Universal Joint Shafts - Brochure

High-Performance Universal Joint Shafts Products | Engineering | Service2Universal Joint Shafts and Hirth CouplingsWe are the experts for cardanic power transmission compo-nents and Hirth couplings within Voith Turbo. Voith Turbo, the specialist for hydrodynamic drive, coupling and braking systems for road, rail and industrial applications, as well as for ship propulsion systems, is a Group Division of Voith GmbH.Voith sets standards in the markets energy, oil & gas, paper, raw materials and transporta tion & automotive. Founded in 1867, Voith employs almost 40 000 people, generates Euro 5.6 billion in sales, operates in about 50 countries around the world and is today one of the biggest family-owned compan-ies in Europe.3Contents1 Voith high-performance universal joint shafts – What makes them unique?42 Range 63 Designs 83.1 Center sections 83.2 Flanges 93.3 Type designations 94 Applications 105 Definitions and abbreviations 145.1 Lengths 145.2 Torque loads 156 Technical data 166.1 S Series 166.2 R Series 186.3 CH Series 246.4 E Series 267 Engineering basics 287.1 Major components of a Voith universal joint shaft287.2 Telescopic length compensation 307.3 Kinematics of the universal joint 327.4 Two universal joints 357.5 Bearing forces on input and output shafts 367.6 Balancing of universal joint shafts 398 Selection aids 408.1 Definitions of operating variables 418.2 Size selection 428.3 Operating speeds 458.4 Masses 488.5 Connection flanges and bolted connections 529 Service 579.1 Installation and commissioning 589.2 Training 599.3 Genuine Voith spare parts 609.4 Overhaul, maintenance 619.5 Repair and maintenance 629.6 Retrofit and modernizations 6310 Services and supplementary products 6410.1 Engineering 6410.2 Connecting components for universal joint shafts 6510.3 Quick-release coupling GT 6610.4 Voith Hirth serrations 6710.5 Universal joint shaft supports 6810.6 Universal joint shafts with carbon fiber-reinforced polymer (CFRP) components6910.7 High-performance lubricant for universal joint shafts 7010.8 Safeset torque-limiting safety couplings 7210.9 ACIDA torque monitoring systems 7311 Integrated management system 7411.1 Quality 7511.2 Environment 7611.3 Occupational health and safety 774Features Advantages Benefits• Closed bearing eye • Heavy-duty cross-sections without joints or bolts• Minimal notch stresses• Enclosed seal surfaces + Productivity increase + Long service life• Drop-forged journal crosses • Maximum possible torque capacity• FEM-optimized geometry • Optimal design for torque transmission• Minimal notch stresses• High strength tempering and case-hardened steels • Capability to withstand high static and dynamic loads• Load-optimized welded joints • Optimal design for torque transmission• Length compensation with SAE profile (straight flank profile) for larger series• Lower normal forces and thus lower displacement forces• Low surface pressure• High wear resistance + Ease of movement + Long service life• Patented balancing procedure • Dynamic balancing in two planes• Balancing mass where unbalanced forces act + Extremely smooth operation• Engineering and products from a single source • Single contact person when designing the driveline + Time and cost savings + Combined responsibility• Certifications and classifications for rail vehicles and marine vessels• Officially-approved product + Time and cost savings• Made in Germany • Seal of approval for quality, efficiency and precision + Reliability• Voith Engineered Reliability • Competent and trustworthy partner + Innovative product and system solutions1 Voith High-Performance Universal Joint ShaftsWhat makes them unique?215Features Advantages Benefits• Closed bearing eye • Heavy-duty cross-sections without joints or bolts• Minimal notch stresses• Enclosed seal surfaces + Productivity increase + Long service life• Drop-forged journal crosses • Maximum possible torque capacity• FEM-optimized geometry • Optimal design for torque transmission• Minimal notch stresses• High strength tempering and case-hardened steels • Capability to withstand high static and dynamic loads• Load-optimized welded joints • Optimal design for torque transmission• Length compensation with SAE profile (straight flank profile) for larger series• Lower normal forces and thus lower displacement forces• Low surface pressure• High wear resistance + Ease of movement + Long service life• Patented balancing procedure • Dynamic balancing in two planes• Balancing mass where unbalanced forces act + Extremely smooth operation• Engineering and products from a single source • Single contact person when designing the driveline + Time and cost savings + Combined responsibility• Certifications and classifications for rail vehicles and marine vessels• Officially-approved product + Time and cost savings• Made in Germany • Seal of approval for quality, efficiency and precision + Reliability• Voith Engineered Reliability • Competent and trustworthy partner + Innovative product and system solutions1 Assembly building for Voith universal joint shafts2 Welding robot3 Balancing machine4 Shipping436Series Torque rangeMz [kNm] Flange diametera [mm]Features ApplicationsS 0.25 to 35 58 to 225• Standard design of Voith universal joint shafts• Non-split bearing eyes thanks to single-piece forged flange yoke• Length compensation with involute profile• Paper machinery• Pumps• General industrial machinery• Marine vessels• Rail vehicles• Test stands• Construction machinery and cranesR 32 to 1 000 225 to 550• High torque capacity• Optimized bearing life• Flange in friction and positive locking design (see page 9)• Length compensation with involute profile up to size 315; from size 350 with SAE-profile (straight flank profile, see page 30); optional tripod• Optimized torsional rigidity and deflection resistance in a low-weight design• Particularly suitable for use with high-speed drives• Optional: Low-maintenance length compensation through use of plastic-coated (Rilsan®) involute spline profile• Rolling mill drives• Heavy-duty industrial drives• Paper machinery• Pumps• Marine vessels• Rail vehiclesCH 260 to 19 440 350 to 1 400• Very high torque capacity • Optimized bearing life• Flange with Hirth connection for transmitting maximum torque• Length compensation with SAE-profile (straight flank profile, see page 30)• Rolling mill drives• Construction of heavy machinery• Paper machineryE 1 600 to 14 000 590 to 1 220• Maximum torque capacity• Optimized bearings for exceptionally demanding applications• Patented 2-piece flange yoke• Flange with Hirth connection for transmitting maximum torque• Length compensation with SAE profile (straight flank profile, see page 30)• Heavy-duty rolling mill drives2 RangeVoith high-performance universal joint shafts offer an ideal combination of torque capacity, torsional rigidity and deflection resistance. We supply stand ard universal joint shafts, customer-specific adaptations, as well as special designs. Technical consultation, simulation of torsional vibrations and measurement of operating parameters complete our range of services.7Series Torque rangeMz [kNm] Flange diametera [mm]Features ApplicationsS 0.25 to 35 58 to 225• Standard design of Voith universal joint shafts• Non-split bearing eyes thanks to single-piece forged flange yoke• Length compensation with involute profile• Paper machinery• Pumps• General industrial machinery• Marine vessels• Rail vehicles• Test stands• Construction machinery and cranesR 32 to 1 000 225 to 550• High torque capacity• Optimized bearing life• Flange in friction and positive locking design (see page 9)• Length compensation with involute profile up to size 315; from size 350 with SAE-profile (straight flank profile, see page 30); optional tripod• Optimized torsional rigidity and deflection resistance in a low-weight design• Particularly suitable for use with high-speed drives• Optional: Low-maintenance length compensation through use of plastic-coated (Rilsan®) involute spline profile• Rolling mill drives• Heavy-duty industrial drives• Paper machinery• Pumps• Marine vessels• Rail vehiclesCH 260 to 19 440 350 to 1 400• Very high torque capacity • Optimized bearing life• Flange with Hirth connection for transmitting maximum torque• Length compensation with SAE-profile (straight flank profile, see page 30)• Rolling mill drives• Construction of heavy machinery• Paper machineryE 1 600 to 14 000 590 to 1 220• Maximum torque capacity• Optimized bearings for exceptionally demanding applications• Patented 2-piece flange yoke• Flange with Hirth connection for transmitting maximum torque• Length compensation with SAE profile (straight flank profile, see page 30)• Heavy-duty rolling mill drives83 Designs3.1 Center sectionsType Description…TUniversal joint shaft with standard length compensation…TLUniversal joint shaft with longer length compensation…TKUniversal joint shaft with short length compensation…TRUniversal joint shaft with tripod length compensation1…FUniversal joint shaft without length compensation (fixed-length shaft)…GKJoint coupling: short, separable joint shaft without length compensation…FZIntermediate shaft with a joint head and bearing…Z Intermediate shaft with double bearing1 Technical data: Please request separate catalog93.2 FlangesExample R T 250.8 S 285 / 315 R 2 560Series S, R, CH, ECenter-section designT, TL, TK, TR, F, GK, FZ, ZSize Flange designS, K, Q, HFlange size input end / output end, see section 7.1 (Page 28)Profile coating S: Steel (Standard) R: Rilsan®Length lmin or lz min in mm3.3 Type designationsType DescriptionSFriction flange, torque transmission by a non-positive connectionQFlange with face key for torque transmissionType DescriptionKFlange with split sleeves for torque transmission (DIN 15 451)HFlange with Hirth coupling for torque transmission1022111 1 Rolling mills (horizontal rolling stand) 2, 3 Rolling mills (edging mill stand)4 Applications331221131 Rail vehicle drives2 Paper machines3 Marine propulsion4 Pumps5 Test stands 6 Special drives (mine hoist)4635145 Definitions and abbreviations5.1 LengthsUniversal joint shaft with length compensationlB : Operating length (to be specified when ordering)lz : Shortest length of the universal joint shaft (fully collapsed)lv : Available length compensationThe distance between the driving and the driven machines, together with any length changes during operation, deter mines the operating length:Optimal operating length: lB,opt ˜ lz + lv __ 3 Maximum permissible operating length: lB,max = lz + lvUniversal joint shaft without length compensationlB : Operating length, which corresponds to the universal joint shaft length l (to be specified when ordering)lB,maxlz