Overview: The document is a product catalog for Brevini® E Series planetary gearboxes, designed for industrial applications requiring high performance in compact spaces. The gearboxes offer torques ranging from 230 Nm to 36,600 Nm.
Technological Features: The E Series emphasizes technological excellence, mechanical efficiency, and operational economies. Key innovations include overhung pins, reduction stages with four planetary gears, and ground gears with optimized profiles. These features enhance modularity, a concept championed by DANA for over fifty years.
Performance Benefits: The E Series provides several advantages: extended service life due to increased load capacity, quieter operation from perfectly meshed gears, reduced size and weight, and compatibility with previous DANA planetary gear ranges, allowing for interchangeability in various applications.
Product Specifications: The E Series includes 9 sizes with torque from 1,200 Nm to 26,000 Nm. It is available in both in-line and right-angle configurations, with up to 4 reduction stages (expandable to 6 on request). Reduction ratios range from 1:3 to over 1:3,000.
Configurations and Accessories: The gearboxes offer flexible and modular structures with various output versions, including flanged and foot-mounted options. They support electric and hydraulic motors and come with a wide range of brakes and accessories for diverse application needs.
Integration and Delivery: The E Series integrates with the DANA S Series for heavy-duty applications and offers prompt delivery due to efficient manufacturing and logistics processes.
Applications: The gearboxes are suitable for sectors such as renewable energy, mining, industrial equipment, custom applications, and the food and beverage industry.
Input Configuration: The document outlines various configurations for input and mounting positions, including universal input and specific mounting positions like B3 and V6. These configurations are crucial for adapting the gear units to different mechanical setups.
Technical Specifications: The document provides detailed specifications for gear units, including nominal output torque (T2N), transmissible output torque (T2), and maximum output torque (T2MAX). These values are calculated according to ISO standards and are essential for selecting the appropriate gear unit size.
Braking Systems: The document discusses multi-disc brakes, including input braking torque (TB) and required input braking torque (TBR). It emphasizes the importance of calculating these values accurately to ensure safety and performance.
Performance Factors: Various factors affecting performance are listed, such as power increase factor (fI), thermal factor (fK), and environmental factor (fR). These factors are critical for assessing the operational efficiency and longevity of the gear units.
Operational Parameters: Key operational parameters include input speed (n1), maximum input speed (n1MAX), and output speed (n2). The document provides formulas for calculating these speeds, which are vital for ensuring the gear units operate within safe limits.
Power and Efficiency: The document details the calculation of input power (P1) and output power (P2), highlighting the importance of dynamic efficiency (hd) in these calculations. This information is crucial for optimizing the power transmission and efficiency of the gear units.
Thermal Power Specifications: The document outlines the conditions under which a gear unit can continuously transmit thermal power (PT) of a specified value. These conditions include splash lubrication without auxiliary cooling, horizontal mounting, an input speed of 1,500 rpm, a maximum oil temperature of 80°C (ISO VG150 viscosity), and an ambient temperature of 20°C. Adjustments to PT are necessary if these conditions vary, using correction factors fK, fV, and fR.
Correction Factors: - Thermal Factor (fK): Adjusts PT for intermittent use and ambient temperatures different from 20°C.
- Speed Factor (fV): Adjusts PT for input speeds different from 1,500 rpm, considering different mounting positions.
- Environmental Factor (fR): Adjusts PT for gear units located in confined spaces or outdoors.
Power Calculations: - Input Power (P1): The power applied at the input, calculated using the required output torque and output speed.
- Output Power (P2): The power transmitted at the output, calculated using the dynamic efficiency of the gear unit.
Dynamic Efficiency: Dynamic efficiency (hd) is the ratio of output power (P2) to input power (P1) and depends on factors like transmitted power, input speed, lubricant viscosity, operating temperature, and reduction ratio.
Temperature Recommendations: The recommended ambient temperature range is -20°C to +40°C, with an ideal operating temperature between 50°C and 70°C. For high or low ambient temperatures, appropriate lubricants and seals are necessary.
