technical instruction of apex rack and pinion instruction of apex ra… · technical instruction of...

Technical Instruction

of

APEX Rack and Pinion

Confidential! For APEX Agents only!

APEX DYNAMICS, INC.

2017.04.

Content

1

1. General Instruction of Rack

2. Physics and Technology of Rack

3. Quality Policy of APEX Rack

4. Introduction of Induction Hardening

5. Specification of APEX Rack

6. General Instruction of APEX Pinion

7. Selection of Rack and Pinion

2

5

20

27

41

71

86

Page

1. Trend in Industry (especially Automation and CNC machine tools)

1-1. Function of the rack switches from pure movement or power transmission

over to accurate positioning, even without optical scale or linear scale.

1-2. Replacement of ball-screw

Moving speed on the rack is much higher than that on the ball-screw.

A long ball-screw tends to hang down in the middle part which is

unfavorable for a smooth and high-speed movement.

Rack can be connected to any length while the ball-screw length is limited.

While the ball-screw hangs only via both ends in the machine, rack is fully

fixed on the machine bed, so less influence by thermal expansion.

By racks, it’s easier to apply lubrication and rack has a longer life-time.

2. Requirement from Industry

High precision, high speed, high rigidity, low noise, wearing resistance


2


3

Module Number of Rack

Pitch

Circle

Pitch d

Pitch

z = Teeth No.

d = Pitch Circle Diameter

Module No. M = d / z

Pitch P = (d x π) / z = π x M

4

Pitch of Rack


θ

PitchHelical

PitchStraight

PitchHelical Cos θ

θ = 19°31’42” (19.5283°)

PM3 H Cos (19.5283°)

PM3 S

Cos (19.5283°)

π x 3

10.000014 mm

PitchStraight

PitchHelical

5

Physics of Long Metal Bar

Thermal Expansion 1°C difference the 1000mm length

metal bar changes ~ 12 μm.

Machining on Teeth

& Sides

Inducing heat and internal tension,

leading to deformation and torsion

Teeth on one Side Asymmetry in geometry,

leading to deformation and torsion

Heat-Treatment and

Induction Hardening

Leading to deformation and torsion

Important requirement of high precision rack :

Geometrical Accuracy

Heat-Treatment and Hardening Process

Geometrical tolerance of high precision rack = ~10 μm


6

Requirement and Reason Technology needed

Good Straightness, Less Torsion

• Influence the accuracy of pressure angle, helical

angle and pitch error

• Influence the gear coupling with pinion

• To avoid re-straightening work after long-term

stock due to slowly out-let of internal tension

Heat-Treatment

Straightening

Machining on all sides

Teeth milling and grinding

Teeth induction hardening

Quality of Rack / Geometry

τ L

L

q


7


Measurement in Free Position Measurement in Fixed Position

Quality of Rack / Straightness

By

20°C

!!

8


Quality of Rack / Straightness

1000 mm Rack Q4 ~ Q6 Q6M Q8 ~ Q9 Q10

Free Fixed Free Fixed Free Fixed Free Fixed

M1 ~ M2, milled - - 0.45 0.04 0.45 0.05 0.5 0.08

M1 ~ M2, ground 0.4 0.02 - - - - - -

M3 ~ M6, milled - - 0.45 0.04 0.45 0.05 0.5 0.08

M3 ~ M6, ground 0.3 0.02 - - - - - -

M8 ~ M12, milled - - 0.45 0.04 0.45 0.05 0.5 0.08

M8 ~ M12, ground 0.25 0.02 - - - - - -

APEX declares : (mm)

9


Good Parallelism and Perpendicularity

• Influence the accuracy of pressure angle, helical

angle and pitch error.

• Influence the gear coupling with pinion.

