Drive Technology Slewing Gears - ZOLLERN
Drive TechnologySlewing gears
The ZOLLERN GroupZOLLERN is one of the pioneersin the metal industry. At several locationsin Europe, North America and Asia,2,400 employees develop, produce andservice a wide range of high-qualitymetal products. ZOLLERN suppliessophisticated solutions for a wide rangeof applications with its business areasof drive technology, investment casting,sand casting and forging, mechanicalengineering elements and steel profiles.ContentSideSlewing Units3Features and design4Gear unit selection9Application Factor k10Classification guidance10Technical Data11Installation instructions14Gear reduction ratios15Recommended lubricants17Application Questionnaire18Remarks and special operating conditions19
Slewing UnitsSlewing UnitsZOLLERN Slewing Unitshave proved highly successful under extreme operatingconditions. Their principal features and most significantadvantages are compact dimensionslong operation lifemodular design of gear unitease of maintenancehigh performancefunctional designWith these characteristics the machine designer willget a ready to install unit and will achieve economicsolutions even in confined space conditions.Potential applications mobile cranes material and working elevators shipboard and deck cranes dockyard and harbour cranes container gantries yaw & pitch drives for wind turbines construction cranes and conveyors loading and cargo handling cranes rescue and wrecker salvage trucks offshore cranes access platformsZOLLERN gears use components common to ourcomplete range (Winches, Slewing Units, IndustrialGears, Free Fall Winches) giving the advantage ofvolume production: cost savings from standard parts,reduced lead times, tested and proven designs acrossthe whole range and readily available spares for unitsin service.02 // 03
Features and designCoaxial designThree planetary stagesRatios i 46 to 177Drive by electric motorLong output shaftFastening by reaction torque armInput shaft and output shaft havethe same direction of rotationCoaxial designThree planetary stagesRatios i 46 to 177Drive by electric motorShort output shaftInput shaft and output shafthave the same direction ofrotation.Slewing UnitOutput torques from 1.400 to 1.550.000 Nm Ratiosi 17 to 1.209 (other ratios available on request).When determining the torque, the acceleration and thedeceleration as well as wind effect and other inducedloads must be taken into consideration (see page 9).RatingThe output torques Tdyn max mentioned in tablepage 10 refer to FEM I 3rd edition, collective load L2,duty cycle class T5, corresponding to ‘transmissiongroup M5’. Ambient temperature 20 C.(FEM-Fédération Européenne de la Manutention).Gear teeth designOptimized for best possible tooth flank and root loadcapacity and minimum sliding speeds in accordancewith DIN 3990. Externally toothed gears case hardenedand ground, internal gears heat-treated and nitrided.
Features and designCoaxial designThree planetary stagesRatios i 46 to 177Drive by hydraulic motorLong output shaftInput shaft and output shafthave the same direction ofrotation.OiloutletOiloutletOil outlet04 // 05Coaxial designTwo planetary stagesRatios i 17 to 35Drive by hydraulic motorShort output shaftInput shaft and output shafthave the same direction ofrotation.LubricationAll gears and anti-friction bearings are splash lubricated. Output bearings are grease packed for lifetimeoperation –requiring no further service attention.Service intervals and recommended lubricants aregiven in the table on page 15. Oil level is checked byeither dip stick or sight glass.EfficiencyThe efficiency per planetary stage is 98 % and for theoutput shaft bearing including sealing 99 %.Example: Slewing gear with 2 planetary stagesŋ total 0,98 x 0,98 x 0,99 0,95BearingsAll components carried in antifriction bearings. Needleroller bearings and cylindrical roller bearings in theplanetary wheels. Generously dimensioned self aligningroller bearings in the output shaft housing, supportingthe pinion.InstallationVertical or horizontal as specified
