Thomson Micron Planetary Gearhead Presentation 2013

Micron Planetary Gearheads

February 2013 - Micron Update

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What we will cover today

Micron Overview Micron Differentiators. Lead Times, OTD and Gearhead Express. Short Product Overview. Customization Capabilities Micron Motioneering, how it can help you. Troubleshooting Noise Backlash Sealing

Food and Beverage Market Needs. Market Strategy. Micron Value Proposition. AquaTRUE Features and Benefits.

Competitive Comparison

Back Deck Slides. Gearing Technology, mounting, lubrication.



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Who are we?

Micron: Six decades of excellence and innovation in high precision gearing.

50K Sq, Ft, Facility in Amherst NY for Micron Gearheads, Deltran Clutches and Brakes and Harowe Resolvers.



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Unmatched Product Breadth Micron manufactures the largest selection of Planetary Gearheads in the world.

Over 1500 size and ratio combinations make Micron the gearhead of choice at both Distributors and OEMs.

The Helical Advantage

Micron’s UltraTRUE and ValueTRUE design takes our True Planetary technology one step further. All of the gears are not only in a True Planetary orientation but are also cut at a steeper helix angle than any of our competitors for higher torque, higher precision and smoother, quieter operation.

RediMount System

Micron uses the most flexible mounting system in the world. The RediMount system is an error free, three step mounting system who’s modular design allows fast delivery, gearheads to be stocked separately and easy field changes.

Delivery

1-2 week delivery on almost every gearhead in our catalog as well as the fastest delivery on the market with the 24hr Gearhead Express Program now including all in-line and right angle gearheads.

Ease of Customization

Although Micron’s standard catalog has the largest selection on the market, we do not stop there. We welcome modification requests to existing designs as well as “white sheet of paper” custom opportunities.

Micron Key Differentiators – 2013



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Product Availability – Gearheads 2013

Lead Time Update

All In-Line Gearheads: 1 week All Right Angle Gearheads: 2 weeks XTRUE Gearheads: Now 1 week AquaTRUE Gearheads: 4 weeks

OTD Update

Continued improvement throughout 2012 in both OTD and late

backlog reduction. In 2013, we plan to use our delivery as a lever to help gain new business with market best lead times including our Gearhead Express program.

Gearhead Express is back and better than ever! 24 hour delivery on every ratio, both in-line and right angle in all frame sizes 140mm and smaller (UT, VT, NT, DT and now including XT products).

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In 2013, we are committed not to loose a single gearhead order due to delivery! ELECTROMATEToll Free Phone (877) SERVO98


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Product Overview - 2013

Precision - 13-18 arc-min backlash NemaTRUE NemaTRUE 90 NemaTRUE Plus XTRUE – NEW! AquaTRUE – NEW!

High Precision - 8 arc-min backlash DuraTRUE DuraTRUE 90 DuraTRUE 90 Dual Shaft DuraTRUE 90 Hollow Shaft

Ultra Precision - 4 arc-min backlash UltraTRUE UltraTRUE 90 EverTRUE ValueTRUE ValueTRUE 90



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7 Available Frame Sizes (3 in right angle) • English: NT17 / NT23 / NT34 / NT42 • Metric: NT60 / NT90 / NT115 • Right Angle: NTR23 / NTR34 / NTR42

RediMount system provides error free installation to any motor All ratios and frame sizes available for 24 hr shipment through Gearhead

Express. Exact ratios from 3:1 to 100:1 (up to 500:1 in R/A) RediMount System accommodates any motor 13 arc-minutes of backlash Lubricated for Life

NemeTRUE (English & Metric)



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4 Available Frame Sizes (inline and right angle) • In-Line: DT60, DT90, DT115, DT142 • Right Angle: DTR60, DTR90, DTR115, DTR142

RediMount system accommodates any motor All ratios and frame sizes in stock 24 hr shipment through Gearhead

Express. Exact ratios from 3:1 to 100:1 (up to 500:1 in R/A) Dual and Hollow shaft options available in RA Lubricated for Life 8 arc-min max backlash

DuraTRUE



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8 Available Frame Sizes (7 in Right Angle) • 60, 75, 90, 100, 115, 140, 180 & 220mm

Helical Crowned True Planetary Gearing RediMount system provides error free installation to any motor All ratios in select frame sizes in stock 24 hr shipment through

Gearhead Express. Exact ratios from 4:1 to 100:1 (up to 50:1 in RA) 4 arc-minutes of backlash Lubricated for Life

UltraTRUE



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ValueTRUE

Helical Crowned True Planetary Gearhead

Features and Benefits

8 Available Frame Sizes: 60mm to 220mm. Inline and Right Angle (All UltraTRUE Sizes)

Helical Crowned True Planetary Gearhead

Value – High performance at a low price.

