G E A R I N G I N D U S T R I E S

ELECON COUPLINGS

HFC -A HIGHLY FLEXIBLE

COUPLING

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INFRASTRUCTURE
INFRASTRUCTURE

WORLD’S MOST TECHNOLOGICALLY ADVANCED GEAR MANUFACTURING FACILITY

BHANUBHAI MEMORIAL CENTRE OF EXCELLENCE (BMCE)

In the last seven decades, Elecon have conducted intensive research in gear technology and manufacturing
techniques. We have developed a variety of products in the transmission industry from worm gears to helical,
from planetary to variable speed fluid couplings. This development has demanded a significant investment in
manufacturing capability from gear cutting right through to heat treatment and profile grinding. This new plant
has the capacity to manufacture sufficient helical gears to produce 1000 assembled gear units per month.
This plant is a tribute to our founding Chairman, Lt. Shri Bhanubhai Patel, who wanted to remain “Always a step
ahead in technology”
 HIGHLY FLEXIBLE COUPLINGS:
HFC-A SERIES
HIGHLY FLEXIBLE
01.Elecon Products Overview 02

02. Introduction 06

03. Design and Configurations 07

04. Configuration 08

05. Technical Specification 10

COUPLINGS

06. Coupling type NNC 12

07. Coupling type FNC 13

01
1. PRODUCTS OVERVIEW

1.1 Elecon products catalogue overview

1.2 Elecon other products
PRODUCTS
OVERVIEW

02
RELIABLE SOLUTION FOR
ALL INDUSTRY

Steel Industry

Crane Industry Marine Industry

‘ELECON’
Plastic Industry Solution for Power Industry

Industry

Sugar Industry Cement Industry

Rubber Industry Mining Industry

03
ELECON PRODUCTS
CATALOGUE OVERVIEW

Geared Coupling Fluid Coupling

Torque: up to 6270 kN.m Toque: up to 1300 kW

Flexible Coupling General Application

Torque: up to 27060 Nm Torque: up to 2320 kW

Torque Shaft Coupling

Toque: up to 6270 kNm

04
ELECON OTHER
PRODUCTS

Helical Gear Unit Sugar Mill Drive

Ratio: 2:1.....400:1 Gear Box Ratio: 63:1 to 500:1
Torque: 140 kNm...1400 kNm Output Torque: up to 8000 kNm

Vertical Rolling Mill Dual Tandam (kiln drive and

Ratio: 16:1 to 50:1 Sugar mill drive)
Toque: up to 2500 kNm Ratio: 45:1 to 250:1
Torque: up to 2070 kNm

High Speed Gear Unit Marine Application

Prime Mover Power: up to 50 MW
Input Speed: up to 14000 rpm

05
2. INTRODUCTION

HIGHLY FLEXIBLE COUPLINGS (HFC-A)

HFC-A couplings have a high torsional flexibility.

HFC-A couplings are suited for machines with a
non-uniform load distribution due to their low
torsional rigidity and damping characteristics. This
couplings are suitable for shaft misalignment. HFC-A
couplings are available as solid shaft-to-shaft (NNC)
or flange-to-solid shaft connections (FNC). One
request, a special link can be made.

The coupling is delivered preassembled. The flexible rings are completely assembled. On the type NNC, the
coupling halves have to be bolted together after the hub has been mounted. On the type FNC, after mounting
the coupling hub, only the outer flange has to be connected to the machine.
Special outer flanges with different connection dimensions are available for the type FNC.
If the flexible rings are irreparably damaged or worn, the metal parts can rotate freely against one another, they
are not in contact with one another.

Key Features
- The split flexible rubber rings can be changed without having to move the coupled machines. The flexible
rings are mounted without backlash and give the coupling progressive torsional stiffness.
- The HFC-A coupling is available in 9 sizes having nominal torque between 1550 Nm to 89500 Nm. The
coupling is suitable for ambient temperatures of between -40 °C and +80 °C.
- The HFC-A coupling is utilized in tough operating conditions to ensure long service life.
- HFC-A couplings are suitable for drives subject to high shock loads or large shaft misalignment. Also
suitable for drive with periodically excited systems.
Applications:
▪ Cement mill.
▪ Sugar Cane mill.
▪ Tube mill.
▪ Marine drive.
▪ Crushers.
▪ Compressor drive
▪ Pump drive

06
3. DESIGN AND CONFIGURATIONS

The flexible ring is a key component of HFC-A coupling which determine its transmission characteristics. The
flexible rings are made from natural rubber with a number of fabric lining. This flexible ring is split into four
pieces that can be replaced without moving the motor or equipment.
Bolts and nuts connect the flexible rings to the hub and outer flanges.
On the FNC type, the outer flange is designed with connection dimensions for connection.
The flexible rubber rings are connected to the hub with a clamping ring and to the outer flange with a
clamping ring, using pins and bolts.

