DRIVE SOLUTIONS FOR TEST BENCHES - Vulkan

TORQUE FOR HEAVY DUTIES – WORLDWIDEOperating with fi ve international production locations, with 17 subsidiary companies and over 30 agencies worldwide, we ensure that

VULKAN Drive Tech expertise is available on–site throughout the world. This means that our customers have rapid access to our

specialists and that the necessary solutions are quickly available exactly where they are needed.

TORQUE FOR HEAVY DUTIES

Production SubsidiaryHeadquarters Subsidiary

DRIVE SOLUTIONS FORTEST BENCHES

www.vulkan.com

VULKAN DRIVE TECH IS A DIVISION OF THE VULKAN GROUP WITH OVER 120 YEARS OF EXPERIENCE IN DESIGNING AND MANUFACTURING POWER TRANSMISSIONS COMPONENTS AND HIGH POWER BRAKES SYSTEMS FOR DEMANDING INDUSTRIAL DRIVES.

PUBLISHER:Division: VULKAN Drive TechHead Offi ce: VULKAN Kupplungs- und Getriebebau Bernhard Hackforth GmbH & Co. KGHeerstraße 66, 44653 Herne / GermanyPhone: + 49 (23 25) 922-0 Fax: + 49 (23 25) 71110 E-mail: [email protected]

CONCEPT AND DESIGN:Hackforth Holding GmbH & Co. KGMarketing Service CenterHeerstraße 66, 44653 Herne / GermanyE-mail: [email protected]

STATUS: 09/2013 All duplication, reprinting and translation rights are reserved. Further remarks for the VULKAN Kupplungs- und Getriebebau Bernhard Hackforth GmbH & Co. KG assembly are available on request. TORQUE FOR HEAVY DUTIES

ENERGY – Power generation by means of wind turbines,

hydro turbines and steam turbines, requires drive solutions that

are capable of withstanding high dynamic torque load and high

speed. VULKAN Drive Tech responds to such requirements with

high-quality hydraulic brakes, composite materials and integrated

electronic power controls.

SPECIAL APPLICATIONS – The unique skills and

knowhow developed during more than 120 years of experience

makes VULKAN Drive Tech a reliable partner for drive components

that simply cannot be selected out of a catalogue. Test benches,

railways, agricultural machinery and gantry cranes for aerospace

equipment are just a few of the challenges that we deal with on a

daily basis.

OIL & GAS – Onshore & offshore plants involve the

large-scale use of compressors, blowers, pumps and fans within

the processing chain of fl uids and gasses. Our torsional fl exible

& torsional rigid couplings and brakes will preserve the best

functionality of diesel engines, electric motors and turbines in

the vast majority of working profi les and environments.

MINING – Stackers, reclaimers, regenerative conveyors

belt, mills and crushers are just a few examples of the heavy

duty machinery that requires specifi c high speed & low speed

couplings, service & emergency braking systems, backstops and

resilient mounts. Our approach to such demanding applications is

to deliver engineered tailor-made solutions.

INDUSTRIAL APPLICATIONSVULKAN Drive Tech provides a wide range of fl exible couplings, braking systems and resilient mounts, based engineering and know how applied into more than 20 different types of applica-tions, within six different industrial markets segments.

IRON & STEEL – Continuous ingot castings and hot

& cold laminating machinery are typical examples of steelwork

equipment where the drives are subjected to dust, dirt and high

temperatures. Operational safety and reliability of the drive com-

ponents and minimum service downtime are the main require-

ments that our pneumatic disc brakes, maintenance-free fl exible

couplings and disc couplings must fulfi ll.

BULK MATERIAL HANDLING – Gear couplings,

electromagnetic service brakes, hydraulic emergency brakes,

hydraulic rail clamps for E.O.T. gantry cranes, torsional highly

fl exible couplings and resilient mounts for construction machinery

underline the wide product portfolio and engineering capacity of

VULKAN Drive Tech.

CUSTOMER BENEFITSOur mission is to offer our customers the most reliable products, with the right level of customization, state-of-the-art design, deli-vered within the requested time, supported by local service closest to where it is needed. Choosing VULKAN Drive Tech means to choose innovation, technological leadership, and highly specifi c solutions with maximum customer benefi t.

