esco nexus

Composite Disc Couplings

Application Engineering Data

esco nexus Composite Disc Couplings

Application Engineering Data
Introduction: esco nexus Composite Disc couplings were developed through research and testing with the goal of providing increased endurance and fatigue life beyond the currently available composite couplings on the market today. The design stems from ACPTs composite experiences with military vehicles such as tanks, amphibious assault vehicles and trucks, rotary winged aircraft, performance racing and various industrial applications. Product Description: esco nexus composite couplings are non-lubricated, disc type couplings made from advanced composite materials. The floating spacer shaft and flanges are made from composite materials that ensure strength and endurance while delivering light weight, corrosion resistance and ultra-violet light protection. The disc type flexible elements are made from a combination of stainless steel bushings, advanced composite disc-links and a urethane encapsulation to provide a unitized assembly with a theoretical infinite fatigue life. The flexible elements are rated for 1 misalignment and carry a 4 times peak overload rating when applied at 2.0 service factor. The hubs and hardware are made from stainless steel for added corrosion protection in aggressive environments. The combination of high peak overload capacity and highstrength composites makes this product a heavy-weight title contender despite its light weight.
Bolt, Hex, Washer Head Stainless Steel Spacer Bush ing Stainless Steel Nut, Hex w/ Nylon Lock Ring Stainless Steel Set Screw Stainless Steel

Hub Stainless Steel

Floating Spacer Shaft Composite

Flexible Element, Nexus Composite Disc, Unitized

The floating spacer shafts are made from Graphite and/or E-glass fibers embedded in an epoxy matrix. The epoxy resin is filled with a UV protective additive and cured at high temperature. This system provides corrosion resistance that exceeds stainless steel. There are five sizes of flexible elements that range from 75 kW to 675 kW to serve most electric motor driven applications. These flexible elements are combined with matching hubs, hardware kits and floating spacer shafts to provide the most economical selection for a given application Nomenclature: Coupling size, i.e. A300, refers to the A series disc couplings followed by the flexible element kilowatt rating at 1.0 service factor. In this example the A300 is rated for 300 kW or about 225 horsepower @ 1800 RPM. SES stands for Shaft End Separation and is the distance between the faces of the connected equipment shafts. In the case of a cooling tower this length is between the face of the gear box shaft (driven) and the face of the electric motor shaft (driver). SES is sometimes referred to as DBSE (Distance Between Shaft Ends).

Sep2004

esco couplings N.V. Culliganlaan 3 B 1831 Diegem Belgium tel + 32 2 7156560 www.esco-coupling.com

esco nexus Composite Disc Couplings

Application Engineering Data
Table 1 - General Dimensions (inches)
1 Coupling Size A75 2 Max. Bore 2.13 3 A 5.25 4 B 2.25 5 C 2.93 6 D 0.50 7 Spacer Shaft 8 Spacer Tube O.D. 9 Min. SES "L" (inches)
1

10 Maximum SES @ 1800/1500 RPM (inches)

S3 82 / 92 9 M3 100 / 110 3.3 S3 82 / 92 9 A150 2.88 5.25 2.25 2.93 0.50 M3 100 / 110 114 / 125 L3 M4 120 / 132 4.3 L4 137 / 150 A225 4.00 7.03 3.13 3.88 0.63 12 L5 5.3 153 / 168 L6 6.3 168 / 184 M4 120 / 132 4.3 L4 137 / 150 A300 4.00 7.03 3.13 4.38 0.75 12 L5 5.3 153 / 168 L6 6.3 168 / 184 L6 6.3 168 / 184 L7 7.3 181 / 198 A675 4.19 9.50 3.75 5.50 0.75 14 L8 193 / 211 8.3 X8 212 / 232 XH8 226 / 248 1) Maximum SES is based on a 1.30 minimum critical speed safety factor per Cooling Technology Institute, Chapter 10 specifications.
L = SES

Spacer Tube O.D.

Table 2 - Engineering Data

1 Coupling Size 2 Max. Continuous Torque (lb-in.) @ 1.0 sf 3,600 7,200 3 Peak Overload Torque (lbin.) 7,200 14,400 4 Axial Capacity Per End (inches) 0.03 0.03 5 Spacer Shaft S3 M3 S3 M3 L3 M4 L4 L5 L6 M4 L4 L5 L6 L6 L7 L8 X8 XH8 6 Weight @ Min. SES (lbs) 13.1 13.0 11.6 11.5 11.3 31.4 31.0 35.7 41.4 36.2 35.8 40.5 46.2 69.5 77.8 87.4 87.4 87.4 7 Weight Change Per Inch (lbs) 0.105 0.089 0.105 0.089 0.063 0.154 0.110 0.136 0.162 0.154 0.110 0.136 0.162 0.162 0.189 0.215 0.215 0.215 8 Wr @ Min. SES 2 (lb-in ) 35 35 33 33 32 134 132 162 214 134 132 162 214 630 735 896 896 896
2

A75 A150

A225

10,800

21,600

0.04

A300

14,400

28,800

0.04

A675

32,500

65,000

0.05

9 2 Wr Change Per Inch 2 (lb-in ) 0.218 0.185 0.218 0.185 0.131 0.666 0.472 0.902 1.536 0.666 0.472 0.902 1.536 1.536 2.413 3.573 3.573 3.573

Sep2004 esco couplings N.V. Culliganlaan 3 B 1831 Diegem Belgium tel + 32 2 7156560 www.esco-coupling.com

Esco Couplings
Coupling Selection: Step1: Coupling selection is determined by comparing the full load motor (driver) torque times required safety factor to the coupling Continuous Torque rating at 1.0 service factor. Electric motor full load torque (lb-in) is established by multiplying the nameplate horsepower rating (Hp) by 63,025 and then dividing by nameplate full load RPM (usually between 1750 and 1790 for 4 pole electric motors). Formula is as follows:

