High-Performance Universal Joint Shafts

Transcription

1 High-Performance Universal Joint Shafts

2 Fair. Reliable. Innovative. This is our promise to our customers. And it is the demand we place on ourselves in the Paper, Energy, Mobility and Service markets. Paper Energy Mobility Service

3 Maxima 40 CC: The world s most powerful single-engine diesel-hydraulic locomotive. Introduced in 2006.

4 Fair Cooperation Voith banks on a consistent partnership and on long-term, trusting cooperation. Long-standing customer relations, some more than 100 years old attest to this fact. We abide by our promises and will never let our customers down. Reliable Actions Voith means continuous, dynamic growth with solid returns and annual sales of 4 billion Euros. Our customers can be confident that we will continue to support their objectives even in years to come with integrative and competent cooperation. Innovative Thinking For 140 years Voith has stood for inventiveness and innovation: with around 400 new patents per year, with substantial investments in R & D and from the professional accomplishments of our 37,000 employees around the world.

5 Contents 1 Range 4 2 Designs 6 3 Applications 7 4 Definitions and abbreviations Lengths Torque loads 11 5 Technical data Series S Series M Series W Series H Series P 20 8 Selection aids Definitions of operating variables Size selection Operating speeds Masses and mass moments of inertia Installation: Connection flanges, bolted connections 50 9 Voith Universal Joint Shaft Service Service Excellence for our customers Installation and commissioning Training Voith genuine spare parts Overhaul, maintenance Repairs Modernization, retrofits 60 6 Complementing products and services Engineering Connecting components for universal joint shafts Quick release coupling GT Voith Hirth serrations Universal joint shaft supports Safeset safety couplings ACIDA torque monitoring systems Quality Environment Safety Quality Environment Health and safety High-performance lubricant: Voith WearCare Engineering basics Major components of a Voith universal joint shaft Kinematics of the universal joint Double universal joints Bearing forces on input and output shafts Balancing of universal joint shafts 37 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 3

6 1 Range Voith high-performance universal joint shafts offer an ideal combination of torque capacity, torsional rigidity and deflection resistance. We supply standard universal joint shafts, customerspecific adaptations as well as special designs. Technical consultation, simulation of torsional vibrations and measurement of operating parameters complete our range of services. Series Torque range M z [knm] Flange diameter a [mm] S 0.25 to to 435 M 32 to to 350 W 55 to 1, to 550 H 260 to 10, to 1,200 P from 1,370 from Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

7 Features Applications n Standard design of Voith universal joint shafts n Non-split bearing eyes thanks to single-piece forged flange yoke n Length compensation with involute profile n Optimized torsional rigidity and deflection resistance in a low-weight design n Particularly suitable for use with high-speed drives n Low-maintenance length compensation through use of plastic-coated (Rilsan ) involute profile n Paper machines n Pumps n General engineering n Marine vessels n Rail vehicles n Test stands n Construction machinery and cranes n Paper machines n Pumps n General industrial machinery n Marine vessels n Rail vehicles n High torque capacity n Optimized bearing life n Flange with face key, flange with Hirth serration upon request n Length compensation with involute profile up to size 390; from size 440 with SAE profile (straight flank profile, see page 21) n Rolling mill drives n Heavy-duty drives in general engineering n Very high torque capacity n Optimized bearing life n Flange with Hirth serration to transmit maximum torque n Length compensation with SAE profile (straight flank profile, see page 21) n Rolling mill drives n Construction of heavy machinery n Maximum torque capacity n Patented 2 piece flange yoke with closed bearing eye n Flange with Hirth serration to transmit maximum torque n Length compensation with SAE profile (straight flank profile, see page 21) n Heavy-duty rolling mill drives Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 5

8 2 Designs Type T Description Universal joint shaft with standard length compensation TL Universal joint shaft with extra long length compensation TK Universal joint shaft with shortcoupled length compensation TR Universal joint shaft with tripod length compensation Technical data: Please request separate catalog F Universal joint shaft without length compensation (fixed-length shaft) G Joint coupling: short, separable joint shaft without length compensation FZ Intermediate shaft with a joint head and bearing Z Intermediate shaft with double bearing Example of type designation STL : S TL Size 250 (flange diameter 250 mm) Universal joint shaft with extra-long length compensation "S" Series universal joint shaft 6 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

9 3 Applications Rolling mills (horizontal rolling stand) Rolling mills (vertical rolling stand) Paper machines Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 7

10 Rail drive lines Pump drives Test stands 8 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

11 Marine propulsion Special drives (winding gear) Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 9

12 4 Definitions and abbreviations 4.1 Lengths Universal joint shaft with length compensation Universal joint shaft without length compensation l B,max l z l v l B (=l) l B : Operating length (to be provided with order.) l B : Operating length, corresponds to the universal joint shaft length l (to be provided with order.) l z : Shortest length of the universal joint shaft (collapsed) l v : Available length compensation The distance between the driving and driven machines, together with any length changes during operation, determines the operating length: Optimum operating length: Maximum permissible operating length: l B,opt l z + l v 3 l B,max = l z + l v 10 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

13 4.2 Torque loads Designation Explanation M (t) Components M DS M DW Is the reversing fatigue torque rating. M DW The shaft will have infinite fatigue life up to this torque. 0 t M DS Is the pulsating one-way fatigue torque rating. The shaft will have infinite fatigue life up to this torque level. Here: M DS 1.5 M DW M K Maximum permissible torque. Above this value, plastic deformation may Note: occur. M DW, M DS and M Z are load limits for the universal joint shaft. For torque values near the load limit, the transmission capability of the flange connection must be checked, especially when Hirth serrations are not being used. Bearing M Z Permissible torque for rarely occurring peak loads. At torque values above M Z, the bearing tracks might suffer from plastic deformation. This can lead to shorter bearing life. Flange connections Designed individually Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 11

14 5 Technical data 5.1 Series S SF SG SFZ l l fix l l d ØD t a g a Size M z [knm] M DW [knm] CR [knm] ß max [ ] General data ST S a k b ± 0.1 c H7 h C12 l m r t z g LA l v I z min LA A, B A, B A, B A, B, C A, B, C A, B, C A, B, C C C C C C A, D B, C A, D B, C A, D B, C A, D B, C A, D B, C A, D B, C A, D Dimensions in mm 12 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

