2012 rack and pinion (1)

Geared to a higher standard™

Rack & Pinion DrivesRack & Pinion DrivesRack & Pinion DrivesRack & Pinion Drives• ZTRS – Small pinion with bearing support

• ZTR – Small pinion without additional bearing support

• ZR – Traditional style flange mounted pinion

• Rack

• Lubrication

• Mounting

ZTRS Part NumberingZTRS Part NumberingZTRS Part NumberingZTRS Part Numbering

Support Housing PositionSupport Housing PositionSupport Housing PositionSupport Housing Position

ZTRS Rack & Pinion DrivesZTRS Rack & Pinion DrivesZTRS Rack & Pinion DrivesZTRS Rack & Pinion Drives4 Case Sizes Available:PH(A)7 – PH(A)(Q)10

Pinion System:Helical & Straight ToothModule 2 – 10Quality 5 (DIN, AGMA 12)

Feed Force:Up to 124kN / 27,875lbs helical toothUp to 121kN / 27,200lbs straight tooth

Feed Speed:Up to 4.7 m/s

Linear Backlash:Standard ZTRS-PH 21 – 72 µmReduced ZTRS-PHA 7 – 24 µm

High Force Helical / Straight Tooth SystemHigh Force Helical / Straight Tooth SystemHigh Force Helical / Straight Tooth SystemHigh Force Helical / Straight Tooth System

Know-how and competence from two drive specialists

Integrated lubrication by felt pinion (optional) ready to connect to the central lubrication or to a grease cup

Linear backlash reduction more than 50%

Gear unit and gear rack perfectly matched to each other, optimal utilization of the gear unit due to support bearing cover.

Directly attached STÖBER servo motors possible

Concentricity of the pinion ≈ 25µm (optional ≤ 10µm)

Also available as right-angle gear unit PHK / PHKX

Optimal adaption to the mass moment of inertia by varying the gear ratios / number of pinion teeth

Linear stiffness can be increased up to ten times

Torque reduction more than 50%

Smaller gear unit ratio1 stage instead of 2 stages

Removable pinion If necessary, the pinion can be changed.

Information for selection, assembling and lubrication of rack and pinion drives

ZTRS – PH Rack & Pinion DrivesZTRS – PH Rack & Pinion DrivesZTRS – PH Rack & Pinion DrivesZTRS – PH Rack & Pinion Drives

ZTR Part NumberingZTR Part NumberingZTR Part NumberingZTR Part Numbering

ZTR Rack & Pinion DrivesZTR Rack & Pinion DrivesZTR Rack & Pinion DrivesZTR Rack & Pinion Drives6 Case Sizes Available:PH(A)4 – PH(A)10

Pinion System:Helical & Straight ToothModule 2 – 8Quality 5 (DIN, AGMA 12)

Feed Force:Up to 57kN / 12,800lbs helical toothUp to 45.5kN / 10,225lbs straight tooth


Linear Backlash:Standard ZTR-PH 12 – 50 µmReduced ZTR-PHA 4 – 17 µm

ZTR– PH Rack & Pinion DrivesZTR– PH Rack & Pinion DrivesZTR– PH Rack & Pinion DrivesZTR– PH Rack & Pinion Drives


Linear backlash reduction more than 50%

Gear unit and gear rack perfectly matched to each other


Concentricity of the pinion ≈ 25µm (optional ≤ 10µm)



Linear stiffness can be increased by up to five times

Torque reduction more than 50%

Smaller gear unit ratio1 stage instead of 2 stages

Removable pinion If it´s necessary, a new pinion is attachableInformation for selection, assembling

and lubrication of rack and pinion drives

Helical / Straight Tooth SystemHelical / Straight Tooth SystemHelical / Straight Tooth SystemHelical / Straight Tooth System

ZR Part NumberingZR Part NumberingZR Part NumberingZR Part Numbering

ZR Rack & Pinion DrivesZR Rack & Pinion DrivesZR Rack & Pinion DrivesZR Rack & Pinion Drives

6 Case Sizes Available:PH(A)4 – PH(A)7

Pinion System:Helical OnlyModule 2 – 4Quality 5 (DIN, AGMA 12)

