to Datasheet
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1. 1 M4 0 7 x 10 0 a M6 1 00 4X im aie eae a oS Pinion Shown Mounting M6 1 00 THRU uppiieg WISYVaSDerS x S Terence 98 013 4 00 Desp Not Included 4 Holes Located as Shown KARMA Supplied Customer Mounting Surface Details Mounting Surtace 8 Wrench See View to Right s Hex 8 mm Wrenc M6 1 0 X 20 0 5 16 12 0 2 Screws 2x Supplied M6 1 0 8 0 Dee 2 Holes Locate As Shown f 2142 86 2109 0 M5 0 8 X 16 0 8 Screws Supplied 990 0 bc 62 5 M8 1 25 4X Gearhead i bra Shoulder Cap Screw Pinion Shown Mounting Surface 125 0 i 210 013 4 00 Dee EE yep wi yyashers ior Reference 4 Holes Located as Shown M8 1 25 THRU 17 Preloader Dimensions RPS PRE ISO 110 3 Product Number 960852 Preloader Details Hex 8 mm Wrench M5 0 8 X 16 0 16 Screws M6 1 0 X 20 0 12 0 2x 6 0 Supplied T iE Min Max je 194 1 204 0 Geena Supplied Mounting Surtace See View to Right 1 I I I 1 1 I 1 1 1 i I i l i 1 1 s Zone amp M8 1 25 6X Shoulder Cap Screw Supplied w Washers 22 5 Typ lt 160 0 Pinion Shown for Reference Not Included RPS PRE ISO 140 3 Product Number 960853 Preloader Details 50 0 Hex 8 mm Wrench 12 0 x Y 6 0 M6 1 0 X 20 0 2 Screws Sup2. TNT AEN Surface 0 10 0 Dee 2 Holes Lo M10 1 50 THRU 912 013 4 13 Deep 8 Holes Located as Shown cated As Shown 30 0 15 0 LE E 123 5 87 5 2x X 2x 8752x 123 5 Y 2x 108 0 Corrosion Resistance Nexen makes no corrosion resistance claims for specific applications but does offer various corrosion countermeasures that include stainless steel and various surface treatments or coatings Nexen will convey all material and coating specifications but it is up to the customer to determine application suitability based on this information and or thorough sample testing Life Rating Pinion life is an estimate rounded down to the next 1 000 revolutions and based on maintaining published accuracy specifications when operated with allowable dynamic loading for 60 000 000 pinion revolutions or individual roller contacts 10 000 hours at a constant 100 rpm The rack and gears have their own specific life ratings depending on model and in some cases RPS size and is based on tooth contacts at allowed loads and speeds The combined pinion and rack or gear that makes up a given RPS or RPG system will have the combined life of the lower rated component and will be greatly effected by machine design RPS or RPG installation operating patterns and receiving recommended lubrication intervals while operated in a clean dry 20 C environment Pinion performance tends to be constant over its life wi
3. B esee onoma 8 Gontzct Neron enoma B Contact Neren exema B 906898 exma B 266725 otma 8 36 es E M me 20 am ao EN 49 1 See the Definitions Section on page 19 for more information on these attributes e o 2300 1908 Tao EE 1268 oo r o After choosing a gear or arc segment note the RPS size and series letter color and proceed to pages 13 14 for pinion selection 12 RPS Pinion Selection Nexen s Roller Pinions are available in shaft mount versions that use a keyless mechanical compression coupling to secure it to a shaft or flange mount versions that conform to the ISO 9409 specification The shaft mount pinions are only available in the one bore size listed Nexen recommends using the flange mount pinions when practical since they are easier to find reducers for easier to install and minimize reducer overhung load issues make for a more rigid system and allow the use of Nexen preloaders if you choose to not design your own The pinion ratings differ from some of the rack or gear ratings so the combined system would be the lesser of the two The pinions are available in B and C series and must be matched to the same series called for by the specific size of rack or gear to work properly together The rack uses B series on all sizes The gears use C series pinions on RPS sizes 16 through 25 and B series pinions on RPS32 and larger See page 14 for more inf
4. RPS Rack Model vs Size vs Thrust Capacity Table also on page 7 to determine the correct RPS size If the Premium rack model is selected due to it s corrosion resistance and ability to run without lubrication at speeds 0 5 m s or less it requires an RPS size 25 or greater If the Universal rack model is selected then an RPS size 32 or greater is required Now review the RPS Rack Size Common Specifications Table at the bottom of page seven for other limiting factors like speed life temperature range or other attributes that may effect RPS suitability The following additional calculations are optional and assume that RPS25 Premium model rack has been selected Required Pinion Torque 1 F x Meshing Pitch Circle Diameter 2000 Tp 1718 2 N x 79 6 mm 2000 68 4 Nm Pinion RPM R 60 000 x v Linear Distance Per Pinion Revolution R 60 000 x 0 5 m s 250 0 mm 120 0 RPM Motor Power Required P T x R 9549 P 68 4 Nm x 120 0 RPM 9549 0 9 kW Daily Travel Distance T Travel Distance x Cycles Per Day x 2 T 5 4 m x 1000 CPD x 2 10 800 m Estimated Rack Life L Tooth Contact Life Cycles Per Day 2 L 30 000 000 1000 2 15 000 Days Estimated Pinion Life L Pinion Revolution Life x Distance Per Rev T L 60 000 000 x 0 25 m 10 800 m 1389 Days D 1 Motor Power Required is an estimate that does not include reducer inefficiencies Estimated Life is based on the Life Rating criteria