lv lB (=l)155.2 Torque loadsDesignation ExplanationComponentsMDW This is the reversing fatigue torque rating. The shaft will have an infinite fatigue life up to this torque level.MDS This is the pulsating, one-way fatigue torque rating. The shaft will have infinite fatigue life up to this torque level.Here: MDS ˜ 1.5 · MDWMK Maximum permissible torque. If this level is exceeded, plastic deformation may occur.BearingMZ The permissible torque for rarely occuring peak loads. At torque levels in excess of MZ, the bearing tracks might suffer plastic deformation. This can lead to a reduced bearing life.Flanged connectionsIndividually designedNoteMDW , MDS and MZ are load limits for the universal joint shaft. In the case of torque values that are close to the load limit, the transmission capability of the flange connection needs to be checked, especially when Hirth couplings are not being used.Torque definitionsM (t)MDSMDW0t16LA: Length compensation A: without profile guardB: with profile guardC: Rilsan® coating with profile guardGeneral specifications ST1 STK 1 STK 2 STK 3 STK 42 SF SGK SFZ SZ SFZ, SZSize Mz [kNm]MDW [kNm]CR [kNm]ßmax [°]a k b ± 0.1 c H7 h C12 lm r t z g LA lv Iz min LA lv Iz fix LA lv Iz fix LA lv Iz fix LA lv Iz fix Imin Ifix Imin Imin Id d ga ta058.1 0.25 0.08 0.09 30 58 52 47 30 5 30 28 x 1.5 1.5 4 3.5 A, B 25 240 B 25 215 B 25 195 B 25 175 B 20 165 160 120 - - - - - -065.1 0.52 0.16 0.16 30 65 60 52 35 6 32 32 x 1.5 1.7 4 4 A, B 30 260 B 30 235 B 30 220 B 30 200 B 20 180 165 128 - - - - - -075.1 1.2 0.37 0.23 30 75 70 62 42 6 36 40 x 2 2.2 6 5.5 A, B 35 300 B 35 270 B 35 250 B 35 225 B 25 200 200 144 - - - - - -090.2 2.2 0.68 0.44 20 90 86 74.5 47 8 42 50 x 2 2.5 4 6 A. B, C 40 350 B, C 40 310 B, C 40 280 B, C 40 250 B, C 25 225 216 168 - - - - - -100.2 3.0 0.92 0.62 20 100 98 84 57 8 46 50 x 3 2.5 6 7 A, B, C 40 375 B, C 40 340 B, C 40 310 B, C 40 280 B, C 30 255 250 184 - - - - - -120.2 4.4 1.3 0.88 20 120 115 101.5 75 10 60 60 x 4 2.5 8 8 A, B, C 60 475 B, C 60 430 B, C 60 400 B, C 50 360 B, C 35 325 301 240 - - - - - -120.5 5.4 1.6 1.4 20 120 125 101.5 75 10 60 70 x 4 2.5 8 9 A, B, C 60 495 B, C 60 450 B, C 60 420 B, C 50 375 B, C 35 345 307 240 - - - - - -150.2 7.1 2.2 2.0 20 150 138 130 90 12 65 80 x 4 3 8 10 C 110 550 C 80 490 C 80 460 C 80 400 C 40 360 345 260 - - - - - -150.3 11 3.3 2.6 35 150 150 130 90 12 90 90 x 4 3 8 12 C 110 745 C 110 680 C 110 640 C 80 585 C 40 545 455 360 - - - - - -150.5 13 4.3 3.3 24 150 158 130 90 12 86 100 x 5 3 8 12 C 110 660 C 110 600 C 80 555 C 45 495 C 40 400 430 344 - - - - - -180.5 22 6.7 4.6 30 180 178 155.5 110 14 96 110 x 6 3.6 8 14 C 110 740 C 110 650 C 60 600 C 45 560 C 60 500 465 384 - - - - - -225.7 35 11 6.9 30 225 204 196 140 16 110 120 x 6 5 8 15 C 140 830 C 110 720 C 80 650 C 55 600 C 40 550 520 440 533 586 171 80 25 4Dimensions in mm 1 Longer lv on request2 shorter lZ upon request6 Technical data6.1 S SeriesSF SGKlfixl17LA: Length compensation A: without profile guardB: with profile guardC: Rilsan® coating with profile guardGeneral specifications ST1 STK 1 STK 2 STK 3 STK 42 SF SGK SFZ SZ SFZ, SZSize Mz [kNm]MDW [kNm]CR [kNm]ßmax [°]a k b ± 0.1 c H7 h C12 lm r t z g LA lv Iz min LA lv Iz fix LA lv Iz fix LA lv Iz fix LA lv Iz fix Imin Ifix Imin Imin Id d ga ta058.1 0.25 0.08 0.09 30 58 52 47 30 5 30 28 x 1.5 1.5 4 3.5 A, B 25 240 B 25 215 B 25 195 B 25 175 B 20 165 160 120 - - - - - -065.1 0.52 0.16 0.16 30 65 60 52 35 6 32 32 x 1.5 1.7 4 4 A, B 30 260 B 30 235 B 30 220 B 30 200 B 20 180 165 128 - - - - - -075.1 1.2 0.37 0.23 30 75 70 62 42 6 36 40 x 2 2.2 6 5.5 A, B 35 300 B 35 270 B 35 250 B 35 225 B 25 200 200 144 - - - - - -090.2 2.2 0.68 0.44 20 90 86 74.5 47 8 42 50 x 2 2.5 4 6 A. B, C 40 350 B, C 40 310 B, C 40 280 B, C 40 250 B, C 25 225 216 168 - - - - - -100.2 3.0 0.92 0.62 20 100 98 84 57 8 46 50 x 3 2.5 6 7 A, B, C 40 375 B, C 40 340 B, C 40 310 B, C 40 280 B, C 30 255 250 184 - - - - - -120.2 4.4 1.3 0.88 20 120 115 101.5 75 10 60 60 x 4 2.5 8 8 A, B, C 60 475 B, C 60 430 B, C 60 400 B, C 50 360 B, C 35 325 301 240 - - - - - -120.5 5.4 1.6 1.4 20 120 125 101.5 75 10 60 70 x 4 2.5 8 9 A, B, C 60 495 B, C 60 450 B, C 60 420 B, C 50 375 B, C 35 345 307 240 - - - - - -150.2 7.1 2.2 2.0 20 150 138 130 90 12 65 80 x 4 3 8 10 C 110 550 C 80 490 C 80 460 C 80 400 C 40 360 345 260 - - - - - -150.3 11 3.3 2.6 35 150 150 130 90 12 90 90 x 4 3 8 12 C 110 745 C 110 680 C 110 640 C 80 585 C 40 545 455 360 - - - - - -150.5 13 4.3 3.3 24 150 158 130 90 12 86 100 x 5 3 8 12 C 110 660 C 110 600 C 80 555 C 45 495 C 40 400 430 344 - - - - - -180.5 22 6.7 4.6 30 180 178 155.5 110 14 96 110 x 6 3.6 8 14 C 110 740 C 110 650 C 60 600 C 45 560 C 60 500 465 384 - - - - - -225.7 35 11 6.9 30 225 204 196 140 16 110 120 x 6 5 8 15 C 140 830 C 110 720 C 80 650 C 55 600 C 40 550 520 440 533 586 171 80 25 4Dimensions in mm 1 Longer lv on request2 shorter lZ upon requestldødldl lta taga gaødST / STK SFZ SZlztlmlvgøh øh øhøbøc øk ørøbz = 445° 45°øbz = 6øbz = 822.5°45°øa18LA: Length compensationB: with profile guardC: Rilsan® coating with profile guardGeneral specifications RT RTL1 RTK 1 RTK 22 RF RGK RFZ RZ RFZ, RZSize Mz [kNm]MDW [kNm]CR [kNm]ßmax [°]k lm r LA lv Iz min LA lv Iz min LA lv Iz fix LA lv Iz fix Imin Ifix Imin Imin ld d ga ta198.8 32 16 8.6 25 198 110 160 x 10 C 110 780 - - - - - - - - - 480 440 535 568 171 80 25 4208.8 55 20 11.4 15 208 120 170 x 12.5 B, C 120 815 B, C 370 1 110 B, C 100 725 B, C 80 640 520 480 626 732 229 90 32 5250.8 80 35 19.1 15 250 140 200 x 12.5 B, C 120 895 B, C 370 1 280 B, C 110 800 B, C 70 735 620 560 716 812 251 110 34 6285.8 115 50 26.4 15 285 160 220 x 12.5 B, C 140 1 060 B, C 370 1 430 B, C 120 960 B, C 100 880 720 640 804 883 277 130 42 6315.8 170 71 36.6 15 315 180 240 x 16 B, C 140 1 170 B, C 370 1 470 B, C 120 1 070 B, C 100 980 805 720 912 1 019 316.5 160 45 7350.8 225 100 48.3 15 350 194 292 x 22.2 B 140 1 240 B 400 1 640 B 130 1 160 B 110 1 070 855 776 980 1 087 344.5 200 48 7390.8 325 160 67.1 15 390 215 323.9 x 25 B 170 1 400 B 400 1 800 B 150 1 280 B 100 1 200 955 860 1 023 1 091 346.5 200 48 9440.8 500 250 100 15 435 260 368 x 28 B 200 1 540 B 400 2 100 B 170 1 380 B 100 1 300 1 155 1 040 - - - - - -490.8 730 345 130 15 480 270 406.4 x 32 B 220 1 870 B 400 2 300 B 200 1 680 B 170 1 520 1 205 1 080 - - - - - -550.8 1 000 500 185 15 550 305 470 x 32 B 220 1 940 B 400 2 500 B 170 1 775 B 100 1 680 1 355 1 220 - - - - - -Dimensions in mm 1 Longer lv on request 2 Shorter lz on request Flange dimensions: Pages 20 to 236.2 R SerieslfixlRF RGK19LA: Length compensationB: with profile guardC: Rilsan® coating with profile guardGeneral specifications RT RTL1 RTK 1 RTK 22 RF RGK RFZ RZ RFZ, RZSize Mz [kNm]MDW [kNm]CR [kNm]ßmax [°]k lm r LA lv Iz min LA lv Iz min LA lv Iz fix LA lv Iz fix Imin Ifix Imin Imin ld d ga ta198.8 32 16 8.6 25 198 110 160 x 10 C 110 780 - - - - - - - - - 480 440 535 568 171 80 25 4208.8 55 20 11.4 15 208 120 170 x 12.5 B, C 120 815 B, C 370 1 110 B, C 100 725 B, C 80 640 520 480 626 732 229 90 32 5250.8 80 35 19.1 15 250 140 200 x 12.5 B, C 120 895 B, C 370 1 280 B, C 110 800 B, C 70 735 620 560 716 812 251 110 34 6285.8 115 50 26.4 15 285 160 220 x 12.5 B, C 140 1 060 B, C 370 1 430 B, C 120 960 B, C 100 880 720 640 804 883 277 130 42 6315.8 170 71 36.6 15 315 180 240 x 16 B, C 140 1 170 B, C 370 1 470 B, C 120 1 070 B, C 100 980 805 720 912 1 019 316.5 160 45 7350.8 225 100 48.3 15 350 194 292 x 22.2 B 140 1 240 B 400 1 640 B 130 1 160 B 110 1 070 855 776 980 1 087 344.5 200 48 7390.8 325 160 67.1 15 390 215 323.9 x 25 B 170 1 400 B 400 1 800 B 150 1 280 B 100 1 200 955 860 1 023 1 091 346.5 200 48 9440.8 500 250 100 15 435 260 368 x 28 B 200 1 540 B 400 2 100 B 170 1 380 B 100 1 300 1 155 1 040 - - - - - -490.8 730 345 130 15 480 270 406.4 x 32 B 220 1 870 B 400 2 300 B 200 1 680 B 170 1 520 1 205 1 080 - - - - - -550.8 1 000 500 185 15 550 305 470 x 32 B 220 1 940 B 400 2 500 B 170 1 775 B 100 1 680 1 355 1 220 - - - - - -Dimensions in mm 1 Longer lv on request 2 Shorter lz on request Flange dimensions: Pages 20 to 23lzlmlvøkørldødltagaldltagaødRFZRT / RTL / RTKRZ20S flange: friction flangek1 a b ± 0.2 c H7 g h C12 t z Note198225 196 140 15 16 5 8 Standard250 218 140 18 18 6 8285 245 175 20 20 7 8208225 196 140 15 16 5 8 Torque MDW = 18 kNm250 218 140 18 18 6 8 Standard285 245 175 20 20 7 8315 280 175 22 22 7 8250250 218 140 18 18 6 8 Torque MDW = 25 kNm285 245 175 20 20 7 8 Standard315 280 175 22 22 7 8350 310 220 25 22 8 10285285 245 175 20 20 7 8 Torque MDW = 36 kNm315 280 175 22 22 7 8 Standard350 310 220 25 22 8 10390 345 250 32 24 8 10315315 280 175 22 22 7 8 Torque MDW = 52 kNm350 310 220 25 22 8 10 Standard390 345 250 32 24 8 10435 385 280 40 27 10 10350350 310 220 25 22 8 10 Torque MDW = 75 kNm390 345 250 32 24 8 10 Standard435 385 280 40 27 10 10390390 345 250 32 24 8 10 Torque MDW = 100 kNm435 385 280 40 27 10 10 StandardDimensions in mm. Additional flanges on request.1 Rotation diameter of the universal joint shaft.økøcøbøb øbøaz = 8 z = 10øhtgøh22.5° 36°45° 36°21Q flange: flange with face keyk1 a b ± 0.2 c H7 g h t x h9 y z Note208225 196 105 20 17 5 32 9 8 Standard250 218 105 25 19 6 40 12.5 8285 245 125 27 21 7 40 15 8250250 218 105 25 19 6 40 12.5 8 Standard285 245 125 27 21 7 40 15 8315 280 130 32 23 8 40 15 10285285 245 125 27 21 7 40 15 8 Standard315 280 130 32 23 8 40 15 10350 310 155 35 23 8 50 16 10315315 280 130 32 23 8 40 15 10 Standard350 310 155 35 23 8 50 16 10390 345 170 40 25 8 70 18 10350350 310 155 35 23 8 50 16 10 Standard390 345 170 40 25 8 70 18 10435 385 190 42 28 10 80 20 16390390 345 170 40 25 8 70 18 10 Standard435 385 190 42 28 10 80 20 16480 425 205 47 31 12 90 22.5 16440435 385 190 42 28 10 80 20 16 Standard480 425 205 47 31 12 90 22.5 16550 492 250 50 31 12 100 22.5 16490480 425 205 47 31 12 90 22.5 16 Standard550 492 250 50 31 12 100 22.5 16550 550 492 250 50 31 12 100 22.5 16 StandardDimensions in mm. Additional flanges on request.1 Rotation diameter of the universal joint shaft.z = 8 z = 10 z = 16øh øh øh22.5° 10° 20°30°45°30°20°øb øb øbøa øb øc x øktyg22K flange: flange with split sleevek1 a b ± 0.2 c H7 g h C12 t z d e h12 Note198225 196 140 15 16 5 8 192 21 Standard250 218 140 18 18 6 8 214 25208250 218 140 18 18 6 8 214 25 Standard285 245 175 20 20 7 8 240 28250285 245 175 20 20 7 8 240 28 Standard315 280 175 22 22 7 8 270 30285315 280 175 22 22 7 8 270 30 Standard350 310 220 25 22 8 10 300 32315350 310 220 25 22 8 10 300 32 Standard390 345 250 32 24 8 10 340 32350390 345 250 32 24 8 10 340 32 Standard435 385 280 40 27 10 10 378 35390 435 385 280 40 27 10 10 378 35 StandardDimensions in mm.Additional flanges on request.1 Rotation diameter of the universal joint shaft.