TAILOR-MADE SOLUTIONS – We propose to our customers diversifi ed systems solutions that can respond positively

to their requirements in terms of products features, custom solution design, and the operating conditions and economy of the

application. VULKAN Drive Tech provides the reliable products and related engineering services that your application needs.

ENGINEERING – We have considerable experience and knowhow regarding the most advanced braking technology and

torsional & linear vibrations calculations and measurements. Besides the most advanced 3D CAD CAM systems that are used

by our Design Department, we have developed state-of-the-art calculations programs to to simulate product performances in

relation to the specifi c application. More than fi fty of our engineers dedicate themselves on a daily basis to fulfi lling the require-

ments of our customers.

IN-HOUSE TESTING – VULKAN Drive Tech has in-house test center to perform either static or dynamic tests up to 5.000

kNm. This ensures we can back up the claims regarding technical performances that are listed in our catalogue, recreating the

most severe operating conditions our products will face within their lifetimes. This strategic service is performed to implement our

engineering know-how and create a new breakthrough into state-of-the-art power transmission and braking systems technology.

PRODUCTION – VULKAN Drive Tech comprises fi ve wholly-owned manufacturing sites worldwide and this is where the

core of our products come to life. International Quality Standards guarantee our customers that the Services and Products

purchased from VULKAN Drive Tech are simply Top Quality Products which deserved to be branded with our “V” Logo.

WORLD-WIDE SERVICE – 17 wholly-owned subsidiaries and more than 30 offi ces worldwide demonstrate the close

contact we can offer to our customers. Our key areas of competence include application engineering, sales, after sales and

technical support. Furthermore, service and spare part depots have been established throughout the world. And the shortest

routes for material to their point of installation, as well as the fl exibility and mobility of our technicians, ensure a prompt backup

service all over the world.

Market Oil & Gas Mining Bulk Material Handling Iron & Steel Energy Special Applications

ApplicationCompressors /

BlowersPumps /

Fans

Belt Conveyors /Stackers /

Reclaimers

Crushers /Mills /

Separators /Agitators

E.O.T. CranesConstruction and MobileMachinery

Casting andLaminationMachinery

Hydro and Wind Generators

Test Benches

HIGHLY FLEXIBLE COUPLINGSRATO S Series •

RATO R SERIES •

RATO DS SERIES •

EZR SERIES • •

VULASTIK L SERIES • • •

VULKARDAN E SERIES • • •

VULKARDAN L SERIES • • •

VULKARDAN P SERIES • • • •

INTEGRAL SHAFT SUPPORT • •

MEGIFLEX B SERIES • •FLEXIBLE COUPLINGS

FLEXOMAX G SERIES • • • • •

FLEXOMAX GSN SERIES • • • •

FLEXOMAX GBN SERIES • • • •

SPEFLEX SERIES • •

PINOFLEX SERIES • • •RIGID COUPLINGS

DENFLEX SERIES • • • •

DISCFLEX SERIES • • • • •BRAKES

ELECTROMAGNETIC DISC BRAKES • • • • •

ELECTROMAGNETIC DRUM BRAKES • • • •

PNEUMATIC DISC BRAKES • •

ELECTROHYDRAULIC DISC BRAKES • • •

ELECTROHYDRAULIC DRUM BRAKES • • •

HYDRAULIC DISC BRAKES • • • • •

RAIL CLAMPS • •BACKSTOPS AND FLYWHEELS

HIGH SPEED BACKSTOPS • • •

LOW SPEED BACKSTOPS • •RESILIENT MOUNTS

T SERIES • • •

VD SERIES • • •

VDM SERIES • • •

CV 2000 SERIES • • •

DRIVELINE COMPONENTS COMPOSITE SHAFTING •

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Contents

Application requirements

Solutions

EZR

VulkARdAn E

VulkARdAn l&P

InTEGRAl SHAFT SuPPORT

dISCFlEX

Product Range

Product Application Range

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Contents

VulkAn drive Tech 1drive Solutions for Test Benches













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BlowersPumps /

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ReQUIReMents

2 Drive Solutions for Test BenchesVulkAn drive Tech

Test benches are largely used in the Research and develop-ment departments, as well as for end-of-line inspection in manufacturing or for the repair of diesel engines and electric motors. The requirements of modern test benches are constantly becoming more demanding in relationship to torsional coupling usage.