5. based on past experience the reduction has been modest and far exceeds other mechanical drive alternatives Noise Rating The RPS system is nearly silent at low speeds and typically less than 75 db at full speed This is dependent on machine design proper RPS installation whether lubrication is used or not and is difficult to isolate from other drive train and guiding system noise so your results may vary Operating Temperature Range This is the range that the RPS system will function in Accuracy specifications are based on 20 C and thermal expansion contraction will effect the accuracy of the RPS system It is recommended the RPS system be installed at the highest temperature the system will be operated at and avoid wide temperature swings for maximum accuracy and performance For applications outside of this temperature range or with wide temperature swings contact Nexen for more information Positional Accuracy This is dependent on proper machine design and RPS product installation Positional accuracy is measured at 20 C and subject to variations due to mounting surface irregularities rigidity installation accuracy proper maintenance and ambient temperature To be conservative the RPS rack transmitting accuracy has been rounded up to the next 10 ym Other rack positional accuracy specifications have been rounded up to the next 5 um For RPG gearsets the angular accuracy rating is increased less accurate by 5 and then rounded to
6. on page 19 and going the full Travel Distance each time The combined rack and pinion system will have the life of the lower of the two Individual components can generally be replaced prior to exceeding their Estimated Life or when their performance diminishes and gaining the remaining life of the other components If travel is variable calculate each zone separately Note Always consult the RPS Rack or Gear User Manual before beginning your machine design or installing RPS product to ensure obtaining the highest possible performance and easiest installation User Manuals are available on www nexengroup com on the product pages for any of the product numbers in the left hand column under resources Selecting RPS Rack Models Sizes and Specifications RPS Rack Model Comparison Table me rome ee om SS Stainless Positional Accuracy tum 30 50 80 50 50 Corrosion Resistant Surface Treatment Hard Chrome None Nitrided None or None Hard Chrome Corrosion Resistance Rating High Very High 2 Size 40 amp 4014 2 Size 40 amp 4014 T s slay dps tede perds 5 AlOthers _ 5 All Others Lubrication Free Operation lt 30m min Noise Level db 0 75 Speed Dependent Temperature Range c Next choose the RPS size from the table below using the load requirement calculated on the previous page and the RPS rack model desired RPS Rack Model vs Size vs Thrust Capacity Table Premium Standard Endur
7. 5 Adapter Required For Some Gearhead Sizes M6 1 00 11 Screws Supplied Adapter Required For Some Gearhead Sizes Supplied Reference Surface ISO 9409 Flange Mount Pinion Screw i 0 0Fength Pinion H lj l ru ene Pilot nm f l 11 Screws Supplied Reference Surface 279 995 Supplied Adapter Required For Some Gearhead Sizes 30 18 029 e DP 7 5 Pilot Length M10 1 5 11 Screws at 30 Supplied See the Nexen engineering drawings for your specific product number for additional dimensions and tolerances 16 Pinion Dimensions RPS4014 Shaft Mounted Pinion ISO 9409 Flange Mount Pinion Pinion Adapter 116 0 Kanmun Required For Some Gearhead Sizes 88 0 gt Insertion a 74 Pilot Length Crew 11 5 le gt 35 0 2x es E eran 48 089 995 L 6 For ISO 9409 Refere 12 For Adapter Reference 8 Screws Surface 12 Screws Supplied Surface Supplied Preloader Dimensions RPS PRE ISO 064 3 Product Number 960851 Preloader Details Customer Supplied Customer Mounting Surface Details Mounting Surface Hex 3 0 i i M4 0 7 X 16 0 0 gt Wrench a ee M4 0 70 9 0 mm 2 Screws 2 25 0 2 Holes Located Supplied 8 0 as Shown 12 5 R8 0 964 0
8. 5 Q O E em Q SiS Q P w gem ex BB o o o o o ooo 3 O10 O S 5 7 6 Maximum Backlash arcsec Alignment Tool Number 966706 966615 966734 966740 Product Number Max Dynamic Torque Nm 880 Nm Arc Length Full Ring eeth internal or external external Number of Teeth segment ring 12 192 nner Diameter ID mm 330 420 460 2320 f 710 2230 Outer Diameter OD mm 494 44399 623 2248 916 239 kg 9 4 Moment of Inertia kg 12 4897 6 5 Xo 5 1 E ARS RA o S Q g e Sla Ee olol PILIES LU 2 2 3 Je ols Is e E g o e E D o 8 5 x t6 Error per Pitch arcsec 22 ee Repeatability 7 341 ee ee ee 1 1 j Maximum Backlash Alignment Tool Number Estimated Life 30 000 000 Contacts Per Tooth Operating Temperature Range C Tooth Grease 853901 1 See the Definitions Section on page 19 for more information on these attributes Per Segment I o n o 11 Gear Dimensions and Product Numbers Figure A Figure B Figure C Basic gear dimensions shown for selection purposes only and subject to change Go to www nexengroup com for detailed drawings and CAD models If none of the products below meet your needs contact Nexen and one can be designed to your specifications esser ema 8 esser enema B eseess ema B 968555 enema 8 266705 onoma B 266768 extemal
