application flowchart - CGI Motion

n2 Cycle Time

speed speed

n1

n1 t1 T13 + ... nn tn Tn3

n1 t1 + ... nn tn

RCX RNX RSX RBD speed

time

Direction (A): Cycles per Hour (D):

Motion Profile (B): Hours per Day (E):

Max Speed (C): Shock Load (F): n2

n1 t1 t3 t4

3600 (sec/hr) Cycle Time (sec)

8 Calculate Service Factor (SF)

NO time n1

Inline

1 Stage 2 Stage 3 Stage

Efficiency h

>90% >85% >80%

t1

Direction (A): Unidirectional: Reversing: 0.3 0.4

Motion Profile (B): Continuous: Trapezoidal: Triangular:

Max Speed (C): 0-999: 1000-2999 3000-4999 5000 +:

Right Angle

1 Stage 2 Stage 3 Stage

>85% >80% >75%

DCX DNX DSX DBD time

Determine Motor Peak Torque Determine Motor Continuous Torque Determine Load Inertia Determine Motor Rotor Inertia

Cycles per Hour (D): 0-999: 1000-2999: 3000-4999: 5000 +: 0.1 0.2 0.3 0.4

0.3 0.4 0.5 Hours per Day (E): 0 - 4.0: 4.1 - 8.0: 8.1 - 16.0 16.1 +: 0.1 0.2 0.3 0.4

0.1 0.2 0.3 0.4 Shock Load (F): None: Light: Moderate: Heavy: 0.1 0.3 0.5 0.7

YES

Limit Factor (LF) = 1.0

Efficiency h

CGI, INC. • 3400 Arrowhead Drive • Carson City, NV 89706 • Tel 775.882.3422 • Fax 775.882.9599 • www.cgimotion.com

m = ( n Mean Output Speed Motor / n Mean Output Speed Gearhead )

CGI, INC. • 3400 Arrowhead Drive • Carson City, NV 89706 • Tel 775.882.3422 • Fax 775.882.9599 • www.cgimotion.com

Cycle Time

Run Time

n2

Dwell

3, 4, 5, 5.5, 7, 10 15, 16, 20, 22, 25, 28, 30, 40, 49, 50, 55, 70, 100 160, 280, 400, 550, 700

Deceleration

Acceleration

Dwell

Ratios

40

BOLT HOLE SIZE

Deceleration

Figure 1

1 Stage 2 Stage 3 Stage

Note: The radial and axial bearing load limit information is provided for singular load components only (not combined axial and radial loads). When combining the load components, it is safe to combine a maximum of one component with only 10% of maximum of the other component. (i.e. 100% of the maximum radial load limit can be combined with only 10% of the maximum axial load limit and vise versa). Consult CGI, Inc. if the second component (axial/radial) exceeds 10% of the first component’s load.

F

PLX PMX PNX PTX SIX

* These dimensions can be less than value indicated.

T Cont = ( T Mean * S.F.)

FD

T Mean =

E dimensions MOUNTING BOLT * These can be less than CIRCLE value indicated.

11

Our radial and axial bearing load information for each gearhead was calculated based on the dynamic load ratings for our bearing systems. Besides lubrication, bearing life is also affected by running speed (rpm) and applied load (radial or axial). Keeping required hours of bearing operation as a constant, as rpm increases, bearing load capacity decreases and vise versa (note: static loads do not apply). Additionally, for gearhead applications, output shaft bearings are affected by the location of any applied radial load on the output shaft. As constant radial load on the output shaft is placed farther from the gearhead output face, the resultant radial load at the bearings increases.