Hp =

T RPM Hp 63025 or T = 63025 RPM

Motor nameplate Hp = 100 Motor nameplate full load RPM = 1775 Service Factor = 2.0 (for cooling towers)

Example:

T=

100 63025 2 = 7100lb in 1775

Compare 7100 to the maximum continuous torque ratings in Table 2 - Engineering Data, Column 2 until you find the first size that equals or exceeds this value. In this case the selection is A150. Step 2: Shaft End Separation (SES) is the distance in inches from the face of the gear box shaft to the face of the electric motor shaft (tolerance = 0.06). In this example we will use 95.00. In Table 1 - General Dimensions find the row for A150 and read across to the right in Column 7 and notice the possible selections (in this case S3, M3 or L3). In Column 10 you will find the values for the maximum SES permitted for each type spacer shaft. Select the first one that exceeds the actual SES required for the application. In this case it is M3. The complete model description is the combination of the coupling size (A150) and the spacer shaft (M3) designated as A150-M3. Total Weight of Assembly: Step 1: To establish the total weight of a complete coupling assembly locate the coupling size in Table 2, Column 1; locate spacer shaft in column 5; note the weight at minimum SES in Column 6 and the weight change per inch in Column 7. For this example, A150-M3, the values are 11.5 and 0.089 respectively. Step 2: In Table 1, Column 9, note the minimum SES in inches (9). Subtract this value from the actual SES (95 9 = 86). Multiply the weight change per inch times this adjusted value (86 x 0.089 = 7.654 lbs) and then add the weight at minimum SES to arrive at the total weight (7.7 + 11.5 = 19.2 lbs). Total Wr2 of Assembly: Step 1: Similar to above except substitute the Wr2 in Column 8 and 9 in Table 2 for the same coupling and complete Step 2 above with these substituted values. For this example, A150-M3, the values are 33 and 0.185 respectively. Step 2: In Table 1, Column 9, note the minimum SES in inches (9). Subtract this value from the actual SES (95 9 = 86). Multiply the Wr2 change per inch times this adjusted value (86 x 0.185 = 12.9 lb-in2) and then add the Wr2 at minimum SES to arrive at the total Wr2 (33 + 12.9 = 44.9 lb-in2).

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Esco Couplings
Assembly and Operation Shown below is the complete assembly that includes 2 hubs with set screws, 2 flexible elements, 2 hardware sets and 1 floating spacer shaft. The hardware set includes enough bolts, nuts and bushings to assemble one flexible element to the hub and spacer shaft. The bolts are flanged, hex head to eliminate the need for separate washers that are quite often dropped and lost during the installation process. The bushings are installed in the large clearance holes in the hub and spacer shaft flanges. These bushings locate the self-locking nuts outside the flange faces so that a wrench or socket can be easily used to torque the nuts.

Bushing

Floating Spacer Shaft

Flexible Element

Self-locking Nut

Flanged Hex Head Bolt

Hub

Spacer Flange

Hub Flange

Why is it called a floating spacer shaft? In a disc coupling assembly, the spacer shaft is only affixed to every other hole in the flexible elements. The alternate holes are affixed to the hub flange. In this way, flexible elements act like springs to allow the spacer shaft to move axially to accommodate thermal expansion or axial movement of the connected equipment. The spacer shaft is allowed to float in order to seek a neutral position between the flexible elements and equalize the stresses encountered. Why are there two flexible elements? A single disc type flexible element can accommodate some axial movement and either parallel or angular misalignment, but not both simultaneously. However, two disc type flexible elements separated by a floating shaft can accommodate parallel offset, angular misalignment and axial movement simultaneously while balancing the stresses between themselves. This type of coupling system has relatively low reaction forces that reduce the loads on the connected equipments shaft bearings.

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Esco Couplings

Critical Speed Floating Spacer Shaft

5000
XH8

4500
L8 L7

X8

4000
L5

L6

Critical Speed (RPM)

3500

M4L4

L3

3000
M3

2500
Critical Speed Safety Factor for 1800 RPM

2000
Critical Speed Safety Factor for 1500 RPM S3

1500

1000 80 100 120 140 160 180 200 220 240 260 280 Length (inches)
The critical speed of the floating spacer shaft can be determined from the chart above. Once you know the spacer shaft designation (i.e. L4) and the SES you can plot the point on the chart to determine the critical speed. For example, if the SES is 125 and the spacer shaft is L4 find the intersection of x axis at 125 with the curve marked L4 and read the critical speed on the y axis. In this example the value is 2825 cycles per minute.

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Esco Couplings
Company: Name: Tel, Fax: Email: Date: ACPT Quote No. Prepared By:

Application Data (completed by customer) Motor Frame Motor RPM Motor Nameplate Hp Rating Motor Shaft Diameter Motor Shaft Keyway Gear Box Model Gear Box Ratio Gear Input Shaft Diameter Input Shaft Keyway Fan BHP Load Fan RPM No. of Fan Blades Blade Pass Frequency (CPM) Application Type Required Service Factor Coupling Data (completed by ACPT) Product ID Code Continuous Torque Rating Peak Torque Rating Service Factor (based on motor rating) Lateral Critical Speed Nc Nc Safety Factor 1.30 Floating Shaft OD Misalignment Tolerance 1 /flexible element Dynamic Balance Class Q6.3 Hub and Hardware Material Stainless Steel Flexible Disc Material Composite Maximum Coupling Diameter

Shaft End Separation (SES)

Gear Reducer Motor

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