økøcøbøb øbøaz = 8 + 4 z = 10 + 448° 54°øhtgøhøe øeød ød22.5° 36°45° 36°23H flange: Flange with Hirth connectionsk1 a b ± 0.2 c g h C12 u2 z Note208225 196 180 20 18 48 4 Standard250 218 200 25 20 48 4250250 218 200 25 20 48 4 Standard285 245 225 27 21 60 4285285 245 225 27 21 60 4 Standard315 280 250 32 23 60 4315315 280 250 32 23 60 4 Standard350 310 280 35 24 72 6350350 310 280 35 24 72 6 Standard390 345 315 40 25 72 6390390 345 315 40 25 72 6 Standard435 385 345 42 28 96 6440435 385 345 42 28 96 6 Standard480 425 370 47 31 96 8490480 425 370 47 31 96 8 Standard550 492 440 50 32 96 8550 550 492 440 50 32 96 8 StandardDimensions in mm.Bore on internal gear tooth.Additional flanges on request.1 Rotation diameter of the universal joint shaft.2 Number of teeth of Hirth coupling.økøcøbøb øb øbøaz = 4 z = 6 z = 845°60°22.5°45°øh øh øhg246.3 CH Seriesl lfixlzlmlvgøa øbøk ørz = 1230°øbz = 1630°øb22.5° 22.5°z = 24øb15°15°CHTCHF CHGKøhøhøh25LA: Length compensationA: without profile guardGeneral specifications CHT2 CHF2 CHGKSize Mz1 [kNm]MDW1 [kNm]CR [kNm]ßmax [°]a k b ± 0.2 h lm r z g LA lv Iz min Imin Ifix350.8 260 140 48.3 10 350 350 320 17.5 210 292 x 22.2 12 45 B 170 1 684 1 050 840390.8 350 190 67.1 10 390 390 355 20 230 323.9 x 25 12 50 B 170 1 874 1 160 920440.8 560 280 100 10 440 440 405 20 260 368 x 28 16 55 B 190 2 104 1 300 1 040490.8 730 390 130 10 490 490 450 22 290 406.4 x 32 16 60 B 210 2 344 1 460 1 160550.8 1 010 560 185 10 550 550 510 24 330 470 x 32 16 70 B 250 2 644 1 620 1 320590.40 1 330 890 212 10 580 590 535 26 350 508 x 50 24 75 B 250 2 784 1 740 1 400620.40 1 430 1 030 228 10 610 620 565 26 370 508 x 50 24 75 B 250 2 864 1 820 1 480650.40 1 800 1 190 284 10 640 650 590 30 390 558.8 x 55 24 80 B 250 3 034 1 940 1 560680.40 1 920 1 360 304 10 670 680 620 30 405 558.8 x 55 24 80 B 250 3 094 2 000 1 620710.40 2 390 1 550 362 10 700 710 645 33 420 609.6 x 60 24 90 B 250 3 284 2 100 1 680740.40 2 550 1 760 385 10 730 740 675 33 440 609.6 x 60 24 90 B 250 3 364 2 180 1 760770.40 3 150 1 980 472 10 760 770 700 36 460 660.4 x 65 24 95 B 250 3 554 2 300 1 840800.40 3 330 2 220 500 10 790 800 730 36 480 762 x 60 24 95 B 250 3 634 2 400 1 920830.40 4 090 2 480 588 10 820 830 765 39 500 762 x 60 24 105 2 000860.40 4 310 2 760 620 10 850 860 795 39 510 790 x 85 24 105 2 040890.40 5 050 3 060 706 10 880 890 805 45 535 790 x 85 24 115 2 140920.40 5 300 3 380 742 10 910 920 835 45 550 790 x 85 24 120 2 200950.40 6 070 3 720 847 10 940 950 865 45 570 790 x 85 24 120 2 280980.40 6 360 4 080 887 10 970 980 895 45 580 865 x 90 24 120 2 3201 010.40 7 340 4 470 1 015 10 1000 1 010 920 45 590 865 x 90 24 130 2 3601 040.40 7 660 4 880 1 060 10 1030 1 040 940 52 620 865 x 90 24 135 2 4801 070.40 7 880 5 170 1 090 10 1060 1 070 975 52 640 915 x 90 24 135 2 5601 090.40 9 100 5 620 1 275 10 1080 1 090 995 52 660 966 x 90 24 145 2 6401 120.40 9 480 6 090 1 328 10 1110 1 120 1 025 52 670 1 000 x 90 24 145 2 6801 170.40 11 620 6 940 1 592 10 1160 1 170 1 065 62 700 1 000 x 90 24 150 2 8001 200.40 12 070 7 490 1 654 10 1190 1 200 1 095 62 720 1 100 x 90 24 150 2 8801 250.40 14 010 8 480 1 889 10 1240 1 250 1 145 62 740 1 100 x 90 24 160 2 9601 280.40 14 510 9 100 1 957 10 1270 1 280 1 175 62 760 1 200 x 90 24 160 3 0401 320.40 16 570 9 980 2 215 10 1310 1 320 1 215 62 790 1 200 x 90 24 170 3 1601 360.40 17 330 10 920 2 316 10 1350 1 360 1 255 62 815 1 300 x 90 24 170 3 2601 400.40 19 440 11 910 2 583 10 1390 1 400 1 285 70 840 1 300 x 90 24 180 3 360Dimensions in mm.From size 350.8 to 550.8 without internal bearing ring.1 Values for forged components. 2 From size 830.40 to customer specification.266.4 E SeriesE Series high-performance universal joint shaftFeatures Advantages BenefitsJoints • Flange geometry with optimal design for torque transmission• Reinforced journal crosses• Optimized cross-sections and transition radii on all torque-transmitting components• Significantly higher torque capacity than with previous universal joint shaft designs• Optimized to withstand torque peaks + Productivity increase + Long service life + Reduced maintenance costs + Capability to roll higher strength steels• Patented 2-piece flange yoke, with serrations alignment on the symmetry axis• One-piece bearing eye• Heavy-duty cross-sections without joints or boltsStorage • Maximum utilization of available space for installation with largest possible bearings and journal crosses• Increased bearing life and capability to withstand high static and dynamic loads• Optimized incorporation of bearings• Best leverage ratios at journal cross• Long bearing life• Uniformed load distribution throughout bearing• Capability to withstand high static and dynamic loads• Roller bearings with outer and inner rings • Individually replaceable cartridge style roller bearings• Optimized rolling element design • Optimized to withstand torque peaks• Improved rolling element lubrication • Improved hydrodynamic lubricationConnection technology • Flange with Hirth coupling • Reliable transmission of the highest torques• Optimal centering• Easy to assemble + Low assembly and maintenance costs + Productivity increase• Full flange design • No weakening of components as a result of necking or reduced cross-sections + Capability to roll higher strength steels + Able to withstand overloads• ET, EF and EGK designs• Sizes up to 1 220• Torque capacities upon requestE Series high-performance universal joint shafts with size comparison27E Series high-performance universal joint shaftFeatures Advantages BenefitsJoints • Flange geometry with optimal design for torque transmission• Reinforced journal crosses• Optimized cross-sections and transition radii on all torque-transmitting components• Significantly higher torque capacity than with previous universal joint shaft designs• Optimized to withstand torque peaks + Productivity increase + Long service life + Reduced maintenance costs + Capability to roll higher strength steels• Patented 2-piece flange yoke, with serrations alignment on the symmetry axis• One-piece bearing eye• Heavy-duty cross-sections without joints or boltsStorage • Maximum utilization of available space for installation with largest possible bearings and journal crosses• Increased bearing life and capability to withstand high static and dynamic loads• Optimized incorporation of bearings• Best leverage ratios at journal cross• Long bearing life• Uniformed load distribution throughout bearing• Capability to withstand high static and dynamic loads• Roller bearings with outer and inner rings • Individually replaceable cartridge style roller bearings• Optimized rolling element design • Optimized to withstand torque peaks• Improved rolling element lubrication • Improved hydrodynamic lubricationConnection technology • Flange with Hirth coupling • Reliable transmission of the highest torques• Optimal centering• Easy to assemble + Low assembly and maintenance costs + Productivity increase• Full flange design • No weakening of components as a result of necking or reduced cross-sections + Capability to roll higher strength steels + Able to withstand overloadsThree-dimensional, sectioned model of an E Series joint28Journal crossFlange yokeWelded yokeTubeSplined hub7 Engineering basics7.1 Major components of a Voith universal joint shaftHub yoke, output endDesign29Splined journalProfile guardDirt scraperWelded yokeFlange yokeJournal cross set7 Engineering basics7.1 Major components of a Voith universal joint shaftIrrespective of their series, all versions and sizes of Voith uni-v er sal joint shafts share many of the same common at tri -butes that contribute to ensuring reliable operation:• Yokes and flange yokes with optimized geometry• Drop-forged journal crosses• Low maintenance roller bearings with maximum load capacity• Use of high-strength tempering and hardened steels• Optimal welded jointsShaft yoke, input endDesign307.2 Telescopic length compensation1 SAE profile (straight flank profile)2 Involute profile21For many applications, length compensation of the universal joint shaft is required. In comparison with other driveline products, in the case of universal joint shafts, length compe-nsation is achieved by the center section and offset by the universal joints. Two types of length compensation are used in Voith universal joint shafts: the SAE profile (straight flank profile) and the involute profile. The universal joint shaft series and size deter mine the type of length compensation.For smaller universal joint shafts, which typically experience lower loads, the involute profile is a suitable solution with a good cost-benefit ratio. The SAE profile (straight flank profile) is a better solution for large, high-performance universal joint shafts.31Length compensation with SAE profile (straight flank profile)Features Advantages Benefits• Straight flank, diameter-centered profile• Separation of torque transmission and centering functions + Long service life• Almost orthogonal introduction of force• Lower normal forces and thus lower displacement forces + Ease of movement• Large contact surfaces • Low surface pressure + Long service life• Favorable pairing of materials for hub and spline shaft• Spline shaft nitrated as standard• High wear resistance + Long service life• Patented lubrication mechanism in the grease distribution groove for uniform distribution of grease across the full diameter of the profile• Tooth shape incorporates lubri ca-tion reservoir for reliable supply of lubricant to sliding surfaces + Extended maintenance intervalsSAE-profile (straight flank profile)Involute profileFN ˜ FUFN > FUFUSAE-profile (straight flank profile)Involute profileCentering functionTorque transmissionForce introduced during torque transmission Torque transmission and centering32W1bG1W2a2M1, v1M2, v2a1G1 Standard universal jointW1 Input shaftW2 Output shafta1, a2 Angle of rotationb Deflection angleM1, M2 Torquesv1, v2 Angular velocitiesUniversal joint7.3 Kinematics of the universal joint• When the input shaft W1 rotates at a constant angular vel-ocity (v1 = const.), the output shaft W2 rotates at a varying angular velocity (v2 ? const.).• The angular velocity of the output shaft v2 and the differen-tial angle w = (a1 – a2) vary in a sinusoidal manner, their values depending upon the deflection angle b.• This characteristic of universal joints is called the gimbal error and must be taken into consideration when selecting a universal joint shaft.33b = 12° b = 12° b = 6° b = 6° a1 wb b b b blwmaxlfor b = 12° 1 – cos 12° 0.8° 0.4° 0° -0.4° -0.8° 1.021.011.000.990.980° 90° 180° 270° 360° • With one rotation of the shaft W1, the differential angle w changes four times, as does the angular velocity v2.