The key to the optimal design and lifespan of your drive technology.
What is the operating factor (fB) and why is it crucial for my gear box?
The operating factor (fB), also known as the application factor, is a safety factor, which reflects the actual operating conditions of your machine. A correctly chosen operating factor is critical for the lifespan and reliability of your gear box, as it prevents overloading and premature wear. A miscalculation can drastically shorten the gear box lifespan.
What factors influence the operating factor the most?
The main influencing factors are the daily operating duration of the system, the type of load (even, uneven, or shock-like) and the switching frequency (number of starting processes per hour). The drive type and ambient conditions can also play a role.
How is the correct operating factor determined for my specific application?
The determination is done through a precise analysis of the operating conditions of your machine, including runtime, load profile, and switching frequency. These values are then used to determine the operating factor using manufacturer tables and technical expertise . For complex cases, an individual calculation is recommended.
What are the consequences of a wrongly chosen operating factor?
Ein An underestimated operating factor often leads to premature gear box wear, unexpected system failures, and high repair or replacement costs.A factor that is too high can lead to unnecessarily expensive over-dimensioning of the gear box.
Is there a difference between operating factor and service factor?
Yes, they are two different metrics.The operating factor (fB) takes into account the application conditions (load, runtime, switching). The service factor (sf) usually describes the ratio between the maximum permissible torque of the gear box and the driving torque of the motor. Both are important for a correct design.
How does ATEK Drive Solutions support the selection of the right operating factor?
ATEK Drive Solutions offers comprehensive technical consulting and assists you in the precise analysis of your application conditions. With our decades of experience and our know-how in gear box construction, we help you determine the optimal operating factor and choose the suitable gear box from our modular system or as a custom special solution .
Der The correct operating factor is critical for the maximum lifespan und efficiency of gear boxes; a miscalculation can reduce lifespan by over 70% and lower the availability of the system by up to 20%..
Important factors influencing the operating factor are the daily operating duration, the type of load (even, uneven, shock-like) and the switching frequency; these must be precisely analyzed for a reliable design. It is important to clearly distinguish the
Es ist wichtig, den operating factor (fB) vom service factor (sf), to avoid costly design errors. ATEK Drive Solutions offers expertise and tailored solutions for the optimal and economical drive design..Learn everything about the operating factor (fs) for gear boxes: what it means, how to calculate it correctly, and why it is crucial for the longevity of your systems. Including practical tips and application examples!
The operating factor is a key parameter for the design of gear boxes. An incorrect calculation can lead to premature wear and costly failures. Need help selecting the right gear box? Contact us with our experts now!
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Understand: What is the operating factor and why is it crucial?
The optimal design and lifespan of drive technology largely depends on the correct operating factor (fs) for gear boxes. This article explains the importance of the design factor, its calculation, and its influence on the longevity of systems. We are here to provide customized consulting to optimize your drives.
Definition of the operating factor: More than just a number
A wrongly evaluated operating factor is often the cause of unexpected system downtime. This value (fB or fs), also known as the application factor, is a safety factor that reflects real operating conditions. An underestimated factor of 0.25 can halve the gear box lifespan. The correct determination of this key figure is fundamental for operational safety.
The critical role for longevity and efficiency
A correctly determined operating factor, e.g., 1.5 for moderate shock loads and 16h daily runtime, prevents overloading and premature wear. This reduces maintenance costs and production downtime. An adjusted design factor maximizes the lifespan of the gear boxes.Learn more about gear boxes and motors here.
Consequences of a misjudgment of the operating factor
An excessively low operating factor, e.g., 1.0 instead of the required 1.75 for a heavily loaded machine, can drastically reduce the gear box lifespan – often by over 70%. This leads to production downtimes and high repair costs. A precise design that considers the correct load factor avoids such consequences. We also offer modular industrial gear boxes for various requirements.Identifying: What factors significantly influence the operating factor?
Operating duration: From short-term to continuous operation
The daily runtime influences the operating factorsignificantly. A system in 24-hour three-shift operation usually requires a higher application factor than a machine with only 2 hours of daily activity. The difference can be up to 0.5. Daily operational time is a key influencing factor for this metric. For continuous operation, we recommend special maintenance-free gear boxes..
- Daily operating duration: The total time a system is in operation per day directly affects the factor.
- Type of load: There is a distinction between even (U), uneven (M), and heavily shock-like (H) load profiles.
- Switching frequency: The number of on-and-off cycles per hour plays a significant role in the design factor.
- Effect of the runtime: A system in 24-hour operation requires a higher factor than one with only 2 hours of daily activity (difference of up to 0.5).
- Load profile dependence: A crushing machine (H-load) may require a operating factor of 2.0, a conveyor belt (U-load) often only 1.0.