9. 64 2036 4764 Arc Length Full Ring eeth internal or external Number of Teeth segment ring 500 375 300 250 214 150 150 38 16 nner Diameter ID mm 70 120 160 190 260 652 656 1830 4444 Outer Diameter OD mm Moment of Inertia kgm 0 006 0 017 0 039 0 080 0 116 0 2607 0 329 2 300 13 285 7 arcsec gt m 3 gt Q O e 9 s 15 15 2 l 38 16 2 7 E i t t Error per Pitch arcsec Repeatability arcsec Maximum Backlash arcsec Alignment Tool Number 966557 966557 966656 966556 Yellow Yellow Product Number 966705 966614 966733 966560 966561 966562 966563 966564 966739 Ei 14 15 138 3 4 5 6 75 716 859 330 _ 410 490 6 Weight 18 26 37 53 51 22 272 267 267 7 lt E o A z o e 9 g c oO 0 oO D 8 A B mx o Bii yu Max Dynamic Torque Nm 716 859 330 410 490 660 4277 Nm 1337 1432 1719 480 660 820 980 1320 8554 Arc Length Full Ring eeth internal or external Number of Teeth segment ring 107 100 83 640 480 384 320 256 40 nner Diameter ID mm 770 906 1020 120 190 260 330 460 3640 Outer Diameter OD mm 880 1038 1120 254 331 405 481 596 3760 i kg 377 50 38 63 95 128 164 199 690 Moment of Inertia kg 83 Error per Pitch Repeatability N gt
10. AD140 BDB 180 PLFN40 PSBF621 2 PNFX450 721 2 PH A KX RPS4014 RPS40 amp 966698 960854 TP110 AD200 BDB 250 PLFN 200 PSBF721 2 N 821 2 This is a partial list Other gearheads may apply PH A KX RPS20 RPS16 amp 966688 960851 TPoo4 ADoe4 BDBos5 PLFE N 64 PSBF221 2 N A E IA IA Pinion Dimensions RPS10 Shaft Mounted Pinion RPS12 RPS50 Shaft Mounted Pinion 29 0 Minimum Shaft Insertion Reference B Surface RPS16 Shaft Mounted Pinion B 52 5 C 56 0 B 38 5 42 0 B 27 5 T 1 0 Minimum Shaft Insertion 12 0 2x 220 000 Reference Surface RPS20 Shaft Mounted Pinion B 58 5 C 62 0 B 42 5 C 46 0 Minimum B 32 0 Shaft C 35 5K Insertion gt 12 0 2x 925 000 C1 0 B 15 5 C 20 0 Reference Surface B4 31 0 Minimum Shaft Insertion ISO 9409 Flange Mount Pinion Pinion 8 M4 x 0 7 Screws Shown included for ISO Adapter 966688 es e9 0 Thru Pilot 911 995 Reference Surface B 38 5 B 11 5 C 16 5 Shaft Mounted Pinion Insertion 42 0 2 Reference Surface B4 Adapter Required For Some Gearhead Sizes o 5 2 Screw Length Supplied 1 4 M3 x 0 5 x 45 mm screws Not Shown included for use with APEX ADO47 ISO 9409 Flange Mount Pinion Pinion M5 08 at 45 B 42 5 Nexe
11. ERIAL HANDLING www nexengroup com In accordance with Nexen s established policy of constant product improvement the specifications contained in this document are subject n e e n a to change without notice Technical data listed in this document are based on the latest information available at the time of printing and are Nexen Group Inc 800 843 7445 also subject to change without notice For current information please 560 Oak Grove Parkway Fax 651 286 1099 consult www nexengroup com or contact Nexen s Technical Support Vadnais Heights MN 55127 www nexengroup com Group at the location to the right i Nexen has sales offices throughout the United States Europe Japan and Australia ISO 9001 Certified 2013 Nexen Group Inc FORM NO L 21262 C 0113
12. PRECISION MOTION CONTROL ne xcen THE ROLLER PINION SYSTEM gt gt gt Application and Selection Guide Introducing Innovative High Performance Motion Control Technology sees eeeeeettennntetnnttetnnttttnnt testet ttttnttttnsis 1 Dulce m 2 Flow the RPS Technology Works e M 3 AD DIIGATIONS ce rr PPEREERE 4 RPS Linear Drive Selection Process 2 5 oie ester ee a te teed eee ee eee ee eee ee ees 5 Models Sizes and SpeCiiCatlOnS 7 ann iicet nina dant ER HEU ko FE EEE ERE ghana anand RE ELE ore ERE 7 Dimensions and Product Numbers it oraret qe i te P a i e ne op Ee ara enh 8 RPG Rotary Drive Selection PROCESS aasiuensmciniienmunasa nma noun mein niai et m ashen aa nsu m n qn cr ERREUR DIRE 9 Standard Gears Specifications and Product Numbers sse tentent tnter tenter tete tent n tete tentes 11 Gear Dimensions and Product Numbers Pinions and Adaptors Options amp Specifications Dimensions and Product Numbers Preloaders Dimensions and Product Numb ets 5t rim ttes E d E Y eR Ru che N dE ov E a a 17 Definitions rra Sees fa Sas ca etc dat enda eat LM n AT AM IUIS AE AL IMMANE LUE 19 Introducing Innovative High Performance Motion Control Technology The Roller Pinion System Nexen offers an advanced technology that revolutionizes li
13. al Application Information Calculating RPS Requirements Based on the information on the preceding page perform the calculations listed below If the acceleration or deceleration times are different or there are other changes in velocity over the run calculate the acceleration forces for each interval and use the highest one for RPS selection purposes Actual peak acceleration from a servomotor and reducer supplier is preferred to acceleration curves based on velocity time since they may underestimate the true acceleration forces The following example assumes a single pinion driving an axis Axis driven by multiple pinions should take load distribution issues into account Load Acceleration a v t or known acceleration a 0 5 m s 0 5 s 1 0 m s Force Due to Acceleration F m x a F 150 0 kg x 1 0 m s 150 0 N Force Due to Gravity F m x g x sin degrees from horizontal F 150 0 kg x 9 81 m s x sin 60 1274 4 N Force Due to Friction F mass x p x gravity x cos degrees from horizontal F 150 0 kg x 0 01 x 9 81 m s x cos 60 74 N Total Force F F p R AF F ect F 150 0 N 1274 4 N 7 4 N 1431 8 N Total Force with Shock Factor F F x K F 1431 8 N x 1 2 1718 2 N Now proceed to the RPS Rack Model Comparison Table at the top of page 7 and determine which rack model best fits your needs Then compare the Total Force with a Shock Factor of 1718 2 N as calculated above to the rack model desired in the
