APPLICATION NOTES

Custom Gearbox Powers Intelligent Lifting Device

GAM solution for Gorbel^® G-Force^® costs less than competitive off-the-shelf products

Project Objectives:
After a successful initial collaboration, Gorbel Inc. challenged GAM Gear to develop a gearbox for its new line of G-Force Intelligent Lifting Devices (ILDs) that would fit tight space constraints, provide the necessary torque in three capacities to handle loads up to 660 lbs. and cost less than the components they have used in the past.

The co-development project between the two companies, which began as a cost-reduction initiative, ultimately had two main drivers, says Jeff McNeil, Gorbel director of marketing. "We wanted to double our highest capacity from 330 lbs. to 660 lbs. and we wanted to use standardized components in all three capacities."

The Co-development Process:
New York-based Gorbel's patented G-Force technology provides more precise, controllable action than traditional hoists while being more responsive than air balancers. Standard hoists feature a pendant with up and down buttons. G-Force devices sense hand movement and speed and automatically react accordingly. Other features, such as "virtual limits," can be programmed into the lifting devices via custom software to integrate then with a customer's specific application.

GAM was brought in early in the redesign and, working closely with Gorbel's product development engineers, designed a custom gearbox solely for use in G-Force ILDs. Both rotating and mating components were looked at with a view to eliminating anything that was functionally unnecessary.

The Successful Results:
In the final design, the gearbox provides the required torque to the lift through a rotating housing that acts like a powerful driven pulley. "The GAM components allowed us to achieve our goal of doubling capacity while using standardized components across the line," McNeil states. Functionally, McNeil adds, the G-Force devices provide fast, precise servo-controlled lifting without any valve changes. With light-weight jobs, the product competes against manual lifting and workers won't use it if it slows them down. At higher capacities – engine assemblies for example – G-Force lifts may be required to place 400 to 500 lb. pieces together very precisely. "You can't risk damaging expensive parts or causing a crushing injury to an operator's hand," McNeil notes.

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Dyna Series Replaces Several Mechanical Components and Lowers Overall System Cost

Objective:
Replace numerous mechanical components with a Dyna Series

Solution:
GAM was asked to quote our low cost in-line planetary gearbox. There were numerous competitors also bidding for the business so price was the driving factor in the customer’s eyes. After reviewing the application the customer was driving a shaft via a motor, gearbox, and coupling arrangement. The shaft also had its own bearing support. GAM replaced all of the bearings, couplings, and the in-line gearbox with a hollow output right angle Dyna Series.

Before: After:

Operation:
The Dyna Series employs large taper roller bearings on the output shaft of the gearbox. These bearings have a very high axial and radial load carrying capability. The shaft is passed through the hollow gearbox where the gearbox bearings become the shaft support.

Results:
The bearing support, coupling, and gearbox mounting system were eliminated. The customer saved money on the overall system, even though the Dyna Series gearbox was more expensive than the in-line gearbox proposed. Overall the system has better performance and better aesthetics because of the Dyna Series.

GAM Gear Unique Application Story

Objective:
To create a gearbox that is non corrosive and food environment friendly. This was for a 100-200 piece/year application with approximately 20 piece releases.

Solution:
GAM and German engineers collaborated to create an all stainless steel economy series gearbox. The single piece stainless steel housing, stainless shaft, stainless input adapter, stainless bolts and viton seals accomplish the completely non corrosive design. Use of special food grade grease achieves compatibility with common food application health standards.

Result:
GAM provided an economical solution to a common situation where high corrosion resistance is very important. The EPL-W-064 series stainless gearbox is able to maintain the standard output mounting dimensions while only expanding in length and OD by about 10mm and 8mm respectively.

More Information:
GAM is now stocking the Stainless Gearbox with common ratios. For stock gearboxes we can fit it with the right adapter plate for your motor and ship quickly. Single piece quantities or high quantity orders for OEM applications can be accommodated.

Please contact GAM inside sales at 847-649-2500 for more information.

