IM Series Gearbox - impelmotors.com

1 IM Series Gearbox Low RPM with High Efficiency Gear Speed Reducers TO SHAPE THE FUTURE OF THE SOCIETY BY DISCOVERING NEW TECHNOLOGIES AND SHARE OUR RESOUCES WITH THE WORLD. All types of industries are invariably required to install different types of electric motors as prime mover for driving process equipment participating in their respective production line up. The continuous process of technical development has resulted into availability of highly diversified types of electric motors. Having mastered the art of providing quality products, IMPETUS TURNOMATICS proudly introduces TEFC ENERGY EFFICIENT induction motors and GEAR SPEED REDUCERS, designed to meet diverse needs of future industry. Built from the motor industry s most successful modular platform, each module is designed to match a broad variety of demanding application requirements while having the flexibility to be adapted to highly specific configurations.

2 At Impetus Turnomatics, one of our Strong principle is that we work together with men as Partners in the gospel bringing our gifts and talents for the greater good of all. We are creators, Leaders and self-starters. We try new things. We challenge conventions and we are not afraid to fail. We are genuine to our BRAND, CORE PURPOSE & CORE VALUES. We are always honest and transparent as we can be. Our Vision doesn t end with small business and entrepreneurs. We believe in in empowering our team to create their own life s work too. 1. To think creativity to go out of the box is not a luxury, it is necessity for us and our dignity as a human being, so. 2. A quick jump out of the box is more insightful than a life time of the standard thinking. Introduction One-piece gear case, with external ribs, is made of close-grained cast iron and provides for rigid gear and bearing support.

3 It also offers excellent heat dissipation. Double lip, spring-loaded seals guard against oil leakage and prevent dirt from entering. Stepped shafts with oversized ball and tapered roller bearings. Carbon steel shafts for greater strength. High tensile strength cast bronze worm wheel and hardened and ground alloy steel worm made integral with the shaft for long and trouble-free life. Every unit test run prior to shipment. Universal mounting with bolt-on feet. Highly modifiable design. All this at substantially lower prices than you have been accustomed to paying for reducers of lesser quality. Features & Benefits Data require for selection of Gear box :- Type of input motor , it s HP and RPM Reduction ratio or output RPM Duration of working hours in a day Type of drive (1) input motor to Gearbox and (2) gear box to machine Required power to drive machine and load type Ambient temperature , corrosion and humidity Position of output shaft (vertical or horizontal) Available space for installation and service of Gearbox Load classification.

4 - Type of machine Application Type of load Conveyors Uniformly loaded U Non uniformly loaded M Elevators Bucket continuous load U Centrifugal discharge U Gravity discharge U Clay processing machinery Brick press H Briquette machine H Plug mill M Agitators & mixture Pure liquid U Liquid and solid M Liquid with various density M Wire making machines Drawing M Flattening M winding M Rubber and plastic industries Crackers H Fixing mills H Laboratory equipment M Refiners M Cutting M Strainers M Warming mills M Crushers Stone H Sugar M Bucket heavy load M Paper mill Bleacher conveyors press M Winder H Agitators M Technical Details Calculation of Service factor for motor input :- Selection of Gear box is very important it is made by comparing actual loads with catalogue ratings. Catalogue ratings are made according to a standard set of loading conditions where actual load conditions may vary according to type of application.

5 Service factors are used to calculate an equivalent load to compare with catalogue ratings. Duration of Service (Hours per Day) Uniform Load Moderate Load Heavy Shock Extreme Shock Occasional hour Less than 3 hours 3 10 hours Over 10 hours Overhung Load:- Overhung load is the radial force imposed on a shaft by a mounted pinion, pulley, or sprocket. The overhung load ratings expressed in this catalog are the allowable load measured at a distance of one shaft diameter from the housing. When one of the above items is mounted on the output shaft of a reducer a calculation should be made to determine whether the resulting overhung load exceeds the overhung load rating of the reducer. calculation should be made to determine the overhung load in Newton on the shaft, using the formula : P = KW x 9550 x K N x R P = equivalent overhung load in newton KW = power carried by shaft in Kilo Watts N = of the shaft R = pitch radius of sprocket, pinion, sheave or pulley in meter K = factor Mounted Member Factor Sprocket Timing belt Pulley Pinion V belt Sheave Flat belt Pulley Variable Pitch Pulley W = 100 LBS.