Features and designSealsThe input is sealed by a radial shaft sealing ringwith a dust lipa) by two radial shaft sealing ringsb) by the grease packing in the output shaft housingc) by another radial shaft sealing ringso that safe protection against oil loss and againstpenetration of dirt and water is assured.Eccentric adjustmentFor accurate adjustment of backlash between theoutput pinion and the driven ring gear, the outputshaft assembly can be provided with eccentric adjustment in relation to the flange and output pinion.EccentricityFlange I x 2,5Flange II x 1,5Flange III x 1,5Painting PrimerThis is a specially developed multi-primer witha two-component zinc-dust epoxy resin base.Colour: Grey white. A two component epoxyresin is most suitable for the finish coat.Parking brakeAmply dimensioned spring-applied multi-discparkingbrake, hydraulically released, to hold theslewing mass and to brake the slewing mass in caseof emergency. Not to be used as a service brake.Output pinionAddendum modification coefficientx 0,5Gear cutting quality 9eTip relief0,02 · mPressureBack pressuremin. 15 barsmax. 250 barsmax. 0,5 bar allowedPlease consult us if back pressure value exceeds thisfigure. Connecting line 8 x 1 tubing to DIN 2391 C,as short as possible.Service brake to hold and brake the slewing mass,hydraulically, pneumatically or mechanically operated(optional extra).0,4 · mInput OptionsZOLLERN’s modular system provides for hydraulicor electric motor input interfaces. Flange mountedor free shaft with key to DIN 5480.tip relief
Features and designOutput Pinion Options06 // 07Output Pinion SpecificationTough 42CrMo4V hardened gear steel tempered to 700–900 N/mm2 Teeth surface hardened HRC 57 7 (Case hardened Pinions with ground gearing available on request)Selection of gear unit sizeIn order to determine the correct gear unit for a givenapplication, the output torque Tdyn has to be multiplied with the factor k, page 10.Tnom Tdyn x k TdynmaxWorking conditionsThe slewing gears are designed for operation in European conditions or similar. Permissible oil temperatures-20 C to 70 C.Forged one piece pinion shaft – standardWorking environment such as salt water, high salt levelin air, dust, sludge, flying stones, overpressures, severevibration or shock, excessive ambient temperatures oraggressive media have to be specified.Gear unit mountingreaction torque armby flange Iby flange IISplined Output ShaftPinion fitted with splines to DIN 5480.
Gear unit selectionGear unit selectionDetermination of the imposed maximum torques onthe output pinion of the slewing gear unit can only beundertaken with the exact knowledge of the generalview.The following has to be consideredacc. to section I, 3rd edition 1998SMF maximum torque due to frictional forcesSMW8 maximum torque due to wind effect 80 N/m2SMS maximum torque due to inclined positionSMA maximum torque due to accelerationSMW25 maximum torque due to wind effect 250 N/m2γm a mplifying coefficient of loading dependingon mechanism group factorRegular servicewind effectwithoutSM max I (SMF SMA) γmSMF greatest value, SMF average valueRegular servicewithwindeffectSM max II (S MF S MA SMW8) γmSM max II (SMF SMW25) γmRegular service with wind effect andinclined positionSM max II (SMW8 SMS) γmSM max is the result of the most unfavourable combination of torques which may occur at the same timebut not the sum of the maximum individual values.08 // 09