• During the course of one rotation, the shaft W2 twice passes through the points of maximum acceleration and deceleration.• At larger deflection angles b and higher velocities, con-siderable forces can be generated.The following equations apply:w = a1 – a2 (1) tan a1 ______ tan a2 = cos b (2)tan w = tan a1 · (cos b – 1) _________________ 1 + cos b · tan2 a1 (3)This gives the ratio of the angular velocities between the two shafts W1 and W2: v2 __ v1 = cos b _______________ 1 – sin2 b · sin2 a1 (4)change to maximum: v2 ___ v1 | max = 1 _____ cos b at a1 = 90° and a1 = 270° (4a)change to minimum: v2 ___ v1 | min = cos b at a1 = 0° and a1 = 180° (4b)As regards the torque ratio, the following equation applies: M2 ___ M1 = v1 ___ v2 (5)change to maximum: M2 ___ M1 | max = 1 ______ cos b at a1 = 90° and a1 = 270° (5a)change to minimum: M2 ___ M1 | min = cos b at a1 = 0° and a1 = 180° (5b) Movement relation34One indicator of the variation is the variation factor U:U = v2 ___ v1 | max – v2 ___ v1 | min = 1 _____ cos b – cos b = tan b · sin b (6)Finally, as regards to the maximum differential angle wmax the following equation applies:tan wmax = ± 1 – cos b _________ 2 · v_____ cos b (7)Uwmaxwmax4.4°4.0°3.6°3.2°2.8°2.4°2.0°1.6°1.2°0.8°0.4°0.440.400.360.320.280.240.200.160.120.080.040° 3° 6° 9° 12° 15° 18° 21° 24° 27° 30°UbVariation factor, differential angleAll of the components of the universal joint shaft should lie in one planeAConclusionsA single universal joint should only be used if the following requirements are met:• The variation in the rotational speed of the output shaft is of secondary importance• The deflection angle is very small (b < 1°)• The forces transmitted are lowG1G235Conditions for the synchronous rotation of the input and output shafts:The three conditions A, B and C ensure that joint G2 operates with a phase shift of 90° and fully compensates for the gimbal error of joint G1. This universal joint shaft arrangement is known as the ideal universal joint shaft arrangement with complete motion compensation.7.4 Double universal jointsSection 7.3 shows that the output shaft W2 always rotates at the varying angular velocity v2 when connected via a single universal joint at a given deflection angle b.Universal joint shaft in Z-arrangement, the input and output shafts lie parallel to each other in one planeBoth yokes of the center section of the shaft lie in one planeThe deflection angles b1 and b2 of the two joints are identicalUniversal joint shaft in W-arrangement, the input and output shafts lie parallel to each other in one planeIf, however, two universal joints G1 and G2 are connected to-gether correctly in the form of a universal joint shaft in a Z- or W-arrangement, the variations in the speeds of the input and output shaft fully cancel each other out.This is the arrangement to be aiming for. If just one of the three conditions is not satisfied, then the universal joint shaft no longer operates at constant input and output speeds, i.e. it no longer operates homo-kinetically. In such cases, please contact your Voith Turbo representative.CBb2 b1 b2 b1 G1G2b1 b2 G1G236Maximum values for radial bearing forces on universal joint shafts in a Z-arrangement a bMdA BLb1b2E Fe fG1G2b1 ? b2 b1 = b2a1 = 0° B1 F1A1 E1A1 = Md · b · cos b1 _________ L · a · (tan b1 – tan b2)B1 = Md · (a + b) · cos b1 _____________ L · a · (tan b1 – tan b2)E1 = Md · (e + f) · cos b1 ____________ L · f · (tan b1 – tan b2)F1 = Md · e · cos b1 _________ L · f · (tan b1 – tan b2)A1 = 0B1 = 0E1 = 0F1 = 0a1 = 90° B2 E2A2 F2A2 = Md · tan b1 ______ a B2 = Md · tan b1 ______ a E2 = Md · sin b2 ________ f · cos b1 F2 = Md · sin b2 ________ f · cos b1 A2 = Md · tan b1 ______ a B2 = Md · tan b1 ______ a E2 = Md · tan b1 ______ f F2 = Md · tan b1 ______ f 7.5.1 Radial bearing forcesDue to the deflection of the universal joint shaft, the connection bearings are also subjected to radial loads. The radial forces on the bearings vary from no forces to their maximum, twice per revolution.7.5 Bearing forces on input and output shafts 37Maximum values for radial bearing forces on universal joint shafts in a W-arrangement abMdABLb1 b2EFefG1 G2b1 ? b2 b1 = b2a1 = 0° B1 F1A1 E1A1 = Md · b · cos b1 _________ L · a · (tan b1 – tan b2)B1 = Md · (a + b) · cos b1 _____________ L · a · (tan b1 – tan b2)E1 = Md · (e + f) · cos b1 ____________ L · f · (tan b1 – tan b2)F1 = Md · e · cos b1 _________ L · f · (tan b1 – tan b1) A1 = 2 · Md · b · sin b1 ________ L · a B1 = 2 · Md · (a + b) · sin b1 ____________ L · a E1 = 2 · Md · (e + f) · sin b1 ____________ L · f F1 = 2 · Md · e · sin b1 ________ L · f a1 = 90° B2 F2A2 E2A2 = Md · tan b1 ______ a B2 = Md · tan b1 ______ a E2 = Md · sin b2 ________ f · cos b1 F2 = Md · sin b2 ________ f · cos b1 A2 = Md · tan b1 ______ a B2 = Md · tan b1 ______ a E2 = Md · tan b1 ______ f F2 = Md · tan b1 ______ f Designations and formulasG1, G2 Universal jointsA, B, E, F Connection bearingMd Input torqueA1/2, B1/2, E1/2, F1/2 Bearing forcesa1 Angle of rotationb1, b2 Deflection angle387.5.2 Axial bearing forcesIn principle, the kinematics of a universal joint shaft do not generate any axial forces. However, axial forces that need to be absorbed by adjacent bearings occur in universal joint shafts with length compensation for two reasons:1. Force Fax, 1 as a result of friction in the length compensa-tion assemblyAs the length changes during the transmission of torque, fric-tion is generated between the flanks of the spline profiles in the length compensation assembly. The frictional force Fax,1, which acts in an axial direction, can be calculated using the following equation:Fax,1 = m · Md · 2 ___ dm · cos bwhere:m Coefficient of friction; m ˜ 0.11 to 0.14 for steel against steel (lubricated) m ˜ 0.07 for Rilsan® plastic coating against steelMd Input torquedm Pitch circle diameter of the spline profileb Deflection angle2. Force Fax, 2 as a result of the pressure build-up in the length compensation assembly during lubricationDuring the lubrication of the length compensation assembly, an axial force Fax, 2 , occurs which depends on the force ap-plied while lubricating. Please note that information on this subject is available in the installation and operating instructions.1 Balancing machine 2 Balancing of universal joint shafts2139Type of machine – general examples Balance quality level GComplete piston engines for cars, trucks and locomotives G 100Cars: wheels, rims, wheel sets, universal joint shafts; crank drives with mass balancing on elastic mountsG 40Agricultural machinery; crank drives with mass balancing on rigid mounts; size reduction machinery; input shafts (cardan shafts, propeller shafts)G 16Jet engines; centrifuges; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed of up to 950 rpm; electric motors with a shaft height of less than 80 mm; fans; gearboxes; general industrial machinery; machine tools; paper machinery; process engineering equipment; pumps; turbochargers; hydro-power turbinesG 6.3Compressors; computer drives; electric motors and generators with a shaft height of at least 80 mm and a maximum rated speed of over 950 rpm; gas turbines, steam turbines; machine tool drives; textile machineryG 2.57.6 Balancing of universal joint shafts As with any other torque transmitting shaft, a universal joint shaft also has a non-uniform distribution of mass around the axis of rotation. This leads to unbalanced forces during oper-ation wich has to be compensated depending on the case of application. Depending on the operating speed and the spe-ci fic applica tion, Voith universal joint shafts are dynamically balanced in two planes.The balancing procedure employed by Voith for universal joint shafts is based on that prescribed in DIN ISO 1 940-1 ("Mech-anical vibration – Balance quality requirements for rotors in a constant (rigid) state – Part 1: Specification and verification of balance tolerances"). An extract from this Standard lists the following approximate values for balance quality levels:Depending on the application and maximum operating speed, the balance quality levels for universal joint shafts lie in the range between G 40 and G 6.3. The reproduction of the mea-surements can be subject to wider tolerances due to the influence of various physical factors. Such factors include:• Design characteristics of the balancing machine• Accuracy of the measuring method• Tolerances in the connections to the universal joint shaft• Radial and axial clearances in the universal joint bearings• Deflection clearance in length compensationThe benefits of balancing: + Prevention of vibrations and oscillations, resulting in smoother operation + Longer service life of the universal joint shaft408 Selection aidsThe design of a universal joint shaft depends on a number of factors. Reliable, verified calculations and tests prevent any danger to the surrounding area. Consideration of the costs that arise over the entire product lifecycle also comes into play.Three-dimensional bendingThe design procedures described in this chapter are only intended to provide approximate guidelines. When making a final decision about a universal joint shaft, you can rely on our sales engineers for their technical knowledge and many years of experience. We will be happy to advise you.The following factors have a major influence upon any decision regarding universal joint shafts:• Operating variables• Main selection criteria: Bearing lifetime or durability• Installation space• Adjacent bearingsbv1bh1bv2bh2418.1 Definitions of operating variablesDes ig-nationUsual unitExplanationPN [kW] Rated power of the drive motornN [rpm] Rated speed of the drive motorMN [kNm] Rated torque of the drive motor, where:MN = 60 _______ 2p · nN · PN ˜ 9.55 · PN ___ nN with MN in kNm, nN in rpm and PN in kWME [kNm] Equivalent torqueThis torque is an important operating variable if bearing lifetime is the main criterion in the selection of a universal joint shaft. It takes operating conditions into account and can be calculated for situa-tions involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently known, the rated torque can be used as an initial estimate.nE [rpm] Equivalent speedThis speed is an important operating variable if bearing lifetime is the main criteria in the selection of a universal joint shaft. It takes operating conditions into account and can be calculated for situa-tions involving combined loads (see section 8.2.1). If the operating conditions are not sufficiently known, the rated speed can be used as an initial estimate.Mmax [kNm] Peak torqueThis is the maximum torque that occurs during normal operation.nmax [rpm] Maximum speedThis is the maximum speed that occurs during normal operation.nz1 [rpm] Maximum permissible speed as a function of the deflection angle during operationThe center section of a universal joint shaft in a Z- or W-arrangement (b ? 