Overview

This document details the technical specifications, features, and accessory options for CLEAN-GEARTECH Brushless-Tech gearboxes designed specifically for servomotors. These gearboxes offer high protection ratings (IP66 and IP69k), making them suitable for washdown and hygienic environments. They incorporate specialized input shafts with internal seals optimized for brushless motor compatibility.

Unique Features

• Special input shaft design with internal seal tailored for brushless motors.
• All gears are hardened and ground to ensure durability and precision.
• High-quality oil seals standard, with optional FKM seals available on request.
• Flanges and couplings are stocked for rapid assembly.
• Drawings for small production runs are accessible online.

Product Range and Materials

The gearboxes are offered in multiple configurations and materials to suit various applications:

• Aluminum worm gearboxes.
• Full stainless steel worm gearboxes.
• Full stainless steel helical bevel gearboxes.

Each type supports different torque capacities and sizes, with comprehensive dimensional data provided for flanges, bushings, and couplings to aid selection and installation.

Accessories and Kits

Accessory kits include reduction bushings, couplings, and flanges specifically designed for servomotor integration. Each accessory is precisely coded and dimensioned to fit particular motor shaft diameters and gearbox models.

Technical Specifications

• Torque Ratings: Range from 21 Nm for smaller units up to 675 Nm for larger stainless steel helical bevel gearboxes.
• Output Speeds: Various output speeds supported; maximum input speed typically around 1400 min⁻¹.
• Load Capacities: Detailed tables specify allowable radial and axial loads, with explicit restrictions such as prohibition of strong axial loads in the DX direction.
• Lubrication: Gearboxes come pre-filled with synthetic oil for extended life; food-grade oil is available upon request. Oil quantities are standardized (e.g., 0.04 L per gearbox).
• Service Factors: Provided based on operating hours, load types (uniform, moderate, heavy), and number of starts per hour, differentiated for gear and worm gear types.

Installation and Assembly

Motor assembly instructions emphasize correct flange and coupling selection. Fixing holes on flanges are offset by specific angles (25°, 30°, 35°) depending on the model to accommodate diverse mounting needs.

Design and Construction Notes

• All gears are ground and hardened for precision and longevity.
• Seals utilize Viton material with stainless steel 316L protective shields for enhanced chemical and temperature resistance.
• Brushless flanges and special input shafts ensure full compatibility with brushless motors.
• Optional stainless steel protection caps are available for additional environmental protection.

Recommendations and Limitations

• Strong axial loads in the DX direction are prohibited to prevent damage.
• Gearbox selection should prioritize torque ratings over power to avoid overload conditions.
• Frequent start-stop cycles and rapid rotation reversals require careful consideration of service factors.

Summary Tables and Dimensions

The document includes extensive tables covering:

• Dimensions and codes for flanges, bushings, and couplings (diameters, lengths, bolt sizes).
• Torque and power ratings by gearbox size and series.
• Load capacities and service factors based on operational conditions.
• Recommended oil types and quantities for lubrication.

These tables are essential for correct gearbox and accessory selection and installation.

Additional Guidelines

1. Gearbox Selection and Operating Speed

For motor speeds 0–1500 rpm, use ratings from the general catalog. For speeds 1500–3000 rpm, reduce nominal torque by 20%. For speeds above 3000 rpm, consult the manufacturer. High-speed applications should consider C3 clearance bearings and optional FKM oil seals on couplings. Oil breather plugs are recommended for input speeds above 2000 rpm to manage internal pressure.

2. Service Factors and Special Options

Additional service factors may apply under certain conditions. Special gearbox options are available upon request to meet specific needs.

3. Mounting Positions and Lubrication

Recommended mounting positions include B3, B6, B7, and B8. Vertical mounting is critical for helical and bevel gearboxes, requiring 2Z or 2RS bearings for proper sealing. Continuous operation with frequent starts/stops is discouraged as it may damage the lower oil seal. In critical cases, oil quantity may need adjustment; technical support should be consulted.

4. Motor Assembly Instructions

1. Remove protection screws from input flange.
2. Loosen coupling fastening screws.
3. If using reduction bushings, mount with a rubber hammer.
4. Ensure motor shaft is keyless and coupling screw aligns with flange hole.
5. Clean contact surfaces on motor and input flange.
6. Tighten screws to specified torque values (e.g., M4: 3 Nm, M8: 25 Nm, M10: 45 Nm) using class 8.8 screws.
7. Apply anti-loosening paste on screw threads before fixing.
8. Position gearbox with hollow input shaft upward, ensuring no load on gearbox and free output shaft rotation.
9. Seal motor-flange interface with Loctite SI 5699 or equivalent; consult technical office if flange holes are present.
10. Replace protection screws after assembly.

5. Coupling Assembly Instructions

1. Tighten coupling screws (socket-head, class 8.8) to recommended torque (e.g., M4x14: 3.5 Nm, M5x16: 6 Nm, M6x20: 10 Nm).
2. Tighten screws on both sides twice in sequence.
3. Do not exceed recommended torque to avoid coupling damage.
4. Apply hydraulic sealant before tightening set screws.

6. Critical Checks and Recommendations

• Verify alignment of coupling screws with flange holes before mounting.
• Use 2Z or 2RS bearings for critical mounting positions.
• Consider oil breather plugs for high-speed applications to prevent pressure buildup.
• Consult technical support for lubrication adjustments and special options.

Contact Information

Clean-Geartech Division
Via Cordellina, 81, 36077 Altavilla Vicentina VI, Italy
Tel: +39 0444 1240920
Fax: +39 0444 1240921
Email: [email protected]
Website: www.cleangeartech.com