15 36 ST/STL/STK l z l m øb øb øb øb øa øb øc øk ør t g l v z=4 øh z=6 øh z=8 øh øh z=10 SZ l l d ød t a g a LA: Length compensation A: without profile protection B: with profile protection C: Rilsan coating with profile protection D: Rilsan coating without profile protection TL 1 STL 2 STK 1 STK 2 STK 3 STK 4* SF SG SFZ SZ SFZ, SZ l v I z min LA l v I z min LA l v I z fix LA l v I z fix LA l v I z fix LA l v I z fix I min I fix I min I min I d d g a t a B B B B B B B B B B B B l z and l v vary, values upon request B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C B, C C C C C C C C C C C C C C C C C A, D C C C C A, D B, C B, C B, C B, C A, D B, C B, C B, C A, D B, C B, C B, C A, D B, C B, C B, C A, D B, C B, C B, C A, D B, C B, C B, C *shorter l Z upon request Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 13

16 5.2 Series M MT MF l z l l m øb øb øa øb øc øk ør t g l v z=8 øh øh z=10 General data MT Size M z [knm] M DW [knm] CR [knm] ß max [ ] a K b ± 0.1 c H7 h C12 l m r t z g LA l v I z min C C C C C Dimensions in mm 14 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

17 MG MFZ l fix l l d ØD t a g a MF MG MFZ I min I fix I min I d d g a t a LA: Length compensation C: Rilsan coating with profile protection Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 15

18 5.3 Series W WT/WTL/WTK l z l m øb øb øb øa øb øc øk ør x t g l v y z=8 øh øh z=10 øh z=16 General data WT Size M z [knm] M DW [knm] CR [knm] ß max [ ] a K b ± 0.2 c H7 h l m r t z g x h9 y LA l v B B B B B B B B B 240 Dimensions in mm 16 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

19 WF WG l l fix WTL 1 WTL 2 WTK 1 WTK 2 WTK 3 WF WG I z min LA l v I z min LA l v I z min LA l v I z fix LA l v I z fix LA l v I z fix I min I fix 920 A A B B B A A B B B A A B B B A A B B B A A B B B A A B B B A A B B B A A B B B A A B B B LA: Length compensation A: without profile protection B: with profile protection Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 17

20 5.4 Series H HT l m l z øb øb øb øa øb øk ør g l v øh z=12 øh z=16 øh z=24 General data HT HF HG Size M z [knm] M DW [knm] CR [knm] ß max [ ] a K b ± 0.2 h l m r z g LA l v I z min I min I fix B B B B B B B B B B B B B Sizes larger than 800 to 1,200 upon request. Dimensions in mm LA: Length compensation B: with profile protection 18 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

21 HF HG l l fix Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 19

22 5.5 Series P P High-performance universal joint shaft General Features n Flange geometry optimized for torque transmission n Reinforced journal crosses n Larger cross-sections for torque-transmitting components n Optimized incorporation of bearings n Space between bearing bore and journal cross optimized to permit use of larger rolling elements n Patented 2-piece flange yoke with closed bearing eyes and serrated teeth on the axis of symmetry Connection technology (Hirth couplings) n Flanges with Hirth serration n Larger flange neck cross-sections Length compensation (SAE profile) n Length compensation with SAE profile (straight flank profile) n Large contact surfaces n Almost perpendicular introduction of forces n Favorable pairing of materials for hub and spline shaft n Spline shaft nitrided as standard n Improved lubrication n Patented lubricating mechanism in the grease distribution groove for uniform distribution of grease over the entire diameter of the profile 20 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

23 F N F U F N > F U F U SAE profile (straight flank profile) Involute profile Benefits n Approx. 20% more torque capacity than previous shaft designs n PT, PF and PG designs n Sizes from 580 n Torque capacities upon request n Long bearing life n High static load capacity n Reliable transmission of high torques n Optimum centering n Lower stress levels in regions subjected to high loads n Separation of torque transmission and centering functions n Low surface pressure n Low normal forces and thus lower displacement forces n High wear resistance n Gaps between the teeth are optimized to ensure sufficent grease reserves Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 21

24 6 Complementing products and services 6.1 Engineering Project planning for a drive line using CAD software FEM analysis for a working roll with a split connecting roll end hub (illustration: roll journal and half of a roll end hub) We supply not only products, but also ideas. You too can benefit from our many years of engineering expertise in all-around project planning of complete drive systems: from design calculations, installation and commissioning, to questions about cost-optimized operating as well as maintenance concepts. Engineering services Special universal joint shafts n Preparation of specifications n Preparation of project-specific drawings n Torsional and bending vibration calculations n Design and sizing of universal joint shafts and connecting components n Clarification of special requirements from the operator n Preparation of installation and maintenance instructions n Documentation and certificates n Special acceptance tests conducted by classifying and certifying agencies n Condition monitoring n Torque measurements Designing special universal joint shafts to match your drive system and your operating conditions is just one of the everyday engineering services we offer. These include: n All necessary design work n Integrity checks and optimization of design through application of FEM analysis n Reliability trials based on dynamic testing 22 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

25 6.2 Connecting components for universal joint shafts Connecting parts used in rolling mills to connect universal joint shafts to the rolls (roll end hubs) Description Applications Features Input and output-end connecting parts to the universal joint shaft reliably transmit the torque, e.g.: n Roll end hubs n Connecting flanges n Adapter flanges n Adapters n Rolling mills n Paper machines n Pumps n General industrial machinery n Test stands n Construction machinery and cranes n Individual adaptation to all adjoining components n Precision manufacturing through the use of state-of-the-art machining centers n Transmission of maximum torque through use of high-quality materials n High level of wear resistance through hardened contact surfaces Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 23

