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Two-speed gearbox goes inline for machine tools

A ZF Great Britain product story
Edited by the Engineeringtalk editorial team Jan 29, 2004

A new two-speed inline gearbox is designed to improve the speed range of machine tools while maintaining consistent torque delivery and accuracy.

A new two-speed inline gearbox is designed to improve the speed range of machine tools while maintaining consistent torque delivery and accuracy.

The Duoplan series is designed to mount directly between the drive motor and spindle, minimising vibration and maintaining torsional rigidity.

Using a two speed gearbox improves both high- and low-speed machine tool performance by maintaining consistent torque across the speed range, allowing the machine to effectively tackle both hard and soft materials.

Compared with alternative twin speed designs that use pulleys or offset gears to transmit torque to the spindle, the Duoplan units direct inline mounting provides increased accuracy by reducing vibration and maintaining a highly rigid machining head assembly.

Inline mounting is achieved through the use of planetary reduction gears, a feature that also significantly reduces backlash and results in a more compact machining head.

The compact gearing system allows for an increased machining area in existing machine tools or reduces dimensions in new designs; it also broadens the number of machine types that can benefit from a two-speed arrangement.

The use of two speed gearboxes allows the transmission system to make the most of the available motor power, and as a result, a smaller motor can be specified and considerable savings made.

This is especially true in the lower speed ranges where a high level of torque is needed to achieve high material removal rates and fast cycle times.

Optimising the power of main spindle drives below their normal constant power range is a simple matter of downshifting with the two-speed gearboxes.

Extremely efficient downshifting is achieved thanks to a solenoid driven auto-changer.

Due to the use of fewer parts than other shifting arrangements, the solenoid based design dramatically increases operating speed and improves reliability.

ZF have introduced eight sizes of gearbox ranging from a frame size of M100-225.

Output torque figures are up to 12,000Nm on the larger sizes, and a wide range of standard first and second gear ratios are available.

The gearboxes are stocked in kit form, with adapter and drive hub units to suit a wide range of motors available, which can be mounted in any orientation.

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