Duty Factor (fS): The duty factor depends on the type of prime mover and driven machine, accounting for load variations and transmission impacts. It varies based on the type of load (uniform, moderate shock, heavy shock) and the type of drive (electric, hydraulic, endothermic).
Specifications: The document outlines the classification of machines based on load type into three groups (a, b, c) as indicated in Table 5. It discusses the operational factor (fS), which depends on the type of primary motor and the machine driven by the gearbox. This factor is empirical, based on experience, and considers load variations, transmission balance, and parameter uncertainties.
Procedures: The document provides a detailed selection process for gear units, requiring the collection of application-specific data. This includes output torque (T2R), maximum output torque (T2RMAX), output speed (n2), input speed (n1), output power (P2), required radial and axial loads on output and input shafts (FrR2, FaR2, FrR1), and other operational parameters like duration (hR), intermittence factor (I), number of starts per hour (N), and ambient temperature (ta).
Standards and Recommendations: Permissible radial and axial loads on shafts are specified, with diagrams provided for different gear unit sizes. The document advises consulting a DANA area contact person if radial and axial loads are present simultaneously on the output shaft or if the duration factor n2xh is less than 25,000 cycles. Specific instructions are given for gear units with female output shafts (FE version) and hollow shafts (FS and FCP versions).
Key Data from Tables and Diagrams: Table 6 categorizes various machines and their applications, such as agitators, conveyors, cranes, crushers, dredges, elevators, extruders, feeders, hoists, laundry machines, metal mills, and more, based on the type of load they handle. Diagrams illustrate permissible radial loads (Fr2, Fr1) and axial loads (Fa2) on shafts, with values dependent on the distance X from the load application point to the shaft shoulder and bearing duration factors (n1xh, n2xh).
Critical Information: For gear unit sizes E160 and E260, radial load values are valid only if both spigots on the customer's support structure are used. If not, consultation with a DANA contact is recommended. The document emphasizes the importance of selecting the correct gear unit based on detailed application data to ensure optimal performance and longevity.
Specifications and Requirements: The document outlines the necessary data for selecting a gear unit, including application type, required output torque (T2R), maximum output torque (T2RMAX), output speed (n2), input speed (n1), output power (P2), radial and axial loads, required duration (hR), duty cycle, number of starts per hour, and work environment temperature. It also specifies the type of configuration, output support, parking brake requirements, and motor type (hydraulic, electric, endothermic, or other).
Selection Procedure: The selection process involves choosing the appropriate duty factor (fS) based on application, drive type, and number of starts. It requires calculating the required duration factor and reduction ratio. The gear unit should be selected from tables in the desired configuration (in-line or angle) with characteristics that meet the specified equations. The reduction ratio should be as close as possible to the required value. For applications with variable loads and speeds, consultation with a DANA contact is recommended.
Verification of Gear Unit: After selection, verify that the input speed (n1) and maximum torque (T2RMAX) are within permissible limits. Check that radial and axial loads on shafts are below specified limits. If loads vary significantly or the application involves frequent reversals, further consultation is advised. Ensure applied power (P1) is below corrected thermal power (PT1). If a brake is selected, verify that the braking torque is within limits.
Motor Selection: Guidelines for selecting a drive motor for the gear unit are provided, with a focus on hydraulic motors. The selection should be based on application requirements, with values serving as a guide.
Specifications and Recommendations: - Ensure that the applied power (P1) is always less than the corrected thermal power (PT1) as per formula (8). If PT1 is less than the power to be transmitted at any point, an auxiliary cooling circuit is required. Consult the DANA contact for circuit selection.
- If an input brake is selected, verify that the calculated output braking torque is less than the maximum transmissible output torque (T2MAX).
Motor Selection: - Choose the appropriate motor type (orbital, gear, radial piston, axial piston, cam) based on application type and operating pressure.
- Calculate the required input torque (T1R) and theoretical displacement (VR) for the hydraulic motor using provided formulas.
- For electric motors, calculate input power (P1) and ensure it satisfies the nominal power (Pn) requirements, considering duty cycles S2 and S3 for potential power increases.