Application Factor k for slewing gearsSymbolRunningMean running time per daytimein hours, related to one yearclassificationLife in hours8 years, 200 days/yearT2T3T4T5T6T7T8over 0,25to 0,5over 0,5to 1over 1to 2over 2to 4over 4to 8over 8to 16over 16400 to800800 to1.6001.600 to3.2003.200 to6.3006.300 to12.50012.500 to25.00025.000 to50.000Load conditions Collective coefficient kmL1L2L3L4MlogLlogLDrive unit class Application Factor kto 0,125M10,90M20,93M30,95M41M51,07M61,18M71,240,125 to 48M81,52M81,65M81,97MMlogL0,250 to 0,500logL0,500 to 1.000MClassification guidanceAccording FEM section I 3rd edition, table T.2.1.3.5.Type of appliance DesignationParticulars concerningnature of use (1)Type of mechanismHoisting SlewingErection cranesLuffingTraverseTravelM2 - M3M2 - M3M1 - M2M1 - M2M2 - M3Stocking and reclaiming transportersHook dutyM5 - M6M4-M4 - M5M5 - M6Stocking and reclaiming transportersGrab or magnetM7 - M8M6-M6 - M7M7 - M8M6M4-M4M5M8M6-M6 - M7M7 - M8M6 - M7M4 - M5M5 - M6M4 - M5M3 - M4-M6 - M7M4 - M5M4 - M5M4 - M5M8M5 - M6M3 - M4M7 - M8M4 - M5Workshop cranesOverhead travelling cranes, pigbreaking cranes, scrapyard cranesGrab oder magnetBridge cranes for unloading, bridge cranes for containersOther bridge cranes (with crab and/or slewing jib crane)a) Hook or spreader dutyb) Hook dutyBridge cranes for unloading, bridge cranes (with crab an/or slewing jib crane)Grab or magnetDrydock cranes shipyard jib cranes, jib cranes for dismantlingHook dutyM5 - M6M4 - M5M4 - M5M4 - M5M5 - M6Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricksHook dutyM6 - M7M5 - M6M5 - M6-M3 - M4Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricksGrab or magnetM7 - M8M6 - M7M6 - M7-M4 - M5M3 - M4M3 - M4M3 - M4--M4M3 - M4M3 - M4M2M3M5 - M6M3 - M4M3 - M4M4 - M5M3 - M4M4M5M4M3M3DerricksM2 - M3M1 - M2M1 - M2--Railway cranes allowed to run in trainM3 - M4M2 - M3M2 - M3--M3 - M4M2 - M3M2 - M3--Floating cranes and pontoon derricks for very heavy loads (usually greater than 100 t)Deck cranesHook dutyDeck cranesGrab or magnetTower cranes for buildingMobile cranesHook
10 // 11Application Factor K for slewing gears / Classification guidance / Technical DataTechnical Dataflange Istandardflange IIflange IIIØ B6B4C6C4C5H1Lmax.e15Lmin.B5H2A5A4F1F2Ø A6e2e1C1C2Mmin.,1,2,3Ø B1Ø A2Ø B2Ø A3Ø B3C3Fmin.55Ø A1Ø D2 min.Ø D1 min.Nominal Output torque1)sizeZHPInput Flange mountingsspeed1)(Nm)(rpm)h7 0,2A3A4A53.131.4002.100 3.000 180 210 24020153.153.8505.770 3.000 210 240 27020A611flange IIB1B2B3B4B5B6h7 0,212 8.8------15 13,524 8.8 178 200 2207415-flange IIIC1C2C3C4C5C6h7 0,2Scrwestrength rating(Nm)A2NumberA1Scrwestrength ratingnmax.NumberTstat maxNumberflange ITdyn maxScrwestrength rating2)- 140 200 2201810 13,512 8.81118 10.9 180 200 22020151124 10.93.197.15010.700 3.000 250 290 3202515 13,524 8.8 210 235 2608518 13,524 10.9 210 235 2602515 13,524 10.93.2011.00016.500 3.000 285 325 3552520 13,524 10.9 230 258 2828724 13,524 10.9 230 258 2822560 13,524 10.93.2219.00028.500 3.000 320 365 3953020 17,524 10.9 265 296 326 11220 17,524 10.9 255 345 3753065 17,524 10.93.2425.00037.500 2.800 355 400 4303020 17,524 10.9 295 330 368 111202224 8.8 280 330 36830852224 10.93.2533.00049.500 2.800 390 440 47535202224 8.8 325 362 400 121202224 10.9 280 395 43035632224 10.93.2645.00067.500 2.800 430 475 51540202224 10.9 365 400 437 136202224 10.9 365 400 44035252224 10.93.2761.00091.500 2.800 465 525 57545202624 8.8 395 435 480 151202624 10.9 395 435 48045512624 10.93.2991.000136.500 2.300 550 600 66050302624 10.9 460 510 565 170203324 8.8 435 485 54045523324 8.83.31150.000225.000 2.300 630 680 74050302624 10.9 530 580 635 204303324 10.9-------3.32230.000345.000 2.300 680 750 82055303324 8.8 580 635 685 235303324 10.9-------3.33290.000435.000 1.900Available on request3.34370.000555.000 1.900Available on request3.36590.000885.000 1.900Available on request3.381.100.000 1.650.000 1.900Available on request3.401.550.000 2.325.000 1.900Available on requestAccording to FEM section IDrive unit class M5Load conditions L2 (P const. / nab 15 rpm)Running time classification T52)Changes possible depending on motor size-ZOLLERN have a policy of continuousproduct improvement, and details maybe changed without notice.