Stainless steel output housing and output shaft.

Ultra Precision Backlash: 4 arc-min

RediMount compliant.

All in-line ratios in stock for 24 hour delivery through Gearhead Express.

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XTRUE – Our Fastest Growing Product Line

True Planetary Gearhead

High Performance at an Economical Price. Features and Benefits

• 9 Available Frame Sizes. • 5 Classic XT Sizes (40, 60, 80, 120, 160). • 4 New Frame Sizes (50, 70, 90, 110).

• True Planetary Gearing. • RediMount Compliant. • Drop in Dimensional replacement for most competitive gearheads. • Precision Backlash: 13 arc-min (High Precision available – 8 arc-min). • Now all sizes and ratios are available to ship in 24 hours through Gearhead

Express



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Customization

Micron can make many different modifications to it’s standard products.

• Output Shaft Modifications • Shorter/Longer shafts • Larger/Smaller diameters • Added tapped holes or keyways

• Special Grease Options • Low Temperature • Food Grade • Vacuum

• Special Paint or Plating Options • Food Grade Paint • Stainless Steel

• Custom RediMounts to any motor

• Higher Accuracy (down to 4 arc-min)

• Custom Ratios

• Improved Sealing (IP65 and IP67) ELECTROMATE


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Micron Troubleshooting Slides - Highlights



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There is a certain amount of clearance needed in order for a gearhead to

function properly. This helps avoid excessive heat or wear in the gearing and insures proper lubrication. Clearance in the gear mesh means there is a small gap between the gear teeth which leads to lost motion. The figure below shows the rotation of the geahead shaft with an applied load.

What is lost motion?

Lost motion basically occurs in two ways

1) Backlash – clearance between

the gear teeth

2) Torsional Stiffness – wind up within the gearhead.

Torque CWTorque CCW

Shaft Rotation

Backlash

Slope of line =Torsional Stiffness

Some backlash is essential, too much causes lost motion in the application. ELECTROMATE


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Gearhead backlash is the angular rotation of the output shaft measured in arc-minutes (1/60th of a degree) in both directions. This is basically a measurement of the space between the gear teeth. There is no strict standard mandating how backlash should be measured for a gearhead. This leads to some confusion and misconceptions in the market concerning backlash, precision and lost motion. At Micron, Backlash is measured at 2% of the rated output torque and is a maximum value at every point on the output shaft for the life of the gearhead.

What is backlash?

There is no standard for testing backlash in the market. This leads to confusion and specification issues. ELECTROMATE


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• Reason’s why some backlash ratings are not accurate. • 1) Zero backlash claims: For the reasons outlined on the previous slides, zero backlash is

not possible in a planetary design. This is usually rounded down from a specification of <1 arc-min.

• 2) Average value measurements: Some manufacturers may take an average of 4 or more points on the output shaft to come up with a backlash spec. For example, a unit with backlash measurements of 4, 6, 10 and 12 would have a rating of 8 arc-min. By Micron’s standard, this is a 12 arc-min measurement.

• 3) Lower Torque measurements: Instead of using 2% of the rated toque, some manufacturers may use 0.5% or less. Using a lower applied torque will produce a better backlash measurement.

• 4) “Out of the box” ratings: Backlash will increase over time. This is why Micron’s backlash is guaranteed for the life of the gearhead. Many competitors may send you an 8 arc-min gearhead but after six months, the backlash is up to 15. Knowing the accuracy of their machine over its lifetime is an important specification for most customers.

Troubleshooting - Backlash

Micron Backlash Specifications •2% of the rated torque •All points on the output shaft •Maximum value for the life of the gearhead

Ex/ Just because a competitor has 2 arc-min in their catalog, does not mean it is more accurate than a 4 arc-min Micron product. ELECTROMATE


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Troubleshooting – Ratio Selection

Gear Ratio = #teeth on ring gear +1 #teeth on pinion gear

10:1 - Highest ratio available in single stage planetary design, torque limited by smaller size of 10:1 pinion gear.

3:1 - Lowest ratio available in single stage planetary design, output torque limited by smaller 3:1 planet gears, speed limited by larger size of 3:1 pinion gear.

