ELECON
HEAVY DUTY PLANETARY GEAR UNIT-FOR MILL DRIVE PCF Series
8 0 / 1 1 / G / 6 9 1 : . o N e u g o l a t a C
m o c . n o c e l e . w w w
ELECON India’s largest manufacturer of industrial gears Way back in 1951, Elecon set out on is its journey to scale new heights of technical excellence, creating landmarks at every juncture, From elevators and conveyors, to high quality gears and material handling equipments. Elecon set up a separate Gear Division in the year 1976. Elecon is also known for its pioneer ing acts in India. The first to introduce modular design concept, case-ha rdened and ground gear technology in India. These path breaking efforts are backed by full fledged departments employing a strong, skilled work force. It has supplied hi-tech equipments to major core sectors such as Fertilizer Plants, Cement Plants, Coal and Lignite Mines, Power Plants, Textile Plastic, Steel Plants, Sugar Plants, Sponge Iron Plants and Port Mechanization in India and abroad.
MODERN INFRASTRUCTURE • Deploying modern technology - CAD / CAM in Engineering and Manufacturing on a continuous basis is the selling point of the company. • Elecon Gear Division is acknowledged as the most modern in the industry. More than 90% of ELECON's machinery is computer controlled (CNC) ensuring high degree of precision in Manufacture, design and quality
testing of gear components to DIN / AGMA international specifications. • Elecon's expertise in providing customised gear boxes for Steel Mill, High Speed Turbine, Sugar Mill, Rubber
Mixing Mill, Marine, Coast Guard and Navy Ship, Plastic Extrusions, antenna drives and Satellite for the Indian Space programe. • Elecon is prepared to deliver within deadlines. It is made possible through highly on-line computerised system of advanced Planning and Scheduling software.
Gear Grinding & Testing
1
PCF - Series Planetary Gear Units in operation at 45 x 90 Sugar Mill
Advantages •
•
•
•
•
•
•
Planetary Gearboxes have much higher mechanical rating compared to parallel shaft Gearbox as the power being transmitted gets equally distributed among three to five streams in each stage thus reducing the induced stresses which very much optimizes the size as well allows to accommodate higher ratio to eliminate open pair. The reduction in floor space as compared to conventional drive i.e with open gearing, almost to the tune of 50% reduction in floor space. Heaviest gear internal such as annuli are stationary thus requires no bearing and automatically improves the stability and reduces the Vibration level and in turn noise. Low noise level of 80-85 db as well as low vibration level going up to 4.5 mm/sec can be achieved. Direct drive eliminating open gears, bearings for same, coupling in between secondary gearbox and Open gearing - thus saving 5 to 6 % power consumption. For example, for a 45x90 Mill for power 1100 kW which also includes the drive power of TRPF/GRPF we can get a saving which is approximately equivalent to 20% of the additional expenditure for drive-part i.e. within five seasons additional expenditure is recovered and sugar starts earning additional Profit due to this solution. Planetary Gearbox have an advantage that the planet bearings are only loaded where as in case of Bearings supporting Sun or Carrier loads are more or less nullified by virtue of higher no of planets and their equal and opposite forces. Lubrication of planetary gearbox is quite simple as the rotating gear train partially act as pump thus allowing splash lubrication. We are proposing three-to five stage planetary gearbox in each stage Sun is input and carrier is the output keeping annuli stationary as well acting as casing and supported on saddle as shown in Drawing. 2
