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The installation of gearheads can smooth the operation of servosystems as well as reduce system costs. The addition of a gearhead to the system does not necessarily add to overall operating costs because its purchase price can be offset by reductions in operating costs. Smaller servomotors inherently draw less current than larger ones, thus reducing operating costs, but those power savings are greatest in applications calling for low speed and high torque because direct-drive servomotors must be considerably larger than servomotors coupled to gearheads to perform the same work.
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Small direct-drive servomotors assigned to high-speed/low-torque applications might be able to perform the work satisfactorily without a gearhead. In those instances servo/gearhead combinations might not be as cost-effective because power consumption will be comparable. Nevertheless, gearheads will still improve efficiency and, over time, even small decreases in power consumption due to the use of smaller-sized servos will result in reduced operating costs. The decision to purchase a precision gearhead should be evaluated on a case-by-case basis. The first step is to determine speed and torque requirements. Then keep in mind that although in high-speed/low-torque applications a direct-drive system might be satisfactory, low-speed/hightorque applications almost always require gearheads. Then a decision can be made after weighing the purchase price of the gearhead against anticipated servosystem operating expenses in either operating mode to estimate savings. The planetary gearbox is one of the most efficient and compact gearbox designs. Its internal coaxial layout reduces efficiency robbing side loads on the gear s shafts. Figure 2-29 and the following tables give the formulas required to calculate the input/output ratios. In spite of its higher cost, a planetary gearbox is frequently the best choice for medium ratio power transfer. Because of its even greater precision requirement than spur gears, it is usually better to buy an off-the-shelf gearbox than to design your own.
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Figure 2-29 Simple Planetaries and Inversions
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COUPLINGS
At some point in a mobile robot designer s career there will be a need to couple two shafts together. Fortunately, there are many commercially available couplers to pick from, each with its own strengths and weaknesses. Couplers are available in two major styles: solid and flexible. Solid couplers must be strong enough to hold the shafts ends together as if they were one shaft. Flexible couplers allow for misalignment and are used where the two shafts are already running in their own bearings, but might be slightly out of alignment. The only other complication is that the shafts may be different diameters, or have different end details like splined, keyed, hex, square, or smooth. The coupler simply has different ends to accept the shafts it is coupling. Solid couplers are very simple devices. They clamp onto each shaft tight enough to transmit the torque from one shaft onto the other. The shafts styles in each end of the coupler can be the same or different. For shaped shafts, the coupler need only have the same shape and size as the shaft and bolts or other clamping system to hold the coupler to the shaft. For smooth shafts, the coupler must clamp to the shaft tight enough to transmit the torque through friction with the shaft surface. This requires very high clamping forces, but is a common method because it requires no machining of the shafts. As for online sources of couplers, and more detailed information about torque carrying ability, check out these web sites: powertransmission.com dodge-pt.com flexibleshaftcouplings.com wmberg.com mcmastercarr.com
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METHODS FOR COUPLING ROTATING SHAFTS
Methods for coupling rotating shafts vary from simple bolted flange assembles to complex spring and synthetic rubber assembles. Those including chain belts, splines, bands, and rollers are shown here.
Figure 3-1 Figure 3-2
Figure 3-3
Figure 3-4
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