Products for rectangular force transmission

ATEK offers a wide and versatile product range as well as solutions for gearbox manufacturing and gearbox development in the field of rectangular force transmission. Our modular design system enables us to deliver customized gearboxes of highest quality for all drive-engineering challenges within a short time.

Placing orders with ATEK

ATEK gearboxes are available in many variants. When a gearbox is first ordered, we will define a unique article number. In case of follow-up orders, it is enough to specify our article number to reorder exactly the same gearbox type.

Legal classification

The gearboxes are “incomplete machines” within the meaning of the Machinery Directive. They are designed for the European market. In non-EU countries, the respective provisions must be observed. The gearbox must not be put into service until it has been ascertained, if appropriate, that the machine into which the gearbox is to be installed complies with the Directive 3006/42/EC.

Gear sets

  • Spiral-toothed bevel gear sets
  • High-quality worm gear sets
  • Gear ratios: i = 1:1 up to 83:1
  • Maximum output torque: 13,720 Nm
  • Module toothing from 0.8 up to 12.5 mm
More details

Gearbox motors

  • Type SLM – Type SL with motor
  • Nominal gear ratios: i = 10:1 up to 83:1
  • Maximum driving torque: 1765 Nm
  • Power outputs of 0.18 up to 35 kW
  • IEC standard motor
More details

Worm gearboxes

  • Robust, powerful, low-noise
  • Housing made of grey cast iron
  • Axial offset between drive and output
  • Maintenance-free
More details

Our motto is Vmax...
and not only with regard to the rotational speed of our products

Drive

Our hallmark: Excellent ability to supply

Efficient logistics: High parts availability at our locations and those of our partners

Fast and almost constant reachability

Know-how

Realisation of our high quality standards through selected, highly specialised suppliers and a qualified and experienced staff team

Our processes are subject to continuous monitoring

Our management system is certified

Performance

Whether standard or special manufacture, maintenance or advisory service… Your drive-engineering task definition is our challenge!

We set benchmarks as to reliability, dynamics, and high precision.

We stand for long-standing partnerships, loyalty and confidence.

General information on ATEK gearboxes

General information on ATEK gearboxes

“A gearbox is a machine element used to change movement parameters.
Sometimes, the change of a force or a torque plays the decisive role.
The movement to be changed is often a rotary movement.” (Wikipedia)

ATEK offers angular gearboxes of the following types that deflect the direction of a rotary movement by 90° and, if desired, also change the rotational speed and the torque.

Bevel gearboxes – types

L miniature
V with free shaft ends
VS the through-shaft is rotating fast
VL prepared for the mounting of an IEC standard motor
VLM complete with IEC motor
VC prepared for the mounting of a servo-motor

Hypoid gearboxes – types

H with free shaft ends
HC prepared for the mounting of a servo-motor

Worm gearboxes – types

S with free shaft ends
SL prepared for the mounting of an IEC standard motor
SLM complete with IEC motor
SC prepared for the mounting of a servo-motor

Designations

DESIGNATIONS USED

Drive

The shaft of the gearbox that is supplied with energy is designated as drive shaft.

Designation of gearbox sides

The 6 surfaces of the gearbox housing are designated with the numbers 1–6.
They indicate the fixing side and the installation position.

Die 6 Flächen der Getriebegehäuse sind mit den Nummern 1-6 benannt. Sie kennzeichnen die Befestigungsseite und Einbaulage.

Threaded mounting holes

All gearboxes provide many mounting options on all sides. For details, please refer to the type-specific information.

Fixing side

The fixing side is the side of the gearbox on which it is connected to the machine rack. It is important, among other things, for the determination of the arrangement of the vent filters. For details, please refer to the type-specific information.

Installation position

The installation position defines the gearbox side which is directed downwards during operation.
The information on the installation position is needed for assessing the lubricating conditions, the determination of the vent filter arrangement, and the design of the roller bearings.