Feed Force:Up to 12.3kN / 2765lbs helical tooth


Linear Backlash:Standard ZR-PH 31 – 57 µmReduced ZR-PHA 10 – 19 µm

ZR– PH Rack & Pinion DrivesZR– PH Rack & Pinion DrivesZR– PH Rack & Pinion DrivesZR– PH Rack & Pinion DrivesHelical Tooth SystemHelical Tooth SystemHelical Tooth SystemHelical Tooth System


Gear unit and gear rack perfectly matched to each other


Concentricity of the pinion ≈ 25µmoptional ≤ 10µm



To bridge large distances between gear unit and rack

Small distance between point of force and bearings of the gearbox. high bearing service life low deflection

Cost-efficient alternative

Removable pinion If necessary, a new pinion is attachable

Information for selection, assembling and lubrication of rack and pinion drives

Suitable for high-speed applications, because of the large pinion diameter

Rack & Pinion Drawings on the WebRack & Pinion Drawings on the WebRack & Pinion Drawings on the WebRack & Pinion Drawings on the Web

Gear RackGear RackGear RackGear Rack

Sizes Available:Module 2-10

Lengths Available:0.5, 1.0, 2.0 meters

Quality:AGMA 8 – 12DIN 4 -10Helical & Straight

Precision Levels:Basic = SoftPrecision = Quenched & TemperedHigh-Precision = Induction-HardenedUltra-Precision = Hardened & Ground

Gear Rack PrecisionGear Rack PrecisionGear Rack PrecisionGear Rack PrecisionRack QualityRack Quality

LevelLevel(Lowest to Highest)(Lowest to Highest)

MinimumMinimumBacklash *Backlash *

(Repeatability)(Repeatability)

Rack Pitch Deviation GTRack Pitch Deviation GTff

(Positioning Accuracy)(Positioning Accuracy)TypicalTypical

ApplicationsApplications

SoftSoft(DIN 9, ~AGMA 9)(DIN 9, ~AGMA 9)

~0.06 mm(0.0024”)

< 0.150 mm per meter

(0.0018”/ft)

Light Loads &Medium Accuracy

(Plasma, low loads)

Quenched & TemperedQuenched & Tempered(DIN 8, ~AGMA 10)(DIN 8, ~AGMA 10)

~0.04 mm

(0.0016”)


(0.0012”/ft)

Medium Loads &Medium Accuracy

(plasma)

Hardened & GroundHardened & Ground(DIN 7/8, ~AGMA 10/11)(DIN 7/8, ~AGMA 10/11)

~0.03 mm

(0.0012”)


(0.0008”/ft)

Heavy Loads & High Accuracy

(Machine Tool, Multiple Pinion Contact, lifting axis, water jet)

Hardened & GroundHardened & Ground(DIN 6, ~AGMA 12)(DIN 6, ~AGMA 12)

~0.02 mm

(0.0008”)


(0.0006”/ft)

Hardened & GroundHardened & Ground(DIN 5)(DIN 5)

29 series 29 series


(0.0004”/ft)

Hardened & Precision Hardened & Precision Ground Ground (DIN 4)(DIN 4)

48 series 48 series


(0.0001”/ft)

Heavy Loads &Very High Accuracy

(High precision machine tool)

Heavy to MediumMaterial handeling, woord

working, linear axis)

Rack Part NumberRack Part NumberRack Part NumberRack Part Number 28.20.100

Series NumberModule & Holes Length

25 – Soft First Digit – Module 1.0 to 10.0 025 – ¼ meter

27, 34 – Induction-Hardened Second Digit - Mounting Holes 050 – ½ meter

28 – Hardened & Ground 100/105 – 1.0 meter

29 – Helical Hardened & Ground 150/155 – 1.5 meter

33 – Quenched & Tempered 200/205 – 2.0 meter

35, 37 – Round Rack

36 – Stainless Steel Rack

38 – Helical Quenched & Tempered

39 – Helical Induction-Hardened

46 – Hardened & Ground DIN 4

47 – Helical Soft

48 – Helical Hardened & Ground DIN 4

49 – Integrated Rack

Mounting Mounting Tolerances/InstructionsTolerances/InstructionsMounting Mounting Tolerances/InstructionsTolerances/Instructions

Geared to a higher standard™

Advantages of Removeable Advantages of Removeable PinionsPinionsAdvantages of Removeable Advantages of Removeable PinionsPinions

• The bolt connection of the pinion to the output shaft of the gearbox allows for changing the pinion.