Rating of PCF and SA / PCF Series Gear Units Shaded Ratings are with Primary SA Gear Units 90 n1 1500 1000 750 1500 1000
750 1500 1000
750 1500 1000
1500 1000
545970
643
1295721
947
1896120
1361
2711178
2000
4051127
2502
5072357
3308
177
543561
429
1296450
627
1881554
903
2697008
1337
4061052
1670
5076450
2207
6658550
280
104 225 150
418313 418055 416332
133 290 192
546214 546491 544093
322 718 479
1296669 1295489 1296372
468 1065 707
1872431 1895219 1885966
679 1534 1017
2706192 2716165 2700542
1003 2248 1503
4065306 4047979 4059323
1253 2814 1878
5078360 5071016 5075464
1656 3858 2574
6661134 6649800 6656791
113 253
418321 417998
144 326
542605 547313
359 831
1296666 1295137
527 1183
1876372 1894260
760 1699
2691273 2720712
1129 2496
4064184 4044939
1409 3126
5077486 5069756
1932 4224
6660381 6647802
250
168
416889
217
544691
555
1296110
787
1889929
1126
2704302
1669
4057339
2086
5074875
2819
6655837
224
127 285 189
418265 402708 400447
162 382 253
543068 548357 545691
416 907 605
1296527 1294979 1296033
587 1300 867
1879898 1893133 1893554
842 1856 1230
2694633 2724435 2707805
1254 2867 1918
4062838 4039952 4054520
1565 3594 2399
5077031 5067797 5073915
2115 4773 3186
6659280 6644875 6654461
141 334
397636 417810
189 425
544034 549209
454 1031
1296385 1294567
647 1493
1882858 1891292
919 2099
2697650 2730219
1441 3218
4060763 4035337
1800 4050
5076128 5065810
2391 5321
6658408 6642259
200
223
418095
282
546378
688
1295792
998
1896796
1390
2712604
2154
4051670
2704
5072539
3553
6652558
180
167 364 243
416814 417767 418054
211 463 307
544519 549856 546902
516 1152 769
1296269 1294228 1295525
745 1678 1123
1887926 1889464 1895799
1039 2366 1567
2701857 2735579 2717266
1618 3616 2422
4058964 4030092 4048651
2029 4555 3041
5075386 5063765 5071233
2666 5869 3919
6656864 6639533 6650648
182 407
417235 415976
229 522
545054 550914
577 1334
1296157 1293634
840 1863
1892448 1887640
1170 2694
2705747 2739743
1820 4012
4056776 4024841
2282 5058
5074650 5061425
2942 6473
6655735 6636631
273
418011
346
547678
890
1295178
1247
1894666
1784
2722207
2689
4045664
3378
5069806
4323
6648934
204 477
417723 417617
258 610
545816 552224
668 1455
1295904 1293285
936 2047
1896744 1885891
1332 3034
2710445 2745714
2021 4604
4054390 4016294
2535 5813
5073683 5058007
3245 7545
6654423 6630747
318
417920
404
548802
971
1295034
1371
1893730
2009
2727359
3088
4040704
3883
5068042
5041
6645381
239 522
418076 417416
302 669
546819 553079
729 1636
1295702 1292711
1030 2323
1897063 1883106
1500 3438
2715072 2751980
2322 4999
4051301 4011538
2915 6316
5072344 3785 6651806 5055915 8260 6627492
348
417868
443
549639
1092
1294726
1556
1892043
2276
2732898
3354
4037756
4220
5066791
5520
6643601
261
418061
331
547433
820
1295439
1169
1895808
1699
2720369
2523
4049047
3168
5071625
4144
6650761
590 394 296
417287 417786 417988
758 502 375
554324 550625 548328
1817 1213 910
1292210 1294386 1295275
2598 1880346 1741 1890412 1309 1894688
3843 2544 1899
2758100 2738519 2725162
5587 3752 2823
4003498 4033015 4045664
7069 4724 3547
5052738 5064704 5070036
9329 6237 4683
6621494 6640305 6647969
642 428
417178 417715
851 563
555507 551546
2019 1348
1291534 1293956
2871 1927
1861683 1874603
4317 2857
2764415 2744121
6138 4132
3941008 3979508
7966 5326
5048606 10397 6616192 5062470 6952 6636554
322 725
417952 417006
421 964
549127 556819
1012 2242
1294985 1290838
1450 3209
1880189 1857761
2132 4782
2730737 2745677
3112 6855
3996272 3929452
3999 8915
5068247 5222 6646217 5044272 11462 6610604
484
417611
638
552720
1498
1293549
2156
1872250
3193
2749910
4620
3972841
5962
5059889
7668
6633442
363
417855
476
550212
1124
1294710
1622
1878681
2383
2736029
3482
3991463
4477
5066679
5760
6643823
160
140
125
112
100
750 1500 1000
200
266
750 1500 1000 750
180
417935
750 1500 1000
160
417756
750 1500 1000
140