Gear ratio

“In engineering, an apparatus with a gear/transmission ratio is a device which transforms the value of a physical variable into another value of the same variable where both values are in a constructively determined ratio to each other.” (Wikipedia)

For the gearboxes, the gear ratio (transmission ratio) [i] is defined as:

templ_abb_formel_groessen_x2_euro

The transmitted variables are rotational speed [n] and torque [T]

templ_abb_formel_uebersetzungsverh_x2_euro

Efficiency

The efficiency [ɲ] is the ratio of power output to power input.
The efficiencies specified in the tables can be achieved at maximum permissible rated output during continuous operation.
They are guidance values for run-in gearboxes at operating temperature with standard sealing.

Rotational direction of the shaft

The shaft’s rotational direction is always seen from the shaft end face towards the gearbox centre.

It is indicated as “clockwise” = CW or “counterclockwise” = CCW

 

 

Corrosion protection

PRIME-COATED C1 (STANDARD)

If no additional information is given, ATEK gearboxes are delivered with a prime coat of epoxy-resin based two-component paint base.

Example of order code: V 090 1:1 E0 -9.9- 700/0000

Gearbox part Material Protection Application
Housing Grey cast iron 1x prime coat Layer thickness > 40 µm
Flanges Grey cast iron or steel 1x prime coat Layer thickness > 40 µm
Shafts 1 C 45 greased

The layer thickness of the surface protection alters the fits defined in the dimensional sketches.

If fits are not to receive corrosion protection, please notify us thereof.

VARNISHED C2

Upon request, ATEK gearboxes can be varnished in standard and special colour shades.
Please enquire these.
Example of order code: V 090 1:1 E0 -9.9- 700/C2
The layer thickness of the surface protection alters the fits defined in the dimensional sketches.

If fits are not to receive corrosion protection, please notify us thereof.

Gearbox part Material Protection Application
Housing Grey cast iron 1x prime coat

1x covering varnish

Layer thickness > 80 µm
Flanges Grey cast iron or steel 1x prime coat

1x covering varnish

Layer thickness > 80 µm
Shafts 1 C 45 greased

VARNISHED C3

Upon request, ATEK gearboxes can be equipped with a paint system for the use in an environment exposed to sulphur dioxide.

Please enquire this.
Example of order code: V 090 1:1 E0 -9.9- 700/C3

Gearbox part Material Protection Application
Housing Grey cast iron 2x prime coat

1x covering varnish

Layer thickness > 120 µm
Flanges Grey cast iron or steel 2x prime coat

1x covering varnish

Layer thickness > 120 µm
Shafts 1 C 45 greased

The layer thickness of the surface protection alters the fits defined in the dimensional sketches.

If fits are not to receive corrosion protection, please notify us thereof.

VARNISHED C4

Upon request, ATEK gearboxes can be equipped with a paint system for the use in an industrial environment exposed to salt.

Please enquire this.
Example of order code: V 090 1:1 E0 -9.9- 700/C4

Gearbox part Material Protection Application
Housing Grey cast iron 1x zinc protection

1x prime coat

1x covering varnish

Layer thickness >160 µm
Flanges Grey cast iron or steel 1x zinc protection

1x prime coat

1x covering varnish

Layer thickness >160 µm
Shafts 1 C 45 greased

The layer thickness of the surface protection alters the fits defined in the dimensional sketches. If fits are not to receive corrosion protection, please notify us thereof.

ELECTROPLATED

Chemically plated with nickel.
Example of order code: V 090 1:1 E0 -9.9- 700/KB

Gearbox part Material Protection Application
Housing Grey cast iron Ni ~30 µm
Flanges Grey cast iron or steel Ni ~30 µm
Shafts Stainless steel greased

ALUMINIUM

Valid for all miniature gearboxes
Example of order code: L 045 1:1 E0 -9.9- 700/0000

Gearbox part Material Protection Application
Housing Aluminium
Flanges Aluminium
Shafts 1 C 45 greased

COATED (ANODISED)

Anodised aluminium
Example of order code: L 045 1:1 E0 -9.9- 700/EL

Gearbox part Material Protection Application
Housing Aluminium Anodised ~10 µm
Flanges Aluminium Anodised ~10 µm
Shafts 1 C 45 greased

STAINLESS STEEL

ATEK gearboxes may also be supplied in a stainless steel design.