• Reasons for a pinion change:– Strong contamination leading to increased wear– Strong wear as a result of lubrication failure or lack of

manual lubrication– Crash– Other defects or failures

• The bolt connection of the pinion to the output shaft of the gearbox allows for changing the pinion.

• Reasons for a pinion change:– Strong contamination leading to increased wear– Strong wear as a result of lubrication failure or lack of

manual lubrication– Crash– Other defects or failures

Disadvantages of Welded Disadvantages of Welded PinionsPinionsDisadvantages of Welded Disadvantages of Welded PinionsPinions

• Change of pinion is impossible• Risks of welding:

– Crack formation– Thermal deformations– Notching effect leading to the risk of break down– Welding spots in the gear teeth

• Change of pinion is impossible• Risks of welding:

– Crack formation– Thermal deformations– Notching effect leading to the risk of break down– Welding spots in the gear teeth

Reduction of Torque – ZTRS / Reduction of Torque – ZTRS / ZTRZTRReduction of Torque – ZTRS / Reduction of Torque – ZTRS / ZTRZTR

Higher Precision – ZTRS / ZTRHigher Precision – ZTRS / ZTRHigher Precision – ZTRS / ZTRHigher Precision – ZTRS / ZTR

Reduced Linear Backlash > Reduced Linear Backlash > 50%50%Reduced Linear Backlash > Reduced Linear Backlash > 50%50%

Increase of Linear Stiffness Increase of Linear Stiffness >> 10X10XIncrease of Linear Stiffness Increase of Linear Stiffness >> 10X10X

Increase of Linear Stiffness – Increase of Linear Stiffness – ZTRSZTRSIncrease of Linear Stiffness – Increase of Linear Stiffness – ZTRSZTRS

GearboxC=250Nm/arcmin


d=50mmd=100mm

F=10.000N F=10.000N

• Torque T = F x r 500Nm 250Nm• Tors. Defl. φ = M / C 2arcmin 1arcmin• Lin. Defl. s = d/2 x tan φ 29,1µm 7,3µm• Lin. Stiffn. CL = F / s 344N/µm 1370N/µm

• Increase 400%

• Torque T = F x r 500Nm 250Nm• Tors. Defl. φ = M / C 2arcmin 1arcmin• Lin. Defl. s = d/2 x tan φ 29,1µm 7,3µm• Lin. Stiffn. CL = F / s 344N/µm 1370N/µm

• Increase 400%

Increase of Linear Stiffness – Increase of Linear Stiffness – ZTRS ZTRS Increase of Linear Stiffness – Increase of Linear Stiffness – ZTRS ZTRS

Fv

FA

FB

Fv

FA FB

FS

ZR ZTRS

fZTRS

fZR

At the same feed force the bending in the tooth engagement is approximately half!



d=100mm

F=10.000N F=10.000N

d=50mm

Upgraded Load CapacityUpgraded Load CapacityUpgraded Load CapacityUpgraded Load Capacity

By using the support bearing the bending is halved!

Width crowning optimized for the bending Significantly improved contact pattern Reduced contact pressure at the tooth flank Increased safety, respectively higher lifetime,

especially with dirty or insuffient lubrication

By using the support bearing the bending is halved!

Width crowning optimized for the bending Significantly improved contact pattern Reduced contact pressure at the tooth flank Increased safety, respectively higher lifetime,

especially with dirty or insuffient lubrication

SummarySummarySummarySummary

GearboxC = const.

GearboxC = const.