Materials
HFC-A coupling is available in two types based on metal parts materials, i.e. Cast iron and Steel.

Type
Components
Cast Iron ( HFC-A-SizeC) Steel ( HFC-A-SizeS)
Hub part-1 FG-260 Steel
Hub part-2 Steel Steel
Retaining rings & outer rings FG-260 Steel
Outer flange NNC, FNC FG-260 Steel

Flexible rubber ring material

Material Hardness Marking Ambient Temperature
Natural rubber 70 ShoreA Size-2 -40 to +80°C

HFC-A coupling types

Type Description
NNC Coupling as shaft-shaft connection
FNC Coupling as flange-shaft connection

Type NNC Type FNC

07
4. CONFIGURATIONS

Coupling Selection
The HFC-A coupling is especially suitable for rough operating environments.
In case of machines which excite torsional vibration, Elecon recommends to carry out a torsional vibration
calculation.
Elecon has capabilities to carry out torsional vibration analysis & can provide calculation accordingly.

Coupling load in continuous operation

Application factor for coupling
The operational principles of the driving and driven machines are divided into categories and the application
factor derived from these in accordance with DIN 3990-1. Selection is as per below table.
Table 4.1

Application factor KA

Torque characteristics of Torque characteristics of the driven machines

the driving machine Uniform Uniform with Non uniform Very rough
moderate shock loads

Uniform 1.0 1.25 1.5 1.75

Uniform with moderate shock loads 1.25 1.5 1.75 2.0

Non-uniform 1.5 1.75 2.0 2.5

Temperature change effects on the torsional stiffness. So, temperature factor has been selected from below
table.
Table 4.2

Temperature application factor KT

Temperature Ta on the coupling

Coupling Elastomeric -40 to -30°C -30 to +50°C Up to 60°C Up to 70°C Up to 80°C

material
HFC-A Natural Rubber 1.1 1.0 1.25 1.4 1.6

Examples of torque characteristics of driven machines:

▪ Uniform with moderate shock loads: generators, fans, blowers.
▪ Non-uniform: Reciprocating compressors, mixers, conveyor systems.
▪ Very rough: Crushers, excavator, presses, mill

Coupling size TKN ≥ TN .KA.KT

08
CONFIGURATIONS

Coupling Maximum Torque & Overload conditions

The maximum torque is the highest load acting on the coupling in normal operation.
Maximum torques at a frequency upto 25 times an hour are allowed and must be lower than the maximum
coupling torque. Examples of maximum torque running are: Starting operations, stopping operations or usual
operating conditions with maximum load.
TKmax ≥ Tmax .KT
Overload torques are maximum loads which occur only in combination with special, infrequent operating
conditions. Examples of overload torque conditions are: Motor short circuit, emergency stop or blocking due
of component breakage. Overload torques must be lower than the maximum overload torque of the coupling.
The overload condition may last only a short while, i.e. fractions of a second.
TKOL ≥ TOL .KT

Coupling Load due to Dynamic Torque Load

Applying the frequency factor KF, the dynamic torque load must be lower than the coupling fatigue
torque.
Dynamic torque load
TKW ≥ TW . KT . KF
Frequency of the dynamic torque load
ferr ≤ 10 Hz frequency factor KF=1.0
Frequency of the dynamic torque load
ferr > 10 Hz frequency factor KF= ferr/10Hz

�Checking the maximum speed

For each load operations nKmax ≥ nmax .
Checking permitted shaft misalignment and restorative forces
For all load conditions, the actual shaft misalignment must be less than the permitted shaft
misalignment, as per Table 5.1.
Checking bore diameter, mounting geometry and coupling design
The check must be made on the basis of the dimension tables. On request, coupling with adapted
geometry can be provided.
Checking low temperature and chemically aggressive environment
The permitted coupling temperature is specified in the temperature Factor KT table. In the case of
chemically aggressive environments, please consult the manufacturer.

09
5. TECHNICAL SPECIFICATION

Table 5.1

Power ratings of HFC-A couplings

Allowable shaft
Rated Maximum Overload Fatigue Dynamic torsional missallignment misalignment, ∆K1500
Size torque TKN torque TKmax torque TKOL torque TKw
(Nm) (Nm) (Nm) (Nm) Ctdyn (kNm/rad) Axial, a Radial, r Angular,
(mm) (mm) w (°)
270 1650 4950 6600 660 21 2.1 2.1 0.2
320 2750 8250 11000 1100 38 2.5 2.5 0.2
375 4500 13500 18000 1800 62 2.9 2.9 0.2
430 7000 21000 28000 2800 98 3.3 3.3 0.2
500 11000 33000 44000 4400 154 3.7 3.7 0.2
590 17900 53700 71600 7160 240 4.1 4.1 0.2
690 28000 84000 112000 11200 367 4.5 4.5 0.2
840 44500 133500 178000 17800 684 5 5 0.2
970 89500 268500 358000 35800 1105 5.5 5.5 0.2