Example of order code: V 090 1:1 E0 -9.9- 700/ESA

Gearbox part Material Protection Application
Housing Stainless steel Stainless steel
Flanges Stainless steel Stainless steel
Shafts Stainless steel greased

Protection classes

Protection class Sealing
IP 54 (Standard) Standard seal, NBR; form A
IP 56 Special seal, form AS

Other protection classes are available on request.

 

Shaft types

CONSTRUCTION TYPES

The construction types are classified by rotational direction and design of the output shaft.

Overhung-mounted output shaft A0 F0
Drive shaft and output shaft have the same direction of rotation B0 G0
Drive shaft and output shaft have opposite directions of rotation C0 H0
One continuous output shaft made of solid material D0 J0
One continuous hollow shaft at the output E0 K0

SOLID SHAFT

In the standard design, a shaft fit with the ISO tolerance field 6 is planned.

The parallel keyways of the individual shafts are aligned with each other during the assembly.
Due to the gear meshing, positional deviations may occur.

HOLLOW SHAFT

The order code of the hollow shaft design is coded with 4 characters.
The first two characters define the construction type.

Construction types Force transmission On gearbox side
E0

E1

K0

K1

K2

K splined shaft

N groove

S clamping hub

P polygon shaft

5

6

0 = (5+6)

 

STANDARD HOLLOW SHAFT E0N (K0N)

The output shaft will be constructed as a hollow shaft with the ISO tolerance field 7.
It will then be delivered with a parallel keyway according to DIN 6885, sheet 1.
(Order code E0N, K0N)
Many gearbox sizes can also be delivered with an enlarged hollow shaft bore (order code /SH).

HOLLOW SHAFT WITH SPLINED HUB PROFILE

The hollow shaft gearboxes can also be delivered with a hollow shaft with splined shaft profile according to DIN ISO 14.

(Order code E0K, K0K)

HOLLOW SHAFT WITH SHRINK DISC E0S (K0N)

The hollow shaft with shrink disc enables non-positive (frictional) transmission of the torque.
The bore of the hollow shafts is stepped for easier mounting and has a bronze bushing on the guide side.
(Order code E0S, K0S)

HOLLOW SHAFT WITH POLYGON PROFILE E0P (K0P)

The hollow shaft gearboxes can also be delivered with a hollow shaft with polygon profile according to DIN 32711.
(Order code E0P, K0P)

Lubricants

LUBRICANTS

ATEK gearboxes are factory-filled with synthetic oils.
Especially for applications in machines of the food industry and pharmaceutical industry, the gearboxes can optionally be delivered with NOTOX lubricants (order code /NT) that meet the requirements according to NSF H-1.
All lubricant designations and alternatives can be gathered from the lubricant table in chapter 12.4.

No oil change will be necessary during the gearbox lifetime if the mechanical and thermal limit ratings are observed.
The lifetime of the bearings can be increased by the factor 1.5 if the oil is changed after the first 500 service hours and then every 5000 service hours.

 

Radial shaft seal rings

The rotating shafts are sealed by radial shaft seal rings according to DIN 3761.

In the standard application, the type A made of NBR material (nitrile butadiene rubber) is used.
In a dust-bearing environment, the type AS with an additional dust lip is used.
For oil temperatures up to 130°C, shaft seal rings made of FCR (fluorocarbon rubber) can be used.

 

Gearbox data and layout

LIFETIME

In case of intended use, the lifetime of all gearbox elements will be more than 15,000 hours.
The precondition is that the layout and the operation are according to the guidelines of the catalogue.

NOISE GENERATION

The noise generation depends on many factors.
Examples are gearbox size, speed, direction of rotation, lubrication, and installation position.
Other important influences result from the installation conditions.

