Overload safety couplings also limit torque

Zero-Max Torq-Tender Overload Safety couplings protect critical rotating power transmission components from torque overloads. Torq-Tenders serve both as a safety device and as a coupling in a power transmission system.

Torq-Tenders can be manufactured for systems requiring frequent washdowns such as food manufacturing and packaging applications. With the addition of an O-ring seal and simple housing modifications, Torq-Tenders resist contamination and are easily washed.

These couplings are simple to operate. When a power transmission system’s load exceeds the preset precision-tempered torque spring rating, the Torq-Tender’s drive mechanism pivots out of an engagement slot, disengaging the prime mover from the load providing overload protection. When the overload is removed and the speed is reduced, the Torq-Tender resets itself automatically. The single position re-engagement point maintains equipment timing and positioning.

Available in torque ranges from 2- to 3000 in.-lb, these couplings have tamper proof preset torque settings. The precision torque settings do not require costly and potentially risky calibration procedures.

As a coupling, the Torq-Tender can handle up to 1.5 degrees of angular misalignment and a maximum parallel misalignment of 0.005 to 0.015 in.

They are available in many standard sizes. From the smallest, TT1X (torque ranges 2 to 60 in.-lb) to the largest TT4X (torque ranges 750 to 3000 in.-lb), there are many precision preset factory torque ratings available.

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Flex element insulates couplings and protects from reaction loads

Motion system designers have a new option to arrest electrical current. Zero-Max CD® couplings have composite flex elements that are non-conductive in addition to their primary function.

In addition to protecting from stray electrical current, CD couplings protect generators in a system from transferring lower reaction loads to the generator bearings. The coupling’s composite discs withstand all types of environmental elements, including temperature extremes from -40 to +70° C, and also moisture and chemicals.

Additional operating features include: zero backlash, excellent for reversing loads, smooth operation at high speeds, and compact size with a clamping system that fits most applications. CD couplings have long life cycles and require less replacement over time.

CD couplings are available in many models and sizes, including custom designs for unusually large and challenging applications such as wind turbines. Standard models and sizes include single and double flex models with clamp style hubs with or without keyways. The torque capacities range from 40 Nm to 1436 Nm and beyond with speed ratings from 4400 RPM to 17,000 RPM.

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Wind Turbine couplings deliver 100,000 Nm of torque

Zero-Max Wind Turbine Couplings are now available as an upgrade replacement for existing wind turbines and for OEM applications. These couplings easily handle torque spikes and high misalignment installations. They have composite disk packs at both ends of a center spacer for strength and generous flexibility. The composite disk packs (flex elements) allow a surplus of parallel and axial misalignment while remaining torsionally stiff through all harmonic ranges of the wind turbine’s oscillating load.

Depending on the application, the center spacers can be machined out of steel, composite glass fiber, or 6061-T6 aluminum. Through the use of Finite Element Analysis (FEA), these center spacers can be engineered to withstand in excess of 100,000 Nm of torque.

These wind turbine couplings have many additional design advantages. The flex elements electrically insulate the turbine’s generator from the gear box, eliminating stray electrical current that can leak across the coupling, thus preventing bearing damage to the gear box. The coupling protects the generator by transferring lower reaction loads to the generator bearings. Also, the coupling’s composite material withstands all types of environmental elements, including temperature extremes from -40 to +70° C, and also moisture and chemicals native to the nacelles of wind turbines.

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Couplings reduce thermal transfer

ServoClass® Couplings from Zero-Max reduce heat transfer from servo motors to driven shafts, reducing heat transfer and variations in system accuracy caused by thermal expansion. It features stainless steel discs designed into the center of the coupling that dissipate heat generated from a connected servo motor.

These couplings also provide high torsional stiffness, zero backlash and low hysteresis, further ensuring repeatable precise positioning.

