MAINTENANCE FREE COUPLINGS FOR HEAVY ENGINEERING

Torsionally Rigid Bellows Couplings up to 100,000 Nm

Extreme temperature ranges, high

pollution levels, high vibration levels,
and 24/7/365 operation call for highly
engineered drive components which
can take the abuse. Extending
component maintenance intervals is a
priority for designers at all levels,
since industrial gearboxes, electric
motors, bearings, and drive shafts
typically require at least partial
disassembly and replacement of wear
parts. System operators know that
this is extremely costly, and
depending on the complexity and
number of serviceable components,
very time consuming as the entire
process rests at a standstill. A new
solution presented by R+W, a
German based coupling manufacturer,
involves zero maintenance, stainless
steel bellows couplings for up to
100,000 Nm, engineered to run
smoothly for decades.

Since 1990, R+W, the global leader in

flexible bellows couplings for torque
transmission, limited its standard
offering to a rating of 10,000 Nm.
Hundreds of variations, including
custom materials, flanges, shafts and
connection methods, along with
specialized features for aggressive speed, torque, temperature, and chemical exposure, have
been deployed into many thousands of unique customer applications. Putting this experience to
work, R+W began producing custom heavy duty bellows couplings in 2009.

Naturally, the greatest challenge in the development of this new series was the design of the
metal bellows itself. The bellows serves to alleviate misalignment loading between adjacent
bearing sets while transmitting rotary power. Traditional sizing calculations were used at first,
having been proven successful for high speed servo drive systems, which tend to be some of the
most demanding of the customary applications for bellows couplings. After a very short time it
became clear that a widely marketable high torque bellows coupling could not be designed
without FEA, as the first installed models were two to three times larger than the final product
design. As life testing later confirmed, the software revealed some errors in the initial
interpretation of the sizing, demonstrating that the traditional methods did not scale properly. In
collaboration with a major bellows hydroformer, R+W reviewed and updated these traditional
bellows sizing methods to better reflect the realities of what the formed bellows can tolerate in this
physical size range.
A special welded joint between the bellows, intermediate tubing, and mounting flanges was also
selected, involving a combination of TIG (perfect root) and MAG (low heat generation). This
welding method is a recent development of RWTH Aachen University IME, a world renowned
leader in mechanical and electrical engineering research, and has demonstrated superior fatigue
characteristics in vibration and life testing. With these two important features in place, hubs,
flanges, and intermediate tubing, fabricated from high strength steel, were configured to round off
the complete product line. R+W has been able to launch the all new “BX” series, with a variety of
standard and custom mounting options available, and presently broken down into three specific
series.

BX1 with Flange Mounting

The BX1 is the basic model from which the complete BX series is configured. Mounting flanges
are welded directly to the bellows, which are then used for adaptation to shaft mounting systems
in the cases of the BX4 and BX6. Power is therefore transmitted through the BX1 by means of a
frictional flange connection. A common misconception is that the torque is transmitted through
the bolts themselves. This can have two negative consequences in that the coupling would
exhibit backlash, and that ultimately the bolts would fatigue and fracture. In case of reversing
applications or those with frequent load variation this failure would occur within a very short
amount of time. Basically torque ratings of flanges are calculated based on the pressure
generated by the bolt circle arrangement, the diameter into which they have been arranged, and
the coefficient of friction of the flange surfaces. A number of safety and application factors are
normally added to ensure a pure high pressure frictional connection results.

BX4 with Keyway Mounting

The BX4 is described as a low backlash coupling, which transmits torque purely though the form
fit of a shaft key or spline. Some potential for backlash always exists due to the clearance
required to fit the hub over the shaft. However reduced, this is even in the case of an interference
fit, and especially in cases where only set screws are used for the axial retention of the hub. The
main advantage of a keyway connection is the quick and easy installation and removal of the
coupling hubs. In lieu of keyway connections, spline connections provide additional security and
surface area contact with superior stress distribution characteristics. In consideration of some
extra cost, this can be a good solution for a more compact design, as the necessary shaft
engagement length can then be reduced. Generally speaking, the BX4 is well suited to
unidirectional drive applications, which must accelerate, even to high speeds, and maintain those
speeds for prolonged periods. Drive systems with shock loading, reversals, and high duty cycles
are better served by the BX1 and BX6 designs.

BX6 with Conical Clamping Ring

The BX6 makes use of a high pressure, keyless, frictional clamping connection. The conical
clamping ring system consists of two components: the clamping ring and the hub. The clamping
ring is drawn over a slotted tapered section of the hub by means of a set of fastening bolts.
Sliding the two tapered surfaces against one another creates a high level of surface pressure in
the vertical direction, compressing onto the cylindrical shaft. The resulting contact force
eliminates the need for keyways and is suitable for transmitting extremely high torque levels
depending on the diameter of the shaft. Since the BX6 has many planes of symmetry across its
length, it is also well suited to very high rotational speeds, as a result of the low residual
imbalance.
Variable Length with Internal Support

The intermediate section of the BX series consists of high strength steel tubing with adapter
flanges common to the full product line. The length of the intermediate tubing section can be
specified according to customer requirements and interchanged for machinery modifications as
needed. The adapter flanges are made with a gimbal system which extends through the inside of
the bellows and engages a concave receptacle on the opposite side. This support system
causes the entire mass of the intermediate section to be carried by the shafting rather than the
flexible bellows. It also serves as a safety feature in the event of a machine crash. Should the
bellows or its connection be caused to fail by extreme overload, the tubing would still not be
allowed to escape from the hubs, eliminating the need for coupling guards in some cases. This
safety feature does not exist in flex disc or universal drive shaft products.

Summary and Outlook

The all new “BX” series offers standard torque ratings of up to 100,000 Nm and bore diameters of
up to 280mm. This new technology provides a viable alternative to steel disc couplings, with
improved torsional stiffness, balance, and safety features. Flexible design configurations allow for
the BX to be made to ideally suit customer applications, with specialized flanges, hubs, materials
and surface treatments for even the harshest of environments. The internal support system
provides for a high degree of security unavailable in other similar types of couplings. The
symmetrical design of the series BX1 and BX6 allows for an optimal balance quality in highly
dynamic drive systems and test stands, with ISO Grade 2.5 certification available upon request.

The principle of the formed metal bellows as an equalizing element offers many unique
performance advantages for today’s advanced drive technology. Designs capable of transmitting
up to 2,000,000 Nm are currently in development, as R+W continues to take strides into the
arena of heavy engineering, with new sizes and capabilities in its full line of metallic, elastic, and
torque limiting couplings. To learn more about the full range of possibilities from R+W, visit
www.rw-america.com