OUTPUT AND TORQUE VALUES

The values in the performance tables are valid for the lubrication with synthetic oils.
A lubricant temperature of 90°C is taken as a basis for the thermal limit rating.
If an exceeding of the permissible oil temperature is safely prevented by special measures (e.g. oil cooler) examination of the thermal limit rating may be refrained from.

In special cases, e.g. in case of very short operating time or only static load, an increase of the permissible torques is possible, if appropriate.

The permissible rated power inputs P1N and rated output torques T2N, which are listed in the performance tables, are valid for shock-free operation, 10 hours of daily operation period, 10 run-ups per hour.

The rated thermal outputs P1Nt and output torques T2Nt, respectively, are valid for an ambient temperature of 20°C and continuous operation.

The maximum output torque T2max may be achieved during short-time load peaks, but must not be exceeded.

The operating conditions according to the design factors are presupposed.

ON-PERIOD ED

The on-period (ED, abbrev. for German term Einschaltdauer) designates a maximum permissible operating interval of a piece of equipment after which a rest period is required in order not to damage or destroy the piece of equipment.
The rated modes are specified, inter alia, in the DIN VDE 0530-1.
The on-period can be indicated dimensionless as a percentage value (ratio of useful life to the observation period).
Generally, the utilisation period is indicated in addition to the percentage value.
If not, the utilisation period is considered to be 10 minutes.
(Wikipedia)

VDE 0530-1 operating mode
S1 continuous operation, constant load
S2 short-time operation, constant load
S3 intermittent operation without influence of starting-up phase on the temperature
S4 intermittent operation with influence of starting-up phase on the temperature
S5 intermittent operation with influence of starting-up & braking phase on the temperature
S6 continuous operation with intermittent load
S7 continuous operation with starting-up and braking
S8 continuous operation with load change

ABBREVIATIONS USED

Abbrevation [Unit]   Designation
  [N] Radial force
[N] Axial force
  [-] Actual gear ratio
  [-] Nominal gear ratio
  [kW] effective input power
  [kW] effective output power
  [kW] permissible nominal input power, mechanical
  [kW] permissible nominal input power, thermal
  [kW] corrected input power, mechanical
  [kW] corrected input power, thermal
  [Nm] input torque
[Nm] permissible acceleration torque at the input drive (servo gearbox)
  [Nm] permissible input torque in case of emergency shut-off (servo gearbox)
  [Nm] effective output torque
  [Nm] permissible acceleration torque at the output drive
  [Nm] permissible nominal output torque, mechanical
  [Nm] permissible output torque in case of emergency shut-off
  [Nm] permissible nominal output torque, thermal
  [Nm] corrected output torque, mechanical
  [Nm] maximum permissible output torque
  [Nm] corrected output torque, thermal
  [Nm] starting torque
 J [kgcm2] inertia moment
 J1 [kgcm2] inertia moment related to the fast-rotating shaft
 Jex. .red. [kgcm2] external inertia moments reduced to drive shaft
 Jmot  [kgcm2] inertia moment of the motor
 N1   fast-rotating shaft
 N2   slowly rotating shaft
 f1 [-] operating factor
 f2 [-] starting factor
 f3 [-] lubrication factor
 f4 [-] temperature factor
 f5 [-] duty-cycle factor
 fMB [-] mass acceleration factor
 n1 [rpm] speed of fast-rotating shaft
 n2 [rpm] speed of slowly rotating shaft
 tu [°C] ambient temperature
η [-] efficiency
η’ [-] efficiency in case of driving worm gear

LAYOUT

Calculation of power and torque

The following relations exist between the power (P), the torque (T) and the rotational speed (n):
P1=T1*n1

n1=n2* i
P2=T2*n2
P1: Power is input to the shaft (torque and rotational direction have the same sense of rotation)
P2: Power is taken off (torque and rotational direction have an opposite sense of rotation)
n1: Speed of fast-rotating shaft
n2: Speed of slowly rotating shaft
The following formulas apply to the (normal) case where power is input to the fast-rotating shaft
(the shaft N1 is driven): P2=P1*η
Required input power with given output torque and output speed of the driven machine

templ_abb_formel_antriebsleistung_x2

Formula 1

Available output torque with given input power and input speed of the driving machine

templ_abb_formel_abtriebsdrehmoment_x2

Formula 2

When selecting the gearbox size, it is necessary to consider the influences that the gearbox will be exposed to later.