Heat-Treatment

Straightening






Quality

Cross-Section

Q4 / Q5H / Q5 Q6 Q6M Q8 / Q9 Q10

＞10 ~ 16 0.004 0.006 0.006 0.010 0.015 0.025 0.025 0.040 0.040 0.060

＞16 ~ 25 0.005 0.008 0.008 0.012 0.020 0.030 0.030 0.050 0.050 0.080

＞25 ~ 40 0.006 0.010 0.010 0.015 0.025 0.040 0.040 0.060 0.060 0.100

＞40 ~ 63 0.008 0.012 0.012 0.020 0.030 0.050 0.050 0.080 0.080 0.120

＞63 ~ 100 0.010 0.015 0.015 0.025 0.040 0.060 0.060 0.100 0.100 0.150

＞100 ~ 160 0.012 0.020 0.020 0.030 0.050 0.080 0.080 0.120 0.120 0.200

(mm) APEX declares :

10


Accurate Pressure Angle α and Helical Angle β

• Optimizing gear-coupling with pinion

• Optimizing transmission of torque or feed force

• Good for high speed, low noise, less wearing,

longer life-time

Heat-Treatment

Straightening




Right-hand helical Left-hand helical

β α

α = 20°

β = 19°31’42” (19.5283°)

or 0° (straight teeth)

Standard



11

Why the Helical Angle = 19°31’42” (19.5283°) ??

PitchHelical

β

PitchHelical

PitchStraight

PitchHelical Cos β

β = 19°31’42” (19.5283°)

PH M3 Cos (19.5283)

PS M3

Cos (19.5283)

π x 3

10.000014 mm


Teeth No.

PH M6 = 20.00003 mm x 50 = 1000.0015 mm

PH M12 = 40.00006 mm x 25 = 1000.0015 mm

PH M2 = 6.66668 mm x 150 = 1000.0020 mm

PH M4 = 13.33335 mm x 75 = 1000.0013 mm

PH M8 = 26.66670 mm x 36 = 960.0012 mm

PH M5 = 16.66669 mm x 60 = 1000.0014 mm

PH M10 = 33.33338 mm x 30 = 1000.0014 mm

12


Accurate Over Pin Height H

• A measure of accuracy of teeth profile


• Influence on backlash between rack and pinion

Heat-Treatment

Straightening






＊ Pin Diameter depending on Mn.

Mn = 3 H

＊

13


Low Single Pitch Error Es

Low Total Pitch Error Et

• High positioning accuracy


• Low noise, less wearing, longer life-time

• Influence on backlash

Heat-Treatment

Straightening





Total Pitch Error Et is to be measured between the first and the last tooth of a rack.

Ps Ps Single Pitch


14


Rigidity / Material Hardness

• High strength of rack / High strength of teeth

• No deformation during gear coupling with Pinion

• Transmission of high torque or high feed force

• High speed, less wearing, long life-time

Heat-Treatment


F

Torque

Quality of Rack / Heat-Treatment and Hardness


15


High Surface Hardness Hs

• High strength of rack / High strength of teeth

• Transmission of high torque or high feed force

• High wearing resistance

Heat-Treatment

Induction hardening

Teeth grinding Thickness of Hardened-Layer L

• Preserve accuracy and long lift-time

Symmetry of Hardened-Layer on teeth profiles

• Preserve accuracy and long lift-time in both

moving directions on the rack



Hs Hs

L

Bad Induction Hardening

Bad Teeth Grinding

Unqualified !!

16


Low Surface Roughness

• Low noise / High speed

• Low wearing / Long life-time

Induction hardening

Teeth grinding



(μm)

Profile Lead

Quality Q4 ~ Q6 Q6M Q8 ~ Q9 Q10

Lead Ra ≤ 0.5 Ra ≤ 0.5 Ra ≤ 1.0 Ra ≤ 1.6

Profile Ra ≤ 1.0 Ra ≤ 1.0 Ra ≤ 3.0 Ra ≤ 6.3

Side Ra ≤ 1.25 Ra ≤ 2.0 Ra ≤ 2.0 Ra ≤ 2.0

APEX declares :

17


Low Remaining Magnet

• Prevent adhesion of particles between the rack

and pinion leading to pitting and damage the teeth.

• Smooth running

• Preserve accuracy and long lift-time

Degauss Device

Quality of Rack / Rest Magnet


Magnet

Particle Particle

Each APEX rack has been

degaussed down to under

10 ± 3 Gauss before delivery !!

18


Magnetic Crack Inspection

• Preserve accuracy

• Guarantee of long life-time

Magnetic Crack Inspection

Device

APEX rack has been check by

Magnetic Crack Inspection!