14. ance Universal Stainless Dynamic Static Dynamic Static Dynamic Dynamic Static NA NA 1000 2000 1000 2000 1000 2000 750 1125 1125 0 Static Dynamic Static 2000 1125 1125 1125 1650 2700 40 6000 12000 6000 12000 6000 12000 4500 4500 4500 4014 14000 21000 14000 21000 14000 21000 10500 10500 10500 50 19000 28500 Na NA j NA j NA NA NA j NA Based on the rack model amp RPS size selected verify speed and other application parameters against the common RPS attributes below RPS Size 12 16 Eom 25 32 RPS Rack Common Specifications Comparison Table 26 0 9260 26 0 26 0 26 0 pom ls es Rack Tooth Pith mm 10 12 16 20 25 32 40 40 RekWidh mml 57 57 15 155 198 245 ers 420 420 l Rack Length mm 480 480 812 992 800 1000 800 1000 512 992 820 1000 820 Number of Rack Teeth 48 40 32 62 25 50 20 40 16 81 13 25 13 2 Rack weint kal os oe t1 21 21 41 27 64 42 82 69 122 8 170 1 See the Definitions Section on page 19 for more information on these attributes 42 0 0 1000 10 20 81 16 2 H 5 alf 00 10 8 1 0 Fu 5 7 RPS Rack Dimensions All dimensions shown in mm il C B J Rack i Thickness Ww F Diameter amp Number of Holes Refe
15. e but maintains its performance over its life until the pinion bearings reach the ends of their lives In most applications the rack or gear life will far exceed the pinion life allowing several pinion replacements restoring full rated system performance before needing replacement High Speeds The Roller Pinion System is capable of speeds as high as 11 m sec Even at these speeds the extremely low friction design does not create heat or significant wear on components High Rigidity As machine performance increases rigidity becomes more important Unlike ballscrews with their long unsupported lengths or traditional rack and pinion with their small teeth that flex fatigue and break out the RPS s robust tooth and pinion design eliminate these issues allowing maximum performance The Nexen RPS Advantage Long Life Low Maintenance and High Efficiency The RPS system uses needle bearings to support the rollers that engage the teeth This eliminates the sliding friction found in many other motion control systems and gives it an efficiency greater than 99 This high efficiency means little is lost to friction heat and wear providing a long life of 60 000 000 pinion revolutions up to 36 million meters of travel The rack or gear tooth life rating varies by product model environmental conditions and lubrication intervals Typically the pinion can be replaced numerous times before the rack or gear will need replacement In linear applications th
16. e rack can be run lubrication free if maximum speed is under 0 5 m s and Premium or Endurance models of rack utilized with a small reduction in rack life This is a great advantage in Clean Environments such as food processing pharmaceutical coating or clean room applications requiring low particle emissions Dirty Environments such as wood processing mining or grinding where particles in the environment would be attracted to and mix with the rack lubrication making an abrasive paste that can accelerate the wear rate naccessible Applications where it is very difficult and or hazardous to access machinery for periodic maintenance Modular System Nexen offers the rack in standard meter and half meter lengths that can also be cut as required Standard product lengths make the RPS available for immediate shipment eliminating the lead times required by other products and make it easy for OEMs to keep a limited amount of product on hand while covering a wide range of applications The rotary RPG system is available as solid rings up to 1 7 m diameter and segmented rings or arcs beyond this with no limits on the diameter possible Rack and arc segments are joined with a special alignment tool that uses two tooth valleys on each section to minimize the introduction of positional inaccuracy With these modular components rack runs of any length can be easily created Low Noise The pinion rollers approach the tooth face in a ta