26 6.3 Quick release coupling GT Exploded view of quick release coupling GT Universal joint shaft with ring of the quick release coupling GT Description Applications features The quick release coupling GT is designed to be a very effective connecting device. The GT coupling allows you to quickly assemble and disassemble a very wide range of shaft connections on your machinery, which in turn significantly reduces down times for maintenance and repair. n Drives that require quick and centrally aligned replacement of coupling connections, e.g. universal joint shafts and disc couplings n Roll and cylinder connections, e.g. in paper machines n Positive transmission of torque through claw serrations n Quick and easy assembly/ disassembly n Compact design n Only two major components n Stainless steel version available 24 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

27 6.4 Voith Hirth serrations Positive locking Accurate in indexing Self-centering F a F u Universal joint shaft flanges with Hirth serration Schematic diagram Description Applications Features Voith Hirth serrations transmit maximum torque at specified diameters. n Universal joint shafts with high torque requirements n Connecting flange for universal joint shafts (also when provided by customer) n Machine tools n Turbo compressors n Measuring equipment n Robotic equipment n Nuclear technology n Medical equipment n General industrial machinery n High level of torque transmission, as angular surfaces provide positive locking transmission of most of the peripheral forces. Only a small axial force needs to be absorbed by the bolts. n Self-centering through use of optimized tooth geometry n Highly wear resistance due to the high load-bearing percentage of tooth profile n Excellent repeatable accuracy as a result of the multiple wedge design Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 25

28 6.5 Universal joint shaft supports Universal joint shaft support (red) and roll end hub support (yellow) Description Applications Features Universal joint shaft supports, position and support the universal joint shafts, including the roll end hubs and connecting flanges. n Rolling mills n Customer-specific drives n Increased productivity and system availability as a result of shorter down time for maintenance n Reduced energy and lubricant costs as well as higher transmission efficiency through use of roller bearings n Reduced wear as a result of uniform power transmission 26 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

29 6.6 Safeset safety couplings Three-dimensional section through a Safeset safety coupling (type SR C) Torque-limiting Safeset safety coupling (blue) integrated into a Voith high-performance universal joint shaft Description Applications Features The Safeset coupling is a torquelimiting safety coupling that immediately interrupts the power transmission of the drive line in the event of an overload, thus protecting all of the components such as motor, gearbox, universal joint shafts etc. against damage. n Protects the drive line from potentially damaging overload torques n Rolling mills n Shredders n Cement mills n Sugar mills n Railway drives n Adjustable release torque n Shutdown torque remains constant n Backlash-free power transmission n Compact, lightweight design n Low mass moment of inertia n Minimal maintenance required Placing the safety coupling between the joints, what is known as Voith "integral design", provides smaller deflection angles in the joints and thus a longer lifetime of drive line components. Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 27

30 6.7 ACIDA torque monitoring systems Torque [Nm] Time [s] The drive torque is displayed with high accuracy and dynamic response (blue trace). The dynamic response of other signals, for instance the motor current or the hydraulic pressure, is unsatisfactory (red trace) 1 Rotor: Strain gauge and telemetry. No drive modification. 2 Non-contact operation: Air gap between rotor and stator 3 Stator: Signal reception and inductive power supply Description Applications Features ACIDA torque monitoring systems have proven their value in reliable monitoring of universal joint shafts. Direct measurement of the actual mechanical load on the drive provides important information for process monitoring and system optimization. Analysis modules, for instance load spectra or lifetime observation, have been developed especially for extremely heavy-duty drives and unusually severe load conditions. Additional options include online vibration diagnosis for gearboxes and roller bearings. n Torque monitoring n Vibration monitoring n Process optimization n Condition-based maintenance n Reference systems: Rolling mills, cement mills, briquetting plants, agitators, conveying equipment, marine propulsion systems, rail drive lines, paper machines, mining etc. n Permanent or temporary torque measurement systems n Complete monitoring systems, incl. hardware and software n Report generator with automatic analysis, alarm signaling and reporting n Tele-service with expert support 28 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

31 7 Engineering basics 7.1 Major components of a Voith universal joint shaft All versions and sizes of Voith universal joint shafts, regardless of the Series, share many common attributes that contribute to reliable operation: n Single-piece yokes and flange yokes n Drop-forged journal crosses n Low-maintenance roller bearings with maximum load capacity n Use of high-strength tempering and hardened steels n Superior welded joints Flange yoke 2 Journal cross 3 Welded yoke 4 Bearing 5 Tube 6 Splined journal 7 Splined hub 8 Profile protection 9 Dirt scraper Hub yoke Shaft yoke Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 29

32 7.2 Kinematics of the universal joint a 1 G 1 W 1 W 2 Simple universal joint Input shaft Output shaft W 1 G 1 a 1, a 2 Rotation angle b Deflection angle M 1, M 2 Torque v 1, v 2 Angular velocity a 2 M 1, v 1 b M 2, v 2 W 2 n When the input shaft W 1 rotates at a constant angular velocity (v 1 = const.), the output shaft W 2 rotates at a varying angular velocity (v 2 const.). n The angular velocity of the output shaft v 2 and the differential angle w = (a 1 a 2 ) vary in a sinusoidal manner, their values depend on the deflection angle b. n This characteristic of a universal joint is called the gimbal error and must be taken into consideration when selecting a universal joint shaft. 30 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

33 b b b b b b = 12 w b = 6 l w maxl for b = 12 v 2 v 1 1, b = 12 b = cos a 1 n With one rotation of the shaft W 1, the differential angle w changes four times as does the angular velocity v 2. n During one rotation, the shaft W 2 passes through the points of maximum acceleration and deceleration twice. n At larger deflection angles b and higher velocities, considerable forces can be generated. The following equations apply: This results in the ratio of the angular velocities between the two shafts W 1 and W 2 : v 2 v = cos b (4) 1 1 sin 2 b sin 2 a 1 with the maximum v 2 v 1 = 1 max cos b bei a 1 = 90 and a 1 = 270 and the minimum (4a) w = a 1 a 2 (1) v 2 v 1 min = cos b bei a 1 = 0 and a 1 = 180 (4b) tan a 1 = cos b tan a 2 (2) tan w = tan a 1 (cos b 1) 1 + cos b tan 2 a 1 (3) For the torque ratio, the following equation applies: M 2 = v 1 M v 1 2 (5) with the maximum M 2 M 1 max = 1 cos b bei a 1 = 90 and a 1 = 270 (5a) and the minimum M 2 M 1 min = cos b bei a 1 = 0 and a 1 = 180 (5b) Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 31