Quality of Rack / Rest Magnet


19

Quality of Rack


All the requirements mentioned above are aiming to :

High Positioning Accuracy

High Speed Low-Noise Transmission

High Torque and Feed Force

Long Life-Time


APEX is the ONLY ONE rack manufacturer in the

world who defines explicitly and clearly :

The geometrical tolerance in the engineer-

ing drawing and in the QC-standard

(for all dimensions, helical and pressure

angle, straightness, parallelism and

perpendicularity…)

The surface roughness of the teeth

The hardness and thickness of the hardened

layer on the teeth

20

21


Declaration of Tolerance in Catalog

** All measurements to do by 20°C

** Total Pitch Error shown per 1000 mm

22


Declaration of Tolerance / Angular Deviation

Length Deviation

Angular

Deviation

Angular

Deviation

Length Deviation

Declaration of Tolerance / Angular Deviation

Pressure Angle Helical Angle

23

Declaration of Tolerance / Over-Pin-Height Deviation

＊ Pin Diameter depending on Mn.

Mn = 3

H

＊

H

H


OPH = a measure of the precision of teeth

24

Declaration of Tolerance / Over-Pin-Height Deviation Error Demo !!


(1) To mill or grind the back side of rack after the teeth grinding, in order to

achieve the exact Over-Pin-Height,. Incorrect way !!

d

H H

d OPH OK, Teeth OK OPH OK, Teeth error

(2) To mill or grind the back side of rack, the top

of teeth would be taken as reference surface.

The teeth tops are NOT ground simultaneously

with the teeth profile, hence the OPH is still NOT

correct in this way.

25

Declaration of Tolerance / Single Pitch Error

PitchHelical

Single Pitch Error

PitchStraight

Single Pitch Error


26

Declaration of Tolerance / Total Pitch Error (per 1000mm)

Total Pitch Error

Total Pitch

Total Pitch Error

Total Pitch

The 1st Tooth The last Tooth


27

Declaration of Tolerance

Example: Application in CNC Machine Tools or other high

precision transmission system

Only with high precision rack, it is possible to do a compensation

or correction during the machining process.

About the precision, the other rack manufacturers in the world

declare only Total Pitch Error and rarely Single Pitch Error.

They never declare clearly all about :

The Tolerance of the Dimensions and Geometry

The defined Straightness, Parallelism and Perpendicularit

The Helical Angle and Pressure Angle with Tolerance

Surface Roughness of the Teeth

Defined Hardness and Thickness of the Hardened Layer

on the Teeth.


Mn ≦ 4 Scanning Induction Hardening

Induction

Annealing

4. Introduction to Induction Hardening

Heating with induction coiler

hanging over the rack, temperature

up to 900°~1000°C, then rapid

cooling (quenched) by water shower.

Heating with ~300°C, to adjust

the hardness and to optimise the

metallographic structure.

28

29


Heating from above

Pitch line

Hardness

Hard

Soft

Gear coupling area with

pinion must be hard !


30


Induction

Heat treatment Surface Effective

Hardness (HV) 550 ± 40 440 ± 32

For each Module No., the L is well

defined as the lower limit of the

Effective Hardness.

L

L

Hardness Curve

Upper limit Lower limit


Eng. Drawing

Measurement

31


Thickness of the hardened layer not enough.

Unqualified !!

Pitch line


32

Unqualified Qualified

Cross-Section


Gear coupling area

Effective hardness


33

In order to achieve the thickness of hardened layer, the heat must be induced

into the depth of material. By heating from above (scanning), the top and

surface of teeth can be overheated, even melded.

Decarburization can happen and the metal structure becomes porous.

Porous !


34

Metallographic Analysis of Decarburization

Standard Overheated Coarse Grains

Brittle / Crisp

Reduced Strength

Easy damage on the

tooth profile or even

break up.


35

Mn ≧ 5 Contour Induction Hardening (Tooth-by-Tooth)


36

induction

Heat treatment Surface Effective

Hardness (HV) 550 ± 40 440 ± 32


LLeft

LRight

Hardness Curve

H

L


37

Cross-Section


> 80% area Effective hardness


38

Carburized Induction

After Carburizing After Carburizing

and Induction

Induction


39

Carburized Induction

(Before Annealing)

LLeft

LRight

Hardness Curve


After Carburizing

and Induction

H

L

40

Symmetry after Induction Hardening

and Teeth Grinding

Carburizing and Induction Contour Induction


41

Bad Example !

Bad

induction

hardening

Bad induction

hardening and bad

teeth grinding.