138
750 1500 1000
125
207
750 1500 1000
112
315
750 1500 1000
100
iNom PN (kW) T2N (Nm) PN (kW) T2N (Nm) PN (kW) T2N (Nm) PN (kW) T2N (Nm) P N (kW) T 2N (Nm) P N (kW) T 2N (Nm) P N (kW) T 2N (Nm) P N (kW) T 2N (Nm)
90
750
EXACT RATIO Shaded Ratio are with Primary SA Gear Units 90
100
112
125
140
160
180
200
i actual
i actual
i actual
i Nom
i actual
i actual
i actual
i actual
i actual
315
317.333
322.438
316.655
314.452
312.849
318.159
318.398
315.884
280
291.604
296.294
283.323
279.513
278.088
282.808
283.020
270.758
250
259.203
263.373
244.688
251.561
251.476
254.527
254.718
247.214
224
222.174
225.748
224.297
228.692
230.520
221.328
221.494
218.689
200
196.445
203.016
197.163
198.939
204.309
196.955
196.458
196.066
180
180.517
186.556
176.409
176.834
181.608
175.071
174.630
177.685
160
160.459
165.827
152.353
159.151
159.761
157.564
157.167
161.039
140
137.536
142.138
139.657
144.683
142.128
137.012
136.667
138.033
125
125.577
129.778
124.139
127.321
125.729
126.051
125.733
126.030
112
111.087
114.803
111.725
113.679
112.722
112.546
112.262
111.489
100
102.082
102.527
100.494
101.857
100.583
100.841
99.539
99.955
90
90.303
90.697
90.444
90.943
90.178
90.037
88.874
90.584
6652387
Dimensions of PCF m2 (m2*) m1 (m1*)
l1
l2
2 h
1 d Ø
1 h
l3
c
3 h
n1
n2
n3
n6
n5
n4
1 b
OUTPUT SHAFT b
k
s
s
2 b
Ø d 2 5-Ø d4 Ød3 a4
a3
a2
ROUND END
a5
SQUARE END
a6
a1
DIMENSIONS (MM) SIZE OF GEAR BOX
s
d1
d2
d3
d4
l1
l2
l3
a1
a2
a3
a4
a5
a6
b
b1
PCF 90
250
55
350
340
52
90
280
560
790
510
385
380
175
1190
1400
625
PCF 100
280
65
395
385
65
105
315
630
935
620
385
400
175
1230
1530
675
PCF 112
360
85
510
490
70
135
410
815
1130
725
445
450
220
1441
1860
850
PCF 125
420
90
595
575
78
145
475
950
1200
725
565
515
315
1680
2250
985
PCF 140
460
125
650
625
86
200
520
1040
1260
740
690
555
315
1970
2450
1100
PCF 160
520
135
735
700
86
220
590
1175
1355
770
690
580
315
2185
2450
1100
PCF 180
540
150
760
740
86
240
610
1215
1420
815
690
630
315
2190
2600
1175
PCF 200
580
175
820
790
90
280
655
1315
1540
880
780
745
345
2360
2940
1325
DIMENSIONS (MM) SIZE OF GEAR BOX
b2
c
h1
h2
h3
k
m1
m2
m1*
m2*
n1
n2
n3
n4
n5
n6
PCF 90
625
80
350
1025
225
125
2175
2455
1935
2215
860
580
250
335
250
230
PCF 100
675
100
400
1100
195
195
2355
2670
2105
2420
1005
690
250
375
250
220
PCF 112
850
100
400
1260
335
200
2785
3190
2510
2915
1205
800
300
375
300
320
PCF 125
985
100
450
1470
445
250
2955
3430
2675
3150
1300
825
350
365
300
435
PCF 140
1100
100
550
1690
475
250
3300
3820
2990
3510
1400
880
450
575
350
330
PCF 160
1100
100
550
1725
475
280
3715
4300
3365
3950
1500
915
445
605
410
460
PCF 180
1175
100
550
1765
515
315
3800
4405
3445
4050
1530
925
450
620
425
465
PCF 200
1325
110
550
1930
660
400
4150
4810
3735
4395
1670
1010
530
620
495
475 4
Rating Chart for PCF Gear Units
ELECON 8
7
6
5
1
n / P
4
PCF 200
3
PCF 180
PCF 160 2
PCF 140 PCF 125
1
PCF 112 PCF 100 PCF 90 90
100
110
120
130
140
150
160
170
n1 Gear Box Ratio i = n 2
Rating chart considering Service Factor = 1.0 P = Motor Power in kW n1 = Motor Speed in rpm n2 = Output Speed in rpm
5
180
190
200
Rating Chart for SA / PCF Gear Units
ELECON 4
3.5
3
2.5 1
n / P
SA400/PCF200 2
SA315/PCF180 1.5
SA280/PCF160
1
SA250/PCF140 SA250/PCF125 0.5
SA200/PCF112 SA160/PCF100 SA125/PCF 90
0 180
200
220
240
260
280
300
315
n1 Gear Box Ratio i = n 2
Rating chart considering Service Factor = 1.0 P = Motor Power in kW n1 = Motor Speed in rpm n2 = Output Speed in rpm
6
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Manufactured by:
ELECON ENGINEERING CO. LTD. Post Box # 6, Anand - Sojitra Road, Vallabh Vidyanagar - 388 120, Gujarat, INDIA 2692 236 469 / 236 513, Fax : +91 2692 227 484 E-mail :
[email protected] Website : www.elecon.com | CIN L29259GJ1960PLC001082
Tele. : +91 91
For information and enquiry