17. er that allows the pinion to be moved up or down into the rack while keeping the pinion properly oriented to the rack The pilot in the adjuster plate accommodates common ISO 9409 servo gearhead sizes from your favorite servo gearhead manufacturer The pinion adapter allows the pinion to fit one frame size larger than it would directly mount to and is typically used for reducer availability or motor sizing reasons The preloader and adapter components utilize nickel and zinc plated and stainless steel materials for corrosion resistance Preloader ISO 9409 Roller Pinion ISO 9409 Gearhead Customer Machine Frame ISO 9409 Adapter If Required Gearhead to RPS ISO 9409 Flange Mount Pinion and Adapter Table If directly mounting the pinion to the reducer start in left most column and work across disregarding the second column from the left If going up a reducer frame size an adapter is required and you should start the selection process in the second column from the left RPS Pinion Size s z amp Adapter If Required Pinion Customer Provided Gearhead Brand Series and Size Direct Pinion Pinion with Preloader Alpha Mounting Adapter Mounting Wittenstein N RPS16 N A A N A PH A KX RPS25 RPS20 amp 966676 960850 TPO10 ADO90 BDB 120 PLFE N 90 PSBF321 2 PNFX080 421 2 PH A KX RPS32 RPS25 amp 966674 960852 TP025 AD110 BDB 145 PLFE N 110 PSBF521 2 PNFX250 521 2 PH A KX RPS40 RPS32 amp 966668 960853 TPO50
18. fatigue free high efficiency rotary to linear or rotary to rotary motion conversion The RPS tooth design is conceptually different from traditional gearing It behaves like a cam and follower versus the typical sliding spur gear used with traditional rack and pinion or gear sets As illustrated in the figures below a cycloidal curve is created when a point drawn on a circle at point P rolls on a flat plane to point P without slipping When multiple points are placed on the circle at regular intervals the cycloidal curves are repeatedly created on the flat plane and develop into a tooth like profile A roller then is placed at each point P to act as pinion teeth and modifies the tooth profile to create the rack teeth Normally this concept will not provide zero backlash but a technical innovation was developed to modify the tooth geometry allowing two rollers to remain loaded in opposition at all times eliminating the backlash as the rollers engage the teeth The rollers meet the tooth with a tangent path and smoothly roll down the tooth face This eliminates tooth slap sliding friction fatigue noise and low precision associated with traditional gearing Rollers in Opposition Rotary to Linear Transmission Precision The variations shown in the graph below represent minor errors occurring throughout the pinion s travel The individual waves indicate each roller tooth meshing error and larger wave patterns show pinion rotational error A
19. n Supplied 3 5 Pilot Length 7 0 Screw gt gt weal 3 4 Bolt Head Protrusion B 15 5 C 20 0 219 995 4 L x Adapter Required For Some Gearhead Sizes lt Pilot Length 5 5 Supplied Reference LE Surface Reference amp Surface B Screws for Adapter Mount 7 Screws for Direct Mount Note Blue values are for B series pinions used with rack and size 32 or larger gears Yellow C series pinions with size 25 amp smaller gears See the Nexen engineering drawings for your specific product number for additional dimensions and tolerances 15 Pinion Dimensions RPS25 Shaft Mounted Pinion B 67 5 C 54 0 Minimum aft Ok Insertion 14 0 2x C 24 0 Surface Shaft Mounted Pinion 885_5 lt 68 5 gt Minimum 51 0 gt Insertion le 20 0 2x C1 0 176 0 245 0 y Reference Surface RPS40 Shaft Mounted Pinion 96 5 88 0 Minimum aft Insertion f f 1 Reference Surface ISO 9409 Flange Mount Pinion Pinion B 49 5 C 54 04 lt _ 89 Screw 14 0 Length M6 1 00 6 Custom Screws 45 Supplied 2x Surface ISO 9409 Flange Mount Pinion Pinion Screw Length lt 8 3 Pilot 949 99
20. n the specifications table on page 13 for the RPS16 pinion is 1500 RPM and the gear ratio on page 11 7 1 Therefore the application RPM w x Gear Ratio x 9 55 2 39 rad sec x 7 x 9 55 159 8 RPM so the RPG16G 7 1 gear system is an acceptable choice Compare selected gear set accuracy with the application requirements The RPS25G 7 1 gear set is rated for 40 arcsec which is more precise than the required 60 arcsec so is acceptable If the application requirements call for a more powerful or larger diameter gear set than the listed offerings contact Nexen to evaluate possible RPS custom gear sets Note Always consult the RPS Rack or Gear User Manual before beginning your machine design or installing RPS product to ensure obtaining the highest possible performance and easiest installation User Manuals are available on www nexengroup com on the product pages for any of the product numbers in the left hand column under resources 10 Standard Gears Specifications and Product Numbers Based on the previous calculations choose the gear below that meets or exceeds your requirements If none are a good match Nexen can create one tailored to your needs Yellow Product Number 966550 966551 966552 966553 966554 966667 966657 966655 966555 Gear Ratio 4 5 6 7 15 15 110 140 160 36 36 72 1 a 3 4 40 Max Dynamic Torque Nm 70 90 110 160 Max Static Torque 140 180 220 280 320 764 7