Symmetry after Induction Hardening

and Teeth Grinding


Carburizing and Induction Contour Induction

42


Heat-Treatment: Case-Hardening / Carburizing / Normalizing /

Annealing / Induction / Q&T / Solution

Teeth and Sides: Milling / Grinding / Polishing

Material: Carbon Steel / Alloy Steel / Q&T Steel / Stainless Steel

Coating: Nickel Plating / Phosphate Film / Blackening

Quality: Q4 / Q5H / Q5 / Q6 / Q6M / Q8H / Q8 / Q9 / Q10

43


No international Rack Standard in the world

No DIN, only Quality !!

Very rack maker sets his own Quality standard.

Q6 of Maker A = Q6 of Maker B ??

APEX design and produce the rack according to the

DIN Standard of Gears and Pinions !

44

Specification of APEX Q8

APEX

Material Carbon Steel

Heat-Treatment Normalizing

Teeth Milled

All Sides Milled

Total Pitch Error

(mm/1000mm)

0.065 mm ~ 0.09 mm

(M1) (M12)

Carbon Steel with Normalizing Heat-Treatment

Finer Homogenous Grains

Outlet of Internal Tension

Higher Strength

Higher Feed Force / Torque


45

APEX Q8 vs. ATLANTA Q9 *

APEX ATLANTA

Material Carbon Steel S45C

Heat-Treatment Normalizing None

Teeth Milled Milled

All Sides Milled None (Bright Steel)

Total Pitch Error

(mm/1000mm)

0.065 mm ~ 0.09 mm

(M1) (M12)

≦ 0.150 mm

(M=?)

Advantage ** Higher Torque and Feed

Force, Higher Accuracy


= Cold Drawn of metal bar.

Internal tensions remained in material, leading to

deformation. Morover, no machining on side-

surfaces bad accuracy.

* Comparison made basing on production

process, not necessarily on quality Q.

** Comparison made ONLY for Total Pitch

Error. No other ATLANTA data could be

found for comparison.

46

APEX ATLANTA

Material Carbon Steel S45C / 42CrMo4

Heat-Treatment Normalizing Induction / Q&T

Teeth Milled Ground / Milled

All Sides Milled None (both Bright Steel)

Total Pitch Error

(mm/1000mm)

0.065 mm ~ 0.09 mm

(M1) (M12)

0.060 mm / 0.100 mm

Advantage Higher accuracy on teeth, but

worse on the sides.

Higher wearing resistance


APEX Q8 vs. ATLANTA Q8 (Teeth hardened & ground)

47

Specification of APEX Q8H

APEX

Material Alloy Q&T Steel

Heat-Treatment Quenched and Tempered

Teeth Milled

All Sides Milled

Total Pitch Error

(mm/1000mm)

0.065 mm ~ 0.09 mm

(M1) (M12)

Advantage

Application High Rigidity

For without Back-Support


With Back-Support

Without Back-Support

48

APEX ATLANTA

Material Alloy Q&T Steel S45C / 42CrMo4

Heat-Treatment Quenched and Tempered Induction / Q&T

Teeth Milled Ground / Milled


Total Pitch Error

(mm/1000mm)

0.065 mm ~ 0.09 mm

(M1) (M12)

0.060 mm / 0.100 mm

Advantage Higher accuracy


APEX Q8H vs. ATLANTA Q8 (42CrMo4)

49


APEX


Heat-Treatment Induction on Teeth (of Q8)

Teeth Milled

All Sides Milled

Total Pitch Error

(mm/1000mm)

0.146 mm ~ 0.202 mm

(M1) (M12)

Advantage Higher wearing resistance

Lower accuracy


50

APEX Q10 vs. ATLANTA Q10

APEX ATLANTA


Heat-Treatment Induction on Teeth Induction on Teeth

Teeth Milled Milled

All Sides Milled Milled

Total Pitch Error

(mm/1000mm)

0.146 mm ~ 0.202 mm

(M1) (M12)

0.200 mm



51


APEX ATLANTA

Material Stainless S45C

Heat-Treatment Solution None

Teeth Milled Milled

All Sides Milled None (Bright Steel)

Total Pitch Error

(mm/1000mm)

0.091 mm ~ 0.109 mm

(M1) (M6)

≦ 0.150 mm

(M=?)