Torsional stiffness & damping

The dynamic torsional stiffness is load-dependent and increases in proportion to capacity utilization. The
values specified in the selection table apply to capacity utilization of 100%. The following table shows the
correction factors for various rated loads.
Ctdyn = Ctdyn 100% . FKC

Table 5.2

Load TN/TKN
Correction
20% 50% 60% 70% 80% 100% 200%
factor FKC
0.3 0.56 0.65 0.74 0.82 1 1.9

Torsional stiffness of HFC-A depends on the ambient temperature and the frequency and amplitude of the
vibration excitation.
With flexible couplings the manufacturing process of the rubber elements and their aging primarily influence
the stiffness value Ctdyn. For this reason calculation must be made with a tolerance for the dynamic stiffness of
± 20 %.

Permitted shaft misalignment

The allowable shaft misalignment depends on the operating speed. As the speed increases, lower shaft
misalignment are permitted. The connection factors for different speeds are specified in the following table.
The maximum speed for the respective coupling size must be noted.
ΔKperm = ΔK1500 . FKV

Table 5.3
Speed in rpm
Correction factor, FKV 500 1000 1500 3000
1.6 1.25 1.0 0.7

10
COUPLING SELECTION EXAMPLE

Given
Prime mover:
Electric motor, Pmotor = 1450 kW,
n1 = 990 rpm, Nominal torque, TN = 13994 N.m

Working Machine:
Vertical rolling mill
Required output power, Pe = 1450 kW,
Speed, n2 = 31.94 rpm.

Selection:
Application factor KA considering uniform driving machine (Electric motor) and non-uniform load driven
machine (Vertical rolling mill) from table 4.1, KA = 1.5

Temperature application factor KT considering working temperature 50°C, KT = 1.0

TN x KA x KT = 13994 x 1.5 x 1.0 = 20991 N.m
From table 5.1, select coupling with TKN ≥ 20991 N.m.
Therefore coupling of size 690 is selected.

Torsional stiffness correction:

Load TN/TKN = (13994/28000) x 100 = ~ 50%
Therefore, correction factor for torsional stiffness from table 5.2, FKC = 0.56
Actual dynamic torsional stiffness of selected coupling, Ktdyn = 367 x 0.56 = 205.5 kNm/rad

Misalignment correction:
Shaft misalignment correction factor from table 5.3 for 990 rpm, FKV = 1.25.
ΔKperm = ΔK1000 x FKV = 4.5 x 1.25 = 5.625 mm.

11
TECHNICAL SPECIFICATION

TYPE NNC

T1 T2
J1 J2

OD2
OD1
DA

d
D

H
L1 L2

SIZE: 270 …. 430 SIZE: 500 …. 970

Maximum speed Dimensions in mm

Rated Mass moment of
torque Cast Steel inertia Weight,
Size Keyway DIN 6885
TKN iron type type DA OD1 OD2 L1 L2 H T1 T2 W L m kg
(Nm) nkmax nkmax
D min D max d min d max J1, kg.m² J2, kg.m²
270 1650 3000 4250 45 80 45 70 270 128 94 73 155 17 14 86 40 245 0.18 0.031 28
320 2750 2500 3600 55 100 55 85 320 160 115 93 180 13 16 97.5 50 286 0.44 0.078 50
375 4500 2100 3100 65 115 65 105 375 184 143 113 205 17 18 112 60 335 0.97 0.17 81
430 7000 1900 2650 75 130 75 120 430 208 165 133 235 15 22 126 65 383 1.9 0.34 115
500 11000 1600 2300 90 150 90 150 500 240 202 150 160 122 25 140 72 432 3.9 0.69 175
100 140 224 7.7 255
590 17900 1360 2000 100 170 590 230 180 190 140 28 163 90 510 1.4
140 180 288 8.0 285
110 140 224 15.5 350
690 28000 1200 1650 140 180 110 200 690 288 278 210 220 150 32 176 100 580 15.6 3.2 371
180 210 336 15.8 386
140 180 288 47 700
840 44500 1000 1350 140 240 840 340 270 280 135 42 231 74 685 10.2
180 220 352 48 726
160 200 320 96 1270
200 240 384 98 1315
970 89500 850 1180 160 280 970 390 340 350 177 70 290 87 867 25
240 280 448 101 1360
280 320 512 104 1415