4:1 to 8:1 – Optimal pinion and planet gear size, higher performance and longer life. >10:1 – Additional planetary stage would normally add to length and price. < 3:1 – Not possible with a planetary design since it would require the pinion and

outer ring gear to be the same diameter (no room for planet gears).

3:1 5:1 10:1 Failure Mode Failure Mode

Every ratio has different gearing, noise levels and other performance characteristics. ELECTROMATEToll Free Phone (877) SERVO98


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Troubleshooting - Noise

Are you experiencing higher than expected noise from your current gearhead solution?

Factors that contribute to gearhead noise: Input Speed Gearhead Ratio Output Torque Radial and axial loads Mounting errors ***

Following the proper mounting procedure is critical to

minimizing noise and maximizing performance. Many gearheads (Micron included) need to be mounted to the

servo motor in a vertical orientation first. This allows the motor shaft to center the gearhead. After being mounted to the motor, it can be used in any orientation.

Vertical Mounting

Vertical mounting is critical for any Micron product. ELECTROMATEToll Free Phone (877) SERVO98


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Sales Tools - Micron Motioneering

* The most accurate and user friendly gearhead sizing tool on the market. • Available at www.micronmotioneering.com

What can you do with Micron Motioneering? • Choose the right gearhead for your application quickly and

accurately. • Get your full gearhead part number (including RediMount) by

selecting from a list of motors or manually entering a set of motor dimensions.

• Download a 2D and 3D model for any standard catalog gearhead. • Use requirements such as speed, torque, ratio, backlash and radial

and axial load in the selection process. • Build an entire motion profile in seconds. • Calculate the life of several gearhead solutions in your application. • Choose the most economical option with list price referenced for

every solution.



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http://www.micronmotioneering.com/

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Food and Beverage – Value Proposition Micron Gearheads



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Food Packaging/Processing Market Needs.

10 Sanitation Principles for Equipment Suppliers to consider. 1) Product must be easily cleanable (sealing, smooth surfaces). 2) Must use compatible materials (stainless steel). 3) Must be accessible for Inspection. 4) No liquid collection (shape, design). 5) Hollow areas eliminated or sealed. 6) No niches (pits, cracks, gaps). 7) Sanitary operational performance. 8) Validating cleaning and sanitizing protocols. 9) Separate processes whenever possible. 10) Meet hygiene and sanitation requirements.



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Change is coming…

• A growing concern over cross contamination, salmonella and other hygienic problems have driven stricter guidelines. What was once acceptable to this market no longer is in many cases.

• In the past painted or nickel plated solutions were commonly used. Now

stainless steel has become a must. • More applications are driving to an IP66, or 69K requirement rather than

the typical IP65. • Square housings with corners and chamfers are no longer acceptable

and round housings with smooth surfaces are specified. • FDA approved grease is critical. • Label, tags or any difficult to clean accessories are restricted.



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Strategy to Market

How Micron will be successful in the food packaging/processing market New Products – AquaTRUE – Released in 2011, the AquaTRUE is a

completely stainless steel, IP67 sealed food grade gearhead which meets all of the requirements and is a perfect fit for this market.

Product Enhancements – UltraTRUE – When higher precision and

performance is needed along with some of the strict requirements of this industry, Micron is able to enhance it’s UltraTRUE product line to meet these specific demands. IP65 sealing, epoxy paint, stainless steel housings and food grade grease options are just a few of the common modifications.

Customization – All Products – Micron’s ability to make both minor and major modifications to their standard product offering with minimal impact to both price and delivery help to meet the demands of any market.



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Value Proposition - AquaTRUE

The AquaTRUE series of Gearheads is the first on the market of its kind. It has IP66, IP67 and IP69K protection standard, is completely stainless steel, has no external seams and can handle high pressure washdown from all angles. These traits can save an average size customer over

$50K/yr by eliminating additional costs of components such as enclosures, shielding or mechanical transmissions.



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AquaTRUE – Product Overview

Now Available!

All sizes and ratios are now available in a 4 week lead time.

IP66, IP67 and IP69K protection. 300 series stainless steel

housings. Laser etched permanent label. 1pc housing, no seems or areas

of ingress. Round design, easy to clean. Designed to mount to either

round or square motors.



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AquaTRUE vs. Conventional Gearheads

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The AquaTRUE addresses each of the problem areas introduced by conventional gearheads with a solution that can be used in even the most harsh environments.



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AquaTRUE – Designed to handle any washdown environment.

IP67 Immersion Test – 1m water depth for 30 mins. IP66 Washdown Test – Pressure wash from all directions for 5 mins. Third Party Certification (NSF/ANSO STD 169).