Advantage Higher Accuracy

(even by Stainless Steel

which is harder to machine)


Specification of APEX Q6M

APEX Rack Q6M

Q6M : M = Milling on the 3 sides of rack

Q6M = Quality 6 Q7 = Quality 7

Total Pitch Error 0.033 mm ~ 0.046 mm

(M2) (M10)

0.047 mm ~ 0.060 mm

(M1) (M12)

Milling vs. Grinding Same dimension, different surface roughness

All sides milled FIXED on the machine-bed, no movement.

Roughness not important!

52

53

Specification of APEX Q6M

APEX


Heat-Treatment Induction on Teeth

Teeth Ground

All Sides Milled

Total Pitch Error

(mm/1000mm)

0.033 mm ~ 0.046 mm

(M2) (M10)

Advantage Higher teeth precision,

Higher wearing resistance


54

APEX Q6M vs. ATLANTA Q8 (Teeth hardened & ground)

APEX ATLANTA

Material Carbon Steel S45C / 42CrMo4

Heat-Treatment Induction on Teeth Induction / Q&T

Teeth Ground Ground / Milled


Total Pitch Error

(mm/1000mm)

0.033 mm ~ 0.046 mm

(M2) (M10)

0.060 mm / 0.100 mm



55

APEX Q6M vs. ATLANTA Q7

APEX ATLANTA



Teeth Ground Ground

All Sides Milled Ground

Total Pitch Error

(mm/1000mm)

0.033 mm ~ 0.046 mm

(M2) (M10)

0.052 mm

Advantage


The same material and

same process like by Q6

Unqualified Q6 Q7 ??

56


APEX



Teeth Ground

All Sides Ground

Total Pitch Error

(mm/1000mm)

0.033 mm ~ 0.046 mm

(M1) (M12)

Advantage


57


APEX ATLANTA

Material Carbon Steel 16MnCr5 / S45C

Heat-Treatment Induction on Teeth Carburized & Induction

/ Induction

Teeth Ground Ground

All Sides Ground Ground

Total Pitch Error

(mm/1000mm)

0.033 mm ~ 0.046 mm

(M1) (M12)

0.036 mm

(M2~M4 / M1.5~M12)

Advantage


58


APEX

Material Carbon Steel Alloy Steel

Heat-Treatment Induction on Teeth Carburized & Induction

Teeth Ground Ground


Total Pitch Error

(mm/1000mm)

0.028 mm ~ 0.033 mm

(M4) (M12)

0.024 mm ~ 0.026 mm

(M2) (M3)

Advantage Rigidity :

Alloy Steel > Carbon Steel


59

APEX Q5 (Alloy Steel) vs. ATLANTA Q6 (16MrCr5)

APEX ATLANTA

Material Alloy Steel 16MnCr5 / S45C

Heat-Treatment Carburized & Induction Carburized & Induction

Teeth Ground Ground


Total Pitch Error

(mm/1000mm)

0.024 mm / 0.026 mm

(M2) (M3)

0.036 mm

(M2~M4)

Advantage Higher Accuracy


60

Specification of APEX Q5H, “Heavy Duty”

APEX

Material Alloy Steel

Heat-Treatment Case Hardening

Teeth Ground

All Sides Ground

Total Pitch Error

(mm/1000mm)

0.024 mm ~ 0.031 mm

(M2) (M10)

Advantage

Application High Rigidity

For without Back-Support


With Back-Support

Without Back-Support

61

APEX Q5H Heavy Duty vs. ATLANTA Q5 Strong Line

APEX ATLANTA

Material Alloy Steel 16MnCr5

Heat-Treatment Case Hardening Case Hardening

Teeth Ground Ground


Total Pitch Error

(mm/1000mm)

0.024 mm ~ 0.031 mm

(M2) (M10)

0.026 mm

(M3~M6)

Advantage Wide Rang of Module No.


62

APEX



Teeth Ground

All Sides Ground

Total Pitch Error

(mm/1000mm)

0.02 mm ~ 0.023 mm

(M5) (M12)

Application High-End CNC /

Measurement Equipment



63

APEX Q4 vs. ATLANTA Q3 (Q4 in old catalog)

APEX ATLANTA



Teeth Ground Ground


Total Pitch Error

(mm/1000mm)

0.02 mm ~ 0.023 mm

(M5) (M12)

0.012 mm

(same as Q4 in old Catalog)

Advantage Higher Accuracy (?)

