Good vibrations with high performance steel grid coupling

In the mining sector, an effective grid coupling needs to stand up to earth-shattering vibrations, while at the same time, lending some flexibility to an application.

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&#;A heavy shock load can devastate a coupling arrangement even on the most robust equipment, which is why Rexnord developed the Falk Steelflex T-design range,&#; says Steve Hittmann, BSC&#;s National Product Manager for Mechanical Drive Systems & Belt Drives. &#;The aim with this product was to surpass competitors in performance and durability under high-impact conditions.&#;

&#;In mining and quarrying, grid couplings will generally be used in the crushing, grinding, and agitating of material,&#; explains Steve. &#;They are also used in pump, conveyor, dragline, and high-speed gearbox applications, where they are really about the protection of the driven unit through their ability to absorb massive amounts of vibrations,&#; he adds.

&#;Third party testing found that Falk Steelflex grid couplings are 4.7x more durable than a leading competitor&#;s grid coupling and 16x more durable than other brands,&#; furthers Steve. &#;Even though many grid couplings appear similar, a huge gap in performance remains between brands,&#; he emphasises.

The technology was originally used in the production of aircraft components that carry heavy loads and deflect high vibrations in air. According to Steve, the key is torsional ability.

&#;The Steelflex Grid Couplings employ torsion to deflect normal shock or vibratory loads, making them durable and flexible to changing load conditions,&#; says Steve.

&#;In addition to this, Steelflex tunes the drive system. It absorbs the energy of impact by spreading it over increments of time, dampening the vibrations and reducing peak loads by as much as 30%,&#; he adds.

The Falk Steelflex T10 Grid couplings are fabricated from steel for maximum strength; machined to within 0.001 inches, permitting utilisation of any hub surface for measurement of shaft alignment.

&#;The tapered grids are made of high strength alloy steel, quenched, and tempered to spring hardness,&#; explains Steve. &#;The grid surface is then precision shot peened to compress the surface molecules for increased strength.&#;

&#;The effect is a dramatic increase in rating, providing reserve strength for longer life or allowing a smaller size coupling to be selected,&#; he enthuses.

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First of all, the definition of high speed. Strictly speaking, if the coupling speed reaches 750r/min-1, it has already reached the high speed requirement. In the actual use process, it is generally recognized that the speed reaches r/min-1 and above, and a dynamic balance experiment is required to ensure the normal use of the coupling.

With the increase of speed, the requirements of dynamic balance level are getting higher and higher, and dynamic balance is not a panacea. If the machining accuracy and concentricity cannot meet the requirements of dynamic balance, or the quality deviation is too large, it may cause the dynamic balance experiment to fail. Proceeding, or the required balance accuracy cannot be achieved. Here is a concept expressed-high speed, which depends on the machining accuracy and dynamic balance adjustment level.

High-speed couplings are mainly used in test benches, dynamometers, and high-speed running power sources to output torque.

The main selection principles or characteristics of high-speed couplings:

First, the weight is light, and the material selection is based on this principle. The lighter quality is selected as much as possible to facilitate the later adjustment of quality deviations and dynamic balance.

Second, micro-correction, elastic components. No matter how high the accuracy of the mechanical transmission is, the deviation of concentricity and the unbalance of quality are unavoidable. However, the direct rigid connection at high speed generally has the problems of on-site noise and vibration. In terms of practical application, elastic elements are basically necessary. If you really can't find a suitable elastic element, you can temporarily connect it with a rigid coupling, but long-term use, the result of vibration is often easy to damage the connection part, and it will be more difficult to re-install and center.

Third, high-strength elastic elements. Now the most used elastic element is the diaphragm, and the main material of the diaphragm is stainless steel. The choice of stainless steel sheet requires high thickness uniformity, high tensile strength, good surface gloss, excellent and uniform material, and good resilience. The price of stainless steel that is generally suitable for manufacturing high-speed elastic components should be above medium, and the material directly affects the elastic components Service life.

Finally, the machining accuracy. Generally, the machining accuracy with a rotation speed of more than 10,000 revolutions generally needs to be controlled at a higher level.The key size of the coupling, the aperture and keyway, must be within 1 wire tolerance, and the center deviation can be guaranteed at this level.

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