Configuration based variables

ΦD: Without finished bore

With Finish bore

Φd: Without finished bore

With Finish bore

12
COUPLING DIMENSION

TYPE FNC

SIZE: 270 …. 430 SIZE: 500 …. 970

Rated Maximum speed

Mass moment of
torque Cast Steel inertia Weight,
Size Keyway DIN 6885 Flange connection dimensions
TKN iron type type DA OD2 H L2 W L m kg
(Nm) nkmax nkmax D2 min D2 max DFA DFK FB ZF DFB J1, kg.m² J2, kg.m²

466.7g7 438.2 8 13 0.47 27

270 1650 3000 4250 45 70 270 94 - - 40 155 12 0.031
325j6 300 8 14 0.16 19

517.5g7 489 8 13 0.87 42

320 2750 2500 3600 55 85 320 115 - - 50 180 14 0.082
392j6 360 8 18 0.39 33.5

571.5g7 542.9 6 17 1.50 65

375 4500 2100 3100 65 105 375 143 - - 60 205 16 0.21
448j6 415 8 18 0.78 53

673.1g7 641.4 12 17 3.4 100

430 7000 1900 2650 75 120 430 165 - - 65 235 20 0.37
515j6 475 8 22 1.5 78

673.1g7 641.4 12 17 4.0 150

500 11000 1600 2300 90 150 500 202 100 160 72 260 20 0.85
585j6 545 10 22 2.7 140

733.4g7 692.2 12 21 7.0 200

590 17900 1350 2000 100 170 590 230 120 190 90 310 24 1.7
692j6 645 10 26 6.0 190

890g7 850 32 17 15 270

690 28000 1200 1650 110 200 690 278 130 220 100 350 24 3.7
800 750 12 26 11 250

1105g7 1060 32 21 46 530

840 44500 1000 1350 140 240 840 340 115 280 74 395 30 11
960j6 908 16 30 32 470

1385g7 1320 24 31 130 1050

970 89500 850 1180 160 280 970 390 155 350 87 505 35 26
1112j6 1051 16 35 76 920

Configuration based variables

ΦD2: Without finished bore

With Finish bore

13
 ELECON CAPABILITIES

Design, Engineering & Development:

Elecon has advanced and unmatched capabilities in the design, engineering and development of Gearboxes
and Couplings, combined with ultra-modern manufacturing facilities.
Elecon team with legacy of 70 years of business excellence in the field, shown proven customer satisfaction
experience.
Apart from analytical expertise, Elecon has advanced high end simulation facilities:
 FE analysis using Ansys software

 Torsional vibration analysis of Drive train using Advanced Rotating Machinery Dynamics (ARMD) software.

2.0000

1.8000 Operating speed

1.6000
Frequency (Hertz) (E+03)

1.4000
LSS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1.2000

1.0000

0.8000

0.6000

0.4000
1 2 34 15
HSS 5 6 7 8 9 10 11 12 13 14 16 17 0.2000

0.0000
0.0000 0.5000 1.0000 1.5000
Rotational Speed (RPM) (E+04)

 Rotor dynamic analysis of high speed rotors using Advanced Rotating Machinery Dynamics (ARMD)
software.
1.3000
Mode # 1
1.2000 Mode # 2
1.1000 Mode # 3

1.0000
Frequency (CPM) (E+05)

0.9000
0.8000
0.7000
0.6000 24 26
2 4 6 89 10 12 13 14 16 18 20 22
1 3 5 7 11 17 19 21 23
15 25 27
0.5000
0.4000
0.3000
0.2000
0.1000 Operating speed
B
Axial length B
0.0000
0.2000 0.4000 0.6000 0.8000 1.0000
Brg-Stiffness (N/m) (E+11)
14
ELECON CAPABILITIES

MANUFACTURING FACILITY:
Elecon has ultra-modern world class, manufacturing facility, well established process flow with plant
layout for reduced cycle time of products. High precision multi axis CNC machines for hobbing,
surface grinding and teeth grinding and housing machining along with experienced workmen
ensuring reliability of products.

14
15
ELECON CAPABILITIES

QUALITY:
Every Elecon product passes through thorough quality checking right from raw material to final run
test, to verify that product meets its operation.
Elecon has in house metallurgical laboratory with advanced equipment to inspect the raw material
properties such as chemical composition, grain size, inclusions and microstructure.
The equipment and quality instruments undergo pre-defined calibration schedule.

NABL APPROVED LAB

Universal Testing Machine, UTM-2 capacity: 1000Tones Semiautomatic Vicker Hardness Tester �

Brinell hardness Tester Profile Projector

Metallurgical Microscope Impact Testing Machine

16
ASSEMBLY AND TESTING

Fully equipped 2.2 MW test bench with advanced instrumentation and test data acquisition system.
Assembly workmen are well experienced and process is well defined process and layout.

17
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