0°) rotates at a varying speed. It experiences a mass acceleration torque that depends upon the speed and the deflection angle. To ensure smooth operation and prevent excessive wear, the mass acceleration torque is limited by avoiding the exceeding of the maximum speed of the universal joint shaft nz1. For addi-tional information see section 8.3.1.nz2 [rpm] Maximum permissible speed taking bending vibrations into accountA universal joint shaft is an elastic body when bent. At a critical bending speed (whirling speed), the frequency of the bending vibrations equals the natural frequency of the universal joint shaft. The result is a high load on all of the universal joint shaft components. The maximum speed of the universal joint shaft must be significantly lower than this critical speed. For additional information, see section 8.3.2.b [°] Deflection angle during operationDeflection angle of the two joints in a Z or W-arrangement, where: b = b1 = b2If the situation involves three-dimensional deflection, the resulting deflection to angle bR can be determined thus:tan bR = v_______________ tan2 bh + tan2 bV und es gilt: b = bRbmax [°] Maximum possible deflection angleThis is the deflection angle that occurs during normal operation. 428.2.1 Selection based upon bearing lifetimeThe procedure used for calculating the bearing lifetime is based upon that prescribed in DIN ISO 281 ("Rolling bear-ings – Dynamic load ratings and rating service life"). However, when applying this standard to universal joint shafts, several different factors are not taken into account; for instance, the support of the bearing, i.e. deformation of the bore under load. So far, these factors could only be assessed qualitatively.The theoretical lifetime of a bearing in a universal joint shaft can be calculated using the following equation:Lh = 1.5 · 107 ________ nE · b · KB · ( CR ___ ME ) 10 ___ 3 where:Lh is the theoretical lifetime of the bearing in hours [h]CR Load rating of the universal joint in kNm (see the tables in Chapter 6)b Deflection angle in degrees [°]; in the case of three-dimensional bending, the resulting deflection angle bR is to be used; in any case, however, using a minimum angle of 2°KB Operational factornE Equivalent speed in rpmME Equivalent torque in kNmOperational factorIn drives with diesel engines, torque spikes occur that are taken into account by the operational factor KB :Prime mover (driving machine)Operational factor KBElectric motor 1Diesel engine 1.28.2 Size selection There are essentially two selection criteria when choosing the size of a universal joint shaft:1. The lifetime of the roller bearings in the joints2. The fatigue-free operating range, and thus the torque capacity and / or load limitsAs a rule, the application determines the primary selection cri-teria. A selection based upon bearing lifetime is usually made if the drives need to have a long service life and pronounced torque spikes never occur or happen only briefly (for instance, during start-up). Typical examples include drives in paper ma-chinery, pumps and fans. In all other applications, the selection is made on the basis of the fatigue-free operating range.43n1nuEquivalent operating valuesThe equation for the theoretical lifetime of the bearing assumes a constant load and speed. If the load changes in increments, the equivalent operating values can be determined that produce the same fatigue as the actual loads. The equivalent operating values are ultimately the equivalent speed nE and the equivalent torque ME.If a universal joint shaft transmits the torque Mi for a time period Ti at a speed of ni, a time segment qi that normalizes the time period Ti with respect to the overall duration of operation Ttot is first defined:qi = Ti ____ Ttot with ? i = 1 u qi = q1 + q2 + … + qu = 1In this way, the equivalent operating values can be determined:nE = ? i = 1 u qi · ni = q1 · n1 + q2 · n2 + … + qu · nuME = ( ? i = 1 u qi · ni · M i 10 ___ 3 ___________ nE ) 3 ___ 10 = ( q1 · n1 · M 1 10 ___ 3 + q2 · n2 · M 2 10 ___ 3 + … + qu · nu · M u 10 ___ 3 _____________________________________ nE ) 3 ___ 10 Incremental variation of the load on a universal joint shaftConclusions• The bearing's calculated lifetime is a theoretical value that is usually significantly exceeded.• The following additional factors affect the lifetime of the bearings, sometimes to a significant degree: - Quality of the bearings - Quality (hardness) of the journals - Lubrication - Plastic deformation as a result of overloading - Quality of the sealsM, n M1M2n2Muq1 q2 qu q0 1448.2.2 Selection on the basis of fatigue-free operating rangeCalculations regarding the fatigue-free operating range can be made using a load spectrum. In practice though, sufficie-ntly accurate load spectra are seldom available. In this case, one needs to rely on the quasi-static dimensioning proce-dure. In this procedure, the expected peak torque Mmax is compared with the torques MDW , MDS and MZ (see section 5.2).The following estimate is made for the peak torque:Mmax ˜ K3 · MNK3 is called the shock factor. These are empirical values based upon decades of experience in designing universal joint shafts.The peak torque determined in this manner must meet the following requirements:1. Mmax = MDW for alternating load2. Mmax = MDS for pulsating load3. Individual and rarely occurring torque peaks must not exceed the value MZ. The permissible duration and fre quen cy of these torque spikes depends upon the appli ca tion; please contact Voith Turbo for more information.Shock loadShock factor K3Typical driven machineryMinimal 1.1…1.3 • Generators (under a uniform load)• Centrifugal pumps• Conveying equipment (under a uniform load)• Machine tools• Woodworking machineryModerate 1.3…1.8 • Multi-cylinder compressors• Multi-cylinder piston pumps• Light-section rolling mills• Continuous wire rolling mills• Primary drives in locomotives and other rail vehiclesSevere 2…3 • Transport roller tables• Continuous pipe mills• Continuously operating main roller tables• Medium-section rolling mills• Single-cylinder compressors• Single-cylinder piston pumps• Fans• Mixers• Excavators• Bending machines• Presses• Rotary drilling and boring equipment• Secondary drives in locomotives and other rail vehiclesVery severe3…5 • Reversing main roller tables• Coiler drives• Scale breakers• Cogging/roughing standsExtremely severe6…15 • Roll stand drives• Plate shears• Coiler pressure rolls458.3 Operating speeds8.3.1 Maximum permissible speed nz1 as a function of the deflection angleSection 7.3 shows that a universal joint exhibits a varying output motion. A universal joint shaft is a connection of two universal joints in series with one another. Under the condi-tions described in section 7.4, a universal joint shaft in a Z or W-arrangement exhibits homokinetic motion between the input and output. However, the center section of the uni ver-sal joint shaft still rotates at the periodically varying angular vel ocity v2 .Since the center section of the universal joint shaft still exhibits a mass moment of inertia, it creates a moment of resistance to the angular acceleration dv2 / dt. On universal joint shafts with length compensation, this alternating mass acceleration mo ment can cause clattering sounds in the profile. The conse-quences include less smooth operation and increased wear.Approximate values of nz1 as a function of bIn addition, the mass acceleration torque can affect the entire drive chain on universal joint shafts with length compensation, as well as universal joint shafts without length compensation. Torsional vibrations should be mentioned here by way of example.In order to prevent these adverse effects, please ensure the following conditions:nmax = nz1n z1 [rpm]b [°]2 4 6 8 10 12 14 16 18 20 22 24 26 28 30S 058.1S 065.1S 075.1S 180.5 S 225.7R 490.8CH 440.8R 250.8R 285.8 R 315.8 R 350.8CH 350.8R 390.8CH 390.8R 440.8CH 440.8R 550.8CH 550.86 0006008004 0002 0001 000500S 090.2S 100.2S 120.2 S 120.5S 150.2 S 150.3S 150.5R 198.8 R 208.8468.3.2 Maximum permissible speed nz2 as a function of operating lengthEvery universal joint shaft has a critical bending speed (whirl-ing speed) at which the rotational bending speed (bending frequency) matches the natural frequency of the shaft. The result: high loads on all components of the universal joint shaft. Damage to or destruction of the universal joint shaft is possible in unfavorable situations.The calculation of this critical bending speed for a real universal joint shaft in a driveline is a complex task that Voith Turbo performs using numerical computing programs.The critical bending speed depends essentially upon three factors:• Operating length lB• Deflection resistance of the universal joint shaft• Connecting conditions at the input and output endsThe maximum permissible speed nz2 is determined in such a way that it provides a safety allowance with respect to the critical bending speed that is suitable for the particular application.For safety reasons and to prevent the failure of the universal joint shaft, please ensure the following conditions:nmax = nz2For normal connecting and operating conditions, it is pos-sible to specify approximate values for the maximum permi-ssible speeds nz2 as a function of the operating length lB:47Approximate values of nz2 as a function of lB for the S SeriesApproximate values of nz2 as a function of lB for the R and CH Seriesn z2 [rpm]IB [mm]n z2 [rpm]IB [mm]1 000 2 000 3 000 4 000 5 000 6 000S 225.7S 180.5S 150.5S 150.3S 150.2S 120.5S 120.2S 090.2S 100.2S 075.1S 065.1S 058.11002004006008002 0004 0006 0001 000R 550.8CH 550.8R 490.8CH 490.8R 440.8CH 440.8R 390.8CH 390.8R 350.8CH 350.8R 315.8R 285.8R 250.8R 208.8R 198.82 000 3 000 4 000 5 000 6 0005006008002 0004 0001 000488.4 MassesSize Values for the tube based on lengthUniversal joint shafts with length compensation Universal joint shafts without length compensationJoint couplingm'R[kg / m]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL fix[kg]ST / STL / SF ST STL STK1 STK2 STK3 STK4 SF SGK058.1 1.0 1.1Values upon request1.1 1.0 1.0 0.9 0.9 0.8065.1 1.1 1.7 1.7 1.6 1.5 1.4 1.2 1.0075.1 2.0 2.7 2.5 2.4 2.3 2.1 2.0 1.0090.2 2.4 4.8 4.3 4.1 4.0 3.8 3.6 3.2100.2 3.5 6.1 5.8 5.5 5.3 5.1 4.5 4.2120.2 5.5 10.8 10.2 9.8 9.2 8.6 7.7 7.4120.5 6.5 14.4 13.7 13.2 12.3 11.5 10.5 9.2150.2 7.5 20.7 20.7 20.1 17.1 15.8 15.2 13.8150.3 8.5 32.0 27.0 25.9 27.4 26.0 22.1 16.6150.5 11.7 36.4 36.5 34.9 32.4 29.4 25.3 21.6180.5 15.4 51.7 48.5 46.7 43.1 40.9 32.4 30.6225.7 16.9 65 