COMPACT GEARED MOTOR WITH DOUBLE BRAKE

The Compacta slip-on geared motors, manufactured by Framo Morat and distributed in the UK by R. A. Rodriguez, are ideal for repeatable positioning and reversing tasks in stage technology. Their power to weight ratio is extremely high. They are also lightweight, quiet running and exceptionally reliable and the design’s integral and easily adjustable mechanical limit switch contributes to the product’s exceptional flexibility. And with this sector very much in mind a new version of the Compacta has now been developed.

The Compacta AG60 and MR30 models are now available with a double brake to meet the industry’s stringent safety standards. These products are ideal for powering the movement of stage curtains, lighting and stage elements.

As its name suggests Compacta is ideal where space is at a premium. Its smaller dimensions and the low weight are achieved by the use of a spur and worm gear transmission combined with performance-optimised motors.

Models in the range are up to 10 kg lighter than nearest competitors with the same output torque and speed. The ‘Compacta’ also provides 22 output speed options by comparison with the maximum of three available on alternatives and its motor choices offer a wide range of power and duty cycles.

The range can also be equipped with ESA electronic limit switches with up to 10 set points and 2 end positions. These are easy to programme, provide an absolute encoder signal and therefore ensure precise positioning and repeatability.

The modular design of 'Compacta' allows easy customisation from standard parts. As each ‘Compacta’ can be optimised for its specific task it is easy to install and there is generally no need for additional drive components.

DSEi 2009, ExCeL London, 8th – 11th September

For more than 30 years, R. A. Rodriguez worldwide has been providing full engineering support to military and aerospace companies. Indeed its bearing products are fitted to a huge range of military and aircraft applications including many spacecraft. They are also used in many associated leading edge technologies such as optical sighting systems and laser range finding.

Central to its range are the KAYDON® Reali-Slim bearings, ideal for applications where space is at a premium and weight needs to be minimised. These bearings are available in both Imperial and metric ranges and in different radial sections up to 1m diameter from stock - larger to order. Turntable bearings are a KAYDON® speciality. There is a series to suit every need from light to extreme heavy duty. There is also a Reali-Slim® version of this range too offering the benefits of small size and minimum weight.

The success of equipment designed for use in special applications can often rest with one or a combination of bearing features and that’s where KAYDON® custom bearings score highly. Manufactured and tested to the highest quality standards, special attention is paid to balls, bearing raceway geometry, finish and retainer design resulting in optimum bearing performance.

In recognition of its quality products and processes the KAYDON® Bearings Division holds the prestigious Bell Helicopter Premier Supplier Award. Only AS9100 certified suppliers can qualify for this award and the winner must have maintained the consistent delivery of quality-assured products at a minimum frequency rate of 98%.

The helicopter sector is a prime market for the KAYDON® custom-engineering and performance critical bearings. Typical examples are rotor mast and swashplate bearings. The swashplate is a device that translates the pilot's commands via the helicopter flight controls into motion of the main rotor blades.

Following KAYDON®’s acquisition of Avon Bearings, R. A. Rodriguez is now also responsible for the ‘local’ marketing of one of the world’s most comprehensive ranges of slewing ring, turntable and advanced custom bearings. These products are used in a range of industries but typically in systems for the renewable energy, medical, mining, construction and military sectors.

KAYDON® is now able to produce bearings with an outside diameter of over 6m using the most modern facilities and equipment in the industry. The company’s investment in flexible manufacturing also allows R. A. Rodriguez to supply small quantities at an economical price.

SMALLER MODULE GEARS

The KHK range of metric gears from R. A. Rodriguez is already considered to be one of the most comprehensive with 80 standard gear products and more than 3,500 individual items. Japanese manufacturer, KHK, has however found room for even more variation. Its product programme has recently been boosted by 570 configurations of fine pitch gears.

Now available ex-stock are 0.5 and 0.8 modules gears in the most popular sizes; all are manufactured to ISO/JIS gear standard. The company’s continued high investment in its manufacturing techniques ensures these products are of consistently high quality as well as being competitively priced.

The KHK ranges that are extended by the smaller module gear additions are spur gears, racks, pinions and worm gears. Further details are available via the R. A. Rodriguez website at

SIMPLE, FLEXIBLE AND HIGHLY ECONOMICAL ROBOTIC ARM

As far as R. A. Rodriguez is aware, there is nothing to compare with its new Universal Robot. It’s a small, light weight industrial robot arm that has six axes of movement and above all is exceptionally quick and easy to install. A specially developed graphical user interface means no expert programming is needed. Within a couple of hours it can be ready to run. The Universal Robot truly provides plug-and-play productivity.