Gear Unit Selection Example: - Application: Conveyor not uniformly fed.
- Required output torque (T2R): 5,500 Nm; Max output torque (T2RMAX): 10,000 Nm.
- Input speed (n1): 1,500 rpm; Output speed (n2): 12 rpm.
- Required radial load on output shaft (FrR2): 40,000 N.
- Calculate lifetime factor (Lh2) and reduction ratio (i) using provided formulas.
- Select gear unit with characteristics satisfying equations (15) and (16) and a reduction ratio close to i = 125.
Tables and Calculations: - Use tables to determine nature of load, duty factor (fs), and gear unit size.
- Ensure gear unit nominal torque (T2N) is immediately higher than calculated T2R x fs.
Specifications and Performance: The document provides detailed specifications for various gear unit sizes, focusing on the E80 size. It includes performance tables that list transmissible torque values (T2) for different reduction ratios and operational conditions. The gear unit EL803 with a reduction ratio of i = 119 is highlighted as suitable for the required conditions, with a transmissible torque of T2 = 6,800 Nm, which exceeds the required 6,050 Nm.
Procedures: The document outlines the procedure for selecting the appropriate gear unit based on the reduction ratio and operational requirements. It involves identifying the column for n2xh values that meet or exceed the calculated Lh2 value and verifying that the transmissible torque is adequate.
Standards and Recommendations: It is recommended to consult the DANA area contact person for duration factors n2xh < 25,000 cycles. The document also provides guidelines for checking maximum torque and radial loads on shafts, ensuring that the selected gear unit can handle the specified loads.
Thermal Power and Efficiency: The document discusses the calculation of transmitted output power and input power, considering the dynamic efficiency of the gear unit. The selected gear unit EL803 is deemed suitable for operation without auxiliary cooling, as the applied power P1 is less than the corrected thermal power PT1.
Key Data and Tables: Performance tables provide values for transmissible torque, reduction ratios, and operational conditions. The document includes tables for selecting gear units based on thermal power, duty cycle, ambient temperature, and mounting position, ensuring the gear unit's suitability for the application.
Specifications: The document provides detailed specifications for various types of shafts and supports used in mechanical systems. It includes dimensions and load capacities for input shafts, radial loads, and different types of male and female splined shafts. The specifications are categorized by model numbers such as E10, E16, E25, etc., and include measurements like diameter, length, and permissible loads.
Procedures: The document outlines procedures for selecting the appropriate shaft and support types based on the application requirements. It advises consulting selection tables for dimensions and permissible loads. Additionally, it provides guidelines for mounting positions and lubrication requirements, emphasizing the need for adaptation in non-standard mounting positions.
Standards and Norms: The document adheres to specific engineering standards for shaft dimensions and load capacities. It mentions the use of DIN standards for certain components, ensuring compatibility and reliability in mechanical systems.
Recommendations: Recommendations are provided for the use of specific types of supports based on the load conditions. For instance, ISL type supports are recommended for use with flexible couplings when radial loads are minimal. The document also advises on the use of specific oils for lubrication, particularly for brakes, recommending mineral or synthetic oils with ISO VG 32 viscosity.
Key Data from Tables and Figures: The document includes numerous tables and figures that provide detailed measurements and specifications for different shaft types. Key data includes dimensions like diameter and length, load capacities, and specific model numbers for easy reference. The tables also provide information on the permissible loads and the recommended mounting configurations.
Critical Information: Critical information includes the maximum working speed of 1,800 rpm for input supports and the specific conditions under which different types of brakes should be used. The document highlights the importance of using brakes only as parking brakes and not for dynamic braking, due to their automatic engagement in the absence of control pressure.
Installation Guidelines: The document provides detailed instructions for the installation of gear units, emphasizing the importance of trained technical personnel for the task. It highlights the necessity of adhering to technical specifications and ensuring safety for operators and third parties. Key points include:
- Prohibition of unauthorized modifications to the gear unit and accessories.
- Use of appropriate lifting equipment to avoid impacts on shaft ends.