66 64 60 56 36 36RT / RTL / RF RT RTL RTK1 RTK2 RWF RGK198.8 37.0 92 - - - 56 59208.8 49 135 165 126 110 78 85250.8 58 199 222 179 165 115 127285.8 64 291 323 334 246 182 191315.8 89 400 599 387 356 250 270350.8 148 561 624 546 488 377 370390.8 185 738 817 684 655 506 524440.8 235 1 190 1 312 1 050 1 025 790 798490.8 296 1 452 1 554 1 350 1 300 1 014 1 055550.8 346 2 380 2 585 2 170 2 120 1 526 1 524Continued on pages 50 and 5149Size Values for the tube based on lengthUniversal joint shafts with length compensation Universal joint shafts without length compensationJoint couplingm'R[kg / m]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL min[kg]mL fix[kg]ST / STL / SF ST STL STK1 STK2 STK3 STK4 SF SGK058.1 1.0 1.1Values upon request1.1 1.0 1.0 0.9 0.9 0.8065.1 1.1 1.7 1.7 1.6 1.5 1.4 1.2 1.0075.1 2.0 2.7 2.5 2.4 2.3 2.1 2.0 1.0090.2 2.4 4.8 4.3 4.1 4.0 3.8 3.6 3.2100.2 3.5 6.1 5.8 5.5 5.3 5.1 4.5 4.2120.2 5.5 10.8 10.2 9.8 9.2 8.6 7.7 7.4120.5 6.5 14.4 13.7 13.2 12.3 11.5 10.5 9.2150.2 7.5 20.7 20.7 20.1 17.1 15.8 15.2 13.8150.3 8.5 32.0 27.0 25.9 27.4 26.0 22.1 16.6150.5 11.7 36.4 36.5 34.9 32.4 29.4 25.3 21.6180.5 15.4 51.7 48.5 46.7 43.1 40.9 32.4 30.6225.7 16.9 65 66 64 60 56 36 36RT / RTL / RF RT RTL RTK1 RTK2 RWF RGK198.8 37.0 92 - - - 56 59208.8 49 135 165 126 110 78 85250.8 58 199 222 179 165 115 127285.8 64 291 323 334 246 182 191315.8 89 400 599 387 356 250 270350.8 148 561 624 546 488 377 370390.8 185 738 817 684 655 506 524440.8 235 1 190 1 312 1 050 1 025 790 798490.8 296 1 452 1 554 1 350 1 300 1 014 1 055550.8 346 2 380 2 585 2 170 2 120 1 526 1 524Continued on pages 50 and 5150Size Values for the tube based on lengthUniversal joint shafts with length compensation Universal joint shafts without length compensationJoint couplingm'R[kg / m]mL min[kg]mL min[kg]mL fix[kg]CHT / CHF CHT CHF CHG350.8 134.2 685 508 453390.8 149.9 1 018 708 626440.8 189.3 1 415 1 001 895490.8 261.3 1 979 1 379 1 228550.8 305.2 2 807 1 918 1 730590.40 564.7 3 887 2 442 2 154620.40 564.7 4 232 2 787 2 466650.40 683.3 4 949 3 243 2 856680.40 683.3 5 364 3 657 3 232710.40 813.2 6 523 4 286 3 758740.40 813.2 7 020 4 783 4 207770.40 954.4 8 186 5 461 4 759800.40 1 040 8 884 6 085 5 282Values for dimensions and series not listed are available on requestDesignation Explanationm'R Mass of the tube per 1 m of lengthUniversal joint shafts with length compensationUniversal joint shafts without length compensationmL min Mass of the universal joint shaft for a length of… lz min lminCalculations for the entire universal joint shaft:mtot Total mass mges = mL min + (lz – lz min) · m'R mges = mL min + (l – lmin) · m'R51Size Values for the tube based on lengthUniversal joint shafts with length compensation Universal joint shafts without length compensationJoint couplingm'R[kg / m]mL min[kg]mL min[kg]mL fix[kg]CHT / CHF CHT CHF CHG350.8 134.2 685 508 453390.8 149.9 1 018 708 626440.8 189.3 1 415 1 001 895490.8 261.3 1 979 1 379 1 228550.8 305.2 2 807 1 918 1 730590.40 564.7 3 887 2 442 2 154620.40 564.7 4 232 2 787 2 466650.40 683.3 4 949 3 243 2 856680.40 683.3 5 364 3 657 3 232710.40 813.2 6 523 4 286 3 758740.40 813.2 7 020 4 783 4 207770.40 954.4 8 186 5 461 4 759800.40 1 040 8 884 6 085 5 282Values for dimensions and series not listed are available on requestDesignation Explanationm'R Mass of the tube per 1 m of lengthUniversal joint shafts with length compensationUniversal joint shafts without length compensationmL min Mass of the universal joint shaft for a length of… lz min lminCalculations for the entire universal joint shaft:mtot Total mass mges = mL min + (lz – lz min) · m'R mges = mL min + (l – lmin) · m'R528.5 Connection flanges and bolted connectionsWhen installing the Voith universal joint shaft in a driveline, the connection flanges and bolted connections must satisfy a number of requirements:1. Design• When using a universal joint shaft without length compen-sa tion, a connection flange ("coupling") that is moveable in a longitudinal direction is required so that the universal joint shaft can slide over the spigot. The connection flange also absorbs additional length changes arising, for instance, from thermal expansion or changes in the deflection angle.2. Material• The material used for the connection flanges has been selected to permit the use of bolts of property class 10.9 (according to ISO 4 014 / 4 017 and/or DIN 931 - 10.9).• Special case for the S and R Series: If the material used for the connection flanges does not per mit the use of bolts of property class 10.9, the torques that can be transmitted by the flange connection are reduced. The specified tightening torques for the bolts must be redu ced accordingly.3. Dimensions, bolted connections• On universal joint shafts from the S and R Series, the dimen sions of the connection flanges match those of the universal joint shaft, apart from the locating diameter c. The locating diameter provides a clearance (fit H7 / h6). • On universal joint shafts with an H flange, the dimensions of the connection flanges are identical to those of the univ-e rsal joint shaft. The Hirth couplings are self-centering.• On universal joint shafts from the S and R Series, the relief diameter fg on the universal joint shaft flange is not suitable for locking hexagon head bolts or -nuts. A relief diameter fa on the connection flange is suitable for this purpose.53S flange / Q flange K flange H flangeA+B22.5° 22.5° 30°A AAAB 8 x A 4 x B10 x A 4 x BAAAB 8 x A10 x A12 x A16 x A36° 36° 22.5°AAAAAAAAA AAAAFlange connection for universal joint shafts of the S and R SeriesFastener hole pattern for flange connections on the S and R Series of universal joint shaftsA B Ammin Z1g g vyatøbøfgøa øfaøcxZ2mn o pmmin Z1g g vøbøf gøa øfam54Dimensions of the connection flanges Bolted connection (A) Bolted connection with split sleeve (B)Comments 1 2 3 4 5 6 7 8 9 10 11 12Size a b ± 0.1 c H7 fa -0.3 fg g t v x P9 ya +0.5 Z1, Z2 z z z mBoltMA[Nm]EB z nBoltoSleevepWasherMA[Nm]S flange / K flange058.1 58 47 30 38.5 3.5 1.2 -0.15 9 0.05 4 M5 x 16 7 No065.1 65 52 35 41.5 4 1.5 -0.25 12 0.05 4 M6 x 20 13 No075.1 75 62 42 51.5 5.5 2.3 -0.2 14 0.05 6 M6 x 25 13 No090.2 90 74.5 47 61 6 2.3 -0.2 13 0.05 4 M8 x 25 32 No100.2 100 84 57 70.5 7 2.3 -0.2 11 0.05 6 M8 x 25 32 No120.2 120 101.5 75 84 8 2.3 -0.2 14 0.05 8 M10 x 30 64 No120.5 120 101.5 75 84 9 2.3 -0.2 13 0.05 8 M10 x 30 64 No150.2 150 130 90 110.3 10 2.3 -0.2 20 0.05 8 M12 x 40 111 No150.3 150 130 90 110.3 12 2.3 -0.2 18 0.05 8 M12 x 40 111 No150.5 150 130 90 110.3 12 2.3 -0.2 18 0.05 8 M12 x 40 111 No180.5 180 155.5 110 132.5 14 2.3 -0.2 21 0.05 8 M14 x 45 177 No225.7 225 196 140 171 159 15 4 -0.2 25 0.06 8 M16 x 55 270 No 4 M12 x 60 21 x 28 13 82225.8 225 196 140 171 159 15 4 -0.2 15 0.06 8 M16 x 55 270 Yes 4 M12 x 60 21 x 28 13 82250.8 250 218 140 190 176 18 5 -0.2 24 0.06 8 M18 x 60 372 No 4 M14 x 70 25 x 32 15 130285.8 285 245 175 214 199 20 6 -0.5 30 0.06 8 M20 x 70 526 No 4 M16 x 75 28 x 36 17 200315.8 315 280 175 247 231 22 6 -0.5 31 0.06 8 M22 x 75 710 Yes 4 M16 x 80 30 x 40 17 200350.8 350 310 220 277 261 25 7 -0.5 30 0.06 10 M22 x 80 710 Yes 4 M18 x 90 32 x 45 19 274390.8 390 345 250 308 290 32 7 -0.5 36 0.06 10 M24 x 100 906 No 4 M18 x 110 32 x 60 19 274435.8 435 385 280 342 320 40 8 -0.5 40 0.06 10 M27 x 120 1 340 No 4 M20 x 110 35 x 60 21 386Q flange225.8 225 196 105 171 159 20 4 -0.2 25 32 9.5 0.06 8 4 M16 x 65 270 No250.8 250 218 105 190 176 25 5 -0.2 25 40 13 0.06 8 4 M18 x 75 372 No285.8 285 245 125 214 199 27 6 -0.5 26 40 15.5 0.06 8 4 M20 x 80 526 No315.8 315 280 130 247 231 32 7 -0.5 31 40 15.5 0.06 10 4 M22 x 95 710 No350.8 350 310 155 277 261 35 7 -0.5 30 50 16.5 0.06 10 6 M22 x 100 710 No390.8 390 345 170 308 290 40 7 -0.5 40 70 18.5 0.06 10 6 M24 x 120 906 No440.8 435 385 190 342 320 42 9 -0.5 38 80 20.5 0.1 10 6 M27 x 120 1 340 No490.8 490 425 205 377 350 47 11 -0.5 46 90 23 0.1 10 8 M30 x 140 1 820 No550.8 550 492 250 444 420 50 11 -0.5 40 100 23 0.1 10 8 M30 x 140 1 820 NoH flange208 225 196 180 171 159 20 25 18 4 M16 x 65 270 No250 250 218 200 190 175 25 25 20 4 M18 x 75 372 No285 285 245 225 214 199 27 26 21 4 M20 x 80 526 No315 315 280 250 247 230 32 31 23 4 M22 x 95 710 No350 350 310 280 277 261 35 30 24 6 M22 x 100 710 No390 390 345 315 308 290 40 40 25 6 M24 x 120 906 No440 435 385 345 342 322 42 36 28 6 M27 x 120 1 340 No490 480 425 370 377 350 47 36 31 8 M30 x 130 1 820 No550 550 492 440 444 420 50 40 32 8 M30 x 140 1 820 NoDimensions in mm55Dimensions of the connection flanges Bolted connection (A) Bolted connection with split sleeve (B)Comments 1 2 3 4 5 6 7 8 9 10 11 12Size a b ± 0.1 c H7 fa -0.3 fg g t v x P9 ya +0.5 Z1, Z2 z z z mBoltMA[Nm]EB z nBoltoSleevepWasherMA[Nm]S flange / K flange058.1 58 47 30 38.5 3.5 1.2 -0.15 9 0.05 4 M5 x 16 7 No065.1 65 52 35 41.5 4 1.5 -0.25 12 0.05 4 M6 x 20 13 No075.1 75 62 42 51.5 5.5 2.3 -0.2 14 0.05 6 M6 x 25 13 No090.2 90 74.5 47 61 6 2.3 -0.2 13 0.05 4 M8 x 25 32 No100.2 100 84 57 70.5 7 2.3 -0.2 11 0.05 6 M8 x 25 32 No120.2 120 101.5 75 84 8 2.3 -0.2 14 0.05 8 M10 x 30 64 No120.5 120 101.5 75 84 9 2.3 -0.2 13 0.05 8 M10 x 30 64 No150.2 150 130 90 110.3 10 2.3 -0.2 20 0.05 8 M12 x 40 111 No150.3 150 130 90 110.3 12 2.3 -0.2 18 0.05 8 M12 x 40 111 No150.5 150 130 90 110.3 12 2.3 -0.2 18 0.05 8 M12 x 40 111 No180.5 180 155.5 110 132.5 14 2.3 -0.2 21 0.05 8 M14 x 45 177 No225.7 225 196 140 171 159 15 4 -0.2 25 0.06 8 M16 x 55 270 No 4 M12 x 60 21 x 28 13 82225.8 225 196 140 171 159 15 4 -0.2 15 0.06 8 M16 x 55 270 Yes 4 M12 x 60 21 x 28 13 82250.8 250 218 140 190 176 18 5 -0.2 24 0.06 8 M18 x 60 372 No 4 M14 x 70 25 x 32 15 130285.8 285 245 175 214 199 20 6 -0.5 30 0.06 8 M20 x 70 526 No 4 M16 x 75 28 x 36 17 200315.8 315 280 175 247 231 22 6 -0.5 31 0.06 8 M22 x 75 710 Yes 4 M16 x 80 30 x 40 17 200350.8 350 310 220 277 261 25 7 -0.5 30 0.06 10 M22 x 80 710 Yes 4 M18 x 90 32 x 45 19 274390.8 390 345 250 308 290 32 7 -0.5 36 0.06 10 M24 x 100 906 No 4 M18 x 110 32 x 60 19 274435.8 435 385 280 342 320 40 8 -0.5 40 0.06 10 M27 x 120 1 340 No 4 M20 x 110 35 x 60 21 386Q flange225.8 225 196 105 171 159 20 4 -0.2 25 32 9.5 0.06 8 4 M16 x 65 270 No250.8 250 218 105 190 176 25 5 -0.2 25 40 13 0.06 8 4 M18 x 75 372 No285.8 285 245 125 214 199 27 6 -0.5 26 40 15.5 0.06 8 4 M20 x 80 526 No315.8 315 280 130 247 231 32 7 -0.5 31 40 15.5 0.06 10 4 M22 x 95 710 No350.8 350 310 155 277 261 35 7 -0.5 30 50 16.5 0.06 10 6 M22 x 100 710 No390.8 390 345 170 308 290 40 7 -0.5 40 70 18.5 0.06 10 6 M24 x 120 906 No440.8 435 385 190 342 320 42 9 -0.5 38 80 20.5 0.1 10 6 M27 x 120 1 340 No490.8 490 425 205 377 350 47 11 -0.5 46 90 23 0.1 10 8 M30 x 140 1 820 No550.8 550 492 250 444 420 50 11 -0.5 40 100 23 0.1 10 8 M30 x 140 1 820 