PRODUCTS/SERVICES UPDATES

Quick Delivery on Couplings

Did you know that for most sizes of KM, KLC, and EKM couplings, GAM can ship these custom bored on the same day that the order is received for an expedite charge? Second and third day shipments are also possible for a smaller expedite charge. The normal lead time is 5 working days to ship stock couplings. GAM sometimes stocks other series of couplings for fast delivery, please ask GAM for more details.

Linear Slide Kit Simplifies Mounting a Gearbox to a Linear Slide

Did you know that the GAM LSK (Linear Slide Kit) is a quick and easy way for your customer to mount a shaft output gearbox to a linear slide? The kit can be customized to ANY linear slide and ANY ge arbox. The kit includes a coupling and all of the required mounting hardware. GAM can now ship an LSK in 5 working days after receipt of your order which means no delay for your application!

KLH Couplings Resist Corrosion

The KLH series couplings are all stainless steel, making them perfect for washdown and vacuum environments.

The GAM KLH coupling is available in extended lengths, however it is also available in shorter lengths and is composed of all stainless steel. The all stainless steel design allows zero corrosion in any washdown environment. The grade of stainless steel also makes it suitable for high vacuum situations. Many variations in length are available.

Specification Tip to Increase Thermal Limit on High Power Series (HPS)

Did you know that the thermal limit on the GAM High Power Series (HPS) can be increased by 50% just by using viton seals?

This means that when you are sizing the HPS series and your input power requires you to use the next higher frame size due to the thermal limit, you may be able to use the smaller frame size by switching to viton seals. Since ordering with viton seals is much less expensive than going to the next bigger size this could save a great amount of money in your application. The thermal limit calculation is located on the bottom of the HPS specification page in the GAM Gear catalog. In general by using viton seals you can multiply the thermal limit of any HPS size by a factor of 1.5. Note: This does not increase the torque or speed ratings, just the thermal limit.

JPG I.M.P.A.C.T Series Line Extended

GAM now has two larger sizes of the JPG I.M.P.A.C.T series gearbox available!

The JPG-W-1000 and JPG-W-1700 have a nominal output torque capability of 1000 Nm and 1700 Nm respectively. T his allows for the highest precision and torsionally stiff JPG gearbox to be used in high torque applications.

Customized 2D & 3D Drawings Now available for Download!

You can now go to www.gamweb.com in the CAD section and download any gearbox or coupling completely customized to your specifications.

The gearbox drawings can be customized with the proper motor adapter corresponding to the motor dimensions you enter and also any other options you choose. The coupling drawings can be customized with the entered bores, keyways, lengths etc.

Once you customize your drawing you are able to download it in any 2D or 3D format you wish. This feature is available on the website now, you can take advantage of this right away!

For High Speed Applications, Choose ESM or KHS Series Couplings

The GAM ESM and KHS series couplings are specially designed for high speed applications. Low rotational inertia, special balance, and conical clamping hubs make the ESM and KHS series couplings a great choice for your high rotational speed applications.

The KHS is rated for up to 25,000 rpm! Common uses are with spindle drives and testing setups.

For more info on the ESM please go to Elastomer Couplings
For more info on the KHS please go to Bellows Couplings

New Coupling for Food Grade and Vacuum Applications

Did you know that GAM has a brand new coupling available that can perform in temperatures of -180 degrees Celsius and below? The coupling is the KG-VA bellows coupling. It is an all stainless steel design and is available in 10 sizes which have torque ratings from 5 to 1300 Nm. This is also a great coupling for food grade and vacuum applications.

New On-Site Gearbox and Coupling Testing Center

Did you know that GAM Engineering has developed an on-site gearbox and coupling testing center?

GAM now has the capability to more accurately diagnose and verify performance of most gearboxes and couplings that have become damaged.

A competent and fully equipped service center that can take care of unexpected machine crash problems quickly and accurately is just another way GAM is providing excellent customer service.