34 w max w max U U b One indicator of the variation is the variation factor U: U = v 2 v 1 v 2 max v 1 1 = min cos b cos b = tan b sin b (6) Finally, for the maximum differential angle w max the following equation applies: tan w max = ± 1 cos b 2 cos b (7) Conclusion A single universal joint should be used only if the following requirements are satisfied: n The variation in rotational speed of the output shaft is of secondary importance n The deflection angle is very small (b < 1 ) n The forces transmitted are low. A G 1 G 2 A. All components of the universal joint shaft lie in one plane 32 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

35 7.3 Double universal joints b 1 b 1 b 2 b 2 Universal joint shaft in Z arrangement, input and output shafts lie parallel to one another in one plane Universal joint shaft in W arrangement, input and output shafts intersect one another in one plane Section 7.2 shows that the output shaft W 2, when connected via a single universal joint at a given deflection angle b, always rotates at the varying angular velocity v 2. If, however, two universal joints G 1 and G 2 are connected together correctly in the form of a universal joint shaft in a Z or W arrangement, the variations in the speeds of the input and output shaft cancel each other completely. Conditions for synchronous rotation of the input and output shafts: The three conditions A C ensure that joint G 2 operates at a phase shift of 90 and completely compensates for the gimbal error of joint G 1. This universal joint shaft arrangement is called the ideal universal joint shaft arrangement with complete motion compensation. It is the arrangement to strive for in reality. If only one of the three conditions is not satisfied, the universal joint shaft no longer operates at constant input and output speeds, i.e. no longer operates homo-kinetically. In such cases, please contact your Voith Turbo representative. B G 1 C G 1 b 1 b 2 G 2 G 2 B. Both yokes of the center section of the shaft lie in one plane C. The deflection angles b 1 and b 2 of the two universal joints are identical Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 33

36 7.4 Bearing forces on input and output shafts Radial bearing forces Because of the deflection of the universal joint shaft, the connection bearings are also subjected to radial loads. The radial forces on the bearings vary between 0 and their maximum value twice per revolution. Maximum values of radial bearing forces on universal joint shafts in a Z arrangement a b L M d b 1 A B G 1 b 2 e f G 2 E F b 1 b 2 b 1 = b 2 A 1 = M d b cos b 1 (tan b L a 1 tan b 2 ) A 1 = 0 a 1 = 0 B 1 F 1 A 1 E 1 B 1 = M d (a + b) cos b 1 (tan b L a 1 tan b 2 ) E 1 = M d (e + f) cos b 1 (tan b L f 1 tan b 2 ) B 1 = 0 E 1 = 0 F 1 = M d e cos b 1 (tan b L f 1 tan b 2 ) F 1 = 0 A 2 = M d tan b 1 a A 2 = M d tan b 1 a a 1 = 90 A 2 F 2 B 2 E 2 B 2 = M d tan b 1 a E 2 = M d sin b 2 f cos b 1 B 2 = M d tan b 1 a E 2 = M d tan b 1 f F 2 = M d sin b 2 f cos b 1 F 2 = M d tan b 1 f 34 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

37 Designations and formulas G 1, G 2 Universal joints A, B, E, F Connection bearings M d Input torque A 1/2, B 1/2, C 1/2, D 1/2 Bearing forces a 1 Angle of rotation b 1, b 2 Deflection angle Maximum values of radial bearing forces on universal joint shafts in a W arrangement L a b b 1 b 2 e f M d G 1 G 2 A B E F b 1 b 2 b 1 = b 2 A 1 = M d b cos b 1 (tan b L a 1 tan b 2 ) A 1 = 2 M d b sin b 1 L a a 1 = 0 B 1 F 1 A 1 E 1 B 1 = M d (a + b) cos b 1 (tan b L a 1 tan b 2 ) E 1 = M d (e + f) cos b 1 (tan b L f 1 tan b 2 ) B 1 = 2 M d (a + b) sin b 1 L a E 1 = 2 M d (e + f) sin b 1 L f F 1 = M d e cos b 1 (tan b L f 1 tan b 2 ) F 1 = 2 M d e sin b 1 L f A 2 = M d tan b 1 a A 2 = M d tan b 1 a a 1 = 90 A 2 E 2 B 2 F 2 B 2 = M d tan b 1 a E 2 = M d sin b 2 f cos b 1 B 2 = M d tan b 1 a E 2 = M d tan b 1 f F 2 = M d sin b 2 f cos b 1 F 2 = M d tan b 1 f Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 35

38 7.4.2 Axial bearing forces In principle, the kinematics of a universal joint shaft do not generate any axial forces. Nevertheless, axial forces that must be absorbed by the connection bearings arise in universal joint shafts with length compensation for two reasons: 1. Force F ax,1 as a result of friction in the length compensation assembly As the length changes during transmission of torque, friction is generated between the flanks of the spline profiles in the length compensation assembly. The frictional force F ax,1, which acts in an axial direction, can be calculated using the following equation: F ax,1 = m M d 2 cos b d m Where: m Coefficient of friction m for steel against steel (lubricated) m 0.07 for Rilsan plastic coating against steel M d Input torque d m Pitch circle diameter of the spline profile b Deflection angle 2. Force F ax,2 as a result of the pressure build-up in the length compensation assembly during lubrication During lubrication of the length compensation assembly, an axial force F ax,2 arises that depends on the force applied while lubricating. Please note, information with regard to this subject is available in the installation and operating instructions. 36 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