NoH flange208 225 196 180 171 159 20 25 18 4 M16 x 65 270 No250 250 218 200 190 175 25 25 20 4 M18 x 75 372 No285 285 245 225 214 199 27 26 21 4 M20 x 80 526 No315 315 280 250 247 230 32 31 23 4 M22 x 95 710 No350 350 310 280 277 261 35 30 24 6 M22 x 100 710 No390 390 345 315 308 290 40 40 25 6 M24 x 120 906 No440 435 385 345 342 322 42 36 28 6 M27 x 120 1 340 No490 480 425 370 377 350 47 36 31 8 M30 x 130 1 820 No550 550 492 440 444 420 50 40 32 8 M30 x 140 1 820 NoDimensions in mmDesignation Explanation Com-mentsAdditional informationa Flange diameterb Bolt circle diameterc Locating diameterfa Flange diameter, bolt sidefg Flange diameter, nut sideg Flange thicknesst Locating depth in connection flangev Length from the contact surface of the nut to the end of the hexagon head boltx Width of face key in universal joint shaft conne-ction flanges with a face keyya Depth of face key in universal joint shaft conne-ction flanges with a face keyz1 Axial run-out 1 Permissible values for devi-ation in axial runout Z1 and concentricity Z2 at operating speeds below 1 500 rpm. At operating speeds of 1 500 rpm to 3 000 rpm, the values should be halvedz2 Concentricitym Hexagon head bolt to ISO 4 014 / 4 017-10.9 or DIN 931-10.9 with hexagon nuts to ISO 7 040-10 or DIN 982-102 z each per standard conne-ction flange3 z each per connection flange with face key4 z each per connection flange with Hirth coupling5 Dimension of hexagon head bolt with nut6 Tightening torque for a coef-ficient of friction µ = 0.12 and 90 % utilization of the bolt yield pointmmin Minimum length for the installation of boltsLength of the hexagon head bolt m including the height of the bolt headEB Insertion options 7 Insertion of bolts from the joint siden Hexagon head bolt to ISO 4 014 / 4 017-10.9 or DIN 931-10.9 with hexagon nuts to ISO 7 040-10 or DIN 982-108 z each per connection flange9 Dimension of hexagon head bolt with nut12 Tightening torque for a coefficient of friction µ = 0.12 and 90 % utilization of the bolt yield pointo Split sleeve 10 Outer diameter x length of the split sleeve [mm x mm]p Washer 11 Interior diameter of the washer [mm]56Success needs reliable partners.That’s what moves us.579 ServiceFor us, service means quality and dependability that exceeds the expec-tations of our customers. We will support you anywhere in the world throughout the entire lifetime of your Voith equipment. You can count on us from the planning and commissioning phase through to maintenance. With the Universal Joint Shaft capabilities from Voith Turbo, you will incre-ase the reliability, availability and lifetime of your equipment.Original spare parts' supplyModernizations, retrofitsRepairsOverhaulTorque measurements (ACIDA)TrainingInstallationPre-salesAfter-salesCommissioningConsulting and engineeringVoith Turbo Universal Joint Shaft Service58The correct installation of a universal joint shaft provides the basis for trouble-free commissioning. A systematic com mis-sioning procedure with  extensive operational testing is an important factor in achieving the maximum reliability and long operational life of the universal joint shaft and the system as a whole.9.1 Installation and commissioningOur services• Installation and commissioning by our service experts• Training of operation and maintenance personnelYour benefits + Immediate access to expert know-how throughout the start-up phase + Assurance of problem-free and professional commissioning of your universal joint shaft599.2 TrainingEfficiency, reliability and availability are essential factors in ensuring your system is successful. One requirement in this regard is having the best-trained employees in technology and servicing. Initial and ongoing training are worthwhile in vest-ments in ensuring the efficient operation of your universal joint shafts. Our training programs provide specific technical knowledge about your Voith equipment, as well as other potential products to enhance your system. We bring your personnel up to speed with the latest Voith technology – in theory and in practice.Our services• Product training at Voith or on-site at your premises• Theoretical and practical maintenance and repair trainingYour benefits + Safe handling of Voith products + Avoidance of operating and maintenance errors + Better understanding of Voith technology in the driveline60Our services• Inventory of most original and wearing parts located at local service branches• Same day shipment of in-stock parts (orders received by 11 a.m.)• Consultation with your spare parts' management staff• Preparation of spares kits for specific project maintenance• Spares for older and obsolete series of Voith universal joint shafts still availableAvoid risk, use Voith orginal spares and wear parts. These are the only parts manufactured with Voith's know-how, and guarentee the reliable and safe operation of your Voith equip-ment. Ensuring the highest availa bility, in combination with efficient logistics, to ensure rapid deployment of parts globally.Flange yokeJournal cross9.3 Genuine Voith spare partsYour benefits + Safe and reliable operation of all components + Parts of the highest quality that fit precisely first time + Maximum lifetime of driveline components + Manufacturer's warranty + Maximum system availabilty + Efficient and speedy delivery of spare parts61Constant operation subjects universal joint shafts to natural wear, which is  also influenced by the surroundings. Pro-fessional and regular overhauls of your universal joint shaft prevent damage and minimize the risk of expensive production downtimes. You gain operational reliability and save money in the long term.Our services• Maintenance or complete overhaul by our service experts with all the necessary tools and special fixtures• Use of original spare and wearing parts• Consultation regarding your maintenance strategy9.4 Overhaul, maintenanceYour benefits + Safety due to professional maintenance + Manufacturer's warranty + Increased system availability62Even with the best preventive maintenance, unplanned down-time due to  equipment failures cannot be ruled out. The priority then is to repair the components and equipment as quickly as possible. As the manufacturer we not only have the wealth of knowledge about universal joint shafts, but we also possess the necessary technical competence, experience and tools to ensure the most professional of rapid repairs. Our service techni cians can assess the damage in the minimum amount of time, in order to provide suggestions for the rapid rectification of the situation to enable operation of equipment as soon and as safely possible.9.5 Repair and maintenanceOur services• Rapid and professional repairs that comply with the latest safety standards on-site, or at one of our head office-certified Voith Service Centers located strategically around the globe• Experience damage assessment, with analysis of the weaknesses• Immediate delivery of replacement original spare partsYour benefits + Maximum safety due to the best practice repairs + Manufacturer's warranty + Shortest possible outage and downtime of your equipment + Avoidance of repeat outages, or malfunction639.6 Retrofit and modernizationsTechnology is advancing all the time and sometimes the original require ments upon which the design of a system was based can change. Voith Turbo helps you achieve significant improvements in the efficiency and reliability of your equip-ment, through a modernization or retrofit program of old driveline equipment, e.g. slipper spindles. We will analyze, and provide advise as to the latest and most economical tech-nology for your particular driveline application.Our services• Modernization of existing, or new replacement designs for your universal joint shafts and connection components• Even with the best preventative maintenance schedule, unplanned downtime due to equipment failure can never be ruled out Your benefits + Improved reliability, availability and affordability of your driveline + Reduction of operating costs + Universal joint shafts that feature the latest technology64Project planning of a driveline using CAD FEM analysis of a work roll, with a split connection coupling10 Services and Supplementary products 10.1 EngineeringWe not only supply products, but ideas too You too can benefit from our many years of engineering expertise in all-round project planning of  complete drive systems: from design calculations, installation and commissioning, to ques-tions about cost-optimized operating as well as main ten ance concepts.Engineering services• Specification preparation• Preparation of project-specific drawings• Torsional and bending vibration calculations• Design and sizing of universal joint shafts and con-necting components• Clarification of special requirements from the operator and its employees• Preparation of installation and maintenance instructions• Documentation and certification• Special acceptance tests conducted by classifying and certifying agenciesSpecial universal joint shaftsDesigning special universal joint shafts to match your drive system and your operating conditions is just one of the every-day engineering services we offer. These include:• All necessary design work• Integrity checks and optimization of design through the application of FEM analysis• Reliability trials based on dynamic load testing65Connection hubs (wobblers/couplings) to attach universal joint shafts to the work rolls10.2 Connecting components for universal joint shaftsTo ensure maximum reliability of the driveline, the input and output connecting parts of the universal joint shaft, should equally be analyzed for suitability, e.g.:• All couplings• All connecting flanges bolted or otherwise• All AdaptersFeatures• Individual adaptation to all adjoining components• Precision manufacturing through the use of state-of-the-art machining centers• Maximum torque transmission capability through the use of the highest quality materials.