Course audit Reprinted from Motion System Design August 2002

and June 2003

Determining endurance limit slope

E=3 for bearings. E mainly depends upon material,

Sizing gearboxes under

heat treatments, and loading type.

Stress load (log S)

100 E=8.7 for case-hardening steel. With it, life expectancies for
different stress levels can be
found.
E=17 for nitrided steel.

10
E=84 for carbo-nitrided steel.
1
103
Load cycles (log N)
tionship is usually manipulated and
plotted in its logarithmic form: log S
= -1/E x log N or log N = -E x log S.
• The area of unlimited load cy-
cles is the horizontal portion of
the S-N curve.
The exponent E determines steep-
ness of the S-N relationship slope. It
depends on the alloy, heat treatment
conditions, and loading type. E cov-
ers a wide range — about six to 80. A
comparison in the logarithmic scale
allows the slope to appear as a con-
Endurance limit
Area of unlimited load cycles
106 109 1012
do not have a clearly definable en-
durance limit. The high-pressure
loading between rolling elements
and races do not follow the above
described endurance behavior. For
this reason bearings are typically
sized, designed, and rated for a life-
time (say 10,000 hours) with as-
signed a certain statistical probabil-
ity of failure (say L10 life, or a 10%
chance of failure.)
As noted, the relationship be-
tween the load and number of load
cycles is exponential, with an expo-
dynamic loading
Gerhard G. Antony, PhD
standards — AGMA, ISO, DIN —
Neugart USA LP
is to base gearbox torque ratings on
endurance limits and minimum
bearing life. For industrial gear-
boxes, AGMA recommends 5,000
to 10,000 hours.
There is only one true rated
torque for a gearbox — for continu- Day 1 Drive system model
ous duty. Unfortunately for mar- True gearbox rating
keting reasons sometimes ill-de-
fined acceleration torques, peak Topics of discussion:
✔ Servomotor automation Motor Load
torques, or emergency-stop torques
are used as references. Still, only in ✔ Repeated dynamic load cycles
applications where the number of ✔ Selection of gears TM TLR
load cycles is below 2x106 are loads
exceeding rated load permissible.
The majority of real-world automa-
tion applications reach this number lindly assuming the dynamic
of load cycles in a few days, weeks,
or in a best-case scenario, after
some months of operation. As a rule
B peak torques listed on servo-
motor data sheets for a de-
sign almost always results in JM x a
Gearbox

JLR x a
stant linear slope. For a range or set nent of three to 10/3, but with no of thumb: over-sized, inappropriately ex-
of different stress levels and its fre- defined endurance limit. The famil- If the peak load cycle is part of pensive gearboxes. A motor’s ac- A model in which all parameters are reflected to the motor axis helps find the torque
quency of stress level occurrence, iar exponent three is applied to the designed standard working duty celeration peak torque is never transmitted through the gearbox.
damage accumulation calculation bearing calculations and also to cycle of the machinery, the peak transmitted to its gearbox. In
methods are used, including the well- Root Mean Cube or RMC calcula- load should not be higher than the most real applications, a substan- or gearmotor is simple. Here is ing, two conditions should be met:
known Palmgren-Miner rule. tions used to analyze complex load rated torque unless the machinery is tial portion of the motor peak ac- one proven method; its simple First, the true torque rating must be
However, keep in mind if the cycles consisting of different loads only working a very limited time. celeration torque is consumed formulas and minimal required known. Here, true rating refers to
number of the load cycles is above of varying duration. An hour of operation a day qualifies. while accelerating the motor ro- input data facilitate programming a gearbox’s rating based on en-
the 2 x 106 the stress load has to be Another situation where peak tor. Luckily, for most situations and online sizing routines. durance limits of its main compo-
at or below the endurance limit; loads can exceed rated torque is if the proper selection of a gearbox Before using this method for siz- nents — not some ill-defined peak
N t T 3 + N 2 t2T23 + ... + N i tiTi 3
otherwise the component will fail. TRMC = 3 1 1 1 the user and OEM do not expect ex- or acceleration torque. Second, the
As shown in the example, for the N1t1 + N 2 t2 + ... + N i ti tended, maintenance-free life. gearbox application shouldn’t in-
number of load cycles a sun-gear Since simple RMC calculations are Trial run volve frequent jams, emergency
endures over eight hours (2.88 x The exponent of three in this for- not applicable to other internal Consider a typical servo system with an inertia ratio (reflected load Inertia / motor stops, or other sudden, heavy load-
106) the components must be sized mula is valid for bearings, but isn’t gearbox components in such cases, inertia) of 1:1. Because this inertia ratio has the best balance of control characteris- side shocks; these situations re-
and designed to endure unlimited really applicable for the other gear- data should be submitted to the tics and economics, most system designers aim for this optimal value. quire more involved analysis.
load cycles. Gearbox rated torque box components. Specially tailored manufacturer.
must equal the torque level that calculations help identify the expo- Assuming there are only dynamic inertial loads (TLR=0), with the inertia ratio Load cycles
loads all components at or below nents valid for teeth, shafts, and Follow up JLR / JM = 1 the inertia parameter k becomes 1/(1+1) = 0.5, which means TGR = 0.5 x TM. Automation, motion control, and
their endurance limits. other parts. Did you find this article useful? positioning applications are char-
Unfortunately there is another Circle 201 on the Reader Service This implies that in a system with a 1:1 inertia ratio, 50% of the motor peak acterized by the repeated accelera-
phenomenon that makes otherwise Gearbox torque rating Card to see more like it. torque will be consumed while accelerating the motor rotor, leaving only the re- tion and deceleration cycles of
straightforward sizing less transpar- The majority of real-world gear Would you like the entire Course Audit maining 50% to travel through the gearbox to accelerate the load. Using the above starts, stops, and reversals. The re-
ent — the bearing. Rolling element applications far exceed 2 x 106 load series in reprint form? Call (888) 858- equation, an appropriate gearbox can be selected based on the calculated maxi- sulting characteristic load cycle
bearings behave differently than cycles. For this reason, the recom- 8851 to purchase, or e-mail at mum output torque requirement of TGR x i instead of selecting one based on the usually consists of several load
other components; specifically, they mendation of nearly all gear rating reprints@pentonreprints.com. full peak motor torque TM x i. peaks of varied intensity and dura-