Technical Dataflange Iflange IIØ B6B4B55A5KA4F3F4Ø A6e2e1Ø A1Ø B1Ø A2Ø B2Ø A3Ø B3Nominal Output drivesizeZHPHydraulic motor input2-stageKH1H2Lmin. Lmax. Mmin.NFmin. D1min. 81708001505555851001,51,5149299 184334226355 48 215383271421 306456----3.207575163230 1.30021078801151352,51,5191374 231414301451 341491370499 410539-3.229078165250 1.30024085851351602,51,5226415 276465346514 396564437587 4876373.24100100200300 1.3002701081001501802,51,5226415 281470350518 405573442592 4976473.2510078261330 1.3002701161001601902,51,5257471 327541393576 463646504654 5747243.26100100255340 1.3002701251101702052,51,5286500 371585425608 510693537705 6227903.27110110285350 1.7003401311151802252,51,5319598 409688480669 570759600768 6908589333.29140190244420 1.7003801721452202402,51,5350629--525739 615829660843 7503.31160--450 1.7004201701652402802,51,5379---575789 685899714903 824 1.0133.32170--480 1.800450170---2,51,5432---648927 783 10623.33Available on request3.34Available on request3.36Available on request3.38Available on request3.40Available on requestChanges possible depending on motor size796 1010 931 1.145
12 // 13Technical DataElectric motorinputKeyed shaft withØGkeyway toØGØGDIN 6885ØGØGØG77664G33G G5G G54G8GG218Nominal Electric motor inputsizeZHP2-stageG13-stageG2G3G4G5k6G6G7h6 0,2G8G14-stageG2G3G4G5k6G6G7h6 3.152843193838452502808*M12335370382830200 2288*M12----------G6G7h6 0 2808*M12457492382830200 228 8*M123.203483884042503003408*M16434474383845250 2808*M12487527382830200 228 8*M123.223814314048563003408*M16480530383845250 2808*M12572622382830250 280 8*M123.243814364048563003408*M16480535383845250 2808*M12572627382830250 280 8*M123.254405104055653604158*M16550620404250300 3408*M16637707383845250 280 8*M123.264685534060753604158*M16579664404856300 3408*M16668753383845250 280 8*M123.275236134060754505008*M16607697404856300 3408*M16706796383845250 280 8*M123.29--------704794405565360 4158*M16814904404250300 340 8*M163.31--------734844406075360 4158*M16845955404856300 340 8*M163.32--------821956406075450 5008*M16942 1077405565360 415 8*M163.33Available on request3.34Available on request3.36Available on request3.38Available on request3.40Available on request
Installation instructionsThe slewing gear needs to be correctly fitted in themachinery bed frame. Locations need to be concentricand square to the ring gear fitting.The structure must be rigid and sufficiently stiff toresist bending during operation. The table below givesrecommended tolerances.Surface free from oil and greaseNominalsizeAAMax. admissible deformations due to external forcesA6B6MConcentric bores in the assembly,admissible manufacturingThe pinion shaft of the slewing gearmust not be deformed inadmissiblyby external forces and manufacturingtolerances. Max. admissible tolerancesfrom the centre axisLength of output shaft LLength of output shaft L 800 1000 200Nominalsize 800 1000A1B1A2B2 3.130,090,20,3 0,0511–3.150,100,20,3 0,05141115’3.190,120,20,3 0,05141415’3.200,140,20,3 0,05141415’0,14 0,05 0,10 0,10 0,10 0,15 0,25 0,30 0,30 0,40 0,40 3.203.220,160,20,3 0,07181815’0,16 0,05 0,10 0,10 0,15 0,20 0,30 0,35 0,35 0,50 0,50 3.223.240,180,30,5 