 1.25 1.37 1.56 1.76 1.95 2.15 2 to 2.63 0.09 0.14 0.18 0.23 0.27 0.32 0.33 0.36 0.41 0.46 0.55 0.64 0.66 0.73 0.82 0.91 1.09 1.27 1.31 1.46 1.59 1.82 2.05 2.28 2.50 2.64 to 4.47 0.10 0.16 0.21 0.26 0.31 0.36 0.38 0.42 0.47 0.52 0.62 0.73 0.76 0.83 0.94 1.04 1.25 1.46 1.50 1.66 1.82 2.08 2.34 2.60 2.86 2.15 Speed of the 1.00 1.02 1.05 1.10 1.15 1.21 1.30 1.43 1.64 and small pulley 1.02 1.05 1.10 1.15 1.21 1.30 1.43 1.64 2.15 over 20 0.00 0.00 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.01 40 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.02 0.02 0.02 60 0.00 0.00 0.01 0.01 0.01 0.02 0.02 0.02 0.03 0.03 100 0.00 0.01 0.01 0.02 0.02 0.03 0.04 0.04 0.05 0.05 200 0.00 0.01 0.02 0.04 0.05 0.06 0.07 0.08 0.09 0.11 300 0.00 0.02 0.04 0.05 0.07 0.09 0.11 0.12 0.14 0.16 400 0.00 0.02 0.05 0.07 0.09 0.12 0.14 0.17 0.19 0.21 500 0.00 0.03 0.06 0.09 0.12 0.15 0.18 0.21 0.24 0.27 600 0.00 0.04 0.07 0.11 0.14 0.18 0.21 0.25 0.28 0.32 700 0.00 0.04 0.08 0.12 0.17 0.21 0.25 0.29 0.33 0.37 800 0.00 0.05 0.09 0.14 0.19 0.24 0.28 0.33 0.38 0.43 900 0.00 0.05 0.11 0.16 0.21 0.27 0.32 0.37 0.43 0.48 1,000 0.00 0.06 0.12 0.18 0.24 0.30 0.36 0.42 0.47 0.53 1,200 0.00 0.07 0.14 0.21 0.28 0.36 0.43 0.50 0.57 0.64 1,400 0.00 0.08 0.17 0.25 0.33 0.42 0.50 0.58 0.66 0.75 1,600 0.00 0.10 0.19 0.29 0.38 0.47 0.57 0.66 0.76 0.85 1,800 0.00 0.11 0.21 0.32 0.43 0.53 0.64 0.75 0.85 0.96 2,000 0.00 0.12 0.24 0.36 0.47 0.59 0.71 0.83 0.95 1.07 2,400 0.00 0.14 0.28 0.43 0.57 0.71 0.85 1.00 1.14 1.28 2,800 0.00 0.17 0.33 0.50 0.66 0.83 1.00 1.16 1.33 1.50 3,200 0.00 0.19 0.38 0.57 0.76 0.95 1.14 1.33 1.52 1.71 3,500 0.00 0.21 0.41 0.62 0.83 1.04 1.25 1.45 1.66 1.87 4,000 0.00 0.24 0.47 0.71 0.95 1.19 1.42 1.66 1.90 2.14 4,500 0.00 0.27 0.53 0.80 1.07 1.34 1.60 1.87 2.14 2.40 5,000 0.00 0.30 0.59 0.89 1.19 1.48 1.78 2.08 2.37 2.67 5,500 0.00 0.33 0.65 0.98 1.30 1.63 1.96 2.28 2.61 2.94 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 19 Timing belt pulley diameter Standard lengths and length correction factors S6 Standard widths 12, 21, 36, 62 mm Pitch length (mm) Length ­correction factor Number of teeth 640 720 800 896 960 1,000 1,040 1,120 1,200 1,224 1,280 1,440 1,600 1,760 1,792 2,000 2,200 2,240 2,400 2,520 2,600 2,800 2,840 3,048 3,200 3,600 4,000 4,400 4,480 0.79 0.83 0.87 0.91 0.94 0.96 0.97 1.00 1.03 1.03 1.05 1.10 1.14 1.17 1.18 1.22 1.26 1.26 1.29 1.31 1.32 1.35 1.36 1.38 1.40 1.45 1.49 1.52 1.53 80 90 100 112 120 125 130 140 150 153 160 180 200 220 224 250 275 280 300 315 325 350 355 381 400 450 500 550 560 Width factor S7 Belt width Width factor 12 1 21 1.75 36 3.00 62 5.17 Timing belts in custom lengths* Number of teeth Length (mm) Number of teeth Length (mm) 31 36 44 52 248 288 352 416 57 60 68 76 456 480 544 608 * Length correction factors and permissible power output data available on request; may necessitate longer delivery times and minimum purchase quantities. Number of teeth Pitch ø (mm) Outer ø (mm) Number of teeth Pitch ø (mm) Outer ø (mm) 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 56.02 58.57 61.12 63.66 66.21 68.75 71.30 73.85 76.39 78.94 81.49 84.03 86.58 89.13 91.67 94.22 96.77 99.31 101.86 104.41 106.95 109.50 112.05 114.59 117.14 119.68 122.23 124.78 127.32 129.87 132.42 134.96 137.51 140.06 142.60 145.15 147.70 150.24 152.79 155.33 157.88 160.43 162.97 165.52 168.07 170.61 173.16 175.71 178.25 180.80 54.42 56.97 59.52 62.06 64.61 67.15 69.70 72.25 74.79 77.34 79.89 82.43 84.98 87.53 90.07 92.62 95.17 97.71 100.26 102.81 105.35 107.90 110.44 112.99 115.54 118.08 120.63 123.18 125.72 128.27 130.82 133.36 135.91 138.46 141.00 143.55 146.10 148.64 151.19 153.74 156.28 158.83 161.37 163.92 166.47 169.01 171.56 174.11 176.65 179.20 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 183.35 185.89 188.44 190.99 193.53 196.08 198.62 201.17 203.72 206.26 208.81 211.36 213.90 216.45 219.00 221.54 224.09 226.64 229.18 231.73 234.28 236.82 239.37 241.92 244.46 247.01 249.55 252.10 254.65 257.19 259.74 262.29 264.83 267.38 269.93 272.47 275.02 277.57 280.11 282.66 285.21 287.75 290.30 292.85 295.39 297.94 300.48 303.03 305.58 181.75 184.29 186.84 189.39 191.93 194.48 197.03 199.57 202.12 204.66 207.21 209.76 212.30 214.85 217.40 219.94 222.49 225.04 227.58 230.13 232.68 235.22 237.77 240.32 242.86 245.41 247.95 250.50 253.05 255.59 258.14 260.69 263.23 265.78 268.33 270.87 273.42 275.97 278.51 281.06 283.61 286.15 288.70 291.24 293.79 296.36 298.88 301.43 303.98 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 20 Timing belt pitch PC – 14MGT and PC – 14MGT Carbon Calculation of the dimensions and design of belt drive units can be based on the motor side (motor power output) and on the load side (load collectives). Both calculations – depending on the existing safety factors, desired service life or any load-side efficiency losses – can result in designs for drive systems with different over- all widths. In addition to the load value calculation, therefore, we also recommend that you use the following power output table to compare the actual tangential loads with the maximum permissible loads. Maximum permissible tangential loads The values listed in the following tables represent the operationally useable tangential loads. The listed values apply to quasistatic loads, i.e. for low speed ranges (n ≤ 100 rpm) with the use of timing belt pulleys with at least 34 teeth. The initial tensions for mounting of the belts are already included in the power output values and do not have to be subtracted from the listed values. PolyChain® GT2 PolyChain® GT Carbon™ Belt width Fzul (mm) (N) 37 11289 68 20747 90 27460 125 38138 Belt width Fzul (mm) (N) 37 13829 68 25416 90 33639 125 46720 Power output in kW / 20 mm belt width Note: The following power output data was obtained in extensive series of tests on the basis of defined service life values and includes safety factors that were defined internally beforehand to achieve the corresponding service life. Therefore, the power ­ utput data cannot be compared directly with data of other o manufacturers; if you have any questions, please contact our ­application engineers. Poly Chain® GT2 Power output of the small timing belt pulley Speed of the small pulley 28 124.78 10 20 40 80 100 200 300 400 500 600 700 730 800 900 1,000 1,200 1,400 1,460 1,600 1,800 2,000 2,400 2,800 2,880 3,200 3,500 4,000 0.72 1.10 1.80 3.05 3.64 6.40 8.95 11.36 13.68 15.92 18.09 18.73 20.21 22.27 24.30 28.23 32.02 33.13 35.68 39.24 42.70 49.33 55.60 56.82 61.55 65.79 72.48 30 133.69 0.77 1.19 1.95 3.32 3.97 6.99 9.78 12.44 14.98 17.45 19.84 20.55 22.17 24.45 26.68 31.02 35.21 36.43 39.26 43.19 47.01 54.33 61.26 62.61 67.82 72.50 79.84 32 142.60 0.83 1.29 2.10 3.59 4.30 7.57 10.62 13.50 16.28 18.97 21.58 22.35 24.12 26.61 29.05 33.79 38.37 39.71 42.80 47.10 51.27 59.28 66.84 68.31 73.99 79.08 87.04 34 151.52 0.89 1.38 2.26 3.86 4.62 8.16 11.44 14.56 17.57 20.48 23.30 24.14 26.06 28.76 31.40 36.54 41.50 42.96 46.30 50.97 55.49 64.16 72.35 73.93 80.06 85.54 94.08 36 160.43 0.95 1.47 2.41 4.13 4.94 8.74 12.26 15.62 18.85 21.98 25.02 25.92 27.99 30.89 33.73 39.26 44.61 46.18 49.78 54.80 59.67 68.98 77.77 79.46 86.02 91.87 100.95 Number of teeth 38 40 44 Pitch diameter 169.34 178.25 196.08 1.00 1.56 2.56 4.39 5.26 9.31 13.08 16.67 20.12 23.47 26.72 27.68 29.90 33.01 36.05 41.97 47.69 49.37 53.22 58.59 63.80 73.75 83.11 84.91 91.88 98.08 1.06 1.65 2.71 4.66 5.58 9.88 13.89 17.71 21.39 24.95 28.41 29.44 31.80 35.11 38.35 44.66 50.75 52.53 56.64 62.35 67.89 78.45 88.37 90.28 97.64 104.16 1.17 1.83 3.02 5.18 6.21 11.02 15.51 19.78 23.90 27.89 31.77 32.92 35.56 39.27 42.91 49.97 56.79 58.79 63.38 69.76 75.94 87.69 98.66 100.76 108.83 Max. power output = (Table output + additional output) x length factor x width factor Design information on page 23 48 213.90 1.29 2.01 3.32 5.71 6.84 12.15 17.11 21.83 26.38 30.79 35.09 36.36 39.29 43.39 47.41 55.22 62.74 64.95 70.01 77.04 83.83 96.70 108.63 110.90 50 222.82 1.34 2.10 3.46 5.97 7.15 12.71 17.90 22.85 27.61 32.24 36.74 38.07 41.13 45.43 49.64 57.81 65.69 68.00 73.29 80.63 87.71 101.11 113.49 56 249.55 1.51 2.36 3.91 6.74 8.08 14.38 20.26 25.87 31.28 36.53 41.63 43.14 46.61 51.48 56.25 65.50 74.39 77.00 82.96 91.20 99.12 114.00 60 267.38 1.62 2.54 4.20 7.25 8.70 15.49 21.83 27.87 33.70 39.35 44.86 46.48 50.22 55.46 60.60 70.54 80.09 82.88 89.27 98.08 106.52 64 285.21 1.73 2.71 4.50 7.76 9.31 16.58 23.38 29.86 36.10 42.16 48.05 49.79 53.80 59.41 64.90 75.52 85.71 88.69 95.48 104.83 113.76 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 21 Poly Chain® Carbon™ Speed of the small pulley 10 20 40 60 100 200 300 400 500 600 700 800 900 1,000 1,200 1,400 1,600 1,800 2,000 2,400 2,800 3,200 3,500 4,000 28 30 32 34 36 124.78 133.69 142.60 151.52 160.43 0.88 0.94 1.01 1.08 1.15 1.37 1.48 1.59 1.70 1.81 2.28 2.47 2.65 2.84 3.03 3.13 3.39 3.65 3.91 4.17 4.73 5.13 5.53 5.93 6.32 8.45 9.18 9.90 10.62 11.34 11.93 12.97 14.00 15.02 16.04 15.26 16.59 17.92 19.24 20.56 18.47 20.10 21.72 23.32 24.92 21.59 23.51 25.41 27.29 29.17 24.65 26.84 29.01 31.17 33.32 27.63 30.10 32.54 34.98 37.39 30.56 33.30 36.01 38.71 41.39 33.44 36.44 39.42 42.37 45.31 39.06 42.58 46.07 49.54 52.98 44.53 48.55 52.55 56.51 60.44 49.85 54.37 58.85 63.29 67.70 55.05 60.05 65.01 69.92 74.78 60.13 65.60 71.02 76.38 81.70 69.97 76.35 82.65 88.88 95.05 79.41 86.64 93.78 100.83 107.78 88.47 96.51 104.43 112.23 119.92 95.02 103.64 112.11 120.43 128.62 105.49 114.99 124.30 133.43 142.36 Power output of the small timing belt pulley Number of teeth 38 40 44 48 50 56 Pitch diameter 169.34 178.25 196.08 213.90 222.82 249.55 1.22 1.29 1.42 1.56 1.62 1.82 1.92 2.03 2.25 2.46 2.57 2.89 3.21 3.40 3.76 4.13 4.31 4.85 4.42 4.68 5.19 5.69 5.94 6.69 6.72 7.11 7.88 8.66 9.04 10.19 12.05 12.76 14.17 15.57 16.26 18.34 17.06 18.07 20.08 22.07 23.06 26.00 21.86 23.16 25.75 28.31 29.58 33.36 26.51 28.09 31.23 34.35 35.89 40.49 31.04 32.89 36.58 40.23 42.04 47.43 35.46 37.59 41.80 