Zero ingress after all testing. The AquaTRUE was tested at worst case scenario type environments to ensure it meets or even exceeds the market demands. ELECTROMATE


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Design Win – AquaTRUE

Application Overview Wrapper/Stacker Wraps and packages frozen food, cheese, meat and other products. Examples – places wax paper between frozen meat patties, wraps film around

pizza crust, tortillas or baked goods.

Product Solution: AquaTRUE stainless steel planetary gearheads combined with Kollmorgen W series (washdown) motors. 100% stainless steel solution. IP67 sealing rating. Round design with minimal points of ingress. No expensive shielding or external protection needed.

AquaTRUE gearheads and Kollmorgen W Series motors



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Design Win – AquaTRUE

Application Overview Chicken Processing Machine (Legs, Breast). The AQT axis removes chicken parts and separates them for packaging.

Product Solution: AquaTRUE stainless steel planetary gearheads combined with AKM food grade motors. IP67 sealing rating. Round design with minimal points of ingress. Easy to clean. No expensive shielding or external protection needed. Reduces concern for bacteria or contamination.



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Design Win - AquaTRUE

Application Overview Seal Wrapper. Packages and seals different types of frozen food,

meat, pizza.

Product Solution: AquaTRUE and XTRUE planetary gearheads combined with AKM and AB servo motors. IP67 sealing rating. Round design with minimal points of ingress. Easy to clean. No expensive shielding or external protection

needed. Reduces concern for bacteria or contamination. XT product used on lower cost machine used for

packaging books or magazines.



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For Heavier Duty Applications.

Standard UltraTRUE Benefits - Helical Crowned True Planetary Gearing - Stainless Steel output shaft, output housing and hardware - Anodized Aluminum RediMount - Ultra Precision: 4 arc-min - Low noise, smooth operation - IP65 Output Seal - Stainless Steel Hardware Food Grade Enhancements - Food Grade Grease - Nickel Plated or Stainless Steel RediMount - IP65 seal to motor face - Food Grade Paint option

UltraTRUE Food Grade Enhancements



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Micron Backdeck Slides – Highlights Competitive Comparison



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Heat-Treat Process

Micron Feature - Case Hardened Gears to HRC60

Micron Advantage – Case Hardened Gears have over 30 times the hardness depth when compared to the plasma nitride process used by several of our competitors. This “hard shell” over a soft gear will not hold up to the peak torque of a case hardened gear.

Customer Benefit - You can transmit more torque in a smaller package. Save space and $$ by achieving your application requirements in the smallest package. Longer life, lower replacement costs.

Fact: Gears with higher level or hardness will have less wear and will last longer. ELECTROMATEToll Free Phone (877) SERVO98


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Higher Helix Angle

Micron Feature – Improved helix angle of 15 degrees. Competition has 10 and 12.

Micron Advantage – Higher contact ratio, more teeth in mesh, increased load sharing, able to transmit more torque in a smaller package. Smoother and quieter operation.

Customer Benefits Higher precision, higher accuracy machines. Longer life, lower replacement costs. Save space and $$ by achieving your application

requirements in the smallest package possible.

Fact: A higher helix angle means more teeth in mesh, more torque capacity and longer life. ELECTROMATE


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Lubricated for Life

Micron Feature – All Micron Gearheads are grease filled and lubricated for life.

Micron Advantage – Many of our competitors use oil to lubricate their gearheads which require maintenance, could leak and cannot be mounted in any orientation.

Customer Benefits Absolutely no maintenance costs. The ability to mount the gearhead in any orientation allows more flexibility in

the customer’s machine and saves cost.

All Micron gearheads are lubricated for life with no maintenance required. This is not the case with many of our competitors. ELECTROMATE


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RediMount System

Micron Feature – All Micron Gearheads come designed with our innovative RediMount system.

Micron Advantage – The RediMount is not product specific, only motor specific. This allows the same Redimount to be used across the entire Micron product offering. This allows customers to mix and match inventory and keep less spares. The RediMount system mounts to any motor in just 3 simple steps. Fast and error free.

Customer Benefits – Less inventory, shorter assembly time, lower cost.

All Micron gearheads use our innovative RediMount system. The easiest and most flexible mounting system in the world. ELECTROMATE


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Micron Gearheads

Q&A ELECTROMATE


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Thomson Micron Planetary Gearhead Presentation 2013

Technology

Transcript of Thomson Micron Planetary Gearhead Presentation 2013