0,07182210’0,18–0,10 0,10 0,15 0,20– 0,35 0,35 0,50 0,50 3.243.250,200,30,5 0,07182210’ 0,20–0,10 0,10 0,15 0,20– 0,35 0,35 0,50 0,50 3.253.260,200,30,50,10222210’ 0,20–0,10 0,15 0,20 0,25– 0,40 0,40 0,60 0,60 3.263.270,230,30,50,10222610’ 0,23–0,10 0,15 0,20 0,25– 0,40 0,50 0,60 0,80 3.273.290,250,30,50,10263310’ 0,25––0,15 0,20 0,25–– 0,50 0,60 0,80 3.293.310,250,30,50,10263310’ 0,25––0,15 0,20 0,25–– 0,50 0,60 0,80 3.313.320,250,30,50,10263310’ 0,25––0,15 0,20 0,25–– 0,50 0,60 0,80 3.32α 20040060015’ 0,09 0,05 0,05–400600– 0,20 0,20––– 3.130,10 0,05 0,05 0,10 0,10– 0,20 0,20 0,30 0,30– 3.150,12 0,05 0,10 0,10 0,10– 0,20 0,30 0,30 0,40– 3.19–Form- and situation tolerances acc. to DIN 71840,2AThe center line of the toleranced part must be within a cylinderat a diameter of t 0,2, which center line coincides with thecenter line of the reference plane.0,2AThe tolerance of the plane surface must not exceed thetolerance of t 0,2 during one revolution of the workpiece.
14 // 15Installation instructions / Gear reduction ratiosGear reduction ratios// 2-stages – 293.313.323.333.343.363.383.401722263035 // 3-stages – 54177 // 4-stages – 8435501542570650676739780886 Other ratios available on request922 1.007 1.064 1.209
Recommended lubricants for ZOLLERN Slewing gear unitsRecommended lubricantsfor ZOLLERNSlewing gear unitsType/SpecificationLubricants to DIN 51502Synthetic Lubricants acc. Synthetic Lubricants acc. Grease acc.DIN 51 517 T3 CLP HC (PAO) 220 DIN 51 517 T3 CLP PG 220 DIN 51 825 KP 2 KMineral Olic acc.DIN 51 517 T3 CLP 220AralAviaBPCastrolFuchsMobilShellTotalDegol BG 220-Degol GS 220Gear RSX 220Synthogear PE 220-Aralub HLP 2--Avilub Gear PAO 220Gear VSG 220Avialith 2 EPEnergrease LS-EP 2Energol GR-XP 220--Alpha EP 220Alphasyn EP 220Alphasyn GS 220Longtime PD2Alpha SP 220Optigear Synthetic A 220Alphasyn PG 220Spheerol EPL 2Optigear BM 220Optigear Synthetic PD 220Tribol 800/220Tribol 4020/220-2Tribol 1100/220---Renolin CLP 220Renolin Unisyn CLP 220Renolin PG 220Renolit LZR 2 HRenolin CLP 220 Plus--Renolit EP 2Mobilgear 600 XP 220Mobil SHC 630Mobil Glygoyle 220Mobilux EP 2Mobilgrase XHP 222-Mobil SHC Gear 220-Omala 220Omala HD 220Tivela S 220Alvania EP (LF) 2Omala S2 G 220Omala S4 GX 220Omala S4 WE 220Gadus S2 V220 2Carter EP 220Carter XEP 220Carter SH 220Carter SY 220Multis EP 2Lical EP 2Attention: Mineral and PAO-based gearbox oils are not to be mixedwith PG (polyglycol)-based synthetic oil. Greases with differentsoap bases are not to be mixed.Lubrication frequencyOil 1st oil change after 200 operating hours 2nd oil change after 1000 operatinghours further oil change after every1000 operating hours; at least once a yearGrease Once a week or on recommissioningLubrication type only accordingindication in the installation drawingresp. in the maintenance manual.16 // 17