39 7.5 Balancing of universal joint shafts As with any other rotating equipment, a universal joint shaft has a non-uniform distribution of mass around the axis of rotation. This leads to unbalanced forces during operation. Depending on the operating speed and the specific application, Voith universal joint shafts are dynamically balanced in two planes. The benefits of balancing: n Avoidance of vibrations, resulting in smoother operation n Longer lifetime of the universal joint shaft The balancing procedure employed by Voith for universal joint shafts is based on that prescribed in DIN ISO ("Mechanical vibration Balance quality requirements for rotors in a constant (rigid) state Part 1: Specification and verification of balance tolerances"). An extract from this Standard lists the following approximate values for balance quality levels: Type of machine general examples Balance quality level G Complete piston engines for cars, trucks and locomotives G 100 Cars. wheels, rims, wheel sets, universal joint shafts; crank drives with mass balancing on elastic mounts G 40 Agricultural machinery; crank drives with mass balancing on rigid mounts; size reduction machinery; drive shafts (cardan shafts, propeller shafts) Jet engines; centrifuges; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed of up to 950 rpm; electric motors with a shaft height below 80 mm; fans; gearboxes; general industrial machinery; machine tools; paper machines; process engineering equipment; pumps; turbochargers; hydro-power turbines Compressors; computer drives; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed over 950 rpm; gas turbines, steam turbines; machine tool drives; textile machinery G 16 G 6.3 G 2.5 Depending on the application and maximum operating speed, balance quality levels for universal joint shafts lie in the range between G 40 and G 6.3. The reproducibility of measurements can be subject to wider tolerances due to the influence of various physical factors. Such factors include: n Design characteristics of the balancing machine n Accuracy of the measurement method n Tolerances in the connections to the universal joint shaft n Radial and axial clearances in the universal joint bearings n Deflection clearance in the splined center section Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 37

40 8 Selection aids The design of a universal joint shaft depends on a number of factors. Reliable, verified calculations and tests prevent any danger to the surrounding area. Consideration of the costs that arise during the entire product lifecycle also comes into play. The design procedures described in this chapter are merely rough guidelines. When making a final decision about a universal joint shaft, you can rely on our sales engineers with their expertise and many years of experience. We will be happy to advise you. 8.1 Definitions of operating variables Desig nation Usual unit Explanation P N [kw] Rated power of the drive motor n N [rpm] Rated speed of the drive motor M N [knm] Rated torque of the drive motor, where: M N = 60 P 2p n N 9.55 P N N n with M N in knm, n N in rpm and P N in kw N M E [knm] Equivalent torque This torque is an important operating variable if bearing lifetime is the main criterion in selection of a universal joint shaft. It takes operating conditions into account and can be calculated for situations involving combined loads (see Section 8.2.1). If the operating conditions are not sufficiently known, the rated torque is used for an initial estimate. n E [rpm] Equivalent speed This speed is an important operating variable if bearing lifetime is the main criterion in selection of a universal joint shafts. It takes operating conditions into account and can be calculated for situations involving combined loads (see Section 8.2.1). If the operating conditions are not sufficiently known, the rated speed is used for an initial estimate. M max [knm] Peak torque This is the maximum torque that occurs during normal operation. n max [rpm] Maximum speed This is the maximum speed that occurs during normal operation. 38 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

41 The following factors have a major influence on any decision regarding universal joint shafts: n Operating variables n Main selection criterion: Bearing lifetime or durability n Installation space n Connection bearings b v1 b v2 b h1 b h2 Three-dimensional bending Designation Usual unit Explanation n z1 [rpm] Maximum permissible speed as a function of the deflection angle during operation. The center section of a universal joint shaft in a Z or W arrangement (b 0 ) rotates at a varying speed. It experiences a mass acceleration torque that depends on the speed and the deflection angle. To ensure smooth operation and prevent excessive wear, the mass acceleration torque is limited by not exceeding the maximum speed of universal joint shaft n z1. For additional information, see Section n z2 [rpm] Maximum permissible speed taking bending vibrations into account. A universal joint shaft is an elastic body when bent. At a critical bending speed, the frequency of the bending vibrations equals the natural frequency of the universal joint shaft. The result is a high load on all of the universal joint shaft components. The maximum speed of the universal joint shaft must be considerably below this critical speed. For additional information, see Section b [ ] Deflection angle during operation Deflection angle of the two joints in a Z or W arrangement, where: b = b 1 = b 2 If the situation involves three-dimensional deflection, a resultant deflection angle b R is determined: tan b R = tan 2 b h + tan 2 b V and where: b = b R b max [ ] Maximum possible deflection angle Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 39

42 8.2 Size selection There are essentially two selection criteria when choosing the size of a universal joint shaft: 1. The lifetime of the roller bearings in the joints 2. The fatigue-free operating range, and thus the torque capacity and/or load limits As a rule, the application determines the primary selection criterion. A selection on the basis of bearing lifetime is usually made if drives must have a long service life and pronounced torque spikes never occur or occur only briefly (for instance, during start-up). Typical examples include drives in paper machines, pumps and fans. In all other applications, selection is made on the basis of the fatigue-free operating range Selection on the basis of bearing lifetime The procedure used for calculating the bearing lifetime is based on that prescribed in DIN ISO 281 ("Rolling bearings Dynamic load ratings and rating life"). However, when applying this standard to universal joint shafts, several different factors are not taken into account, for instance, support of the bearing, i.e. deformation of the bore under load. To date, these factors could only be assessed qualitatively. Operational factor In drives with diesel engines, torque spikes occur that are taken into account by the operational factor K B : Prime mover (driving machine) Operational factor K B Electric motor 1 Diesel engine 1.2 The theoretical lifetime of a bearing in a universal joint shaft is calculated using the following equation: L h = n E b K B ( CR M E ) 10 3 where: L h is the theoretical lifetime of the bearing in hours [h] CR Load rating of the universal joint in knm (see tables in Chapter 5) b Deflection angle in degrees [ ]; in the case of three-dimensional bending, the resultant deflection angle b R is to be used; in any case, however, a minimum angle of 2 K B Operational factor n E Equivalent speed in rpm Equivalent torque in knm M E 40 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