• Pinion diameter factor 1 1.6 – 2.3

• Linear Stiffness factor – only dia. effect 1 2.6 – 5.3

• Linear Stiffness factor – only bend. effect 1 2

• Total Linear Stiffness Factor 1 5.2 – 10.6

• Pinion diameter factor 1 1.6 – 2.3

• Linear Stiffness factor – only dia. effect 1 2.6 – 5.3

• Linear Stiffness factor – only bend. effect 1 2

• Total Linear Stiffness Factor 1 5.2 – 10.6

Ratio Reduction – ZTRS / ZTRRatio Reduction – ZTRS / ZTRRatio Reduction – ZTRS / ZTRRatio Reduction – ZTRS / ZTR

Bearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRS

Fv

FA

FB

Fv

FA FB

FS

ZR ZTRS

By using the same feed force,the bearings are loaded only 25%!

The load at the A-bearing is limiting

the feed force

Bearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRSBearing Load – ZR vs ZTRS

Fv

FA

FB

Fv

FA FB

FS

ZR ZTRS

The feed force can be increased until the maximum torque of the gearbox or rack and pinion is reached!

Felt Pinion to Lubricate – ZTRSFelt Pinion to Lubricate – ZTRSFelt Pinion to Lubricate – ZTRSFelt Pinion to Lubricate – ZTRS

Felt pinion

Location of lubrication port.

LubricationLubricationLubricationLubricationLUBRICATION IS CRITICAL TO MAINTAIN QUALITY AND LIFE

– Felt Lubrication Gear:Available with RH for helical pinionsLH for helical racksAlso straight for straight tooth rack & pinions

– Lubricator:125CC dispensers475cc

Catalog ValuesCatalog ValuesCatalog ValuesCatalog ValuesThe performance data of rack and pinion drives is listed in the STÖBER catalog called Rack and Pinion Drives.

The data in the catalog is prepared to be very user-friendly.All values are converted on the linear axis. M2B Fv2B max. permissable acceleration feed force M2N Fv2N rated feed forceM2NOT Fv2NOT emergency-off feed force∆φ2 ∆s linear backlash without meshing of the teeth at the rack and pinionC2 CLges total linear spring rigidity including the assembled pinionKv Speed constant – speed [m/s] of the linear axis per 1000 RPM of the motorKM1 Torque constant – needed torque at the input per 1000 N feed force

without dynamic effects – mass inertia

For general information as well as for calculation with ServoSoft, some additional gear data is indicated.m moduleZ number of teethdw pitch circle diameter

Catalog ValuesCatalog ValuesCatalog ValuesCatalog ValuesThe calculated specified performance data takes into account all concernedload-bearing components.

Rated feed force – Fv2N – depends on the lowest value of the gearbox ratedtorque and/or the force in case of a bearing lifetime Lh=20.000h atn1=500 1/min.

Max. permissable acceleration feed force – Fv2B – depends on the lowest value of the max. permissable acceleration torque of the gearbox (M2B) and/or the static load carrying capacity of the bearings in connection with a 3 safety factor(2 with ball bearings), 1.25 flange bolting safety factor, and torque of therack and pinion teeth.

Emergency-off feed force – Fv2NOT – depends on the lowest value of theemergency-off torque of the gearbox (M2NOT) and the flange bolting and 2 safety factor of the rack and pinion teeth.

ZTRS / ZTR / ZR Input OptionsZTRS / ZTR / ZR Input OptionsZTRS / ZTR / ZR Input OptionsZTRS / ZTR / ZR Input OptionsMT/MT

MT/ME/MF

Example DMSExample DMSExample DMSExample DMSStober Alpha

PH521F0100MT40mm Mod 2 helical pinion10:1 ratio (single stage)3 arcmin (55Nm/arcmin)0.5m/s velosity ////1.0m/s2 acc/dec5500 lb load DETAILS0.017mm linear backlash (317% >)1.3 arcmin of torsional deflection (196%>)7.5µm of linear deflection (369%>)477.3N/µm of linear stiffness (367%>) $4024.00 GB & Pinion $490.00/meter

SP140-MF2-2875mm Mod 3 helical pinion28:1 ratio (single stage)5 arcmin (53Nm/arcmin)0.5m/s velosity ////1.0m/s2 acc/dec5500 lb load

0.054mm linear backlash2.54 arcmin of torsional deflection27.7µm of linear deflection129.9N/µm of linear stiffness$4356.00 GB & Pinion ($590.00/meter)

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2012 rack and pinion (1)