• Hardened contact surfaces to ensure maximim levels of wear resistance.Applications• Rolling mills• Paper machinery• Pumps• General industrial machinery• Test stands• Construction equipment and cranes66Schematic diagram of the quick-release GT coupling Universal joint shaft with a ring from a quick-release GT coupling10.3 Quick-release GT couplingThe quick-release GT coupling is designed to be an efficient and effective quick release connection device. The GT coup-ling allows you to assemble and disassemble a wide range of shaft connections, which in turn significantly reduces the amount of required downtime associated with maintenance and repair. which in turn significantly reduces downtimes for maintenance and repair.Features• Positive transmission of torque through radial drive dog design• Quick and easy assembly / disassembly• Compact design• Only two major components• Stainless steel versions availableApplications• Drivelines that require a quick release while retaining accurate radial alignment, e.g. universal joint shafts and disc couplings• Roll connections, e.g. on paper machines67Universal joint shaft flanges with Hirth couplingPositive locking Accurate indexing Self-centeringPrimary functions of the Hirth serration10.4 Voith Hirth couplings Voith Hirth couplings transmit maximum torque at the speci-fied diameters.Features• Highest torque transmission capability, as the angular surfaces provide positive locking of most of the peripheral forces. The bolts only need to accomodate a small amount of axial force.• Self-centering by means of optimized tooth geometry• A high load bearing on the tooth profile, significantly inreases wear resistance of the hirth serration.• Repeatability accuracy maximized as a result of the multiple tooth design.FaFuApplications• High performance universal joint shafts, for high torque applications• Connection flange for universal joint shafts (also when provided by the customer)• Machine tools• Turbo compressors• Measuring equipment• Robotic equipment• Nuclear technology• Medical equipment• General industrial machinery68Universal joint shaft support (red) and coupling support (yellow)10.5 Universal joint shaft supportsTo position and support a universal joint shaft and its connec-tion coupling and flanges, a support mechanism is required.Features• Increased productivity and system availability as a result of shorter downtime for maintenance• Reduction of energy and lubrication costs, together with higher transmission efficiency through the use of roller bearings• Reduced wear as a result of uniform power transmissionApplications• Rolling mills• Customer-specific drives69Universal joint shaft with CFRP tube10.6 Universal joint shafts with carbon fiber-reinforced polymer (CFRP) componentsUniversal joint shafts with CFRP components increase the efficiency and performance of machines and plants. CFRP use in universal joint shaft construction, reduces masses, vibrations, deformations and power consuption of the ma-chines. We offer not only the characteristic know-how, but also the production know-how of CFRP components – all from a single source.Features• Depending on the requirements of the specific application, universal joint shafts can incorporate CFRP tube, or solid shafts• Reduced dynamic loads, due to lower masses• Extremely smooth operation and low vibration induced wear, as a result of the higher rigidity of CFRP• Lower acceleration / deceleration torques as a result of the lower mass of intertia of CFRPApplications• Long drivelines without the need for intermediate bearing supports• Drivelines with low masses• Drivelines that require optimized vibration behaviour• Pumps• Marine vessels• Rail vehicles• General industrial machinery7010.7 High-performance lubricant for universal joint shaftsVoith development engineers have combined their universal joint shaft know-how with the tribological knowledge and experience of renowned bearing and lubricant manufacturers. The result of this cooperation is an innovative and exclusive lubricant with properties that far exceed those of conventional lubricants. This lubricant gives bearings in universal joint shafts operating at low speeds and under high loads an even longer life. In addition, lubrication intervals can be extended and emergency dry-running characteristics are improved sig nifi-cantly.1 Voith WearCare 500 in 45 kg and 180 kg drums171Characteristics of the Voith WearCare 500 high-performance lubricantAdvantages• Optimum adhesion and surface wetting + Lubricating film even in the event of poor lubrication + Formulated for oscillating bearing motion• Exceptional corrosion protection + Ideal for rolling mills• Maximum ability to withstand pressure + Hydrodynamic lubricating film even under maximum torque conditions• Optimal and long-lasting lubricating action + Minimal abrasive wear in the bearing + Extended lubrication intervals + Reduced maintenance costs• Can be mixed with lithium-based greases + Simple changeover to Voith's high-performance lubricant• High resistance to aging + Long shelf life• Excellent compatibility with all bearing components + No softening of bearing seals + Does not corrode non-ferrous metals• Free of silicone and copper-based ingredients + Suitable for aluminum rolling millsRelative metal particles in the lubricant10 3 6 9 15 18 21 24Operating time in months121.50.5Extended operating timeReference wear conditionField trialMetal particles in the bearing lubricant of a high-performance universal joint shaft used in a rolling mill driveFE8 test stand trialBearing wear in an axial cylindrical roller bearingRelative bearing wear110Voith WearCare 500515 Standard lubricantStandard lubricantVoith WearCare 500723D cut away section through a Safeset safety coupling (type SR-C) Safeset torque limiting safety couplings (blue) 'integral design' in a Voith high performance universal joint shaft10.8 Safeset torque-limiting safety couplingsThe Safeset coupling is a torque-limiting safety coupling that instantaneously disengages the power transmission of the driveline in the event of a potentially catastrophic torque over-load event. Thus it protects all of the drive components in the driveline such as motors, gearboxes, universal joint shafts etc. against costly and time consuming damage.By integrating the Safeset safety coupling into the universal joint shaft, which is known as the Voith 'integral design', reduces the deflection angle of the universal joints, and thus increases the lifetime of driveline components.Features• Adjustable release torque• The Safeset coupling reacts instantaneously to a torque overload event• Backlash-free power transmission• Compact, lightweight design• Low mass moment of inertia• Minimal maintenance requiredApplications• Protects drivelines from potentially catastrophic overload damage• Rolling mills• Shredders• Cement mills• Sugar mills• Rail vehicle drives73Torque [Nm]Time [s]62.84 63.90 64.95 66.00 67.06 68.11 69.16 70.22-4610325340155010.9 ACIDA torque monitoring systems1 Rotor: Strain gauges and telemetry (requires no drive modifications)2 Air gap: No contact between rotor and stator3 Stator: Signal reception and inductive power supplyLight blue: ACIDA monitoring systems measure torques and dynamics with extreme accuracy.Dark blue: Conventional systems measure, for example, the motor current or hydraulic pressure with insufficient signal dynamics.ACIDA torque monitoring systems have proven their worth in accurately measuring dynamics in universal joint shafts. The direct measuring of the actual, mechanical drive load provides important information for process observation and plant optimization. Analysis modules, for instance load spectra or lifetime observation, have been developed especially for extremely heavy-duty drives and unusually severe load condi-tions. Additional options include online vibration diagnosis for gearboxes and roller bearings.Features• Permanent or temporary torque sensors• Complete monitoring systems, incl. hardware and software• Report generator with automatic analysis, alarm signaling and reporting• Tele-service with expert supportThe ACIDA monitoring system in comparisonNon-contact torque monitoring systemApplications• Torque monitoring• Vibration monitoring• Process optimization• Condition-based maintenance• Reference systems: Rolling mills, cement mills, briquetting plants, agitators, conveying equipment, marine propulsion systems, locomotives, paper machines, mining, etc.1237411 Integrated management systemAt Voith, our top priority is to ensure the affordability, reliability, environ-mental compatibility and safety of our products and services. In order to maintain these principles in the future just as we do today, Voith Turbo has a firmly established integrated management system focused on quality, the environment, and health and safety at work. For our customers, this means that they are purchasing high-quality capital goods that are manufactured and can be used in safe surroundings and with minimal environmental impact.175211.1 Quality1 Certificates for management systems according to ISO 9 001: 2 000 (Quality), ISO 14 001: 2 000 (Environment) and OHSAS 18 001: 1 999 (Occupational Health and Safety)2 Flange for a high-performance universal joint shaft on a 3-D-coordinate measuring machine• We employ state-of-the-art 3-D-coordinate measuring machines for quality assurance.• To ensure perfectly welded joints, we conduct X-ray inspections in-house.• We offer our customers a variety of product and application-specific certifications and classifications.• Production and assembly fixtures are inspected on a regular basis.• Quality-relevant measuring and testing instruments are subject to systematic monitoring.• In the case of the welding methods employed, process controls according to ISO 3834-2 are used. Welding technicians are qualified to EN287 and our welding equipment is constantly monitored.• Employees performing non-destructive testing are qualified to ASNT-C-1A and / or EN 473.7611.2 Environment• Voith universal joint shafts are fitted with sealed roller bea rings. These offer two major advantages over slipper and gear type spindles:11. Lubricant consumption is considerably lower because of the seals.2. Efficiency is enhanced, as rolling friction is significantly less than sliding friction. This translates into reduced CO2-emissions and helps to protect the environment.0.32 kW99.10 %71.1 kWSlipper spindle99.49 %41.1 kWGear spindleVoith universal joint shaft99.996 %Comparison of efficiency and power loss in the main drive of a rolling millInput power 8 000 kW, deflection angle 2° Efficiency Power loss771 An employee coats the roller bearing of a universal joint shaft with Voith WearCare 500 high-performance lubricant2 Voith universal joint shafts receive their final finish in a modern paint booth11.3 Occupational health and safety• When painting a Voith universal joint shaft, Voith paint tech nicians use a modern paint system that meets all of the requirements for health and safety at work, and envi-ronmetal protection.• The paint is electrostatically applied to reduce overspray and waste.• An exhaust system extracts any residual mist that is created as part of the paint process.• An exhaust air treatment system with combined heat reco-very reduces the impact on our employees, as well as the environment.2G830 en, aik / CM, 08.2012, 1 500. Data and illustrations without obligation. Subject to modifications.