43 M, n M 1 M u M 2 n 1 n 2 n u 0 1 q 1 q 2 q q u Incremental variation of the load on a universal joint shaft Equivalent operating values The equation for the theoretical lifetime of the bearing assumes a constant load and speed. If the load changes in increments, equivalent operating values that produce the same fatigue as the actual loads can be determined. The equivalent operating values are ultimately the equivalent speed n E and the equivalent torque M E. If a universal joint shaft transmits the torque M i for a time period T i at a speed n i, a time segment q i that normalizes the time period T i with respect to the overall duration of operation T ges is first defined: u q i = T i with q T i = q 1 + q q u = 1 ges i = 1 In this way, the equivalent operating values can be determined: u n E = i = 1 q i n i = q 1 n 1 + q 2 n q u n u u ( i = 1 M E = 10 3 q i n i M i n E 10 = ( q 1 n 1 M 1 ) q 2 n 2 M q u n u M u ) Conclusions n The calculated lifetime of the bearing is a theoretical value that in practice is usually exceeded by a considerable amount. n The following additional factors affect the lifetime of the bearings, sometimes to a significant degree: Quality of the bearings Quality (hardness) of the journals Lubrication Overloading that results in plastic deformation Quality of the seals n E Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 41

44 8.2.2 Selection on the basis of fatigue-free operating range Load peaks Shock factor K 3 Typical driven machinery Calculations regarding the fatigue-free operating range can be performed using a load spectrum. In practice, however, sufficiently accurate load spectra are seldom available. In this case, one relies on the quasi-static dimensioning procedure. Here, the expected peak torque M max is compared with the torques M DW, M DS and M Z (see Section 4.2). The following estimate is made for the peak torque: M max K 3 M N K 3 is called the shock factor. These are empirical values based on decades of experience in designing universal joint shafts. The peak torque determined in this manner must satisfy the following requirements: 1. M max < M DW for alternating load 2. M max < M DS for pulsating load 3. Individual and rarely occurring torque spikes must not exceed the value M Z. The permissible duration and frequency of these torque spikes depends on the application; please contact Voith Turbo for more information. Minimal n Generators (under a uniform load) n Centrifugal pumps n Conveying equipment (under a uniform load) n Machine tools n Woodwork machinery Moderate n Multi-cylinder compressors n Multi-cylinder piston pumps n Light-section rolling mills n Continuous wire rolling mills n Primary drives in locomotives and other rail vehicles Severe 2 3 n Transport roller tables n Continuous pipe mills n Continuously operating main roller tables n Medium-section rolling mills n Single-cylinder compressors n Single-cylinder piston pumps n Fans n Mixers n Excavators n Bending machines n Presses n Rotary drilling and boring equipment n Secondary drives in locomotives and other rail vehicles Very severe 3 5 n Reversing main roller tables n Coiler drives n Scale breakers n Cogging/roughing stands Extremely severe 6 15 n Roll stand drives n Plate shears n Coiler pressure rolls 42 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

45 8.3 Operating speeds Maximum permissible speed n z1 as a function of deflection angle during operation Section 7.2 shows that a universal joint exhibits a varying output motion. A universal joint shaft is a connection of two universal joints in series with one another. Under the conditions described in Section 7.3, a universal joint shaft in a Z or W arrangement exhibits homokinetic motion between the input and output. Nevertheless, the center section of the universal joint shaft still rotates at the periodically varying angular velocity v 2. In addition, the mass acceleration moment can affect the entire drive line on universal joint shafts with length compensation as well as universal joint shafts without length compensation. Torsional vibrations should be mentioned here by way of example. To prevent these adverse effects, please comply with the following conditions: Since the center section of the universal joint shaft still exhibits a mass moment of inertia, it creates a moment of resistance to the angular acceleration dv 2 /dt. On universal joint shafts with length compensation, this alternating mass acceleration moment can cause clattering sounds in the profile. The consequences include less smooth operation and increased wear. n max < n z1 Approximate values of n z1 as a function of b ST WT MT ST ST ST ST ST ST ST ST ST ST ST ST n z1 [rpm] HT HT WT WT ST WT WT HT ST WT MT ST WT MT ST WT MT ST WT MT b [ ] Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 43

46 8.3.2 Maximum permissible speed n z2 as a function of operating length Every universal joint shaft has a critical bending speed at which the rotational bending speed (bending frequency) matches the natural frequency of the shaft. The result: high loads on all components of the univer sal joint shaft. Damage to or destruction of the universal joint shaft is possible in unfavorable situations. Calculating this critical bending speed for a real universal joint shaft in a drive line is a complex task that Voith Turbo performs using numerical computing programs. The critical bending speed depends essentially on three factors: n Operating length l B n Deflection resistance of the universal joint shaft n Connecting conditions at the input and output ends The maximum permissible speed n z2 is determined in such a way that provides a safety allowance with respect to the critical bending speed that is suitable for the particular application. For safety reasons and to prevent failure of the universal joint shaft, please comply with the fol lowing conditions: n max < n z2 For normal connecting and operating conditions, it is possible to specify approximate values for the maximum permissible speeds n z2 as a function of operating length l B : Approximate values of n z2 as a function of l B for the S Series 6000 ST ST ST ST ST ST ST ST ST n z2 [rpm] ST ST ST ST ST ST ST ST ST I B [mm] 44 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

47 Approximate values of n z2 as a function of l B for the M and H Series MT MT MT MT MT HT HT HT HT HT n z2 [rpm] I B [mm] Approximate values of n z2 as a function of l B for the W Series WT WT WT WT WT WT WT WT WT n z2 [rpm] I B [mm] Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 45

48 8.4 Masses and mass moments of inertia Size Values for the tube based on length Universal joint shafts with length compensation m R J R m L min J L min m L min J L min m L min J L min m L min J L min m L min J L min [kg/m] [kg m 2 /m] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] ST/STL/SF ST STL 1 STL 2 STK 1 STK Values upon request Values upon request MT/MF MT WT/WTL/WF WT WTL 1 WTL 2 WTK 1 WTK Continued on page 48/49 46 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

49 Universal joint shafts without length compensation Joint coupling m L min J L min m L min J L min m L min J L min m L fix J L fix [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] STK 3 STK4 SF SG MF MG WTK 3 WF WG Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 47

50 Size Values for the tube based on length Universal joint shafts with length compensation m R J R m L min J L min m L min J L min m L min J L min m L min J L min m L min J L min [kg/m] [kg m 2 /m] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] HT/HF HT Values for P Series upon request Designation Explanation m R Mass of the tube per 1 m of length J R Mass moment of inertia of the tube per 1 m of length Universal joint shafts with length compensation m L min J L min Mass of the universal joint shaft for a length of Mass moment of inertia of the universal joint shaft for a length of l z min Calculations for the entire universal joint shaft: m ges Total mass m ges = m L min + (l z l z min ) m R J ges Total mass moment of inertia J ges = J L min + (l z l z min ) J R 48 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