“Thermal transfer is a growing concern in servo motor system design,” reports Robert Mainz, Zero-Max sales manager. “As cycles become faster and heat increases, especially in tightly enclosed designs, these couplings minimizes heat transfer through the shaft components.”

Three new sizes have been added to the line. They handle bore diameters from 0.875 in. (20 mm) to 1.378 in. (35 mm) and operating torque from 885 to 2213 in. lb (100 to 250 Nm). Many additional sizes are available starting with the smallest bore size 0.157 in. (4 mm) and larger.

All ServoClass couplings are manufactured of RoHS compliant materials. They are lightweight and are designed with 304 stainless steel disc packs and 7075-T6 aluminum hubs and center members. They are available in single and double flex models in inch and metric sizes. All models and sizes feature clamp style hubs with corrosion resistant socket head cap screws.

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Zero Maintenance Bearings– New Option For Schmidt Offset Couplings

Zero maintenance bearings are now available as an option for Schmidt Offset couplings from Zero-Max. This new coupling feature eliminates periodic coupling lubrication and the resulting system downtime.

Schmidt Offset couplings deliver precision for parallel offset shafts. They transmit constant angular velocity and torque in a range of parallel shaft misalignments. They are used in a range of machine applications including printing, embossing, paper converting, pharmaceutical, and automated assembly systems.

The new Schmidt sealed bearing coupling feature incorporates needle bearings with internal micro-poly lubrication. There are no lube fittings making for a cleaner coupling setup. Compact in design, Schmidt Offset couplings with the new zero maintenance bearing option keep out contaminants and foreign matter, enabling the couplings to be used in less than ideal operating environments.

Schmidt Offset couplings are designed to handle high amounts of parallel offset up to 17 in. and are available with torque capacities up to 459,000 in.-lbs. They impose no side loads on shafts or bearings and eliminate radial shaft vibrations.

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Low Inertia Aluminum Couplings Reduce Cycle Time

The aluminum CD® model is a low inertia, lightweight coupling with high torsional stiffness for servo motor applications. It is available in single and double flex versions.

“We surveyed design engineers to find out what was the most desirable feature when specifying couplings for servo motor applications,” reports Robert Mainz, Zero-Max sales manager. “Low inertia was the most important.” These engineers said they continually look for ways to reduce cycle time and improve system productivity. A lightweight yet high strength coupling design will let you increase the speed of the actuator. Lightweight couplings will also have an effect on the energy consumption in their designs.

The working part of the CD® coupling is made of a special composite material. The composite disc design withstands the stresses of a servomotor’s high acceleration rates and high torque capacity better than other coupling designs. This results in lower energy requirements, and longer life of the motor and other operating components while ensuring uninterrupted system operation.

Zero-Max CD couplings are available in single and double flex models with or without keyways. The double-flex version is for precision applications requiring misalignment capacity greater than the single flex design. The single flex models have a torque capacity range from 40 Nm to 1436 Nm and beyond with speed ratings from 4400 RPM to 17,000 RPM.

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ServoClass® Couplings deliver high torsional stiffness

ServoClass® Couplings suit applications using ac and dc servomotors that need precise positioning and the ability to handle high reverse loads. These couplings have zero-backlash and low hysteresis.

Three new sizes have been added to the ServoClass coupling line. They handle bore diameters from 0.875 in. (20 mm) to 1.378 in. (35 mm) and operating torque from 3937 to 9843 lb-in., (100 to 250 Nm). Additional sizes are available starting with the smallest bore size 0.157 in. (4 mm) and larger.

All ServoClass couplings are manufactured of RoHS compliant materials. They are lightweight and designed with 304 stainless steel disc packs and 7075-T6 aluminum hubs and center members. They are available in single and double flex models in inch and metric sizes. All models and sizes feature clamp style hubs with corrosion resistant socket head cap screws.

“ServoClass couplings provide a better option compared to beam or bellow style couplings,” reports Robert Mainz, Zero-Max sales manager. “As the cycle becomes faster, they outperform beam couplings, which experience harmful windup. Their robust design also outperforms the fragile design of bellows couplings.”