21. near and rotary motion control The Roller Pinion System RPS is based on an innovative pinion consisting of bearing supported rollers and a unique tooth profile This unique drive system provides very high positional accuracy near zero backlash virtually no cumulative error low velocity ripple unlimited length very high speeds high rigidity low noise low in some cases no maintenance corrosion resistance long life and 9996 efficiency This opens up new machine design possibilities and provides the capability to achieve much higher levels of performance High Positional Accuracy The RPS system is capable of positional accuracy up to 30 um and repeatability of 5 um at its meshing line or circle Near zero backlash of less than 3 2 um is achieved by multiple rollers engaging the rack or gear teeth in opposition at all times Due to the very high manufacturing precision of the RPS system and the special section joining tool cumulative error is virtually nonexistent over any rack run length or segmented gear diameter The RPS system also provides very low velocity ripple for applications where uniform motion is essential This allows for high precision linear or rotary systems of any size that can rely on the servo encoder for positioning without the need for separate linear or rotary encoders in many applications Unlike many other drive technologies the RPS system s positional accuracy does not start to degrade progressively after a short tim
22. ngent path and then move smoothly along the face of each tooth This reduces noise levels often associated with other motion control systems like tooth slap or ball return noise Product Options The RPS rack is available in five models Premium Endurance Standard Universal and Stainless Steel Universal Each offers performance characteristics and price to suit a wide range of applications Some pinion and rack models are available with corrosion resistant surface treatments and or made from 17 4 stainless steel for difficult applications Pinions are available in shaft mount with a keyless mechanical compression coupling or ISO 9409 flange mount versions for optimal machine design flexibility The RPS ISO 9409 flange mount pinions make reducer selection and mounting easier allows the use of Nexen pinion preloaders and gives maximum system performance Overcomes the Limitations of Other Motion Control Technologies The RPS s unique design eliminates many of the problems found in these other commonly used drive systems e Batt Screws Limited by Length maximum speed cumulative error rigidity and thermal expansion Also suffers from noise vibration particle emissions low efficiency and life high maintenance and can require liquid cooling in demanding applications e TRADITIONAL Rack amp PINION OR GEAR Systems Limited by Backlash low accuracy speed and life Positional accuracy continuously degrades due to tooth wear Continuous lubrica
23. ormation on the flange mount ISO 9409 system 400 _ 4 0 6 0 818 4000 9 5 14 3 Nickel Flnge N A O8 40 50 9 N N ojo N Stainless Flange N A 0 8 40 o Nickel Flange N A O9 42 Nickel Shaft 20 08 412 200 63 7 e Nickel Flange N A 68 1680 Stainless Fange N A 68 1680 Ds Nickel Shaft e0 124 5940 Stainless Shaft 60 124 5940 E CNE AN A On RN E Oo N oo o on 458 4 916 8 Nickel Shaft 60 20 9 1180 0 Stainless Shaft 60 20 9 11800 Shaft 60 000 000 Revolutions or atina Terit 5 to 40 OON GICA 853901 Contacts per Roller ae EE ES Pinion torque is for reference only Some rack models are not rated for full pinion torque Hard Chrome is an alloy steel with a thin dense hard chrome coating Nickel is an alloy steel with a nickel plating and Stainless is stainless steel with or without a hard chrome coating Other corrosion resistant options available upon request 3 See the Definitions section on page 19 for more information on these attributes 13 12478 1871 6 A A 1815 2721 ISO 9409 Flange Mount Pinion And Preloader Nexen s RPS ISO 9409 flange mount pinion and pinion preloader simplifies the integration of the RPS rack or RPG system gear into your machine design and gives the highest level of performance The preloader has high precision ground surfaces and an adjust
24. plied M6 1 0 X 20 0 24 Screws Supplied pa Min Max _ 239 6 2 d PN M8 1 25 8X Shoulder Cap Screw 185 0 gt Supplied With Washers Preloader Details Hex 8 mm Wrench M6 1 0 X 20 0 2 Screws Supplied 9233 0 Am aX 140 0 294 1 304 0 M12 1 75 Shoulder Cap Screws 8 Supplied w Washers 1 3 s A o 1 KW 2 Typ I 250 0 1 25 X 20 0 24 Screws Supplied 14 0 70 He mH cone Supplied Mounting Surface See View to Right l i Ukra 3 he be 3 3 I Gearhead amp Pinion Shown for Reference Not Included Customer Supplied Mounting Surtace See View to Right ra i Gearhead Pinion Shown for Reference Not Included 18 Customer Mounting Surface Details M6 1 0 8 0 Dee 2 Holes Located As hown M8 1 25 THRU 210 013 4 00 Deep 6 Holes Located as Shown Mounting Surface 1 lt 70 0 gt 1 Se 9 lt 40 0 gt Customer Mounting Surface Details M6 1 0 10 0 Deep 2 Holes Located As Shown Mounting Surface M8 1 25 THRU 210 013 4 00 Deep 8 Holes Located as Shown 30 0 15 0 gt aH Customer Mounting Surface Details 34 Max M6 1 0 O 03 1 85