Slewing gears Application QuestionnaireCompany/AddressDateProper departmentPerson concernedNumber of inquiryPhoneFaxe-mailDemandApplication (e.g. mobile crane, ship-offshore-harbour cranes, tower cranes)Used for// Operating conditions – Design criteria// Technical dataPower/RatingDynamic laodOutput torqueTdyn(Nm)Output speednab(rpm)Tdyn is equivalent to SM max II acc. to FEM Section IInstalled powerP(kW)Static loadOutput torqueTstat(Nm)Rating according to FEM Section IDrive unit class Load conditions Running time class M L TOutput pinionModulem(Nm)Numberof teethFace width(rpm)(rpm) DNV RMRS GL Othersnab(rpm)Time slice(%)1234 (standard)Splined pinion shaft Hardened and tempered, machinedteeth, tooth flank induction hardened,gear quality 9e (standard), ZOLLERNspecial improved surface finish. Case hardened with grinded toothflanks, gear quality 8eRatioi100 %ManufacturerTypeAvailable oil flow Q(l/min)Available differentialpressure Øp(bar)// Drive electric motorManufacturerTypePowerSpeed(kW)(rpm)Control (Frequency inverter; ON/OFF; Softstarter)Voltage, AC/DCStarting torque TA(Nm)Breakdown torqueTK(Nm)Power-on timeED(%)Starting per hour(mm)// BrakeApply as Parking brake Flange connection Flange I Flange IICalculated life time(hour)Safety against(–)Length ofoutput housing L(Nm)Mounting positionPinion up down Yield strength Breakwith Tdyn Tstat(kW) Pinion shaft forged in one pieceRing gearzbx Internal teeth External teethAlternative ratingLoadTdynconditions (Nm)zbAddendummodification xStandard x 0,5 for output pinionApproval acc. to classification society ABS LRS// Drive hydraulic motor% Flange III(mm) Service brakeExecution Spring loaded multi disc brake with backstop Brake motor Disc brake Drum brakeActuation hydraulically electricmin. release pressuremax. release pressureexpected back pressure horizontal// Scope of supply MotorLoad holding valveBrake for drive unit CouplingMotor flangeReaction torque arm Incremental encoderHydraulic power packFrequency control Hydraulic controlApprovalMaterial Certificates(bar)(bar)(bar)
Slewing gears Application Questionnaire / Remarks and special operating conditionsRemarks andspecial operating conditionsPlease fill in all known data.18 // 19
Subsidiaries & local officesPlantsZOLLERN GmbH & Co. KGHeustrasse 188518 HerbertingenGermanyT 49 7586 959-0F 49 7586 959-575zat@zollern.comwww.zollern.com ZOLLERN I 08.16 I 060 I www.creaktiv-werbung.com Errors and amendments excepted. Pictures and illustrations similar.Group headquarters
Workshop cranes M6 M4 - M4 M5 Overhead travelling cranes, pigbreaking cranes, scrapyard cranes Grab oder magnet M8 M6 - M6 - M7 M7 - M8 Bridge cranes for unloading, bridge cranes for containers Other bridge cranes (with crab and/or slewing jib crane) a) Hook or spreader duty b) Hook duty M6 - M7 M4 - M5 M5 - M6 M4 - M5 M3 - M4-M6 - M7 M4 - M5 .
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Pendant type over-winding cut out device with audio-visual (FAILURE lamp/BUZZER) warning system. SLEWING Hydraulic axial piston motor driven through planetary slewing speed reducer. Continuous 360 full circle slewing on ball bearing. Equipped with manually locked/released slewing brake. A positive slewing lock for travel modes, manually .
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kadar asam folat di bawah normal, yaitu folat serum 3 ng/ml dan folat eritrosit 130 ng/mL (Mayes, 2007). Defisiensi folat ini dapat terjadi karena akibat langsung dari kurangnya konsumsi .