- Prohibition of welding on gear units.
- Ensuring the gear unit is stopped during installation or maintenance to prevent accidental activation.
- Use of the DANA E00 Universal adapter system for motors up to 100 kg and 1,000 Nm torque, with specific adapters for heavier motors.
- Provision of adequate accident-prevention devices for connections involving rotating parts.
Shaft Assembly: Before assembly, mating surfaces should be cleaned and lubricated with anti-seizure products. Installation and removal should be done using suitable equipment to avoid damage. For driven shaft sizes, refer to the section “Outputs.”
Flange and Foot Mounting: Mating surfaces must be machined to ensure the required coefficient of friction. Alignment between the gear unit, motor, and driven machine must respect specified tolerances.
Fixing Screws: Use class 10.9 screws with ISO 7089 washers for mounting gear units. Screws should be tightened according to specified torque values, and lubrication before tightening is discouraged to prevent overload. Torque should be checked after initial machine operation.
Shrink Disc: Shrink discs are mounted on the output shaft of FS type supports. Key steps for assembly include cleaning and degreasing the shaft, lubricating the coupling seat with molybdenum disulfide grease, and ensuring the coupling is fitted without tightening screws initially.
Assembly Instructions: - Ensure the shaft and its seat are clean and free of grease. Use a suitable bearing to center the shaft for easier disassembly later.
- Lubricate the coupling seat with molybdenum disulfide grease. New couplings do not require disassembly for lubrication.
- Mount the coupling to the gearbox without tightening the screws. Ensure the coupling is secure, especially in vertical installations with the shaft facing downward.
- Fit the shaft into its seat without interference, ensuring precise alignment using lifting equipment. Avoid applying axial forces that could damage bearings.
- Position the coupling against the shaft shoulder before tightening screws.
- Tighten screws in a circular sequence using a torque wrench, initially set to the specified torque, then increase by 3-5% for final tightening. Ensure no further tightening is possible.
- Protect the coupling area with a sheet casing if there is a risk of debris.
Disassembly Instructions: - Loosen screws gradually until the coupling can move on the hub. Do not fully remove screws until rings separate naturally to avoid violent disassembly.
- If rings do not separate, use screws in extraction holes to separate the inner and outer rings.
- Use appropriate equipment to support and separate the gear unit from the machine shaft. If necessary, use hydraulic pushers.
- For long-term disassembly, clean and lubricate all surfaces before reassembly.
Torque Arm Assembly: - The torque arm must allow axial movement and have sufficient play to accommodate small oscillations without overloading the gear unit.
- Use long-life ball joints with PTFE protection or steel-to-steel joints with periodic greasing.
- The anchorage rod should be parallel to the torque arm to ensure side clearance for free movement.
- The fixed support must provide adequate anchorage for the load.
- Avoid any welding work involving the gear unit.
- Always use a torque wrench for tightening connection screws.
Specifications and Procedures: - The torque arm must move freely in the axial direction and have sufficient play to accommodate minor fluctuations without overloading the gearbox. Use ball joints for optimal performance.
- Durable ball joints with PTFE-protected friction surfaces are recommended. Alternatively, steel-on-steel joints can be used but require regular lubrication.
- The connecting rod should be parallel to the torque arm to ensure lateral play and structural movement freedom.
- The fixed end of the connecting rod must ensure proper load anchoring.
- Avoid welding on the gearbox, even for grounding purposes.
- Always use a torque wrench to tighten screws.
Recommendations for Torque Arm Installation: - The torque arm must be perfectly straight.
- Welded parts should be sanded, normalized, and corrected for deformations.
- The contact area of the torque arm at the gearbox flange must be perfectly flat.
- Remove all grease traces from contact surfaces before connecting the torque arm to the gearbox.
Assembly Considerations: - The correct configuration depends on the gearbox rotation direction. The connecting rod should be in traction, not compression. If necessary, mount the torque arm on the opposite side shown in Fig. 23.
- In shaft mounting assemblies, consider the weights of the gearbox, torque arm, and connected elements, as they create loads and tipping moments supported by the output bearings. Minimize the weight of components connected to the gearbox and decentralize non-essential elements.