51 Universal joint shafts without length compensation Joint coupling m L min J L min m L min J L min m L min J L min m L fix J L fix [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] [kg] [kg m 2 ] HF HG Universal joint shafts without length compensation l min m ges = m L min + (l l min ) m R J ges = J L min + (l l min ) J R Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 49

52 8.5 Installation: Connection flanges, bolted connections When installing the Voith universal joint shaft in a drive line, connecting flanges and bolted connections must satisfy several requirements: 1. Design 3. Dimensions, bolted connections n When using a universal joint shaft without length compensation, a connecting flange ("roll end hub") that is moveable in a longitudinal direction is required so that the universal joint shaft can slide over the spigot. The connecting flange also absorbs additional length changes arising, for instance, from thermal expansion or changes in the deflection angle. 2. Material n The material used for the connecting flanges has been selected to permit use of bolts in property class 10.9 (to ISO ). n Special case for S, M and W Series: If the material used for the connecting flanges does not permit use of bolts in property class 10.9, the torque that can be transmitted by the flange connection is reduced. The specified tightening torques for the bolts must be reduced accordingly. n On universal joint shafts from the S, M and W Series, the dimensions of the connecting flanges match those of the universal joint shaft, except for the locating diameter c. The locating diameter provides a clearance (fit H7/h6). n On universal joint shafts from the H Series, the dimensions of the connecting flanges are identical to those of the universal joint shaft. The Hirth couplings are self-centering. n On universal joint shafts from the S, M and W Series, the relief diameter f g on the universal joint shaft flange is not suitable for locking hexagon head bolts or nuts. A relief diameter f a on the connecting flange is suitable for this purpose. 50 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

53 A B A mmin Z 1 m g g v n o p m min Z 1 m g g v z 2 t y a x øa øf a øc øf g øb øa øf a øf g øb S, M, W Series Series H Sketch of the flange connection for S, M, W and H Series universal joint shafts A+B A A A A A A 8 x A 4 x B B A 8 x A A 12 x A A A 10 x A 4 x B A 10 x A A 16 x A A A A B A A A A A Bolt hole pattern for the flange connection on S, M, W and H Series universal joint shafts Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 51

54 Dimensions of the connecting flanges Standard bolted connection (A) Comments Size a b ±0.1 c H7 f a -0.3 f g g t v x P9 y a +0.5 Z 1. Z 2 z z z m M A EB [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] Bolt [Nm] ST/STL/STK/STR/SF/SG M5 x 16 7 No M6 x No M6 x No M8 x No M8 x No M10 x No M10 x No M12 x No M12 x No M12 x No M14 x No M16 x No M18 x No M20 x No M22 x Yes M22 x Yes M24 x No M27 x No MT/MTR/MF/MG M16 x Yes M18 x Yes M20 x No M22 x Yes M22 x Yes WT/WTL/WTK/WF/WG M16 x No M18 x No M20 x No M22 x No M22 x No M24 x No M27 x No M30 x No M30 x No HT/HF/HG M16 x No M18 x No M18 x No M20 x No M22 x No 52 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

55 Bolted connection with split sleeve (B) Explanation Designation Comments Additional information a Flange diameter z n o p M A Bolt Sleeve Washer [Nm] b c Bolt circle diameter Locating diameter f a Flange diameter, bolt side f g Flange diameter, nut side g Flange thickness t Locating depth in connecting flange v Length from the contact surface of the nut to the end of the hexagon head bolt x Width of face key in universal joint shaft connecting flanges with face key 4 M12 x x M14 x x M16 x x M16 x x M18 x x M18 x x M20 x x M12 x x M14 x x M16 x x M16 x x M18 x x y a Depth of face key in universal joint shaft connecting flanges with a face key Z 1 Axial run-out 1 Permissible values for deviation in axial run-out Z 1 Z 2 Concentricity and concentricity Z 2 at operating speeds below 1500 rpm. At operating speeds of 1500 rpm to 3000 rpm, the values should be halved! m m min Hexagon head bolt to ISO with hexagon nut to ISO Minimum length for installation of bolt 2 z each per standard connecting flange 3 z each per connecting flange with face key 4 z each per connecting flange with Hirth coupling 5 Dimension of hexagon head bolt with nut 6 Tightening torque for a coefficient of friction μ = 0.12 and 90% utilization of the bolt yield point value Length of the hexagon head bolt m including the height of the bolt head EB Options for insertion 7 Insertion of bolts from the joint side n Hexagon head bolt to ISO with hexagon nut to ISO z each per connecting flange 9 Dimension of hexagon head bolt with nut 12 Tightening torque for a coefficient of friction μ = 0.12 and 90% utilization of the bolt yield point o Split sleeve 10 Split sleeve dimensions [mm x mm] p Washer 11 Washer dimensions [mm] Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 53

56 9 Voith Universal Joint Shaft Service Service Excellence for our customers Consulting and engineering Pre-Sales After-Sales Installation Training Commissioning Original spare parts supply Overhaul Repairs Modernizations, retrofits Torque measurements (ACIDA) For us, Service Excellence means a level of service quality that exceeds the expectations of our customers. We will be at your side anywhere in the world during the entire lifetime of your system. You can count on us from the planning and commissioning phase through to maintenance. With the Universal Joint Shaft Service from Voith Turbo, you increase the availability and lifetime of your system. 54 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

57 9.1 Installation and commissioning Proper installation of a universal joint shaft provides the basis for problem-free commissioning. A systematic commissioning procedure with extensive operational testing is an important factor in achieving reliable and long-lasting operation of the universal joint shaft and the entire system. Your benefits Our services: n Immediate access to the know-how of experts during the entire start-up phase n Assurance of problem-free and professional commissioning of your universal joint shaft n Installation and commissioning by our service experts n Training of the operating and maintenance personnel Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 55