45.98 48.05 54.21 39.79 42.18 46.92 51.61 53.94 60.85 44.05 46.70 51.94 57.14 59.71 67.36 48.23 51.13 56.88 62.57 65.39 73.76 56.40 59.80 66.52 73.17 76.46 86.22 64.34 68.22 75.88 83.45 87.19 98.28 72.07 76.41 84.98 93.43 97.61 109.96 79.61 84.39 93.84 103.13 107.72 121.27 86.96 92.18 102.46 112.57 117.55 132.21 101.14 107.17 119.03 130.62 136.32 153.00 114.65 121.42 134.70 147.61 153.92 127.48 134.93 149.45 136.66 144.56 151.10 60 64 72 75 80 267.38 1.96 3.10 5.21 7.19 10.94 19.71 27.95 35.87 43.53 50.99 58.28 65.41 72.40 79.27 92.64 105.55 118.04 130.11 141.76 285.21 2.09 3.32 5.56 7.68 11.70 21.07 29.89 38.35 46.55 54.52 62.31 69.93 77.40 84.73 98.98 112.73 126.00 138.80 151.12 320.86 2.35 3.74 6.27 8.66 13.20 23.77 33.72 43.27 52.52 61.51 70.28 78.86 87.26 95.49 111.46 126.82 141.58 155.73 334.23 2.45 3.89 6.54 9.03 13.75 24.78 35.15 45.10 54.74 64.10 73.24 82.17 90.91 99.47 116.07 132.01 147.30 356.51 2.62 4.16 6.98 9.63 14.68 26.44 37.52 48.14 58.41 68.40 78.14 87.65 96.95 106.05 123.67 140.55 156.68 Max. power output = (Table output + additional output) x length factor x width factor Design information on page 23 Additional power output [kW] for step-down ratio Poly Chain® GT2 Speed of the small pulley 200 300 400 500 600 700 730 800 900 1,000 1,200 1,400 1,460 1,600 1,800 2,000 2,400 2,800 2,880 3,200 3,500 4,000 Additional power output [kW] for step-down ratio Poly Chain® CarbonTM 1 to 1.04 1.05 to 1.11 1.12 to 1.19 1.2 to 1.3 1.31 to 1.45 1.46 to 1.65 1.66 to 1.99 2 to 2.63 2.64 to 4.47 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.07 0.11 0.15 0.18 0.22 0.26 0.27 0.29 0.33 0.37 0.44 0.51 0.54 0.59 0.66 0.74 0.88 1.03 1.06 1.18 1.29 1.47 0.15 0.22 0.29 0.37 0.44 0.52 0.54 0.59 0.66 0.74 0.88 1.03 1.07 1.18 1.32 1.47 1.77 2.06 2.12 2.36 2.58 2.94 0.22 0.33 0.44 0.55 0.66 0.77 0.81 0.88 0.99 1.10 1.32 1.54 1.61 1.77 1.99 2.21 2.65 3.09 3.18 3.53 3.86 4.41 0.29 0.44 0.59 0.74 0.88 1.03 1.07 1.18 1.32 1.47 1.76 2.06 2.15 2.35 2.65 2.94 3.53 4.12 4.24 4.71 5.15 5.88 0.37 0.55 0.74 0.92 1.10 1.29 1.34 1.47 1.65 1.84 2.21 2.57 2.68 2.94 3.31 3.68 4.41 5.15 5.30 5.88 6.44 7.35 0.44 0.51 0.59 0.66 0.77 0.88 0.88 1.03 1.18 1.10 1.29 1.47 1.32 1.54 1.76 1.54 1.80 2.06 1.61 1.88 2.15 1.77 2.06 2.35 1.99 2.32 2.65 2.21 2.57 2.94 2.65 3.09 3.53 3.09 3.60 4.12 3.22 3.76 4.29 3.53 4.12 4.71 3.97 4.63 5.29 4.41 5.15 5.88 5.30 6.18 7.06 6.18 7.21 8.24 6.35 7.41 8.47 7.06 8.24 9.41 7.72 9.01 10.30 8.83 10.30 11.77 Speed of the small pulley 20 40 60 100 200 300 400 500 600 700 800 900 1,000 1,200 1,400 1,600 1,800 2,000 2,400 2,800 3,200 3,500 4,000 1 1.03 1.10 1.19 1.30 1.45 1.67 2.02 to to to to to to to to 1.03 1.10 1.19 1.30 1.45 1.67 2.02 2.69 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.02 0.02 0.04 0.08 0.11 0.15 0.19 0.23 0.27 0.30 0.34 0.38 0.45 0.53 0.61 0.68 0.76 0.91 1.06 1.21 1.33 1.51 0.02 0.03 0.05 0.08 0.15 0.23 0.30 0.38 0.45 0.53 0.61 0.68 0.76 0.91 1.06 1.21 1.36 1.51 1.82 2.12 2.42 2.65 3.03 0.02 0.05 0.07 0.11 0.23 0.34 0.45 0.57 0.68 0.79 0.91 1.02 1.13 1.36 1.59 1.82 2.04 2.27 2.72 3.18 3.63 3.97 4.54 0.03 0.06 0.09 0.15 0.30 0.45 0.61 0.76 0.91 1.06 1.21 1.36 1.51 1.82 2.12 2.42 2.72 3.03 3.63 4.24 4.84 5.30 6.06 0.04 0.08 0.11 0.19 0.38 0.57 0.76 0.95 1.14 1.32 1.51 1.70 1.89 2.27 2.65 3.03 3.41 3.78 4.54 5.30 6.06 6.62 7.57 2.69 4.64 and to 4.64 above 0.05 0.05 0.06 0.07 0.09 0.11 0.12 0.14 0.14 0.16 0.18 0.20 0.23 0.26 0.30 0.34 0.45 0.53 0.61 0.68 0.68 0.79 0.91 1.02 0.91 1.06 1.21 1.36 1.13 1.32 1.51 1.70 1.36 1.59 1.82 2.04 1.59 1.85 2.12 2.38 1.82 2.12 2.42 2.72 2.04 2.38 2.72 3.06 2.27 2.65 3.03 3.41 2.72 3.18 3.63 4.09 3.18 3.71 4.24 4.77 3.63 4.24 4.84 5.45 4.09 4.77 5.45 6.13 4.54 5.30 6.05 6.81 5.45 6.36 7.26 8.17 6.36 7.42 8.48 9.53 7.26 8.48 9.69 10.90 7.94 9.27 10.59 11.92 9.08 10.59 12.11 13.62 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 22 Standard lengths and length correction factors S6 Standard widths 37, 68, 90, 125 mm Timing belt pulley diameter Pitch length (mm) Length correction factor Number of teeth 994 1,120 1,190 1,260 1,400 1,568 1,610 1,750 1,890 1,960 2,100 2,240 2,310 2,380 2,450 2,520 2,590 2,660 2,800 3,136 3,304 3,360 3,500 3,850 3,920 4,326 4,410 0.68 0.73 0.75 0.77 0.81 0.85 0.86 0.89 0.92 0.94 0.96 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.07 1.12 1.14 1.14 1.16 1.19 1.20 1.24 1.25 71 80 85 90 100 112 115 125 133 140 150 160 165 170 175 180 185 190 200 224 236 240 250 275 280 309 315 Custom widths available on request. Width factor S7 Belt width Width factor 37 1.85 68 3.40 90 4.50 125 6.25 Number of teeth 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 Pitch ø (mm) 124.78 129.23 133.69 138.15 142.60 147.06 151.52 155.97 160.43 164.88 169.34 173.80 178.25 182.71 187.17 191.62 196.08 200.54 204.99 209.45 213.90 218.36 222.82 227.27 231.73 236.19 240.64 245.10 249.55 254.01 258.47 262.92 267.38 271.84 276.29 280.75 285.21 289.66 294.12 298.57 303.03 307.49 311.94 316.40 320.86 325.31 329.97 Outer ø (mm) 121.98 126.43 130.89 135.35 139.80 144.26 148.72 153.17 157.63 162.09 166.54 171.00 175.45 179.91 184.37 188.82 193.28 197.74 202.19 206.65 211.11 215.56 220.02 224.47 228.93 233.39 237.84 242.30 246.76 251.21 255.67 260.12 264.58 269.04 273.49 277.95 282.41 286.86 291.32 295.78 300.23 304.69 309.14 313.60 318.06 322.51 326.97 Number of teeth 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 Pitch ø (mm) 334.23 338.68 343.14 347.59 352.05 356.51 360.96 365.42 369.88 374.33 378.79 383.25 387.70 392.16 396.61 401.07 405.53 409.98 414.44 418.90 423.35 427.81 432.26 436.72 441.17 445.63 450.09 454.55 459.00 463.46 467.92 472.37 476.83 481.28 485.74 490.20 494.65 499.11 503.57 508.02 512.48 516.94 521.39 525.85 530.30 534.76 Outer ø (mm) 331.43 335.88 340.34 344.80 349.25 353.71 358.16 362.62 367.08 371.53 375.99 380.45 384.90 389.36 393.82 398.27 402.73 407.18 411.64 416.10 420.55 425.01 429.47 433.92 438.37 442.83 447.29 451.75 456.20 460.66 465.12 469.57 474.03 478.49 482.94 487.40 491.85 496.31 500.77 505.22 509.68 514.14 518.59 523.05 527.51 531.96 Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 23 Calculation & formulas Calculation General The basis for determining the timing belt dimensions is a calculation method that takes the following influences into account: * Power * Torques * Speed * Duty cycle of the drive system * Operating characteristics * Number of meshing teeth * Transmission ratio * Centre distance of axes All data concerning the transmitted torque, the speed and the length of a PolyChain® timing belt relates to the pitch line, which is assumed to be centre of the tensile member. The pitch line is precisely defined and is identical to the pitch diameter on the timing belt pulley. Half the difference in diameter between the pitch diameter and outer diameter is equal to the size of the belt tooth root to the centre of the tensile body. Project data sheet During the design and the later dimensioning of a drive system, you should remember that optimum use of the transmission capacity, long service life and high efficiency are possible only if the actual operating conditions are known, so that critical conditions can already be taken into account during the design stage. The project data sheet on page 44 is provided to help you with this task. Preliminary selection Use the diagram on page 5 to make a preliminary selection of the suitable belt pitch. Belt width Taking into account the inherent load of the timing belt, it is always a good idea to select a belt width that is smaller than the diameter of the smallest timing belt pulley. A wider timing belt, if mounted incorrectly, is more likely to cause varying edge tensions, which can prevent optimum running of the belt. In borderline cases, it is often better to select a larger pitch instead of a wider belt. If this is not possible, we recommend a belt pitch in 2 parallel running belt segments (of the same length), to reduce the transverse rigidity of the belt in combination with the small pulley diameters. Pulley diameter Use pulleys with the largest diameters possible! This makes optimal use of the power output range of the belt at high peripheral speeds. Pulleys with larger diameters have less bending stress and the belt does not have to be as wide. Safety factors The table on page 25 shows load factors that include the drive characteristics of various machine types as an increased safety factor. In addition to these safety factors, it can be extremely important to include starting and stopping processes together with the corresponding mass effects of the respective drive system as a design criterion for the safety considerations. Especially during stopping or locking processes, mass effect can cause inertia forces that are far above the maximum permissible tangential loads of the belts listed in the power output tables (pages 17 and 20). The use of suitable regulators (e.g. a soft start ramp controller for starting and stopping) or the use of suitable overload protection can greatly reduce the mass effect to optimize fail-safe operation. Abbreviations α Temperature expansion coefficient a Acceleration A Centre distance of axes b Braking deceleration bR Belt width B Pulley width BW Flexural fatigue Cspez Specific spring constant dB Bore diameter da Outer diameter dw Pitch diameter dwk Pitch diameter of small pulley dwg Pitch diameter of large pulley e Stretching Fa Acceleration force Fb Braking force FB Driving force, calculated FH Lifting force FP Test load for belt tension FR Friction force Ft Span tension FU Tangential load FV Initial tension Fzul Maximum permissible tangential load g Acceleration of gravity hS Belt thickness ht Tooth height i Transmission ratio lw Pitch length lt Taut side M Torque m Mass mL Mass of load mR Mass of belt mges Total weight mZ Mass of timing belt pulley mZ, red Reduced mass of timing belt pulley n Speed nMOT Motor speed P Power output PB Calculated power output PN Rated power output SBruch Security against fracture SG Total application factor S1 Load factor S2 Tooth mesh factor S3 Transmission allowance S4 Bending factor S5 Special application factor S6 Belt length factor S7 Belt width factor t Pitch v Speed z Number of belt pulleys ze Number of meshing teeth zg Number of teeth, large pulley zk Number of teeth, small pulley 1/K m/s2 mm m/s2 mm mm 1/s N mm mm mm mm mm % N N N N N N N N N N m/s2 mm mm mm mm Nm kg kg kg kg kg kg l/min l/min kW kW kW m/s (The formula collection applies to all timing belt catalogs; ­therefore, it is possible that not all abbreviations occur in this catalog). Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 24 Formulas Torque M= Lifting force P · 9.55 · 103 = FU · dW n 2 · 103 FH = m · g [N] [Nm] Friction force Power output M·n = P= 9.55 · 103 FR = m · g · µ [N] FU · v [kW] 103 Mass m = mL + mR + mZred [kg] with mR = IW · mG Tangential load P · 103 = v FU = M · 2 · 103 dw [N] Reduced mass of timing belt pulley mZred = Speed mZ 2 · ( 1 + dB2 ) [kg] da2 3 n = 19.1 · 10 · v [min-1] dw Mass of timing belt pulley mZ = Peripheral speed v= dw · n 19.1 · 103 m s (da2 – dB2) · p · B · V [kg] 4 · 106 V = density Acceleration force Stretching Fa = m · a [N] e = DI · 100 [%] It Braking force Flexural fatigue Fb = m · b [N] 3 Bw = v · z · 10 [1/s] Iw ta : startup time n, v Sa : startup path n, v = const. . . . v = d0 π n = d0 n 60 19,1 startup v ta = a v2 sa = 2 . a tb : braking time Sb : braking path braking s t= v s = v. t tges = ta + t + tb t, s sges = sa + s + sb Motion equations for acceleration and stopping processes Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 25 Load factor S1 The load factor S1 is found in the intersecting point of the previously classified driven machine (row) and in the machine class of the driven machine in question, taking into account the duty cycle (column). Driven machines For machines not listed, select a safety factor that most nearly corresponds to one of the listed groups. Class The different types of driven machines Drive AC and three-phase motors, normal starting torque, e.g. with short circuit rotor motors, compound DC motors, internal combustion engines with more than 4 cylinders AC and three-phase motors, high starting torque, e.g. single-phase and synchronous motors, three-phase braking motors, hydraulic motors, internal combustion engines with up to 4 cylinders short-term operation short-term operation 3 – 8 hours daily normal operation continuous operation 8 – 16 hours 16 – 24 hours daily daily 3 – 8 hours daily normal operation continuous operation 8 – 16 hours 16 – 24 hours daily daily 1 filling systems, measuring devices, medical instruments 1.0 1.2 1.4 1.2 1.4 1.6 2 floor cleaning equipment, sewing machines, office machines, light-duty woodworking machines, band saws, drills and lathes 1.1 1.3 1.5 1.3 1.5 1.7 3 conveyor systems for small packages, wood slats, presses, lathes, washing machines, heavy-duty woodworking machines, sawing machines 1.2 1.4 1.6 1.6 1.8 2.0 4 stirring machines for viscous liquids, dough mixers, conveyor belts: coal, sand, ore, shaft drives, drills, lathes, screwdrivers, peeling machines, grinding machines, circular saws, planing machines, paper machines (except masticators) pressing-embossing machines, shears, printing presses, centrifugal pumps and compressors, vibration machines 1.3 1.5 1.7 1.6 1.8 2.0 5 tile-moulding machines, conveyor belts, fans, generators, centrifugal blowers, elevators / lifting gear, extruders 1.4 1.6 1.8 1.8 2.0 2.2 6 brick and clay machines, conveyor systems: flat and bucket lifts/worm screws, centrifuges, hammer mills, paper machines, textile machines 1.5 1.7 1.9 1.9 2.1 2.3 7 pulverising machines, ventilators for mines 1.6 1.8 2.0 2.0 2.2 2.4 8 piston compressors, mills: ball mill, rubble mill and sawmill equipment, piston pumps 1.7 1.9 2.1 2.1 2.3 2.5 The listed safety factors can be used as reference values for numerous applications, but they cannot replace a detailed technical assessment of the particular application. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 26 Calculation method To select a suitable PolyChain® GT2 timing belt drive system, you need the following data: 1. Power output and type of drive machine and driven machine 2. Operation time 3. Speed of drive machine and driven machine 4. Centre distance of axes of the drive system Step 1: Determine the calculated power output A. To determine the calculated power output, firs you have to define the load factor S1 of the drive from the table on page 25. B. Multiply this load factor times the input power. The result is the calculated power output required for defining the belt drive. PB = PN · S1 Step 2: Select the timing belt pitch A. Enter the calculated power output in the “Selection diagram for belt pitch” (page 5) on the horizontal axis. Use the speed of the faster shaft (or of the small timing belt pulley) for the vertical axis. B. The timing belt belt pitch for further calculations can be found at the point where the two factors intersect. If the point of intersection is near the separation between 8 mm and 14 mm pitch, it is recommended to calculate the drive system for both pitches and to use the drive system that is best suited for your application. Step 3: Select the timing belt width For all transmission and reduction drive systems A. The power output tables on pages 17 and 20 contain the values for the smallest standard belt width. A different width factor has to be used for larger belt widths. The column on the left side of the power output table contains the speed of the small timing belt pulley; the line above the table contains the number of teeth of the timing belt pulley and its pitch diameter. The power output of the timing belt can be found at the point where the pulley speed and the number of pulley teeth intersect. B. Select a belt width and determine the corresponding power output. Multiply this power output value times the timing belt length correction factor S6 , which can be found in the table under the power output table* to determine the corrected power output. PKORR = PTAB, S.17ff. · S6 · S7 * Factors S6 and S7 are explained on pages 19 and 22. If the corrected power output is equal to or greater than the calculated power output, this belt width can be used. If not, repeat this step with the next larger timing belt width. If the largest belt width does not produce satisfactory results, you should use a larger timing belt pulley or, if possible, a larger pitch. PKORR > PB · S2 Note: Depending on the degree of acceleration and braking torque and the frequency of reversal of motion, the timing belt pulley diameter should be as large as possible with a minimum of 12 meshing teeth. If the number of meshing teeth is less than 6, this has to be compensated for with the correction factor S2 in the drive calculation. Tooth mesh factor S2 Number of meshing teeth 5 1.25 S2 4 1.66 3 2.5 2 5.0 Number of meshing teeth Ze on the small pulley: Z d –d Ze = k 3 – wg wk 6 A [ ] C. I f the calculation results in several possible combinations of timing belt pulleys, you should observe the following principles: a. A larger timing belt pulley diameter requires a smaller timing belt width. b. T he belt width should not be greater than the diameter of the smallest timing belt pulley. c. L arge timing belt pulley diameters reduce wear on the bearings and shaft. Step 4: Installation and belt tension Due to the low stretching tendency of the tensile member, ­PolyChain® GT2 belts generally require no re-tightening. Adjustments must be made during installation of the belts to compensate for production tolerances and to set a specified initial tension. The recommended radial settings of the centre distance of axes are listed on page 14. Step 5: Calculation of initial belt tension The initial required tension is calculated based on the equations on page 13. Step 6: Select the drive components Based on the calculated drive system data and geometries, you can select a suitable drive component combination from the standard line of pulleys. In special cases, it may be necessary to manufacture custom pulleys according to your drawing specifications. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 27 Sample calculation Drive data Drive: Three-phase motor, high starting torque P = 5 kW at n1 = 1750 min-1 Duty cycle 6 hours daily Step-up ratio Output: Woodworking machine, n2 = 2150 min-1 Centre distance of axes ca. 430 mm. Calculation steps Results Step 1: Determine the calculated power output PB A. T ype of drive machine: You will find the drive motor used in the third class in the table on page 15. B. Load factor from table (woodworking machines): 1,6. C. Calculated power output = Load factor x drive power PB = S1 x PN Load factor S1 = 1.6 Step 2: Select the pitch Belt pitch = 8 mm Calculated power output = 1.6 x 5 = 8 kW From the “Selection diagram for belt pitch” on page 5 you see that: at 8 kW and 2150 min-1 a pitch of 8 mm is recommended. Select the combination of timing belt pulleys, timing belt length, Calculate the centre distance of axes: 1. Calculation of the transmission ratio i = 2150 = 1.23 1750 2. Select the number of pulley teeth based on the required transmission i e.g. z1 = 34; z2 = 28 i = 1.214 3. Select the timing belt length analogous to the existing pitch lengths of the pitch 8M i = 1.23 selected: z1 8M - 34 S z2 8M - 28 S selected: Timing belt length = 1120 mm e.g. Iw = 1120 mm 4. Calculate the centre distance of axes with the corresponding factors (Separate formula collection, to be provided on request) A = 435.93 mm Step 3: Select the belt width Centre distance of axes: 435.93 mm Belt width b = 21 mm In the power output table on page 17, for a timing belt pulley with 28 teeth at a speed of 2,150 min-1 a power output of PTAB, z1 = PTAB · S6 · S7 = 14,8 kW is specified for a belt width of 21 mm. This power output is higher than the ­calculated power output PB = 8 kW, multiplied by the tooth mesh factor (S2 = 1) Step 4: Installation and mounting data According to the tables on page 14, the minimum travel of a shaft to the initial belt tension is –2.8 mm/+0.8 mm. Minimum travel to belt tension: –2.8 mm / +0.8 mm Step 5: Calculation of initial belt tension Deflection force = 12.6 N Deflection = 4.4 mm Use the equation on page 15. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 28 Standard line of timing belt pulleys Pitch 8 mm Poly Chain® 8M-12 All dimensions in mm Pitch Outer Rim flange 28** 28 28 32 42 56.02 63.66 71.30 76.39 81.49 54.42 62.06 69.70 74.79 79.89 60 70 75 82,5 87 – – – – – 43 49 56 60 66 10 2 2 5 5 20 20 20 20 20 – – – – – 30 22 22 25 25 – – – – – 0.42 0.43 0.60 0.67 0.77 Mass moment of inertia 10-4 (kgm2) 1.44 2.11 3.79 5.16 6.55 1610 1610 1610 1610 2012 42 42 42 42 50 86.58 91.67 96.77 101.86 114.59 84.98 90.07 95.17 100.26 112.99 91 97 102 106 120 – – – – – 69 76 78 85 92 5 5 5 5 12 20 20 20 20 20 – – – – – 25 25 25 25 32 – – – – – 0.88 1.02 1.15 1.19 1.76 8.27 11.06 13.52 15.38 27.16 2F* 2F* 2F* 2F* 2F* 2012 2012 2012 2012 2012 50 50 50 50 50 122.23 127.32 142.60 152.79 162.97 120.63 125.72 141.00 151.19 161.37 128 135 150 158 168 – – – – – 103 104 104 111 111 12 12 12 12 12 20 20 20 20 20 – _ – – – 32 32 32 32 32 – – – _ – 2.16 2.28 2.83 3.24 3.51 39.27 43.43 66.17 87.72 103.96 2* 2* 2* 2012 2012 2012 50 50 50 190.99 203.72 229.18 189.39 202.12 227.58 – – – – – – 111 111 111 12 12 12 20 20 20 – – – 32 32 32 – – – 4.57 5.13 6.37 182.30 234.08 372.11 Timing belt pulley designation Number of teeth Timing belt pulley type Bush number Max. bore holes 8M-22S-12 8M-25S-12 8M-28S-12 8M-30S-12 8M-32S-12 22 25 28 30 32 1F* 2F* 2F* 2F* 2F* VB/12 1108 1108 1210 1610 8M-34S-12 8M-36S-12 8M-38S-12 8M-40S-12 8M-45S-12 34 36 38 40 45 2F* 2F* 2F* 2F* 2F* 8M-48S-12 8M-50S-12 8M-56S-12 8M-60S-12 8M-64S-12 48 50 56 60 64 8M-75S-12 8M-80S-12 8M-90S-12 75 80 90 Diameter A B E F K L M Weight (kg) Poly Chain® 8M-21 All dimensions in mm Pitch Outer Rim flange A B E F K L M Weight (kg) 28** 28 32 32 42 56.02 63.66 71.30 76.39 81.49 54.42 62.06 69.70 74.79 79.89 60 70 75 82,5 87 – – – – – 43 – – – – 10 – – – – 30 30 30 30 30 – 8 5 5 5 40 22 25 25 25 – – – – – 0.57 0.60 0.75 0.83 0.97 Mass moment of inertia 10-4 (kgm2) 1.99 2.92 4.80 6.42 8.40 1610 1610 1610 1610 2012 42 42 42 42 50 86.58 91.67 96.77 101.86 114.59 84.89 90.07 95.17 100.26 112.99 91 97 102 106 120 – – – – – – – – – 92 – – – – 2 30 30 30 30 30 5 5 5 5 – 25 25 25 25 32 – – – – – 1.12 1.29 1.34 1.50 2.03 10.83 13.99 16.02 19.74 32.88 2F* 2F* 2F* 2F* 2F* 2012 2012 2012 2517 2517 50 50 50 60 60 122.23 127.32 142.60 152.79 162.97 120.63 125.72 141.00 151.19 161.37 128 135 150 158 168 – – – – – 103 104 111 124 124 2 2 2 15 15 30 30 30 30 30 – – – – – 32 32 32 45 45 – – – – – 2.24 2.42 3.20. 4.66 5.28 42.90 49.20 80.30 127.25 158.77 75 80 90 2* 2* 9* 2517 2517 2517 60 60 60 190.99 203.72 229.18 189.39 202.12 227.58 – – – – – 198 124 124 124 15 15 – 30 30 30 – – 7.5 45 45 45 – – 7.5 6.77 7.61 8.57 276.69 353.26 499.05 112 140 9* 10* 2517 3020 60 75 285.21 356.51 283.61 354.91 – – 253 324 124 150 – – 30 30 7.5 7.5 45 51 7.5 10.5 12.50 12.79 1155.88 1699.74 Timing belt pulley designation Number of teeth Timing belt pulley type Bush number Max. bore holes 8M-22S-21 8M-25S-21 8M-28S-21 8M-30S-21 8M-32S-21 22 25 28 30 32 1F* 1F* 3F* 3F* 3F* VB/12 1108 1210 1210 1610 8M-34S-21 8M-36S-21 8M-38S-21 8M-40S-21 8M-45S-21 34 36 38 40 45 3F* 3F* 3F* 3F* 2F* 8M-48S-21 8M-50S-21 8M-56S-21 8M-60S-21 8M-64S-21 48 50 56 60 64 8M-75S-21 8M-90S-21 8M-80S-21 8M-112S-21 8M-140S-21 Diameter * Illustrations of the types of timing belt pulley can be found on page 32. ** DIN 6885 T3 VB/12 = pre-bore (min. diameter 12 mm) Comment: The timing belt pulleys are available in grey cast iron or steel. Both types provide the required durability and reliability. We reserve the right to deliver standard pulleys in either version. In case of peripheral speeds higher than 40 m/s, please contact our application engineers. In some cases, the use of standard pulleys – depending on the bore diameter and loads – can exceed the slipping torques of the Taper Lock® clamping bushes. At higher torque loads, therefore, compliance with the maximum permissible values should be ensured. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 29 Poly Chain® 8M-36 Timing belt pulley designation Number of teeth All dimensions in mm Timing belt pulley type Bush number Max. bore holes Diameter Pitch Outer Rim flange A B E F K L M Weight (kg) Mass moment of inertia 10-4 (kgm2) 4.65 6.92 9.26 12.37 15.77 8M-25S-36 8M-28S-36 8M-30S-36 8M-32S-36 8M-34S-36 25 28 30 32 34 1F* 3F* 3F* 3F* 3F* VB/12 1210 1610 1610 1610 32 32 42 42 42 63.66 71.30 76.39 81.49 86.58 62.06 69.70 74.79 79.89 84.98 70 75 82,5 87 91 – – – – – 49 – – – – 10 – – – – 45 45 45 45 45 – – – – – 55 – – – – – – – – – 1.02 1.11 1.22 1.45 1.66 8M-36S-36 8M-38S-36 8M-40S-36 8M-45S-36 8M-48S-36 36 38 40 45 48 3F* 3F* 3F* 3F* 3F* 1610 1610 2012 2012 2012 42 42 50 50 50 91.67 96.77 101.86 114.59 122.23 90.07 95.17 100.26 112.99 120.63 97 102 106 120 128 – – – – – – – – – – – – – – – 45 45 45 45 45 – – – – – – – – – – – – – – – 1.90 2.21 2.36 3.07 3.30 20.28 26.28 31.19 50.17 62.31 8M-50S-36 8M-56S-36 8M-60S-36 8M-64S-36 8M-75S-36 50 56 60 64 75 3F* 3F* 3F* 3F* 2* 2012 2517 2517 2517 3020 50 60 60 60 75 127.32 142.60 152.79 162.97 190.99 125.72 141.00 151.19 161.37 189.39 135 150 158 168 – – – – – – – – – – 150 – – – – 6 45 45 45 45 45 – – – – – – – – – 51 – – – – – 3.58 4.48 5.30 6.19 8.72 72.25 115.19 157.20 191.32 392.22 8M-80S-36 8M-90S-36 8M-112S-36 8M-140S-36 8M-168S-36 8M-192S-36 80 90 112 140 168 192 2* 9* 9* 10* 10* 10* 3020 3020 3020 3020 3525 3525 75 75 75 75 100 100 203.72 229.18 285.21 356.51 427.81 488.92 202.12 227.58 283.61 354.91 426.21 487.32 – – – – – – – 197 253 324 396 457 150 150 150 150 198 198 6 – – – – – 45 45 45 45 45 45 – 3 3 3 10 10 51 51 51 51 65 65 – 3 3 3 10 10 9.96 10.41 14.01 11.98 23.91 26.53 505.75 636.42 1326.76 1747.45 4693.42 7055.91 All dimensions in mm Poly Chain® 8M-62 8M-30S-62 8M-32S-62 8M-34S-62 8M-36S-62 8M-38S-62 30 32 34 36 38 1F* 1F* 1F* 1F* 1F* VB/20 VB/20 VB/20 VB/20 VB/20 42 50** 55** 60** 60 76.39 81.49 86.58 91.67 96.77 74.79 79.89 84.98 90.07 95.17 82,5 87 91 97 102 – – – – – 63 68 69 76 78 12 12 12 12 12 72 72 72 72 72 – – – – – 84 84 84 84 84 – – – – – 2.45 2.82 3.17 3.52 3.91 Mass moment of inertia 10-4 (kgm2) 16.25 21.31 28.47 34.89 44.51 8M-40S-62 8M-45S-62 8M-48S-62 8M-50S-62 8M-56S-62 40 45 48 50 56 3F* 3F* 3F* 3F* 6F* 2012 2012 2517 2517 2517 50 50 60 60 60 101.86 114.59 122.23 127.32 142.60 100.26 112.99 120.63 125.72 141.00 106 120 128 135 150 – – – – 111 – – – – - – – – – – 72 72 72 72 72 – – – – 13.5 – – – – 45 – – – – 13.5 3.76 4.88 5.52 6.03 5.43 49.43 79.37 105.81 123.91 152.66 8M-60S-62 8M-64S-62 8M-75S-62 8M-80S-62 8M-90S-62 60 64 75 80 90 6F* 6F* 6* 6* 6* 2517 2517 3020 3020 3020 60 60 75 75 75 152.79 151.19 162.97 161.37 190.99 189.39 203.72 202.12 229.18 227.58 121 131 159 172 197 – – – – – – – – – – 72 72 72 72 72 13.5 13.5 10.5 10.5 10.5 45 45 51 51 51 13.5 13.5 10.5 10.5 10.5 6.33 7.11 9.99 11.44 14.94 204.79 258.10 485.34 628.73 1045.29 8M-112S-62 8M-140S-62 8M-168S-62 8M-192S-62 112 140 168 192 7* 7* 8* 8* 3020 3525 3525 3525 75 100 100 100 285.21 356.51 427.81 488.92 158 168 – – – – – – – – 253 324 396 457 150 198 198 198 – – – – 72 72 72 72 10.5 3.5 3.5 3.5 51 65 65 65 10.5 3.5 3.5 3.5 14.94 24.77 28.39 32.18 1540.46 3953.51 5812.58 8880.82 Timing belt pulley designation Number of teeth Timing belt pulley type Bush number Max. bore holes Diameter Pitch Outer Rim flange 283.61 354.91 426.21 487.32 A B E F K L M Weight (kg) * Illustrations of the types of timing belt pulley can be found on page 32. ** DIN 6885 T3 VB/12 = pre-bore (min. diameter 12 mm) Comment: The timing belt pulleys are available in grey cast iron or steel. Both types provide the required durability and reliability. We reserve the right to deliver standard pulleys in either version. In case of peripheral speeds higher than 40 m/s, please contact our application engineers. In some cases, the use of standard pulleys – depending on the bore diameter and loads – can exceed the slipping torques of the Taper Lock® clamping bushes. At higher torque loads, therefore, compliance with the maximum permissible values should be ensured. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 30 Pitch 14 mm Poly Chain® 14M-37 All dimensions in mm Pitch Outer Rim flange 50 60 60 60 60 124.78 133.69 142.60 151.52 160.43 121,98 130.89 139.80 148.72 157.63 128 138 154 160 168 88 98 100 109 117 – – – – – – – – – – 51 51 51 51 51 – 3 3 3 – 32 45 45 45 45 19 3 3 3 6 2.97 3.81 4.53 5.06 5.92 Mass moment of inertia 10-4 (kgm2) 62.80 84.85 116.65 142.79 172.60 2517 2517 3020 3020 3020 60 60 75 75 75 169.34 178.25 196.08 213.90 222.82 166.54 175.45 193.28 211.11 220.02 183 188 211 226 240 126 135 – – – – – – – – – – – – – 51 51 51 51 51 – – – – – 45 45 – – – 6 6 – – – 6.51 7.31 9.44 11.44 12.62 230.24 288.92 452.35 646.57 780.73 7F* 7* 7* 7* 7* 3020 3020 3020 3020 3020 75 75 75 75 75 249.55 267.38 285.21 320.86 356.51 246.76 264.58 282.41 318.06 353.71 256 – – – – 207 224 242 278 314 144 159 159 159 159 – – – – – 51 51 51 51 51 0 0 0 0 0 51 51 51 51 51 0 0 0 0 0 12.70 14.23 15.58 17.24 20.32 973.88 1191.25 1489.35 2099.86 3097.72 8* 8* 10* 10* 10* 3020 3020 3525 3525 4030 75 75 100 100 115 401.07 499.11 623.89 748.66 855.61 398.27 496.31 621.09 745.87 852.82 – – – – – 360 456 581 706 812 159 159 206 206 215 – – – – – 51 51 51 51 51 0 0 7 7 12.5 51 51 65 65 76 0 0 7 7 12.5 29.85 27.43 33.55 64.50 83.82 6445.74 9264.40 15022.96 47001.90 81467.11 Timing belt pulley ­designation Number of teeth Timing belt pulley type Bush number Max. bore holes 14M-28S-37 14M-30S-37 14M-32S-37 14M-34S-37 14M-36S-37 28 30 32 34 36 5F* 6F* 6F* 6F* 5F* 2012 2517 2517 