Lubrication Guidelines: - DANA gear units are supplied without lubricant; users must fill them correctly before starting the machine.
- Important oil parameters include viscosity at nominal operating conditions and additives.
- Nominal viscosity is referenced at 40°C and decreases with temperature increase. For operating temperatures between 50°C and 70°C, choose the highest viscosity if high temperatures are expected.
- Use high viscosity oils with Extreme Pressure (EP) additives for heavily loaded and low-speed output stages.
- Use oils with EP and antiwear properties according to ISO 6743-6 L-CKC or DIN 51517-3 CLP standards.
Types of Oils: - Mineral oils, Polyalphaolefin (PAO) synthetic oils, and Polyalkylene glycol (PAG) synthetic oils are available.
- Mineral oils are suitable for gear units with discontinuous cycles and no significant temperature changes.
- Use PAO synthetic oils for heavily loaded gear units with continuous operation and temperature increases.
- PAG oils are not recommended due to incompatibility with other oils and potential chemical activity against seals and internal paints.
Contamination Control: - Metal microparticles can contaminate oil during normal operation, reducing bearing life and causing premature gearbox failure.
- Use an auxiliary circulation system with filtration and cooling to control contamination and stabilize operating temperature.
Lubricant Specifications and Recommendations: The document discusses various types of lubricants suitable for DANA gear units, emphasizing the incompatibility of polyalkylene glycol oils due to their water solubility and potential chemical reactivity. It highlights the use of mineral oils for less demanding conditions and synthetic polyalphaolefin oils for high-load, continuous operations. Hydraulic oils are used for negative brakes, and food-grade oils are specified for the food industry.
Contamination and Maintenance: During operation, metallic microparticles can contaminate the oil, reducing bearing life and causing gear unit failure. To mitigate this, an auxiliary oil circulation system with filtering and cooling is recommended to maintain oil cleanliness and stabilize operating temperature.
Oil Control and Mounting Instructions: For horizontal mounting, the oil level should be at the center line, with adjustments for low-speed applications. A transparent tube can be used for level checks. For vertical mounting, an expansion tank is necessary to accommodate oil expansion due to temperature changes, preventing pressure build-up. The document provides detailed instructions for ensuring proper lubrication and avoiding air bubbles during filling.
Tables of Lubricants: The document includes tables listing various lubricant brands and their specifications, categorized by mineral and synthetic oils, as well as hydraulic and food-grade oils. These tables serve as a reference for selecting appropriate lubricants based on ISO VG ratings and specific applications.
Lubrication and Maintenance: Some drive configurations require oil lubrication along with the gearbox, while others use grease for the output side bearings. In these cases, the shafts are pre-lubricated with Shell Gadus S3 T220 2 grease and are ready for use upon delivery. Periodic lubrication is not necessary for these configurations as they are designed for lifetime lubrication with grease. However, for drive configurations IS and ISL, periodic lubrication is required to maintain a grease-filled chamber that protects the drive-side seal from external contaminants. The recommended grease for periodic lubrication is Polymer 400 NLGI 2 or an equivalent PTFE-based product. Lubrication should be performed with low-pressure systems to avoid damaging the seal, and it is recommended to conduct this maintenance at least every six months.
Oil Change and Quantity: The document provides tables with approximate oil quantities for various configurations. It is essential to verify the oil level as specified in the "Oil Check" sections. The tables list different configurations and their corresponding oil quantities, emphasizing the need for regular checks to ensure proper maintenance.
Mounting Positions: The document outlines different mounting positions, including horizontal and vertical orientations, for various configurations. It provides details on the positioning of components such as the drain plug, oil level plug, and breather and filling plug.
Notes and Legal Information: Reproduction of the catalogue, in whole or in part, is prohibited without written authorization from DANA. DANA reserves the right to modify the specifications in the catalogue without prior notice. The document also includes information about DANA's global presence and its role as a leading supplier of drivetrain, sealing, and thermal technologies.