58 9.2 Training Efficiency, reliability and availability are essential factors in making your system successful. One requirement in this regard is the best-trained employees in technology and servicing. Initial and continuing training are worthwhile investments to ensure efficient operation of your universal joint shaft. Our training programs provide specific technical knowledge about our products. We bring your personnel up to speed with the latest Voith technology in theory and in practice. Your benefits Our services: n Safe handling of Voith products n Avoidance of operating and maintenance errors n Better understanding of Voith technology in the drive line n Product training at Voith or on-site at your premises n Theoretical and practical maintenance and repair training 56 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

59 9.3 Voith genuine spare parts Avoid risks by using original spare and wearing parts. Only these are manufactured with Voith know-how and guarantee reliable and safe operation of your Voith products. High availability, combined with efficient logistics, ensures quick delivery of parts around the world. Your benefits Our services: n Safe and reliable operation of all components n The highest quality and parts that fit exactly n Maximum lifetime of drive elements n Manufacturer s warranty n High degree of system availability n Fast spare parts delivery n Most original spare and wearing parts warehoused at our service branches n Shipment of in-stock parts on the same day (for orders received by 11 a.m.) n Consultation with your spare parts management staff n Preparation of project-specific spare and wearing parts packages n Spare parts also available for older generations of Voith universal joint shafts Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 57

60 9.4 Overhaul, maintenance Constant operation subjects universal joint shafts to natural wear, which is also influenced by the surroundings. Professional and regular overhauls of your universal joint shaft prevent damage and minimize the risk of expensive production down time. You gain operational reliability and save money in the long term. Your benefits Our services n Safety thanks to professional maintenance n Manufacturer s warranty n Increased system availability n Maintenance or complete overhaul by our service experts with all the necessary tools and special fixtures n Use of original spare and wearing parts n Consultation regarding your maintenance strategy 58 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

61 9.5 Repairs Even with the best preventive maintenance, unplanned down time due to equipment failures cannot be excluded. The priority then is to repair machinery and equipment as quickly as possible. As the manufacturer, we not only have a wealth of knowledge about universal joint shafts, but also possess the necessary technical competence, experience and tools to ensure professional repairs. Our service technicians can assess the damage in a minimum amount of time and provide suggestions for rapid rectification of the situation. Your benefits Our services: n Safety thanks to proper repair n Manufacturer s warranty n The shortest possible outage and down time n Avoidance of a repeat outage or malfunction n Fast and professional repairs that comply with our safety standards on-site at your premises or in one of the head office-certified Voith Service Centers around the world n Competent damage assessment with analysis of weaknesses n Fast delivery of original spare parts Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 59

62 9.6 Modernization, retrofits Technology is advancing all the time and sometimes the original requirements on which the design of a system was based change. A custom-engineered modernization or retrofit of your universal joint shaft from Voith Turbo can provide significant improvements in efficiency and reliability. We analyze, provide advice and modernize universal joint shafts including the connecting components to provide you with the latest and most economical technology. Your benefits Our services n Improved reliability, availability and affordability of your drive system n Reduced operating costs n A universal joint shaft that features the latest technology n Modification of or a new design for your universal joint shafts and connecting components n Competent consultation regarding modernization opportunities, including design of the drive line 60 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

63 10 Quality Environment Safety At Voith, our top priority is to ensure the affordability, reliability, environmental compatibility and safety of our products and services. In order to maintain these principles in the future just as we do today, Voith Turbo has a firmly established integrated management system for quality, the environment, and occupational health and safety. For our customers, this means that they are purchasing high-quality capital goods that are manufactured and can be used in safe surroundings and with minimal environmental impact. Certificates for the management systems to ISO 9001: 2000 (quality), ISO 14001: 2000 (environment) and OHSAS 18001: 1999 (occupational health and safety) Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 61

64 10.1 Quality Flange for a high-performance universal joint shaft on a 3-D coordinate measuring machine n We employ state-of-the-art 3 D coordinate measuring machines for quality assurance. n To ensure perfectly welded joints, we conduct x ray inspections in-house. n We offer our customers a variety of product and application-specific certifications and classifications. n Production and assembly fixtures are inspected on a regular basis. n Quality-relevant measuring and testing instruments are subject to systematic monitoring. n For the welding methods employed, process controls to ISO SO are used. Welding technicians are qualified to EN 287 and welding equipment is monitored. n Employees that perform nondestructive testing are qualified to ASNT C 1A and/or EN Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

65 10.2 Environment An employee coats the roller bearing for a universal joint shaft with Voith WearCare 500 high-performance lubricant n Voith universal joint shafts are fitted with sealed roller bearings. These provide two major advantages over slipper and gear spindles when using our universal joint shafts: 1. Lubricant consumption is considerably lower because of the seals. 2. Efficiency is enhanced, as rolling friction is significantly less than sliding friction. This translates into reduced CO 2 emissions and protects the environment % Efficiency Power loss 71.1 kw 41.1 kw 99.49% 0.32 kw Voith universal joint shaft Gear spindle 99.10% Slipper spindle Comparison of the efficiency and power loss in a main drive for a rolling mill. Input power 8000 kw, deflection angle 2 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 63

66 10.3 Health and safety Voith universal joint shafts receive their final finish in a modern paint booth n Voith painting technicians use a modern painting system that meets all requirements for occupational health and safety as well as environmental protection when painting the universal joint shafts. n Electrostatic application of the paint reduces overspray. n An exhaust system extracts any residual mist from painting. n An exhaust air treatment system with combined heat recovery reduces the impact on employees as well as the environment. 64 Voith Turbo I High-Performance Universal Joint Shafts I G 830 en

67 11 High-performance lubricant: Voith WearCare 500 Voith WearCare 500 in 45 kg und 180 kg drums Voith development engineers have combined their universal joint shaft know-how with the tribological know-how of renowned bearing and lubricant manufacturers. The result of this cooperation is an innovative and exclusive lubricant with properties far above those of conventional standard lubricants. This lubricant gives bearings in universal joint shafts operating at low speeds and under high loads an even longer life. In addition, lubrication intervals are extended and emergency dry running characteristics improved significantly. Voith Turbo I High-Performance Universal Joint Shafts I G 830 en 65