6 T = 100 X 3 = 300 In. LBS. The relationship between horsepower and torque is expressed as follows: HP = Torque X RPM 63,025 Torque = 63,025 X HP RPM Engineering Horsepower and Torque One horsepower is the amount of power required to raise 33,000 pounds a distance of one foot in one minute s time. HP = LOAD IN POUNDS X FEET PER MINUTE 33,000 Torque is the product of a force expressed in pounds multiplied by a radius measured in inches from the center of a shaft. This product is expressed in inch pounds. Torque = Force (LBS.) X Radius (inches) Dimensions Gear box size 2 3 4 5 A 133 155 225 254 B 133 155 225 254 C 142 180 250 300 D 95 140 185 220 E 70 102 108 118 F 267 G (UNIT SIZE) 127 H 83 105 115 140 I 11 14 18 18 J (INPUT SHAFT) 16 25 32 35 K 47 50 70 70 L 128 175 215 231 M 125 192 200 260 N 100 160 160 200 O (OUTPUT SHAFT) 25 38 45 50 P 57 75 88 95 Q 8 10 14 14 R 21 33 S 13 21 27 30 T 5 8 10 10 Dimensions and Performance The ratings shown in table below are based on 10 hours per day operation with uniform load.

7 For other duties it is necessary to multiply the motor horsepower by the appropriate service factor in the table below. Rating at Input RPM 1500 Rating at Input RPM 1000 Ratio Output RPM Capacity Size of gear box 2" 3" 4" 5" 200 Input power (KW) 17 Output torque (NM) 338 10 150 Input power (KW) Output torque (NM) 15 100 Input power (KW) Output torque (NM) 1225 20 75 Input power (KW) Output torque (NM) 25 60 Input power (KW) 5 Output torque (NM) 30 50 Input power (KW) 2 Output torque (NM) 40 38 Input power (KW) Output torque (NM) 50 30 Input power (KW) Output torque (NM) 60 25 Input power (KW) Output torque (NM) 490 Ratio Output RPM Capacity Size of gear box 2" 3" 4" 5" 200 Input power (KW) 10 Output torque (NM) 820 10 150 Input power (KW) Output torque (NM)

8 97 15 100 Input power (KW) 7 12 Output torque (NM) 986 20 75 Input power (KW) Output torque (NM) 149 25 60 Input power (KW) 5 9 Output torque (NM) 30 50 Input power (KW) Output torque (NM) 1217 40 38 Input power (KW) Output torque (NM) 1168 50 30 Input power (KW) 5 Output torque (NM) 145 423 764 60 25 Input power (KW) Output torque (NM) 110 434 EXAMPLE - 1 Worm reduction gear box required for belt conveyor where non-uniform material is fed on conveyor belt, operating for 8 hours per day. Speed required at conveyor shaft is 50rpm. The gear unit is driven directly using coupling by KW, 1500 rpm electric motor . SOLUTION STEP: 1 Ratio required Input speed /Output speed 1500/50 =30 =30:1 STEP: 2 Drive m/c - Belt conveyor Material - Non uniform fed Mechanical service factor = for 8 hr/day operation STEP: 3 Input power = motor Power X service factor = x = KW Rating at Input 1500 rpm, Ratio - 30:1(from rating table) Gear unit size: 5 Ratio - 30:1 Input Power = KW Gear unit type/size: 5 NU Ratio - 30:1 EXAMPLE 2 Worm reduction gear required to drive a clay-working machine for continuous 10 hours/day.

9 The power required at clay-working machine is KW at 50 rpm, suggest an electric motor power at 1500 rpm to drive the gear unit. SOLUTION :- STEP: 1 Ratio required Input speed /Output speed 1500/50 =30 =30:1 STEP: 2 Drive m/c =Clay working machinery Mechanical service factor = for 10 running hrs/day continuous Equivalent output power = KW x = KW Equivalent output torque = 9550 x = Nm STEP: 3 From catalogue, refer rating at Input speed 1500 rpm, Ratio - 30:1 Gear unfit size 4" NU, Ratio 30:1 having Input power = KW Output torque = Nm Required Input power = Calculated equivalent output torque x Rated input power Rated output torque x Service factor = = KW Suggest nearest standard electric motor having KW at 1500 rpm to drive gear unit size 4 " NU Ratio 30:1.

10 Efficiency :- To calculate the efficiency of a speed reducer divide the output horsepower by the input horsepower. EFFICIENCY = Output Horsepower Input Horsepower When only the input horsepower and output torque are known the output torque can be converted to output horsepower by the following formula: OUTPUT HORSEPOWER = Output Torque X Output RPM 63,025 Then take the output horsepower and divide by the input horsepower to obtain efficiency. Average weight of gear box :- *actual weight may vary Oil capacity of gear box :- *oil change must be done once in 4 months Recommended Lubricants (Mineral) :- *Ambient Temperature : (-10 C to + 50 C) Gear box size Weight (without oil) 2 11 3 29 4 66 5 95 Gear box size Oil capacity (Ltr) 2 1 3 2 4 5 5 Brand Grade Castrol Alpha SP-320 Bharat Petroleum (BP) C-320 Hindustan Petroleum (HP) Enklo-320 Indian oil Servo mesh SP 320 Veedol Avalon-320 Shell Co.