MOTOR SHAFT LENGTH* PILOT LENGTH* PILOT DIAMETER MOUNTING BOLT CIRCLE PILOTHOLE LENGTH* BOLT SIZE

METRIC 040 060 075 100 140 180

DB EC

18

RADIAL AND AXIAL BEARING LOAD RATINGS

Determine Drive Type

75

17

56

NEMA 017 023 034 042 056 075

42

S.F. = A + B + C + D + E + F

34

t4

23

t3

17

Determine System Inertia Match

75

T Peak = ( T Motor Peak * L.F. * m * S.F. * h)

17 23 34 42 56 NEMA MOTOR MOUNTING DIMENSIONS (INCHES)

Cycles per Hour (D) =

DIMENSION

Desired Inertia Match t2

A MOTOR SHAFT DIAMETER ITEM DIMENSION B MOTOR SHAFT LENGTH* MOTOR SHAFT DIAMETER CA PILOT DIAMETER

Calculate System Inertia

ITEM

t1

(B)

13

(t1 + t2 + t3)

NEMA MOTOR MOUNTING DIMENSIONS (INCHES)

Select Gearhead Size

(t1 + t2 + t3 + t4)

(D)

Calculate Peak Output Torque or Calculate Required Mean Continuous Output Torque

(D)

Determine Gearhead Type Determine Mean Output Speed (RPM) for the Motor Determine Mean Output Speed (RPM) for the Gearhead

(B)

3

(F) HOLE (4X) EQUALLY SPACED ON A (E) B.C. (F) HOLE (4X) EQUALLY SPACED ON A (E) B.C.

12

DC =

Run Time

Acceleration

1

Once the “System Inertia” is calculated, divide this by the motor’s inertia, take the resultant number and see how it compares with the rules above to get a close approximation of the overall system responsiveness that you require.

Limit Factor (LF) = % of Motor Peak

+.0000 -.0005

10

(A)

Is Current being limited to the Motor?

(C)

Calculate Duty Cycle for Application DC (%)

RULE 4: A system will respond “acceptably fast” if the “System Inertia” is between 6 and 10 times larger than the motor’s inertia. Some high performance motor manufacturers state that acceptably fast response can be obtained with reflected inertia matches as high as 20 times.

Determine Direction, Motion Profile, Maximum Speed, Cycles per Hour, Hours per Day, and Shock Load

+.0000 -.0005

Determine Acceleration Time Determine Run Time Determine Deceleration Time Determine Dwell Time

(A)

15 Calculate Gear Ratio See Figure 1 for Standard Ratios

(C)

9

RULE 3: A system will respond “very fast” if the “System Inertia” is 1 to 5 times larger than the motor’s inertia. Some high performance motor manufacturers state that very fast acceleration response can be obtained with reflected inertia matches as high as 10 times.

7

FOR SERVO MOTORS (RULE 3 AND 4)

6

RULE 2: A system will respond “acceptably fast” if the “System Inertia” is between 3 and 10 times larger than the motor’s inertia.

5

RULE 1: A system will respond “very fast” if the “System Inertia” is 1 to 3 times larger than the motor’s inertia.

4

All Gearheads come with a complete mounting kit which includes all hardware necessary for direct attachment to the motor along with easy to follow instruction. The Clamp-On Pinion and Balanced Collar simply slip onto the motor-shaft. The clamp is then fastened by two (2) allen head screws. The motor is then slipped into the gearhead and is held in place by four (4) mounting bolts. This process should take a few minutes at most. No matching or additional components are required.

Any motor matching the mounting dimensions as shown below will attach to any of our Inline Spur, Prime™ Planetary, or Paragon™ Planetary gearheads quickly and easily. If the motor you have selected has a different mounting face than shown, an appropriate adapter can be manufactured to meet your motor’s exact mounting surface specifications.

There are several rules that apply to the acceleration responsiveness of a gearmotor and external load system. (See Inertia Matching Example on page 39.) They are as follows:

PRODUCT SELECTION GUIDE 2

FOR STEP MOTORS (RULE 1 AND 2)

GEARHEAD / MOTOR MOUNTING

INERTIA MATCHING

PRODUCT SELECTION GUIDE

APPLICATION FLOWCHART * 100%

DC < 50% use TPeak DC > 50% use TCont See Below (11)

Inline Right Angle Single Shaft Right Angle Dual Shaft

14

System Inertia = Gearhead Inertia + Input Pinion Inertia + (Load Inertia / (Gear Ratio)2)

System Inertia Match = System Inertia / Motor Rotor Inertia

16

Determine Radial and Axial Loads

Pulley with Belt Lead / Ball Screw Direct Drive Gearhead Input Sprocket with Chain

Gear Head Mount

19

Select Part Number

41A