2517 2517 14M-38S-37 14M-40S-37 14M-44S-37 14M-48S-37 14M-50S-37 38 40 44 48 50 5F* 5F* 3F* 3F* 3F* 14M-56S-37 14M-60S-37 14M-64S-37 14M-72S-37 14M-80S-37 56 60 64 72 80 90 14M-90S-37 14M-112S-37 14M-140S-37 14M-168S-37 14M-192S-37 112 140 168 192 Diameter A B E F K L M Weight (kg) Poly Chain® 14M-68 Timing belt pulley ­designation All dimensions in mm Diameter Pitch Outer Rim flange 100 110** 115** 125** 75 151.52 160.43 169.34 178.25 196.08 148.72 157.63 166.54 175.45 193.28 160 168 183 188 211 – – – – 153 132 131 141 156 – 20 20 20 20 – 84 84 84 84 84 – – – – 16.5 104 104 104 104 51 – – – – 16.5 6.25 6.68 7.46 7.81 11.54 Mass moment of inertia 10-4 (kgm2) 234.69 273.17 359.51 430.15 604.33 3020 3525 3525 3525 3525 75 100 100 100 100 213.90 222.82 249.55 267.38 285.21 211.11 220.02 246.76 264.58 282.41 226 240 256 – – 171 180 207 224 242 – – – – – – – – – – 84 84 84 84 84 – 9.5 9.5 9.5 9.5 51 65 65 65 65 33 9.5 9.5 9.5 9.5 13.74 16.63 21.15 24.28 27.86 850.56 1110.47 1740.42 2250.33 2925.48 7* 7* 8* 8* 8* 3525 3525 3525 3525 3525 100 100 100 100 100 320.86 356.51 401.07 499.11 623.89 318.06 353.71 398.27 496.31 621.09 – – – – 278 314 360 456 581 – – – – – – – – – – 84 84 84 84 84 9.5 9.5 9.5 9.5 9.5 65 65 65 65 65 9.5 9.5 9.5 9.5 9.5 25.74 29.86 31.24 39.25 40.87 3353.92 4827.78 6694.20 13299.34 21569.65 8* 8* 3525 4030 100 115 748.66 855.61 745.87 852.82 – – 706 812 – – – – 84 84 9.5 4 65 76 9.5 4 73.30 94.21 58491.40 99321.99 Number of teeth Timing belt pulley type Bush number Max. bore holes 14M-34S-68 14M-36S-68 14M-38S-68 14M-40S-68 14M-44S-68 34 36 38 40 44 1F* 1F* 1F* 1F* 6F* VB/40 VB/40 VB/40 VB/40 3020 14M-48S-68 14M-50S-68 14M-56S-68 14M-60S-68 14M-64S-68 48 50 56 60 64 5F* 6F* 6F* 6* 6* 14M-72S-68 14M-80S-68 14M-90S-68 14M-112S-68 14M-140S-68 72 80 90 112 140 14M-168S-68 14M-192S-68 168 192 A B E F K L M Weight (kg) Illustrations of the types of timing belt pulley can be found on page 32. * DIN 6885 T3 ** VB/40 = pre-bore (min. diameter 12 mm) Comment: The timing belt pulleys are available in grey cast iron or steel. Both types provide the required durability and reliability. We reserve the right to deliver standard pulleys in either version. In case of peripheral speeds higher than 40 m/s, please contact our application engineers. In some cases, the use of standard pulleys – depending on the bore diameter and loads – can exceed the slipping torques of the Taper Lock® clamping bushes. At higher torque loads, therefore, compliance with the maximum permissible values should be ensured. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 31 Poly Chain® 14M-90 All dimensions in mm Bush number Max. bore holes 36 38 40 44 48 Timing belt ­pulley type 1F* 1F* 1F* 1F* 6F* VB/50 VB/50 VB/50 VB/50 3525 14M-50S-90 14M-56S-90 14M-60S-90 14M-64S-90 14M-72S-90 50 56 60 64 72 6F* 6F* 6* 6* 7* 14M-80S-90 14M-90S-90 14M-112S-90 14M-140S-90 14M-168S-90 80 90 112 140 168 14M-192S-90 192 Timing belt pulley ­designation Number of teeth 14M-36S-90 14M-38S-90 14M-40S-90 14M-44S-90 14M-48S-90 Diameter Pitch Outer Rim flange A B E F K L M Weight (kg) 110** 115** 125** 140** 100 160.43 169.34 178.25 196.08 213.90 157.63 166.50 175.45 193.28 211.11 168 183 188 211 226 – – – – 171 131 141 156 169 – 30 30 30 30 – 106 106 106 106 106 – – – – 20 136 136 136 136 66 – – – – 20 8.15 9.73 10.29 11.92 16.76 Mass moment of inertia 10-4 (kgm2) 333.81 467.27 564.50 805.17 1069.46 3525 3525 3525 3525 3525 100 100 100 100 100 222.82 249.55 267.38 285.21 320.86 220.02 246.76 264.58 282.41 318.06 240 256 – – – 180 207 224 242 278 – – – – 178 – – – – – 106 106 106 106 106 20 20 20 20 20 66 66 66 66 66 20 20 20 20 20 18.38 23.46 26.53 30.30 26.36 1272.88 2016.82 2558.85 3308.24 3633.18 7* 7* 8* 8* 8* 4030 4030 4535 4535 5040 115 115 125 125 130** 356.51 401.07 499.11 623.89 748.66 353.71 398.27 469.31 621.09 745.87 – – – – – 314 360 456 581 706 215 215 215 215 267 – – – – – 106 106 106 106 106 15 15 8 8 2 76 76 90 90 102 15 15 8 8 2 35.61 41.90 70.89 74.56 109.24 5650.71 7979.09 23322.89 39744.58 77064.15 8* 5040 130** 855.61 852.82 – 812 267 – 106 2 102 2 126.05 119340.31 Poly Chain® 14M-125 All dimensions in mm Bush number Max. bore holes 38 40 44 48 50 Timing belt ­pulley type 1F* 1F* 1F* 1F* 6F* VB/50 VB/50 VB/50 VB/50 3525 14M-56S-125 14M-60S-125 14M-64S-125 14M-72S-125 14M-80S-125 56 60 64 72 80 6F* 6* 6* 7* 7* 14M-90S-125 14M-112S-125 14M-140S-125 14M-168S-125 14M-192S-125 90 112 140 168 192 7* 8* 8* 8* 8* Timing belt pulley ­designation Number of teeth 14M-38S-125 14M-40S-125 14M-44S-125 14M-48S-125 14M-50S-125 Diameter Pitch Outer Rim flange 115** 125** 140** 160** 100 169.34 178.25 196.08 213.90 222.82 166.54 175.45 193.28 211.11 220.02 183 188 211 226 240 – – – – 180 141 156 169 185 – 20 20 20 20 – 141 141 141 141 141 – – – – 38 161 161 161 161 65 – – – – 38 11.74 12.23 14.46 14.70 20.93 Mass moment of inertia 10-4 (kgm2) 566.16 673.08 981.64 1239.87 1527.53 3525 4030 4030 4030 4030 100 115 115 115 115 249.55 267.38 285.21 320.86 356.51 246.76 264.58 282.41 318.06 353.71 256 – – – – 207 224 242 278 314 – – – 215 215 – – – – – 141 141 141 141 141 38 32.5 32.5 32.5 32.5 65 76 76 76 76 38 32.5 32.5 32.5 32.5 25.91 30.92 35.34 37.71 42.02 2366.65 3083.08 3979.74 5201.08 7133.19 4030 4535 4535 5040 5040 115 125 125 125 125 401.07 499.11 623.89 748.66 855.61 398.27 496.31 621.09 745.87 825.82 – – – – – 360 456 581 706 812 215 215 215 267 267 – – – – – 141 141 141 141 141 32.5 26 26 19.5 19.5 76 89 89 102 102 32.5 51.29 26 65.64 26 67.90 19.5 120.66 19.5 142.39 11031.63 22771.41 38083.37 90872.96 144192.26 A B E F K L M Weight (kg) * Illustrations of the types of timing belt pulley can be found on page 32. ** DIN 6885 T3 VB/40 = pre-bore (xmin. diameter 40 mm) Comment: The timing belt pulleys are available in grey cast iron or steel. Both types provide the required durability and reliability. We reserve the right to deliver standard pulleys in either version. In case of peripheral speeds higher than 40 m/s, please contact our application engineers. In some cases, the use of standard pulleys – depending on the bore diameter and loads – can exceed the slipping torques of the Taper Lock® clamping bushes. At higher torque loads, therefore, compliance with the maximum permissible values should be ensured. Walther Flender Gruppe PolyChain® GT Timing Belts PAGE 32 Models Type 1F Type 7 Type 2 Type 7F Type 2F Type 3F Type 8 Type 5F Type 9 Type 6 Type 9F Type 6F Type 10 Clamping sets Walther Flender Gruppe Clamping sets Page 34 General features MLC clamping sets provide a positive-locking, backlash-free connection that can be released at any time. This protects components such as the shaft and hub from damage from the phenomenon known as excursion. The applications of the MLC clamping sets range from construction machinery to robots. Distinguishing features include easy mounting and removal with standard tools and easy adjustment without profile end mating. MLC clamping sets transfer torques and axial forces frictionally and backlash-free between cylindrical shafts and bore holes of the drive elements. MLC clamping sets feature the following advantages over positive locking connections: • • • • • • • • • • • • Low-cost manufacture of the cylindrical press fits for the clamping sets on shafts and hubs Backlash-free connection; can be accurately positioned axially and peripherally Reduces notch effect Small shaft diameter due to use of the full, non-weakened shaft diameter Extremely fail-safe under changing and intermittent loads Convenient and reliable dimensioning of the clamping sets Easy to install and remove using standard tools Can be reused and exchanged for numerous applications Ready-to-install and adaptable line of models Excellent squareness and concentricity Prevents fretting corrosion Higher power transmission than feather keys Calculation instructions Transmission elements For dimensioning of a connection between the shaft and hub, the maximum occurring loads (rated value x load factor) have to be reliably determined and included in the calculation. The transmissible values listed in the table for Mt and FAX apply to the tightening torques MS and cannot be transmitted simultaneously. For simultaneous acting torque and axial load, the resulting value MR has to be calculated. This value cannot be greater than the transmissible torque Mt. Operational overloads that cause the clamping set to slip are not permitted. Information on calculation for specific models is provided ­separately. The transmissible forces and torques are based on the axial initial tension of the screws exerted positively through the conical surfaces as normal radial forces onto the shaft and hub connection. Every user has to use a torque wrench to carefully check the ­tightening torques MS. The resulting transmitted torque in the case of simultaneous ­action of torque and axial force is MR = √MB2 + (FAB · d/2)2 (Nm) Condition: MR ≤ Mt Symbols d = shaft diameter (mm) D = inner hub diameter (mm) A = hub/clamping set contact surface (mm2) H, H1, H2, H3 = width dimensions Mt = transmissible torque (Nm) MS = tightening torque per screw (Nm) (mm) MB = rated torque to be transmitted (Nm) FAB = axial force to be transmitted (kN) (kN) pW = surface pressure on the shaft (N/mm2) pW = surface pressure on the hub (N/mm2) L = overall width with screws FAX = transmissible axial force without torque Walther Flender Gruppe Clamping sets Page 35 Hub calculation The hub material is subjected to tensile stress by the pressure of the clamping set in the bore. The required outer hub diameter depends on the material, the installation position of the clamping set and the surface pressure in the hub bore. To keep the stress within the flexible range, the yield point Rp0,2 is the permissible material property value. The following table shows hub diameter factors based on the three parameters mentioned above. The hub factor X is determined based on the installation