Copyright © 2003 by Penton Media, Inc., Cleveland, Ohio 44114

 The k—IMR relationship
tion, which makes the exact cycle Torque through the gearbox
Course Audit
difficult to predict. However, it can
Advanced learning at your desk, at your pace / Multi-part series
be measured and a statistically rep-
resentative load characteristic cycle Friction torque load is 60% of motor peak torque.
100%

Overall torque through the gearbox

compiled.
Typically, when a gearbox
must be selected for a servomo- 80% Precision gearhead

Motor peak torque

tor, the exact load cycle is un-
Pure dynamic load, with no friction torque load.
known. Having basic load-re-
lated data — namely the load
inertia and the non-dynamic
60%

40%
50% motor peak torque
torque rating for automation
load torque (friction and
gravity loads) — makes reli-
able and realistic estimations of
20% and robots
Gerhard Antony, PhD
the required gearbox torque rat- Day 2 Neugart USA, Bethel Park, Pa.
ing possible. 0 1 2 4 6 8 10 www.neugartusa.com
Inertia Match Ratio Topics of discussion:
Dynamic torque load
equilibrium in a drive > Ferrous material fatigue
train: motor—gear—load a = angular acceleration Here, each curve represents the overall > Gearbox torque rating
Knowing the peak torque a gear- (dynamic plus non-dynamic steady-
box is subjected to eases sizing. The torque traveling through the state) torque load through the gearbox The basic limiting factor for elec- example, consider gear teeth. With relationship between stress S and
Consider a system consisting of a gearbox is: as a percentage of the motor peak trical devices is prolonged exposure every wheel rotation each tooth be- the number of endured load cycles
motor, gearbox, and load. All sys- torque. Each curve is for a different to high temperatures which deteri- comes fully loaded on engagement; N that result in no damage actu-
tem parameters are reflected to the TGR = TM − JM × a static load of 0, 20, 40, or 60%. orate insulation layers, boundary then it passes through the action ally levels out at the endurance limit
motor axis so that TGR = TLR + J LR × a layers in transistors, and other parts. area, becomes unloaded, and com- — at about 2 x 10 6 to 10 7 cycles.
JLR = JL/i2 and The inertia parameter k is very
Since generated heat equals R x I2 x t pletes a dynamic load cycle. In the This is valid if the part is subjected
TLR = TL /i closely related to the well-known and the rating limitation of a motor, re- case of a sun gear in a three-planet to bending, shear, tension, or com-
where i is the reduction ratio, JL the Substituting (1) in (2) gives (in servo drive system sizing) fre- lay, or inverter is the RMS value of gearbox, this actually occurs three pression. Based on this we can dis-
load inertia at the gearhead output, quently used Inertia Match Ratio. current. Similarly, the limiting fac- times per revolution due to multiple tinguish two distinct areas of the S-
JLR is the reflected inertia at the in- 1 − JM JM The IMR is defined as ratio of the re- tors of mechanical devices are me- contacts. Assuming the gearbox is N relationship:
TGR = TM × +TLR ×
put (motor axis). T L is the load JLR + JM J LR + JM flected load inertia to the motor rotor chanical stresses — tension, com- driven by a servomotor at a moder- • The area of limited load cycles —
torque at the output and TLR is the inertia: pression, bending shear, and ate 2,000 rpm input speed, in an plots situations resulting in limited
corresponding reflected torque at J LR Herzian pressure. The exponent eight-hour period each sun gear life. This area shows and exponen-
the motor axis. This non-inertial IMR = here is not two, but ranges from 3 to tooth endures 2,000 x 3 x 8 x 60 = tial relationship between S and N,
friction and/or gravity-born torque, The inertia parameter, which is JM 50 and above. 2,880,000 load cycles. mathematically described as S = 1 /
is present in the system under a function of the system inertia, is Countless tests confirm that for N1/E = N1/E or N = 1/SE. Because of
The inertia parameter k can be eas-
steady state as well as under the defined as k = JM/ (JLR + JM). ily expressed in terms of the IMR:
Ferrous material fatigue ferrous materials, the exponential the large range involved, the rela-
acceleration phases. Fatiguing of metallic compo-
Characteristic SN curve for ferrous metals
The torque equilibrium equation By inserting k into (3), torque 1 nents is well documented. Cycli-
k=
during the acceleration can be through the gearbox can be written: IMR +1 cally loaded parts fail even when the
written as: stress load magnitude never exceeds