25. rence Chamfer Surface 4X Bottom 4 A Half Rack Full Rack 50 50 See drawings or CAD models on Nexen s website for your specific product numbers for additional dimensions and tolerances RPS Rack Product Numbers 966507 986775 O Alignment Tool 966775 853901 Next choose the RPS rack product numbers based on the size and model determined in the previous steps RPS10 B Series Blue Pinions RPS 12 B Series Blue Pinions RPS16 B Series Blue Pinions RPS20 B Series Blue Pinions RPS25 B Series Blue Pinions RPS32 B Series Blue Pinions RPS40 B Series Blue Pinions RPS4014 B Series Blue Pinions RPS 50 B Series Blue Pinions Now proceed to page 13 to select the Blue B series pinion to use with the chosen RPS rack size and model 8 RPG Gear Selection Process Proper RPG size selection requires the application data listed below These specifications are needed to determine load mass angular acceleration torque due to acceleration gravity friction and total torque required Sample calculations are shown to calculate the RPG size for your application Typical Friction Coefficients u Rolling Bearing 0 005 0 02 Sliding Bearing 0 1 0 2 Shock Factor K Application Example Programmable electronics assembly indexing table 1 meter in diameter 8 stations equally spaced 60 indexes per minute desired Dwell time 0 33 sec Additional information below Applica
26. s At s i Customer Calculations Ring Gear Torque Ta Nm I kg m x a rad s To 10 kgm x 7 25 rad s 72 50 Nm Ring Gear Torque with Shock Factor 1 Nm t x K t 72 50 Nm x 1 2 8700 Nm K Pinion Thrust Required At Max OD N 2 T Max OD mm x 500 eus N 87 00 Nm 400 mm x 500 108 8 N ax K Pinion Thrust Required at Min ID T N 8700 Nm 200 EDO AEN ey N T Min ID mm x 500 pain VM 9f ms mmx TaN Compare the pinion thrusts calculated above with the Premium Rack Model s Dynamic Thrust Ratings at the far left of the RPS Rack Model vs Size vs Thrust Capacity Table table on page 7 since gear performance is based on Premium rack performance You will see that an RPS16 system rated at 1000 N can satisfy either extreme In some applications different RPS sizes may be required at the extremes The trade offs of cost speed and accuracy and gear availability may need to be evaluated to find the optimal solution Larger diameter gears will give better angular accuracy and possibly a smaller RPS size where smaller diameter gears will give a higher RPM and generally a lower cost Now compare the Ring Gear Torque calculated above to the RPG16 Max Dynamic Torque row in the specifications table on page 11 From this we see that the RPS16G 7 1 has more than enough torque and meets the ring gear ID and OD envelope requirements Next verify that maximum pinion RPM is not exceeded The maximum pinion RPM listed i
27. s the horizontal limits illustrate there is no cumulative error This pattern continues regardless of distance even when crossing joints due to the way the RPS alignment tool transfers the system accuracy from section to section 60 40 Positional Error um 0 100 200 300 400 500 600 700 800 Distance Traveled mm Regardless of the distance traveled positional accuracy remains constant with the RPS System Applications Gantry Router Robotic Arm Indexer Rotopod Additional RPS and RPG Applications Medical Imaging Welding Gantries Measurement Systems Wood Cutting amp Shaping Material Handling Clean Rooms Machine Tools Food Processing Vacuum Environments Plasma and Laser Cutting Multihead on a Common Axis RPS Linear Drive Selection Process Proper RPS model size selection requires the application data listed below These specifications are needed to determine load mass load acceleration force due to acceleration gravity friction and total force of the load See page 6 for sample calculations to determine the correct RPS size for your application Typical Friction Coefficients u This curve will select Profile Guide Rail 0 005 the smallest RPS size Ball Bearing Guide Rail Velocity X i Polymer Bushing Guide F F2 etc Bronze B
28. th a rapid deterioration at the end of life as the needle bearings supporting the rollers fail Rack wear is more linear over its life Application and environmental conditions and lubrication intervals will impact expected product life Depending on the length of the rack or diameter of the gear and usage patterns it is often possible to replace the pinion several times restoring full system performance before the rack or gear would need replacement if the pinion is replaced before reaching the point where its failure starts damaging rack or gear teeth Lubrication Free Operation In some cases the RPS rack can be operated without lubrication on the rack teeth or pinion rollers This is dependent on the specific rack model and the maximum speed being less than 30 m min The no lubrication option generally applies to rack that has received a surface treatment and does not apply to bare steel models of rack or any gearing See specifications for the specific rack model you are considering to know if this is possible Operating without tooth roller lubrication will reduce tooth life but can be beneficial in food pharmaceutical clean room and other applications where the grease could contaminate the environment or applications with high levels environmental contaminates that would be attracted to the grease and accelerate the wear rate Nexen can not calculate a life rating when running without lubrication due to the number of variables that impact life but