This is done through the design factors specified below.

The transmittable power, or the torque, may be reduced by these factors!
In order to determine the gearbox size, the required input power or the output torque must be calculated by means of the operating factors.

Mechanical and thermal influences are taken account of by the formulas.

Mechanical:
P1m = P1*f1*f2*f3
T2m = T2*f1*f2*f3

The following conditions apply:
P1m < P1N
T2m < T2N

Thermal:
P1t = P1*f3*f4*f5

The following conditions apply:
P1t < P1Nt
T2t < T2Nt

Design factors (f1, f2, f3 f4, f5, f6)

Operating factor f1

Determination of load group fMB

templ_abb_formel_betriebsfaktor_x2

fMB Group Examples
< 0,25 G

low load / without shocks

Filling machines, elevators, light conveyor spirals, light conveyor belts, blowers, small agitators, inspection machines, assembly lines, machine tool auxiliary drives, centrifuges, packaging machines.
< 3,00 M

medium load / slight shocks

Reels, agitators, slat conveyors, calendering machines, cargo lifts, mixers, balancing machines, heavy conveyor belts, sheet-metal bending machines, road construction machines, planing machines, shears, extruders, machine tool main drives, kneading machines, weaving looms, light roller beds.
< 10,00 S

high load / severe shocks

Excavators, heavy mixers, presses, edge mills, rolling mills, heavy roller beds, cold-rolling mills, stone crushers, eccentric presses, cutting heads, edge-forming machines, belt conveyors (parcelled cargo/goods), barking drums, running gears, punching machines, piston pumps, rotary furnaces, mills/pulverisers, plate turnover devices.

Determination of operating factor f1

Driving machine Load group Operating hours / day
fMB <0.5 3 10 24
Electric motor G 0.80 0.90 1.00 1.25
Hydraulic motor M 0.90 1.00 1.25 1.50
Turbine S 1.00 1.25 1.50 1.75
Combustion engine G 0.90 1.00 1.25 1.50
4-6-cylinder engine M 1.00 1.25 1.50 1.75
S 1.25 1.50 1.75 2.00
Combustion engine G 1.00 1.25 1.50 1.75
1-2-cylinder engine M 1.25 1.50 1.75 2.00
S 1.50 1.75 2.00 2.25

 

Starting factor f2

Starts per hour up to 10 10-60 60-500 500-1500
f2 1,0 1,1 1,2 1,3

Lubrication factor f3

Synthetic oil Mineral oil Mineral oil
Bevel gearboxes

worm gearboxes

Worm gearboxes Worm gearboxes
All Sizes Size 040-080 Size 100-200
f3 1,0 1,2 1,25

Temperature factor f4

The factor f4 considers the influence of the ambient temperature

tu[°C] 10 20 30 40 50
 f4 0,9 1,0 1,15 1,4 1,7

Operating mode / duty-cycle factor f5

templ_abb_formel_betriebsart_x2_euro

Generally, the utilisation period is indicated in addition to the percentage value.
If not, the utilisation period is considered to be 10 minutes.

Operating mode On-period
S1 Continuous operation more than 60% of the cycle time or longer than 20 minutes
S5 Cyclic operation Here, the on-period is less than 60% of the process procedure and less than 20 minutes

Principally, the limit values for speed, torque, acceleration and temperature must be observed in all operating modes.

Ed in % 100 80 60 40 20
f5 1,0 0,95 0,86 0,75 0,56

Maintenence and starting up

For information on starting-up and maintenance, please refer to the operating instructions.
These can be found on the Internet by accessing www.atek.de/download.

There you can also find information on the Machinery Directive 2006/42 EC.