Area of limited load cycles

TGR = (TM − TLR ) × (1 − k) +TLR With the direct relationship be- static strength (which parts can eas-
TM − TLR − J M × a − J LR × a = 0 tween k and the Inertia Match Ratio, it ily endure without damage.) An-

Stress load (S)

is easy to find the motor torque other well-known phenomenon: If
This easy-to-handle formula is transmitted through the gearbox. the magnitude of the cyclic stress
T − TLR load is decreased enough, parts can
a= M valid for all motor torque inertia
J M + J LR and frictional torque combinations.
Direct connect...
endure unlimited load cycles. This
For long, maintenance-free For more information, visit stress level is called the endurance Endurance limit
where gearbox life, the calculated gear- limit. Described by S-N Curve, this SE
www.motionsystemdesign.com and Area of unlimited load cycles
TM = maximum available motor box peak load T GR x i should be click on Direct Connect. To comment behavior is defined in terms of stress
peak torque equal to or below the gearbox on this article, e-mail the editor at and number of cycles. 2x106
JM = motor rotor inertia torque rating. ● eeitel@penton.com. All major gearbox components Load cycles (N)
are subjected to cyclic stresses, even The constant, horizontal part of the S-N curve is the endurance limit value, at which
if external loads are constant. For a component can withstand unlimited cycles
FORMULAS
TO DETERMINE SELECTION

1) How to calculate torque when horsepower and speed are known

5252 x horsepower x service factor 5252 x hp x k
torque ft lb = T=
speed n
2) Inertia - How to determine inertia when material and shape are known.
(Total system inertia is total inertia of all the components. If the components are not
simple shafts or flanges, break down each of the components into its basic shape and
calculate inertia of that individual component. When inertia is being calculated in
relation to the clutch or brake, remember to adjust for reflected inertia amounts which
may have a significant increase or decrease on the inertia that the clutch has to handle
based upon a speed differential.)
Formula to determine inertia of a solid shaft
wk2 = .000681 x p x Length x Diameter4
(Inertia constants lb. in.3) wk2 = .000681 x p x L x D 4
ρ (aluminum) = 0.0924
ρ (bronze) = 0.321 Formula to determine inertia of a hollow shaft
ρ (cast iron) = 0.26 wk2 = .000681 x p x length x (outer diameter4 - inner diameter4)
ρ (steel) = 0.282 wk2 = .000681 x P x L x (DO4 -DI4 )
Values
wk2 = lb. ft.2 Reflected inertia via gears, chain or belt
D, D0, D 1, L = in. reflected inertia = load inertia divided by the square of the speed ratio
2
wk2R = wk L
r2
3) How to calculate the amount of torque required to accelerate or decelerate a load
when inertia value is known (t = time to speed or time to stop depending if you are
using a clutch or a brake.)
(inertia x the change in rpm) wk2 x ∆ rpm
torque ft lb = T=
308 x the time required 308t

4) Heat Dissipation
Quick reference for determining slip watts for magnetic particle applications.
(Magnetic particle clutches are normally limited to heat dissipation rather than torque
when they are involved in a constant slip application.)
watts = .0118 x torque in inch lbs. x the change in rpm W = .0118 x t x ∆ rpm

5) Linear Speed to Rotational Speed

speed in feet per minute FPM
RPM = RPM =
3.14 x diam. in feet 3.14 x D