Corresponding to DIN Standard of Gears !!


64

About the Feed Force of the Rack Teeth


Basing on Material and Heat-Treatment :

Rigidity of 〔Alloy Steel + Case-Hardening〕

~ 〔Alloy Steel + Carburized & Induction〕

~ 〔Carbon Steel + Induction〕

>>〔Carbon Steel + Normalizing〕

Basing on Quality :

Q4 >> Q5 >> Q6 >> Q7 >> Q8 > Q9 >> Q10*

(* If the heat-treatment also considered, Q10 >> Q8, Q9)

Basing on Teeth Angle :

Helical >> Straight

Basing on Module-No. (Mn) :

Larger Mn >> Smaller Mn

65


About the Noise Level (dB) of the Rack

Basing on Teeth Machining :

dB Value of〔Ground Teeth〕<<〔Milled Teeth〕


Helical << Straight

Basing on Quality :

Q4 << Q5 << Q6 << Q7 << Q8 << Q9 << Q10

Basing on Module-No. :

Smaller Mn << Larger Mn

66

About the Wearing Resistance of the Rack


Basing on Material and Heat-Treatment :

Wearing Resistance of

〔Alloy Steel + Case-Hardening〕

~ 〔Alloy Steel + Carburized and Induction〕

~ 〔Carbon Steel + Induction〕

>> 〔Carbon Steel + Normalizing〕

Basing on Quality :

Q4 >> Q5 >> Q6 >> Q7 >> Q10 >> Q8 ~ Q9


Straight >> Helical (due to less teeth surface)

67

Measurement Report for Q4 / Q5 / Q5H

2016.08.31


GKRDSF

GKRDSF

68

4° Chamfering of APEX Rack (Q6↑)

4° To Avoid

Interference bw.

rack and machine-

bed due to thermal

deformation

Patented !


69

Selection of Rack

Module No.?

Quality ?

Teeth Induction hardened and Ground?

Torque / Feed-Force ?

Total Pitch Error ?

Backlash ?

Rack is to select in combination with Pinion !!

Considering: Torque / Feed Force / Backlash / Noise…


70

APEX Rack Catalog


71

APEX Rack Order Code


72

APEX Rack Order Code


Customization

Material

Heat-Treatment

Module-No.

Special Teeth

Teeth Hardening

Quality

Cross-Section

Length

Screw-Holes

Special Form


73

Customer drawing

APEX drawing for confirm

Customer should accept

± 10% of order volume

Customization

Material

Heat-Treatment

Module-No.

Special Teeth

Teeth Hardening

Quality

Cross-Section

Length

Screw-Holes

Special Form


74

75


APEX Pinion Series

A : Curvic Plate B : Welded Plate C : Teeth Plate C : Teeth Plate with Flange

D : DIN 5480 E / F : Keyway F : Keyway with Shrink-Disc

76

Electron Beam Welding

APEX Pinion Series B “Welded Plate“ (EN ISO 9409-1-A)


77

APEX Pinion Series C “Teeth Plate“ (EN ISO 9409-1-A)


78

Convex Teeth

Concave Teeth

APEX Pinion Series A “Curvic Plate“

Patented !!


1.

2.

79

Curvic-Coupling



80

All-Teeth-Coupling between pinion and gearbox

Zero backlash

Automatical concentricity

High torque transmission

The Round-Out of the gearbox-pinion-set can be adjusted

by switching the curvic positions.

Quick assembly and disassembly / replacement

More suitable pinion teeth-no. can be chosen.

Advantages of Curvic Coupling



81




＊Because of possible interference

bw. pinion-teeth and screw-holes.

Teeth-No. ≧ N Teeth-No. ≦ n＊

82

Teeth-No. ≧ N Teeth-No. ≦ n


With Curvic Plate there is a

wider rang of teeth no. Z

applicable!

Also available: n ≦ Z ≦ N



83


APEX Pinion Series A “Curvic Plate“ vs. Teeth Plate with Flange

Torque is limited by

the screw strength

High Torque-

transmission

Same PCD

84

DIN5480 Interface

APEX Pinion Series D “Spline“ (DIN 5480)


85

APEX Pinion Series D “Spline“ (DIN 5480)


Production process of internal DIN 5480 teeth

ATLANTA Carburized Induction (based on APEX analyze)

APEX Case Hardening

High rigidity, high-precision

(Quality of internal DIN 5480 teeth = DIN 7)

Good concentricity and good round-out

when applied to the gearbox.