position. The calculated surface pressure pN can be taken from the table with the selected clamping set type. The corresponding hub coefficient for these two values is found under the yield point of the hub material in the table. The product of the hub coefficient and the outer diameter D of the clamping set is the minimum outer hub diameter. DN = D · K Installation situation Single clamping sets without hub centring for shortest hub width B ≥ H (length of the adjacent clamping rings) Single clamping sets without hub centring with width B ≥ 2 · H and multiple clamping sets with hub centring and width B ≥ H (1 + z) When selecting the hub material, take into account that the calculated surface pressure pN cannot be greater than the yield point Rp0,2. Examples 1. H ub material C 35 Yield point 270 N/mm2 Clamping set MLC 5000 A 45 x 75 Factor x = 1, pN = 120 N/mm2 Outer hub diameter DN = 75 x 1.62 = ca. 122 mm 2. H ub material GG 25 Yield point 180 N/mm2 Clamping set MLC 7000 55 x 85 Factor x = 1, pN = 80 N/mm2 Outer hub diameter DN = 85 x 1.62 = ca. 138 mm Hub factor X=1 X = 0,8 z = number of clamping sets Single clamping sets with hub centring for hub width B ≥ 2 · H X = 0,6 If the hub is weakened by bores or threads, the following applies: X = 0,8 for B ≥ 2H or B ≥ H1 (1 + z) X=1 for B = H or B = H1 · z Walther Flender Gruppe Clamping sets Page 36 Hub coefficient K Surface pressure pN N/mm2 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 Yield point Rp0,2 of the hub material (N/mm2) Hub factor X 150 180 200 220 250 GG 22 GG 25 GG 38 GG 30 GTS 35 GS 45 St 37-2 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 0.6 0.8 1 1.29 1.40 1.53 1.31 1.45 1.61 1.35 1.49 1.66 1.31 1.53 1.75 1.40 1.59 1.82 1.43 1.64 1.91 1.47 1.70 2.01 1.50 1.76 2.12 1.54 1.82 2.25 1.57 1.89 2.39 1.61 1.97 2.56 1.65 2.05 2.76 1.70 2.14 3.01 1.74 2.25 3.33 1.79 2.36 3.75 1.84 2.49 4.37 1.89 2.64 5.40 1.95 2.81 7.67 2.01 3.01 2.07 3.26 2.14 3.56 2.22 3.97 - 1.26 1.31 1.43 1.26 1.36 1.46 1.27 1.39 1.51 1.29 1.43 1.56 1.32 1.46 1.62 1.35 1.50 1.68 1.37 1.54 1.74 1.40 1.58 1.81 1.42 1.62 1.88 1.45 1.67 1.96 1.48 1.72 2.05 1.51 1.77 2.14 1.54 1.82 2.25 1.57 1.88 2.36 1.60 1.94 2.50 1.62 2.01 2.66 1.67 2.08 2.84 1.70 2.16 3.06 1.74 2.25 3.33 1.78 2.34 3.67 1.82 2.44 4.13 1.87 2.56 4.81 1.21 1.25 1.37 1.23 1.31 1.41 1.25 1.35 1.46 1.26 1.37 1.49 1.29 1.40 1.54 1.31 1.43 1.58 1.33 1.47 1.63 1.35 1.50 1.69 1.37 1.54 1.74 1.40 1.57 1.80 1.42 1.61 1.87 1.44 1.65 1.94 1.47 1.70 2.01 1.49 1.74 2.09 1.52 1.79 2.18 1.55 1.84 2.28 1.57 1.89 2.39 1.60 1.95 2.51 1.63 2.01 2.66 1.66 2.07 2.81 1.70 2.14 3.01 1.73 2.22 3.24 1.19 1.24 1.33 1.21 1.29 1.36 1.23 1.31 1.41 1.24 1.33 1.43 1.26 1.36 1.47 1.28 1.39 1.51 1.29 1.41 1.55 1.31 1.44 1.60 1.33 1.47 1.64 1.35 1.51 1.69 1.37 1.54 1.74 1.37 1.57 1.80 1.40 1.61 1.85 1.44 1.64 1.92 1.46 1.68 1.98 1.48 1.72 2.05 1.51 1.76 2.13 1.53 1.81 2.22 1.55 1.85 2.31 1.58 1.90 2.41 1.61 1.95 2.53 1.63 2.01 2.66 GGG 40 GS 52 AlCu4MgSi 1.16 1.23 1.29 1.19 1.25 1.31 1.19 1.26 1.35 1.21 1.29 1.37 1.22 1.31 1.40 1.24 1.33 1.43 1.26 1.35 1.47 1.27 1.38 1.50 1.29 1.40 1.54 1.30 1.43 1.57 1.32 1.45 1.61 1.34 1.48 1.65 1.35 1.51 1.70 1.37 1.54 1.74 1.39 1.57 1.79 1.41 1.60 1.84 1.43 1.63 1.89 1.45 1.66 1.95 1.47 1.70 2.01 1.49 1.73 2.07 1.51 1.77 2.14 1.53 1.81 2.22 270 300 Hub materials St 50-2 GGG 50 C 35 St 60-2 C 45 1.15 1.13 1.21 1.19 1.26 1.23 1.16 1.14 1.23 1.21 1.29 1.25 1.17 1.16 1.24 1.21 1.31 1.26 1.19 1.16 1.26 1.23 1.34 1.31 1.21 1.19 1.28 1.25 1.37 1.32 1.22 1.20 1.30 1.27 1.40 1.35 1.23 1.21 1.32 1.29 1.42 1.37 1.25 1.22 1.35 1.31 1.45 1.40 1.26 1.23 1.37 1.32 1.49 1.42 1.28 1.25 1.39 1.34 1.52 1.45 1.29 1.26 1.41 1.36 1.55 1.48 1.31 1.27 1.44 1.38 1.59 1.51 1.32 1.29 1.46 1.40 1.62 1.54 1.34 1.30 1.49 1.42 1.66 1.57 1.36 1.31 1.51 1.45 1.70 1.60 1.37 1.33 1.54 1.47 1.74 1.63 1.39 1.34 1.55 1.49 1.79 1.67 1.41 1.36 1.59 1.51 1.83 1.70 1.42 1.37 1.62 1.54 1.88 1.74 1.44 1.39 1.66 1.56 1.93 1.78 1.46 1.40 1.68 1.59 1.99 1.82 1.48 1.42 1.72 1.61 2.05 1.87 350 400 450 600 GGG 60 GS 62 St 70-2 1.11 1.16 1.19 1.12 1.17 1.21 1.13 1.19 1.23 1.15 1.19 1.26 1.16 1.21 1.27 1.17 1.23 1.29 1.18 1.24 1.31 1.19 1.26 1.33 1.20 1.27 1.35 1.21 1.29 1.37 1.22 1.30 1.39 1.23 1.32 1.42 1.24 1.34 1.44 1.25 1.35 1.46 1.26 1.37 1.49 1.28 1.39 1.51 1.29 1.40 1.54 1.30 1.42 1.56 1.31 1.44 1.59 1.32 1.46 1.62 1.34 1.48 1.65 1.35 1.50 1.68 GGG 70 GS 70 C 60 1.10 1.13 1.17 1.11 1.15 1.19 1.12 1.16 1.21 1.13 1.17 1.21 1.14 1.19 1.23 1.15 1.20 1.25 1.16 1.21 1.27 1.16 1.22 1.28 1.17 1.23 1.30 1.18 1.25 1.32 1.19 1.26 1.34 1.20 1.27 1.35 1.21 1.29 1.37 1.22 1.30 1.39 1.23 1.31 1.41 1.24 1.33 1.43 1.25 1.34 1.45 1.26 1.36 1.47 1.27 1.37 1.49 1.28 1.39 1.52 1.29 1.40 1.54 1.30 1.42 1.56 AlZn 5,5 MgCu 25 CrMo4 42CrMo4 1.09 1.12 1.15 1.10 1.13 1.1 1.11 1.14 1.18 1.12 1.15 1.19 1.12 1.16 1.21 1.13 1.17 1.22 1.14 1.19 1.23 1.15 1.20 1.25 1.15 1.21 1.26 1.16 1.22 1.28 1.17 1.23 1.29 1.18 1.24 1.31 1.19 1.25 1.32 1.19 1.26 1.34 1.20 1.28 1.36 1.21 1.20 1.37 1.22 1.30 1.39 1.23 1.31 1.41 1.24 1.32 1.42 1.25 1.34 1.44 1.25 1.35 1.48 1.26 1.36 1.48 1.07 1.09 1.11 1.08 1.10 1.13 1.08 1.11 1.14 1.09 1.12 1.14 1.09 1.12 1.15 1.10 1.13 1.16 1.10 1.14 1.17 1.11 1.15 1.18 1.12 1.15 1.19 1.12 1.16 1.20 1.13 1.17 1.21 1.13 1.18 1.22 1.14 1.19 1.23 1.14 1.19 1.25 1.15 1.20 1.26 1.16 1.21 1.27 1.16 1.22 1.28 1.17 1.23 1.29 1.17 1.24 1.30 1.18 1.24 1.31 1.19 1.25 1.32 1.19 1.26 1.34 Walther Flender Gruppe Clamping sets Page 37 Description of models & tables MLC 3000 Dimensions Size This clamping set is self-centring with excellent concentricity. The extremely small outer diameter is space-saving and suitable for small wheel diameters. The spacer ring between the outer flange and the hub maintains the fitting position in the axial direction to enable exact positioning without a shaft collar. The push-off threads in the outer flanges are used for dismantling. d D H d x D mm 6 x 14 8 x 15 9 x 16 10 x 16 11 x 18 12 x 18 14 x 23 15 x 24 16 x 24 17 x 25 17 x 26 18 x 26 19 x 27 20 x 28 22 x 32 24 x 34 25 x 34 28 x 39 30 x 41 32 x 43 35 x 47 38 x 50 40 x 53 42 x 55 45 x 59 48 x 62 50 x 65 55 x 71 60 x 77 65 x 84 70 x 90 75 x 95 80 x 100 85 x 106 90 x 112 95 x 120 100 x 125 110 x 140 120 x 155 D1 mm 25 27 28 29 32 32 38 44 44 45 47 47 48 49 54 56 56 61 62 65 69 72 75 78 85 87 92 98 104 111 119 126 131 137 143 153 162 180 198 H mm 10 11.5 14 14 13.5 13.5 14 16 16 16 18 18 18 18 25 25 25 25 25 25 30 30 30 32 40 45 45 50 50 50 60 60 65 65 65 65 65 90 90 H1 mm 19.5 22 22 22 23 23 23 33 33 33 33 33 33 33 40 40 40 40 40 40 45 45 45 51 59 64 64 69 69 69 84 84 89 89 89 89 94 120 120 H2 mm 21 25 26 26 26 26 26 36 36 36 38 38 38 38 45 45 45 45 45 45 50 50 50 57 65 70 70 75 75 75 91 91 96 96 96 96 102 128 128 Screws L mm 24 29 30 30 30 30 30 42 42 42 44 44 44 44 51 51 51 51 51 51 56 56 56 65 73 78 78 83 83 83 101 101 106 106 106 106 114 140 140 DIN 912 12.9 M 3 M 4 M 4 M 4 M 4 M 4 M 4 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 Recommended shaft/hub fitting tolerances Torque MS Nm 2 5 5 5 5 5 5 15 15 15 17 17 17 17 17 17 17 17 17 17 17 17 17 41 41 41 41 41 41 41 83 83 83 83 83 83 145 145 145 Mt Nm 14 28 41 46 50 55 64 150 150 162 180 200 210 220 250 270 280 500 520 730 800 900 900 1800 1900 2000 2600 2900 3100 3400 5800 6200 7800 8500 11200 11800 14600 16000 17400 Axial force FAX kN 4.8 7 9 9 9 9 9 19 19 19 23 23 23 23 23 23 23 34 34 46 46 46 46 84 84 84 105 105 105 105 170 170 200 200 250 250 300 300 300 h8/H8 Surface pressures pw pN N/mm2 N/mm2 201 86 197 105 192 108 173 108 164 100 150 100 123 75 208 130 195 130 184 125 187 122 173 120 171 120 168 120 102 70 99 70 95 70 125 90 115 84 155 115 109 81 100 76 95 72 164 125 117 89 97 75 117 90 90 70 90 70 78 60 103 80 89 70 100 80 87 70 112 90 101 80 119 95 78 61 71 55 Walther Flender Gruppe Clamping sets Page 38 MLC 5,000 A Dimensions Size H2 Model 5000A d D H H1 Self-centring clamping sets for larger torques with small, self-locking taper angles. The diameters are the same as for the MLC 1000, but have a significantly higher transmission force. Type B prevents axial displacement between the shaft and hub by means of a stop ring, thus ensuring exact positioning in the axial direction. Due to the additional friction between the hub and the outer ring, the transmissible load is somewhat lower. MLC 5000 B L H2 Model 5000B d D D1 H3 H H1 dxD mm 20 x 47 22 x 47 24 x 50 25 x 50 28 x 55 30 x 55 32 x 60 35 x 60 38 x 65 40 x 65 42 x 75 45 x 75 48 x 80 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 170 x 225 180 x 235 H mm 26 26 26 26 26 26 26 26 26 26 30 30 30 30 30 30 30 40 40 40 40 40 40 45 45 45 45 50 50 50 50 50 H1 mm 37 37 37 37 37 37 37 37 37 37 46 46 46 46 46 46 46 54 54 54 54 54 54 61 61 61 61 68 68 68 68 68 H2 mm 42 42 42 42 42 42 42 42 42 42 51 51 51 51 51 51 51 60 60 60 60 60 60 68 68 68 68 76 76 76 76 76 Screws L mm 48 48 48 48 48 48 48 48 48 48 59 59 59 59 59 59 59 70 70 70 70 70 70 80 80 80 80 90 90 90 90 90 DIN 912 12.9 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 14 M 14 M 14 M 14 M 14 MS Nm 17 17 17 17 17 17 17 17 17 17 41 41 41 41 41 41 41 83 83 83 83 83 83 145 145 145 145 210 210 210 210 210 Mt Nm 530 580 630 660 740 790 1200 1300 1300 1400 2000 2200 3200 3300 3600 3900 4300 7500 8000 8500 11400 12000 12600 15000 16500 22500 29000 32000 41000 44000 54500 57500 Recommended shaft/hub fitting tolerances Size Dimensions dxD mm 20 x 47 22 x 47 24 x 50 25 x 50 28 x 55 30 x 55 32 x 60 35 x 60 38 x 65 40 x 65 42 x 75 45 x 75 48 x 80 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 170 x 225 180 x 235 D1 H H1 H2 H3 L mm mm mm mm mm mm 53 26 37 42 31 48 53 26 37 42 31 48 56 26 37 42 31 48 56 26 37 42 31 48 61 26 37 42 31 48 61 26 37 42 31 48 66 26 37 42 31 48 66 26 37 42 31 48 71 26 37 42 31 48 71 26 37 42 31 48 81 30 46 51 35 59 81 30 46 51 35 59 86 30 46 51 35 59 86 30 46 51 35 59 91 30 46 51 35 59 96 30 46 51 35 59 101 30 46 51 35 59 119 40 54 60 45 70 124 40 54 60 45 