29. the next whole number except in the case of very large gears where rounding may be fractional This allows customers to achieve Nexen accuracy ratings with reasonable effort Higher performance can be obtained if machine design and tolerances are optimized Backlash The innovative design of the RPS tooth allows for a true zero backlash drive system As with any high precision component proper setup and installation is critical Following Nexen s recommended installation procedures practices and tolerances ensures proper performance of your RPS drive components The backlash rating is measured upon setup at the point of preload Series The RPS and RPG pinions racks and gears are made in different series thicknesses depending on the specific product and should not be mixed when matching a pinion to a given rack or gear Series A pinions discontinued are interchangeable with C series pinions and have a wider body with longer rollers than the B series pinions The current rack products only use B series pinions and the gears could use either depending on the RPG size B series pinions will not physically fit on a C series gear and a C series pinion would be compromised if used on a B series rack or gear due to a higher bending moment on the rollers which would reduce their lives 19 CUTTING SYSTEMS GANTRY SYSTEMS zi p 07 180 5 10 DIVIO RS INO 10 03 AEROSPACE MAGHINE TOOL SEMICONDUCTOR INDUSTRIES amp APPLICATIONS MAT
30. tion Data Weight to be Driven W I kgm IPR seconds Rotational Moment of Inertia R Index Time ndexes Per Revolution It or Known Angular Acceleration 0 preferred Dwell Time dt Shock Service Factor K see table above Coefficient of Friction p Other Forces F F etc Angle Gear Rotates Relative To Horizontal Plane rad sec z 3 i 2 Maximum Allowable Ring Gear OD Minimum Allowable Ring Gear ID Ring Gear Tooth Orientation External Internal Required Angular Positional Accuracy P tarcsec 1 Weight to be Driven should include everything in motion Shock Factor indicates the smoothness of operation ndexes Per Day This curve will select the smallest RPG size N Velocity a 10800 RPD Other Forces may include gravitational forces if rotation is not in the horizontal plane with imbalanced loads springs counter balances fluid dampening systems wind resistance etc Selecting an RPG Gear Set If the acceleration or deceleration times vary or there are other changes in velocity calculate the acceleration torque for each interval and use the highest one for RPG selection purposes Application Calculations Acceleration Time Fu s It s 2 A 0 66s 2 0 33s Rotation Per Index EPROR 0 rad 277 IPR 2nr 8 0 ra Max Angular Speed 0 79 rad 0 66 s x 2 2 39 rad Angular Acceleration 2 39 rad s 0 33 s 7 25 rad s a rad s rad
31. tion is required to slow the wear rate and creates a mess that can be a problem in many applications They also suffer from noise vibration particle emissions velocity ripple and tooth fatigue Backlash is a problem unless expensive dual pinion or split pinion systems are employed but they drive up the cost greatly and accelerate wear e Bett Drives Limited by Low load capacity accuracy rigidity length and life Also suffers from backlash belt stretch particle emissions and chemical attack e Chan Drives Limited by Backlash limits positional accuracy meshing is noisy and can cause vibration that can effect control systems and tend to have high wear and maintenance due to stretch and lubrication requirements e Linear Motors amp Direct Drive Rotary StaGes Limited by Low load capacity and efficiency high cost strong magnetic fields and liquid cooling in demanding applications Typically is very expensive especially with long runs or large diameters 2 How the RPS Technology Works The RPS system achieves its incredible performance by using a pinion consisting of bearing supported rollers that engage a unique tooth profile Two or more rollers engage the teeth in opposition at all times eliminating backlash There is no tooth slap as with traditional rack and pinion or gearing instead the RPS rollers approach the tooth face in a tangent path and then roll smoothly down the tooth face This provides a smooth quiet low friction
32. ushing Guide Shock Factor K 0 D groas v Shockless Smooth Operation R Horizontal Normal Operation Operation with Impact Operation with High Impact Weight to be Driven W kg 150 0 kg Maximum Velocity v ms O5ms J Acceleration Time t seconds 0999 0 000000 or Known Acceleration preferred m s Shook Factor sesubeatne aa Other Forces F Fete N ON L Fiional Cocfcent i swiaiewow 9 Angle from Horizontal 0 OP Teana o S OO Cycles Per Day 000 1 Weight to be driven should include all drive components and structures being moved If the axis is driven by more than one RPS system and has a movable or asymmetric mass the load distribution s effect on the load each pinion must carry must be taken into account For example an X amp Y axis gantry where the Y axis shifts on the X axis causing the mass the RPS systems on each side of the X axis to see to vary or other similar situation Acceleration based on time is linear and may not be representative of actual curve A known acceleration from the servo drive provider is preferred 2 Shock Factor indicates the smoothness of operation Other Forces may include cutting forces springs counter balances fluid dampening systems wind resistance etc 5 Cycles Per Day assumes going the full Travel Distance and returning to home each time Gener
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