86

APEX Pinion Series E “Keyway“

Keyway / Key


With Shrink Disc

87

The Teeth Top and Profile of APEX pinions are ground simultaneously !!

Round-out of pinion on the gearbox (basing on teeth-profile)

== Round-out of pinion measured on the teeth top

Round-out of APEX pinion can be adjusted via Teeth Top directly.


88

Pinion APEX ATLANTA

Material Alloy Steel 16MnCr5

Heat-Treatment Case Hardening Case Hardening

Teeth Ground Ground

Welded Plate

Curvic Plate

Teeth Plate

Spline (DIN 5480 )

Keyway

DIN 4

DIN 4

DIN 4

DIN 5＊

DIN 5

DIN 5

--

DIN 5

DIN 5＊＊

DIN 6


＊ : Quality of internal DIN 5480 teeth = DIN 7

＊＊ : Heat-Treatment should be Carburized Induction.

89


APEX Pinion Order Code

Selection of Pinion / Big or Small ??


90

91

Mn = 3 Mn = 3

Z = 12 Z = 40

Torque = Radius x Force

r

R

f F

l L


Torque Transmission is the most important !!


92

Small Pinion / Less Teeth

Low Torque / Low Speed

With low ratio (1 Stg.) Gearbox

Low Cost

High Cycling Frequency

High Wearing / Short Life-Time

More sensitive to Vibration

Big Pinion / More Teeth

Large Torque / High Speed

With high ratio Gearbox (2 Stg. ↑)

Higher Cost

Low Cycling Frequency

Less Wearing / Longer Life-Time

Backlash / Inaccuracy can be enlarged by bigger Pinion Radius

More smooth running



93


Feed Force, Torque / Curvic Plate

94

APEX recommends: ~ 20 Teeth !!

But ATLANTA and Co. said, smaller (z=12~14) better !

Pinion Quality = Rack Quality


Refer to pages

75, 81~83, 91~93!


95

Selection of Rack & Pinion


Calculation of

Torque or Feed-Force

Choose the required

Quality

With or without

Back-Support ?

Life-Time

Environment

Noise?

Stainless? Coating?

Also refer to page

64~66, 94.

96



Material

Heat-Treeatment

Module No.

Width of Teeth (Rack and Pinion)

Quality of Rack

Teeth No. of Pinion

Helical or Straight

Pinion (fixing) on the Gearbox

Rack fixing on the Machine bed

APEX HQ

Customer

Also refer to page

64~66, 94.

97



Also refer to page

64~66, 94.

Calculation of Torque (Feed Force) of Application

Mass, Acceleration/Speed, Motor & Gearbox

Choose the suitable Rack-Pinion Combination

based on the Torque of Curvic Plate

Example: Torque = 450 Nm

Selection basing on Feed Force / Torque


98

99



Also refer to page

64~66, 94.






M3+Z17+Q6 or

M3+Z18+Q5 or

M3+Z20+Q6M or

M4+Z18+Q10 or

M4+Z19+Q8 would be suitable!

100






M3+Z17+Q6 or M3+Z18+Q5 or M3+Z20+Q6M or

M4+Z18+Q10 or M4+Z19+Q8 would be suitable!

Which Type of Pinion?

High Accuracy (with/without Linear Scale)?

Wearing Resistance? (Low Cycling Rate?)

Without Back-Support? (Q8H / Q5H?)

Total Cost (Rack + Pinion + Gearbox + Motor)



Also refer to page

62~64, 91.

101

Selection basing on Feed Force / Torque


No Back-Support

By APEX All in One Hand !!

Quality Guarantee for Customer !!

Gearbox with Rack & Pinion


102

Q6 = Q6 ?? Marketing : Price vs. Quality

Low margin product Laaaaarge Order Discount

Lead Time = ? No screw-holes?

Large oder piece-no. / Stock should be considered

(2 years conservation guarantee in original APEX package)

Package and transport from APEX to APEX Agents (Sea freight !)

Local transport from APEX Agents to customer

Open Issues to APEX Agents


103

APEX DYNAMICS, INC. / TAIWAN

technical instruction of apex rack and pinion instruction of apex ra… · technical instruction of...

Documents