- Influence of starting processes: Many cycles per hour (e.g., 300 for a packaging machine) increase the strain and thus the required factor (up to 0.5 more).
Type of load: Even, uneven, or shock-like?
The load profile is crucial: There is a distinction between even (U), uneven (M), and heavily uneven loads (H). A crushing machine (load type H) requires, for instance, a operating factor of 2.0, while a conveyor belt (load type U) often only needs a value of 1.0. The load characteristics significantly determine the value of the factor.
Switching frequency: Every start counts for the operating factor
The number of switches per hour is relevant. A packaging machine (300 switches/hour) places higher demands on the gear box than a mixer (5 switches/hour). This can increase the necessary factor by up to 0.5. Frequent starts increase material strain and thus influence the operating factor.Determining: How do you precisely determine the operating factor for your application?
Step 1: Analysis of operating conditions
A precise capture of the operating conditions is the starting point, including the actual daily runtime. A textile industry customer reduced the failure rate by 15% by correcting the runtime (from 12 to 18 hours) and adjusting the operating factor.. A realistic runtime analysis is fundamental for determining the correct design factor.
Step 2: Characterization of the load and switching frequency
Load type (U, M, H) and switching frequency per hour must be determined. A robot arm (medium load M, 200 switches/hour) requires a higher application factor than a simple pump with few cycles. Accurate knowledge of load type and switching frequency is necessary for determining the operating factor. For the highest accuracy, we offer precise gear motors..
Step 3: Utilizing manufacturer tables and expertise
Manufacturer documentation and tables serve to determine the operating factor.. Standard values are often only guidelines. ATEK Drive Solutions recommends a bespoke examination for critical applications, as small deviations (e.g., a safety factor being 0.2 too low) can greatly affect lifespan. Manufacturer data is the basis, expertise for precise determination of the operating factor is often necessary.Differentiating: Clearly distinguish between operating factor and service factor to avoid errors!
What fundamentally distinguishes the two factors?
Service factor (sf) and operating factor (fB) are not identical. The service factor (sf) usually refers to the ratio of the gear box nominal torque to motor torque. The operating factor (fB), also known as the application factor, on the other hand, takes into consideration application conditions such as load type and duty cycle. This distinction is essential to avoid design errors.
- Fundamental difference: Service factor (sf) and operating factor (fB) are not interchangeable and address different aspects of drive design.
- Definition of service factor (sf): Usually refers to the ratio of the nominal torque of the gear box to the nominal torque of the motor.
- Definition of Service Factor (fB): It is a safety factor that takes into account the actual application conditions such as type of load, shock loads, and daily duty cycle.
- Avoiding design errors: A clear differentiation between service factor and application factor is crucial to prevent under- or over-dimensioning of the drive.
- Risk of confusion: A gear box with a high sf may still fail prematurely if the operating factor (fB) for the specific application (e.g., shock load) is set too low.
- Insufficient individual consideration: Relying solely on the service factor without considering the actual operating factor is not sufficient for a long-lasting and safe system.
- Expert support: ATEK assists in analyzing the entire drive chain to optimally align both parameters – service factor and operating factor – to ensure clarity and safety.
Why correct differentiation is so crucial
A confusion can lead to problems. A gear box with a high service factor (e.g., 2.0) can fail prematurely if a too low operating factor (e.g., 1.0 for shock load instead of the required load factor) is set. A customer example with a press illustrates this. The consideration of the service factor alone is not sufficient; the service factor is equally critical.
ATEK helps clarify and correctly select
ATEK Drive Solutions analyzes the drive chain to operating factor and optimize service factors, e.g., for 5,000 operating hours/year with frequent load changes. We support clarity and safety in defining the correct application factor. For special environments, we also provide corrosion-resistant gear boxes.Optimize: With the right service factor and ATEK, achieve maximum system efficiency.
The importance of the service factor for your production summarized
A precise determination of the operating factor. taking into account all load cases and operating times reduces maintenance costs. It can increase system availability by up to 20%. The correct design factor positively impacts economic efficiency.
Your partner for optimal design: ATEK Drive Solutions
With years of experience and a comprehensive product portfolio, ATEK Drive Solutions supports gear box selection. We optimize the drive train while considering the specific operating factor., even for complex special solutions (e.g., stage technology, >100 drives/system). Our goal is a tailored, durable drive solution that takes into account the correct application factor. Also discover our IP69K classified gear boxes for wet areas.
Next steps to optimize your drives
An optimal operating factor (e.g., 1.75 instead of an inadequate factor of 1.25) significantly improves lifespan and reliability. We are available for individual consulting and requirement analysis to determine your service factor. Together, the appropriate solution can be developed.