Features like plug-in or flange-fitted connection, simple and robust design, diversified load cycles capacity, tailoredtorsional stiffness and weight limitation are the main va-riables to be considered for coupling’s selection into this application’s field, besides heavy duties operating conditions and limited shutdown time between testing sessions.

The in-house Vulkan Drive Tech Test Center provides comprehensive test capabilities to validate the performance of every tailor made coupling; so to comply with specific stationary and transient conditions of the drives to be tested.

3Drive Solutions for Test Benches Vulkan Drive Tech

solUtIons

Each project is engineered considering the operating profile of the whole test bench, in or-der to identify the most critical conditions the flexible couplings need to support. Working cycles, dynamic load, running hours without maintenance, installation requirements, etc. With the aim of simulation programs, Vulkan

Drive Tech Torsional Vibration analystscould then select the optimal product’s

selection according to the above mentioned application’s requirements and the flexible

coupling technical features. Furthermore the extensive in-house Vulkan Test Centre allows to dynamically test all Vulkan products scale 1:1, to simulate the real requested operating conditions and prove the product’s reliability.

Customised solution with short or long designs of the couplings balance out different installation conditions, which value changes

during operation as a result of process-related transient load conditions, start & stop or gear change operations. Furthermore several diffe-rent machinery could be tested on the same bench, requesting a very versatile connection

interface such as shaft-shaft, shaft-flange, flange-flange according to different DIn or

SaE standards. In many cases a cardan shaft is also used to bridge long distance and angle between the machinery: it is then necessary

to consider a proper coupling application, able to minimize the radial reaction forces trans-mission generated by the cardan shaft itself.

The main function of VULKAN Drive Tech highly flexible couplings in engine/motor test benches is to withstand the load between the driving machine (prime mover) and the braking machine (brake, motor). Moreover, highly flexible couplings compensate misalign-ments of the driving and driven components of the drive system to a limited extent.

Efficiency Tailor-made solutions


lightweight, compact design, endurance, easy and fast installation are the key factors

to be considered and balanced into test benches couplings design. Vulkan Drive Tech provides also an extensive range of elastic elements in heat resistant rubber up to +90°C ambient temperatures; for

most critical high temperature conditions and when progressive stiffness is required, silicone elastic elements are available too.

Vulkan Drive Tech Engineering is committed to develop Total Custom Designs to meet

even the most technical demanding projects.

The main function of VULKAN Drive Tech highly flexible couplings in engine/motor test benches is to withstand the load between the driving machine (prime mover) and the braking machine (brake, motor). Moreover, highly flexible couplings compensate misalign-ments of the driving and driven components of the drive system to a limited extent.

design


solUtIonsProduct portfolio


DISCFLEX page 16VULKARDAN E page 10 VULKARDAN P page 12 INTEGRAL SHAFTSUPPORT page 14

EZR page 8


eZR

EZR

The highly torsional flexible EZR coupling is a fabric reinforced rubber coupling with multidirectional flexibility.

nominal Torque Range: 12.50 – 250.00 knm


The EZR Coupling can be employed in all those applications whe-re two approximately coaxially rotating machines have to be flexi-ble connected. EZR is composed by two elastic elements coupled together and clamped on the outer and inner circumferences to prime mover and driven machinery. The elastic element design allows the coupling to be very flexible in torsional direction with progressive stiffness characteristics. Furthermore the use of syn-thetic fibers within the elastic element guarantees high strength, while allowing high misalignments capacity in all directions. The geometry of the elements allows also to minimize the radial and axial reaction forces generation. Thanks to the possibility to select from various torsional stiffness and damping characteristics, it’s possible to tune the coupling’s performances to the application’s requirements. The design of the metal parts is versatile and could be customized to accommodate any connection required by the machines to be coupled.

Product key facts

High torsional vibrations isolation degree. High misalignment capacity with low reaction forces. Electrical isolation property.