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Schmidt 5D Couplings Handle Axial, Angular And Parallel Shaft Misalignments

Schmidt 5D Couplings suit applications requiring large axial, angular and parallel shaft misalignments. This “all-in-one” coupling design will handle all shaft displacements providing low backlash for precision high torque applications such as roll forming and similar heavy duty fabricating equipment.

Designed to fill an important need in the Zero-Max family of torque-rigid couplings, these couplings allow for easy adjustment to any possible misaligned shaft position without imposing heavy side loads on shafts, bearings or other machine equipment. The coupling can accommodate up to 5 degrees of angular misalignment and as high as 1.5 in. parallel misalignment while maintaining undisturbed power transmission at constant angular velocity. Acting forces within the coupling can be precisely calculated, assuring reliable, trouble-free system operation. This unique design will tolerate high shock and reversing loads with minimal or no maintenance required.

Additional features include: space-saving design and easy installation — couplings can be mounted to shaft hubs or directly to existing machine flanges (no need to reposition either shaft being coupled). Available in standard and inverted hub configurations in bore sizes from 1.500 in. to 6.375 in. or 38 mm to 160 mm. Custom designs can take this coupling design beyond the catalog specifications. The ten different model sizes handle speeds up to 1000 RPM and torque from 2800 to 500,000 in-lb. Special design modifications are available.

“The 5D coupling has very robust design features for use in applications such as roll drive systems used in converting machinery. The unique and flexible design allows for a range of movement to improve the quality of the end product.” reports Robert Mainz, Zero-Max sales manager. “They do a very good job of handling shaft misalignments and protecting drive train components in these high performance systems.”

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Floating Shaft Couplings Span Long Distances

Floating Shaft CD® Couplings are a torsionally stiff, no backlash option for connecting long distances between shaft ends. They can often be a zero-backlash alternative to Cardan Shafts. The flex element made of composite material makes it possible to have zero-backlash, high torsional stiffness and low bearing loads simultaneously.

The composite material is flexible in one plane and stiff in another plane. It is not prone to fatigue and will perform longer than stainless steel. Custom designs are available with torque ranges from 270 in.-lbs (30 Nm) to 550,000 in.-lbs (63,000 Nm) and with speed ranges from 500 rpm to 15,000 rpm. They are available in custom lengths from 46 in. to 196 in. and with outside hub diameters of 2.25 to 12 in.

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Safety Coupling Catalog

Zero-Max has published a 12-page Zero-Max catalog of Torq Tender overload safety couplings. These overload safety couplings disengage motor drives for overload protection. They protect motor and drive systems from jam ups and excessive loading.

System designers will find this new catalog helpful when examining overload protection options for a particular system design. Available in models that will disengage torques from 2 to 3,000 in. lbs., mechanically operated Torque Tenders often are the best design option because they are tamper proof and do not require costly and potentially risky calibration procedures. The torque value is controlled by the Torq Tender part number ordered and preset at the factory.

Torq Tender operation in most mechanical power transmission systems is simple. When the load exceeds the Torq Tender rating preset with precision tempered torque springs, the unit’s drive key pivots out of a slot, disengaging the Torq-Tender coupling. Once the overload is removed and the speed reduced, the Torq Tender resets itself automatically. This automatic resetting action engages the system’s drive shaft and puts the entire drive system back into motion at its original position.

Torq Tenders are available in many standard sizes. The smallest is the TT1X with a 2 to 60 in. lbs. torque rating. The largest is the TT4X with a 750 to 3000 in. lbs torque rating. Special Torque Tender designs are also detailed in the new catalog for handling various mountings, bore sizes and housings.

Inside the new brochure is complete selection and ordering information. Also, you can now size, select and see the right Torque Tender solution with Zero-Max Partstream, the configurable 3D CAD downloads.

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