70 129 40 54 60 45 70 134 40 54 60 45 70 139 40 54 60 45 70 144 40 54 60 46 70 155 45 61 68 52 80 165 45 61 68 52 80 175 45 61 68 52 80 188 45 61 68 52 80 199 50 68 76 58 90 209 50 68 76 58 90 219 50 68 76 58 90 234 50 68 76 58 90 244 50 68 76 58 90 Recommended shaft/hub fitting tolerances Axial force FAX kN 52 52 52 52 52 52 70 70 70 70 100 100 130 130 130 130 130 210 210 210 270 270 280 300 300 370 450 460 550 550 640 640 Torque Surface pressures pw N/mm2 259 235 208 200 196 183 225 206 188 179 214 200 250 240 216 195 175 204 199 180 221 202 192 189 169 193 208 176 200 184 212 196 pN N/mm2 110 110 100 100 100 100 120 120 110 110 120 120 150 150 140 130 120 130 130 120 150 140 135 130 120 140 150 130 150 140 160 150 h8/H8 Screws DIN 912 12.9 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 14 M 14 M 14 M 14 M 14 Torque MS Nm 17 17 17 17 17 17 17 17 17 17 41 41 41 41 41 41 41 83 83 83 83 83 83 145 145 145 145 230 230 230 230 230 Mt Nm 320 360 390 400 450 490 690 750 820 860 1300 1400 2000 2000 2200 2400 2600 4600 5000 5200 7000 7400 7800 9800 10700 14600 19000 23000 30000 32000 39000 41000 Axialkraft FAX kN 33 33 33 33 33 33 43 43 43 43 60 60 80 80 80 80 80 130 130 130 170 170 170 190 190 240 300 330 400 400 460 460 h8/H8 Surface pressures pw N/mm2 165 150 146 140 118 110 131 120 120 114 125 117 150 144 139 120 102 126 123 105 132 116 114 116 99 124 138 122 133 131 146 131 pN N/mm2 70 70 70 70 60 60 70 70 70 70 70 70 90 90 90 80 70 80 80 70 90 80 80 80 70 90 100 90 100 100 110 100 Walther Flender Gruppe Clamping sets Page 39 MLC 5006 Dimensions Size L H2 Model 5006 d D H H1 This is the least expensive and most popular of all clamping sets. It differs from the MLC 5000 in that it has a shorter installation length, making it more suitable for narrow, disk-shaped wheel hubs. The diameters are the same. The MLC 5007 has a larger flange diameter as a stop for axial positioning of the hub. The friction between the outer ring and the hub reduces the transferred torque as compared with the MLC 5006. Both models are self-centring and self-locking in the clamping state. Due to the high demand, these models are always in stock. MLC 5007 L H2 Model 5007 d D D1 H3 H H1 dxD mm 18 x 47 19 x 47 20 x 47 22 x 47 24 x 50 25 x 50 28 x 55 30 x 55 32 x 60 35 x 60 38 x 65 40 x 65 42 x 75 45 x 75 48 x 80 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 H mm 17 17 17 17 17 17 17 17 17 17 17 17 20 20 20 20 20 20 20 24 24 24 24 24 24 26 26 26 34 34 34 34 H1 mm 25 25 25 25 25 25 25 25 25 25 25 25 30 30 30 30 30 30 30 36 36 36 36 36 36 40 40 40 48 50 50 50 H2 mm 28 28 28 28 28 28 28 28 28 28 28 28 33 33 33.5 33.5 33.5 33.5 33.5 40 40 40 40 40 40 44 44 44 52 54 54 54 Screws L mm 34 34 34 34 34 34 34 34 34 34 34 34 41 41 41 41 41 41 41 50 50 50 50 50 50 56 56 56 64 68 68 68 DIN 912 12.9 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 14 M 14 M 14 MS Nm 14 14 14 14 14 14 14 14 14 14 14 14 35 35 35 35 35 35 35 70 70 70 70 70 70 115 115 115 115 185 185 185 Mt Nm 370 390 410 450 490 510 570 610 880 960 1000 1100 2200 2400 2500 2600 2900 3100 3400 6000 6400 6800 9000 9600 10200 12000 13000 16000 23000 25000 30000 38800 Recommended shaft/hub fitting tolerances Size Dimensions dxD mm 18 x 47 19 x 47 20 x 47 22 x 47 24 x 50 25 x 50 28 x 55 30 x 55 32 x 60 35 x 60 38 x 65 40 x 65 42 x 75 45 x 75 48 x 80 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 180 x 235 200 x 260 D1 H H1 H2 H3 L mm mm mm mm mm mm 53 17 25 28 22 34 53 17 25 28 22 34 53 17 25 28 22 34 53 17 25 28 22 34 56 17 25 28 22 34 56 17 25 28 22 34 61.4 17 25 28 22 34 61.4 17 25 28 22 34 67 17 25 28 22 34 67 17 25 28 22 34 72 17 25 28 22 34 72 17 25 28 22 34 84 20 30 33 25 41 84 20 30 33 25 41 89 20 30 33.5 24 41 89 20 30 33.5 24 41 94 20 30 33.5 24 41 99 20 30 33.5 24 41 104 20 30 33.5 24 41 119 24 36 40 29 41 124 24 36 40 29 50 129 24 36 40 29 50 134 24 36 40 29 50 139 24 36 40 29 50 144 24 36 40 29 50 154 26 40 44 31 56 164 26 40 44 31 56 174 26 40 44 31 56 189 34 48 52 39 64 199 34 50 54 39 68 209 34 50 54 39 68 219 34 50 54 39 68 244 44 60 64 49 78 269 44 60 64 49 78 Recommended shaft/hub fitting tolerances Axial force FAX kN 41 41 41 41 41 41 41 41 55 55 55 55 105 105 105 105 105 105 105 170 170 170 210 210 210 235 260 270 350 360 400 480 Torque Surface pressures pw N/mm2 366 346 329 299 271 260 236 220 272 249 231 219 339 317 292 280 255 233 219 275 261 240 279 267 263 247 225 227 215 204 207 223 pN N/mm2 140 140 140 140 130 130 120 120 145 145 135 135 190 190 175 175 165 155 150 175 170 160 190 185 185 170 160 165 155 150 155 170 h8/H8 Screws DIN 912 12.9 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 14 M 14 M 14 M 14 M 14 Torque MS Nm 17 17 17 17 17 17 17 17 17 17 17 17 41 41 41 41 41 41 41 83 83 83 83 83 83 145 145 145 145 230 230 230 230 230 Mt Nm 290 300 320 350 390 400 450 490 700 760 820 870 1700 1800 1900 2000 2200 2400 2600 4600 5000 5300 7000 7400 7800 9700 10700 14600 19000 23000 24500 31300 35000 49000 Axialkraft FAX kN 32 32 32 32 32 32 32 32 43 43 43 43 80 80 80 80 80 80 80 130 130 130 160 160 160 200 200 242 300 330 330 390 390 500 h8/H8 Flächenpresungen pw pN 2 N/mm N/mm2 261 100 247 100 235 100 214 100 208 100 200 100 177 90 165 90 206 110 189 110 171 100 163 100 250 140 233 140 217 130 208 130 185 120 180 120 161 110 204 130 199 130 180 120 221 150 202 140 185 130 203 140 183 130 206 150 180 130 190 140 173 130 197 150 144 110 143 110 Walther Flender Gruppe Clamping sets Page 40 MLC 7000 Dimensions Size This model, similar to the MLC 4000 series, can withstand very high loads and is especially suitable for a smaller diameter range and a shorter installation length. The diameter gradations are the same. These clamping sets are self-centring and self-locking with excellent concentricity and runout properties, also compared with resulting torques. The very small taper angles mean that the clamping travel is relatively large. The inner clamping ring requires greater axial clearance for release (s = 0.02 · d). L H2 Model 7000 H mm 41 41 41 41 41 58 58 58 58 70 70 70 70 70 70 92 92 92 108 108 108 108 132 132 132 132 132 132 134 165 165 H2 mm 45 45 45 45 45 62 62 62 62 76 76 76 76 76 76 98 98 98 114 114 114 114 146 146 146 146 146 146 148 177 177 L mm 51 51 51 51 51 70 70 70 70 86 86 86 86 86 86 110 110 110 128 128 128 128 162 162 162 162 162 162 164 197 197 Torque MS Nm 17 17 17 17 41 41 41 41 41 83 83 83 83 83 83 145 145 145 230 230 230 230 355 355 355 355 355 355 355 690 690 Axial force Mt Nm 700 1200 1400 2000 3200 3600 4000 5400 5800 10300 11000 14000 15000 16000 17000 26000 29000 36400 45400 57000 70000 75000 95000 115000 121500 128000 140500 210000 255000 368000 430000 h8/H8 D Recommended shaft/hub fitting tolerances Screws DIN 912 -12.9 M 6 M 6 M 6 M 6 M 8 M 8 M 8 M 8 M 8 M 10 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 14 M 14 M 14 M 16 M 16 M 16 M 16 M 16 M 16 M 16 M 20 M 20 d H dxD mm 25 x 50 30 x 55 35 x 60 40 x 65 45 x 75 50 x 80 55 x 85 60 x 90 65 x 95 70 x 110 75 x 115 80 x 120 85 x 125 90 x 130 95 x 135 100 x 145 110 x 155 120 x 165 130 x 180 140 x 190 150 x 200 160 x 210 170 x 225 180 x 235 190 x 250 200 x 260 220 x 285 240 x 305 260 x 325 280 x 355 300 x 375 Further information is available at www.maschinenlager.de FAX kN 55 70 70 90 140 140 140 170 170 280 280 340 340 310 340 500 500 600 700 800 900 900 1100 1200 1200 1200 1200 1500 196 262 292 Surface pressures pw N/mm2 160 165 154 163 217 128 124 135 132 157 153 165 162 144 142 145 141 151 138 149 160 144 132 144 132 130 117 140 225 241 244 pN N/mm2 80 90 90 100 130 80 80 90 90 100 100 110 110 100 100 100 100 110 100 110 120 110 100 110 100 100 90 110 180 190 195 Walther Flender Gruppe Clamping sets Page 41 Taper Lock® clamping bushes In addition to the cylindrical clamping elements listed here, we also offer an extensive line of conical TL clamping elements. Disassembly Remove screws, insert one as a pushoff screw into the hole with a half thread in the bush and tighten. Installation Clean and degrease all exposed surfaces. Fit pulley and bush, align holes and screw in screws loosely. This loosens the Taper Lock® bush. Remove the loosened pulley unit – without impact to prevent damage to the machine – by hand. Push pulley with bush onto the shaft, align and tighten screws evenly to the correct torque according to the table. Mounting bores Disassembly bores The empty bores should be filled with grease to prevent penetration by foreign objects. 008 1008 to 3030 3525 to 5050 If high torques have to be transmitted and no feather key is used, the Taper Lock® clamping bush can be driven further into the conical bore by lightly tapping with a hammer, using a suitable sleeve or wooden block. Afterwards, the screws can be tightened a bit more. This procedure can be repeated. Model 3525 3535 4030 4040 4535 4545 5040 5050 5.6 1108 1210 1610 1615 2012 2517 3020 3030 5.6 20 20 20 30 50 90 90 Torque [Nm] 115 115 170 170 190 190 270 270 2 2 2 2 2 2 2 2 2 Number of screws 3 3 3 3 3 3 3 3 1/4“ 1/4“ 3/8“ 3/8“ 5/8“ 5/8“ Screw ø (inches) 1/2“ 1/2“ 5/8“ 5/8“ 3/4“ 3/4“ 7/8“ 7/8“ 3 3 5 5 8 8 Hexagon SLW (mm) 10 10 12 12 14 14 14 14 Taper Lock® ­clamping bush 1008 1108 1210 1610 + 1615 2012 2517 3/8“ 7/16“ 1/2“ 5 6 6 Bush bore (mm) Slipping torque (Nm*) Clamping force N Taper Lock® ­clamping bush 12 19 24 12 19 24 28 16 19 24 32 19 24 38 42 24 38 42 48 50 24 38 42 48 55 60 29 51 66 28 49 64 79 82 105 142 210 98 135 240 265 165 310 340 400 420 220 380 430 510 600 670 3990 4940 5490 – 4630 5220 5720 8840 9800 10900 12300 – 9570 11900 12700 11500 14400 15700 – 16700 – 17000 18500 – 21000 22300 3020 + 3030 3525 + 3535 4030 + 4040 4535 + 4545 5040 + 5050 Bush bore (mm) 38 48 55 60 75 42 60 75 90 48 60 75 100 55 75 100 110 75 100 125 Slipping torque (Nm*) 520 730 890 970 1300 1000 1580 2150 2600 1700 2300 3150 4400 2500 3900 5500 6300 3950 5650 7370 Clamping force N 23900 26100 29900 31500 34500 41000 49800 54800 59000 – 70200 77200 89400 79600 93000 107700 – 91800 106600 119500 * The specified slipping torques were measured on test stands. The screws were tightened to the corresponding torque. Taper Lock® is a trademark of J. H. Fenner and Co. Ltd. Walther Flender Gruppe Clamping sets Page 42 Taper Lock® clamping bushes 4 hole Bush no. 1008 1108 1210 1310 1610 1615 2012 2517 3020 3030 Bush bore mm 10 11 12 14 16 18 19 20 22 24 25 10 11 12 14 16 18 19 20 22 24 25 28 11 12 14 16 18 19 20 22 24 25 28 30 32 14 16 18 19 20 22 24 25 28 30 32 35 14 15 16 18 19 20 22 24 25 28 30 32 35 38 40 42 14 16 18 19 20 22 24 25 28 30 32 35 38 40 42 14 16 18 19 20 22 24 25 28 30 32 35 38 40 42 45 48 50 16 18 19 20 22 24 25 28 30 32 35 38 40 42 45 48 50 55 60 25 28 30 32 35 38 40 42 45 48 50 55 60 65 70 75 35 38 40 42 45 48 50 55 60 65 70 75 * Bore with flat groove Keyway mm wide deep 3 1.4 4 1.8 5 2.3 6 2.8 8 1.3* 3 1.4 4 1.8 5 2.3 6 2.8 8 3.3 8 1.3* 4 1.8 5 2.3 6 2.8 8 3.3 10 3.3 5 2.3 6 2.8 8 3.3 10 3.3 10 1.3* 5 2.3 6 2.8 8 3.3 10 3.3 12 3.3 5 2.3 6 2.8 8 3.3 10 3.3 12 1.3* 5 2.3 6 2.8 8 3.3 10 3.3 12 3.3 14 3.8 5 2.3 6 2.8 8 3.3 10 3.3 12 3.3 14 3.8 16 4.3 18 4.4 8 3.3 10 3.3 12 3.3 14 3.8 16 4.3 18 4.3 20 4.9 10 12 14 16 18 20 3.3 3.3 3.8 4.3 4.4 4.9 5 hole Bush length mm Approx. weight kg 22.3 0.15 to 0.08 Largest ­diameter mm Bush no. 35 3525 0.18 to 0.10 38 25.4 0.17 to 0.30 47.5 25.4 0.19 to 0.33 51 25.4 0.42 to 0.20 57 38.1 0.60 to 0.25 57 31.8 0.80 to 0.38 70 1.7 to 0.80 85.5 22.3 44.5 50.8 76.2 2.8 to 1.5 4.0 to 2.1 3535 4030 4040 4535 4545 108 5040 108 5050 Bush bore mm 35 38 40 42 45 48 50 55 60 65 70 75 80 85 90 95 100 35 38 40 42 45 48 50 55 60 65 70 75 80 85 90 40 42 45 48 50 55 60 65 70 75 80 85 90 95 100 105 110 115 40 42 45 48 50 55 60 65 70 75 80 85 90 95 100 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 55 60 65 70 75 80 85 90 95 100 105 110 70 75 80 85 90 95 100 105 110 115 120 125 70 75 80 85 90 95 100 105 110 115 120 125 Keyway mm wide deep 10 3.3 12 3.3 14 3.8 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 28 4.4* 10 3.3 12 3.3 14 3.8 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 12 3.3 14 3.8 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 28 6.4 32 5.4* 12 3.3 14 3.8 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 28 6.4 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 28 6.4 32 7.4 16 4.3 18 4.4 20 4.9 22 5.4 25 5.4 28 6.4 20 4.9 22 5.4 25 5.4 28 6.4 32 7.4 20 4.9 22 5.4 25 5.4 28 6.4 32 7.4 Bush length mm Approx. weight kg 5.5 Largest ­diameter mm 64 to 127 1.8 6.6 88.9 to 127 3.2 7.4 76 to 146 4.2 10.1 101.6 to 146 5.2 10.7 89 to 162 4.2 13.2 114.3 to 162 7.4 12.2 102 to 178 6.2 15.2 127 to 9.2 178 Walther Flender Gruppe Clamping sets Page 43 Causes of malfunctions Fault Cause Solution Excessive noise levels Misalignment of pulleys Excessive belt tension Overload of drive system Worn timing belt pulley Incorrect pulley profile Rim flange stop face too large Air displacement in hollows Align pulleys Reduce initial tension Increase belt width Replace timing belt pulley Correct profile Use of standard rim flanges with bending radius Custom profile Visible belt elongation Reduction of centre distance of axes due to loosening of the shaft bearings or timing belt pulley mounting Pulley wear (outer diameter) Overload of drive system Heat-up and subsequent cooling of drive system Reset centre distance of axes and reinforce mounting Excessive change in the timing belt material (melting, softening) Replace timing belt pulley Redesign drive system Check thermal expansion coefficient and use other materials, if necessary Reduce temperatures to permissible range Belt runs off to side Belt runs off the side of the timing belt pulley Excessive wear on side of belt Align drive system correctly Align drive system correctly Loosening of rim flanges Misalignment of pulleys, resulting in excessive axial forces Align pulleys Excessive wear on side of belt Incorrect axis parallelism or change in the centre distance of axes due to insufficient strength of bearings and axles Rim flanges defective or not bevelled Damage due to incorrect handling Timing belt too wide Check axis parallelism and/or increase strength of axles and bearings Premature tooth wear Initial tension too high or too low Belt runs off over rim flange Incorrect belt profile for timing belt pulley Worn timing belt pulley Timing belt pulley surface too rough Overload Excessive damage due to foreign objects Correct initial tension Align timing belt pulley/correct initial tension Use PolyChain® timing belt pulleys Replace timing belt pulley Replace timing belt pulley System must be redesigned Timing belt cover Shearing of belt teeth Not enough teeth meshing Overload of drive system Worn timing belt pulley Incorrect belt profile for timing belt pulley Insufficient belt tension Extreme shock loads Increase number of pulley teeth or use smaller pitch Increase belt width Replace timing belt pulley Use correct tooth profile Set correct belt tension System must be redesigned Broken belt Timing belt pulley diameter too small Overload of drive system Foreign objects Incorrect handling of timing belt during installation,­ belt damaged from kinking or bending Increase pulley diameter or belt power output Use wider timing belt Protective drive cover Comply with installation instructions Abnormal wear of timing belt pulley (outer diameter or tooth flanks) Increased belt tension or overload of drive system Timing belt pulley diameter too small Incorrect profile Foreign objects Reduce initial tension or increase belt width; redesign system, if necessary Use correct timing belt pulleys Use correct drive system Protective drive cover Cracks in tooth back Temperature too low Temperature too high Aggressive chemicals Avoid low temperatures Avoid high temperatures Protective drive cover Increased temperature Initial tension too high or too low Incorrect timing belt profile or timing belt pulley profile Outer diameter too large Set correct initial belt tension Use correct drive system Correct outer diameter Vibrations Initial tension too high or too low Loose timing belt pulley Set correct initial belt tension Re-attach timing belt pulleys and mount according to specifications Install a tangential tension pulley Vibrations in the slack side Align or replace rim flanges Follow procedure in assembly instructions Use timing belt pulleys with correct width Walther Flender Gruppe Clamping sets Product overview WF timing belt drive systems WF timing belts are available in 5 basic systems for diverse transmission requirements. The powerful PowerGrip® GT3 and PolyChain belt systems ensure compact power density with high cost effectiveness. Shaped belts and flex belts in fixed lengths of your choice or as polyurethane metre ware in a wide range of pitches are available as an ideal transmission solution for almost all transport and conveyor requirements. These timing belts can additionally be supplied with cams or various coatings on the reverse. Special range of WF timing belt pulleys Special builds of timing belt pulleys based on customer drawings can be produced on the most modern manufacturing machinery. A wide selection of materials and moulded parts in plastic, sintered materials, or die-cast complete the range for series applications. WF shaft couplings Various ranges of shaft couplings in torsion-proof or torsionally flexible versions are available for a multiplicity of applications. WF drive assemblies Supported by 3D CAD systems and their corresponding calculation software, Walther Flender Antriebstechnik develops and supplies complete assemblies for diverse drive technology requirements. At the request of the customer, existing designs are optimised in terms of technology and efficiency. An example of this is the unit shown adjacent, which conveys paper webs. WF conveyor rollers Walther Flender Antriebstechnik designs and builds conveyor rollers for heavy weights ­especially for skid transport in the automotive industry. Two models are shown as ­examples (driven on one and both sides). WF transmissions The WF range of transmissions includes worm gears, straight bevel and cylindrical gears and right angled gears for high torques up to 1,000,000 Nm. All types are available in a practical range of sizes, with or without motors. Page 44 Walther Flender Gruppe Clamping sets Page 45 Project data sheet Data sheet for calculating Belt drive systems Walther Flender GmbH Company Name / Department Street / P.O. Box Zip code / City Phone Fax E-mail Postfach 13 02 80 Schwarzer Weg 100 –107 40593 Düsseldorf Fax: +49.(0)211.70 07-339 E-Mail: info@walther-flender.de Application: yes Existing drive system with to be replaced by Drive data: Type Speed Power output Torque no Driving machine (e.g. electric motor) Make Model n1 P Braking torque Requirement Working machine (e.g. machine tool) min-1 kW Nm n2 P kW Starting torque Starting characteristics (e.g. torque flow, starting type) Pulley diameter Pitch diameter dw1 Outer diameter da1 Permissible diameter range from mm Max. permissible pulley width mm Transmission ratio i imin Existing centre distance of axes a Pulley diameter to Shaft arrangement mm mm Pitch diameter dw2 Outer diameter da2 mm from imax mm mm mm to mm to step-down Centre distance adjustment range mm inner pulley outer pulley amax load side lostum mm horizontal Pmax mm mm dw da mm vertical Operating conditions: Chemical influences (e.g. oil, dust, etc.) Ambient temperature °C Daily operating hours hours/day Desired noise level dBA min-1 kW Nm Type of load uniform non-uniform alternating reversing Centre distance of axes range (for new design) amin Idlers / guide pulleys Quantity/year Number of times switched on / off daily mm step-up fixed mm Notizen Notizen Walther Flender Gruppe Schwarzer Weg 100–107 40593 Düsseldorf Deutschland Tel. : +49.(0)211.70 07- 00 Fax: +49.(0)211.70 07-227 E-Mail: info@walther-flender.de PolCha_en_Nov_09 www.walther-flender-gruppe.de