Customization of all metal parts. Tuning of the coupling by use of elements with different stiffness. nine different standard designs to fit almost any connection possibilities.

Fabric reinforced rubber element to guarantee high strength.Modular design to allow high customization possibilities. High shock absorption capacity.

Efficiency

design

Tailor-madesolutions

featUResHIGHLy fLeXIBLe couPLINGs eZr


VUlkaRdan enominal Torque Range: 0.2 – 25.00 knm

VULKARDAN E BELL-HOUSING

The VulkARdAn E coupling is a highly-flexible rubber coupling with a linear stiffness characteristic.


Torsional highly flexible coupling suitable for either close coupled applications and free standing machinery rigidly fixed or installed on resilient mounts. It is available for connection to SAE J620 flywheel to spline or shaft with keyway, or alternatively for shaft to shaft connection. Four rubber qualities are available in order to tune the coupling to the various system requirements. A sili-cone version of Vulkardan E coupling has been designed to fulfill applications requiring high operating temperature and progressi-ve torsional stiffness of the element. The freestanding design is also equipped with a steel membrane package, so to guarantee a higher axial misalignment capacity, with minimum reaction force generation.

VUlkaRdan e fReestandIng

featUResHIGHLy fLeXIBLe couPLINGs VuLkardaN e BeLL-HousING, VuLkardaN e freestaNdING

Product key facts

Rubber coupling with a linear stiffnesscharacteristic. Operating ambient temperature range from -45°C up to 120°C. Compensate high axial misalignments.

Suitable for either close coupled applications and free standing machinery installed on resilient mounts. J620 SAE 6 ½” – 24” connection.Spline and keyway shaft connection.

Silicone version for high operatingtemperature and progressive torsional stiffness. Radial disassembly of the element. low reaction forces generation.

More products of this series:

Efficiency

design



VUlkaRdan l&pnominal Torque Range: 0.4 – 40.00 knm

VULKARDAN P

The highly flexible VulkARdAn P coupling is a fabric reinforced rub-ber coupling with multidirectional flexibility.


When the driven machine is not in line with the prime mover or when long distances have to be bridged, cardan shafts are used. With a diesel engine as the prime mover, a highly flexible coupling will be required for shifting resonances and damping of torsional vibration. This coupling protects the cardan shaft and the driven machinery from inadmissible vibratory loads. The highly flexible VulkARdAn l&P couplings have been specifically developed for application in conjunction with cardan shafts. The main compo-nents of the VulkARdAn l&P coupling are the highly flexible ele-ment and the inner and outer couplings parts supported against each other. The elements have a high torsional flexibility and good damping properties. On to the support additional damping is achieved.

VulkARdAn l is suitable for all those applications requiring linear torsional stiffness characteristics, while VulkARdAn P coupling is characterized by progressive torsional stiffness feature. Each VulkARdAn l&P size could be also equipped with different dIn (or other standard) flanges connection in order to accommodate several different cardan shafts type.

VulkAn drive Tech also provides full Torsional Vibration Calcu-lation to predict the performances of the coupling and natural frequencies spectrum in relation to the specific project for which the coupling has to be installed.

VUlkaRdan l

featUResHIGHLy fLeXIBLe couPLINGs VuLkardaN L, VuLkardaN P

Product key facts

Self supporting radial bearing to reduce re-action forces generated by the cardan shaft. Self lubricating maintenance free material used for the bearing sytem.High degree of radial and angular misalign-ment capacity.

J620 SAE 8” – 21” connection. different Flange sizes to accommodate several cardan shafts type. different built in length possibilities.

Compact design to reduce load on the crankshaft. linear or progressive torsional stiffness possibility. low torsional stiffness for optimum isolation of the connected machinery.

More products of this series:

Efficiency

design



IntegRal sHaft sUppoRt

INTEGRAL SHAFT SUPPORT

The particular design of the Integral Shaft Support system (ISS system) allows the flexible coupling to minimize the torsional vibrations transmission.

nominal Torque Range: On Request


VulkAn drive Tech developed a specific solution for all those applications requiring a torsional coupling in combination with a cardan shaft with a high installation angle: the Integral Shaft Sup-port or ISS. It is a combination of a torsional flexible coupling with an integrated bellhousing and roller bearings system, whose func-tion is to decouple the radial load, generated by the cardan shaft, from the coupling and the prime mover cranckshaft bearings. The radial load is then unloaded to the prime mover main block. The ISS allows the flexible coupling to minimize the torsional vibration transmission and to properly isolate the prime mover cranckshaft from radial and axial dynamic loads due to the high installation degree of the cardan shaft.

ISS could accommodate different torsional flexible couplings such as the VulkARdAn E series or the VulASTIk l series and it’s equipped with different flanges sizes to accommodate the cardan shaft. The connection to the prime mover is made via a flywheel connection according to SAE J620 in the range from 11 ½” up to 21” and a bellhousing according to SAE J17a.

Product key facts

Torsional vibration isolation. unloading of the crankshaft from radial and angular reaction forces. High angular misalignment capacity.

Possibility to accommodate different torsional couplings model.Custom connection to prime mover flywheel and bellhousing. Custom connection flange for cardan shaft.

Modular design of the component. Sealed bearings system for minimum maintenance. Compact design with minimum built in length.

Efficiency

design


featUResHIGHLy fLeXIBLe couPLINGs INteGraL sHaft suPPort


dIsCfleXnominal Torque Range: 0.12 – 13.00 knm

DISCFLEX

The dISCFlEX coupling is suitable for those applications where a turbine is used as the prime mover. High rotational speed and torque transmission capacity within limited dimensions and weight are the major advantages of this product, together with the complete mainte-nance-free feature that is guaranteed by its materials.


dISCFlEX is also suitable when machinery is subjected to reversals and synchronous torque transmission requirements. It is a valid alternative to torsional flexible couplings in cases where environ-ments are harsh on elastomers. Furthermore, dISCFlEX can with-stand operating temperatures ranging from -40°C to 280°C. Fi-nally, the dISCFlEX coupling complies with the API 610 Standard.

The dISCFlEX coupling is characterised by high torsional stiff-ness without backlash, high rotational speed capacity, high power transmission within limited dimensions and weight, and low axial and radial reaction forces. Furthermore, it is suitable for extreme and hostile environments. The flexible elements of the coupling are composed with stainless steel AISI 301 membranes packages, which are engineered by state-of-the-art FEM Analysis to guarantee the highest rate of misalignment capacity and torque trans-mission within the smallest dimensions and minimum reaction forces. Its modular design allows a wide range of customisations, which include and are not limited to the use of GFRP spools to guarantee the electrical isolation of the coupling itself. When the dISCFlEX is subjected to a nominal rotational speed over 3,800 rpm then the balancing of the coupling is according to API 671 and AGMA 9000.

The dISCFlEX coupling is available in nine versions and features 11 sizes with different spool length to properly fit the requirements of any application as regards dBSE.

Product key facts

Suitable for high speed shaft applications up to 25,000 rpm.Synchronous torque transmission without backlash.High torque transmission capacity, within limited dimensions and inertias.

Intermediate spool available in different length to cover any dBSE requirement. Custom balancing of the parts according to international standards requirements.Windage protection rings and shearing rings available on demand.

Compliant to API 610 standard.Stainless steel membrane packagesoptimize lifetime of the coupling and minimize service operation. Suitable to operate within temperature range of -40° to +280°C.

Efficiency

design


featUResrIGId couPLINGs dIscfLeX


notes

VulkAn drive Tech18 drive Solutions for Test Benches

pRodUCt RangeFor Test Benches

VULKARDAN P INTEGRAL SHAFT SUPPORT

DISCFLEX

EZR VULKARDAN E VULKARDAN Lpage 08

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page 10

page 14

page 12

page 16

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daily basis.


























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BlowersPumps /

Fans


Reclaimers

Crushers /Mills /





Test Benches


RATO R SERIES •

RATO DS SERIES •

EZR SERIES • •




























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daily basis.


























VULKAN Drive Tech.
























BlowersPumps /

Fans


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Test Benches


RATO R SERIES •

RATO DS SERIES •

EZR SERIES • •




























Test Benches

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DRIVE SOLUTIONS FOR TEST BENCHES - Vulkan

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