Universal Robot can benefit virtually every manufacturer and really comes into its own where traditional robots are considered to be too large, too expensive, too noisy or not sufficiently flexible. It is the ideal entry level automation device which can be set up by anyone and operates from a standard 240V electrical supply.

As the Universal Robot weighs just 18 kg it is easily moved around and requires no dedicated base. As a result it can automate a variety of tasks in the production environment for which reprogramming is quickly achieved via a 12 inch touch-sensitive screen. It has a working radius of 85 cm, can handle a payload of 5kg and its joints can rotate at up to 180° a second; repeatability is accurate to ±0.1mm.

Unlike other robots, this new addition to the R. A. Rodriguez range consumes little power, typically less than 200W when using an average programme. It also generates much less noise than larger, more complex robots. With a footprint of just 149mm diameter the Universal Robot is supplied with an electrical interface that is compatible with most industrial sensors and PLCs.

SPACE-SAVING BEARING FOR COMPACT MACHINE TOOL

Deliberately restricting the size of component that its VECTOR machine handles was a shrewd move for Colchester-based Curtis Machine Tools. It has effectively cornered the market in small parts grinding by creating a highly efficient and compact machine, with short distances between grinding and loading, to cut cycle times. In particular, the VECTOR machine is now seen as an automotive industry standard but it is also being used for applications such as cutting parts of power tools.

Now with even greater focus on minimising unit costs Curtis has introduced a variant to its highly successful VECTOR series. For very high volume production the VECTOR can be specified with a twin spindle workhead which allows concurrent loading and grinding. It also makes a range of other applications available including in-cycle gauging.

At the end of the grinding cycle the workhead drum rotates through 180° alternating the positions of the two spindles. Critical elements of this mechanism are KAYDON® thin section bearings. “We needed a precise, low friction bearing that occupied minimum space but was still stiff,” explained Chairman Rick Curtis. “The KAYDON® bearing was ideal and gives us accuracy better than 1 micron.”

A wire race bearing was considered but although it satisfied the low weight need and was attractively priced the running accuracy was not adequate. This is a very important factor as final component accuracy and the consistent quality of a batch of components is determined by the consistent positioning accuracy of the workhead.

Ultimately Curtis Machine Tools designers Roger Marriott and Sarah Allard chose a precision class 3 KAYDON® four-point contact bearing and a radial contact bearing for this application. This is a classic combination selected by designers seeking dependable performance. Pre-load on the bearings is factory-set, minimising assembly time and assuring its consistency.

The KAYDON® four-point contact bearing can accept a combination of radial, thrust and moment loads. This is thanks to the unusual geometry of the ball grooves that creates a ‘gothic arch’ configuration making it possible for two grooves to contact the ball at four points.

High thrust and moment capacity is obtained in a four-point contact ball bearing by its deep raceway grooves. These allow high initial contact angles between the balls and raceways and increase the thrust and moment capacity. The deep grooves also accommodate the contact angle increase which results from ring stretch and ball deflection under load.

The company who Curtis Machine Tools turned to who provided the best bearing solution was R.A. Rodriguez. Factory representatives for KAYDON® Corporation for more than forty years, this Letchworth based supplier of precision engineering components has extensive applications knowledge. Rick Curtis concluded, “R. A. Rodriguez fully understood what we needed to achieve and have supplied a quality product that is working well in the field.”

NEW CATALOGUE DETAILS EXPANDED RANGE

Available from sole UK distributor, R. A. Rodriguez, is the latest edition of the KAYDON® slewing ring and turntable bearing catalogue. It contains several new products and makes it even easier for design engineers to choose the best bearing for their application.

KAYDON® slewing ring and turntable bearings are widely used in a broad variety of arduous applications that require both precision and accuracy. The new catalogue introduces five new product series and new sizes in the KH precision range. Several new four-point contact ball bearing series have been added and its size range expanded to 6.1m.

The eight-point contact ball bearing series is also substantially increased and the new cross roller series and three-row roller series provide designers with many more options. A new section describes KAYDON®’s extensive remanufacturing capabilities and includes a guide to common signs and causes of bearing failure.

Copies of the KAYDON® 390 catalogue are available from the R. A. Rodriguez sales office on 01462 670044 or as a .pdf download from www.kaydonbearings.com

NEW MOTOR DRIVEN LINEAR ACTUATOR

As its name suggests the new Framo LiMax from R. A. Rodriguez is a linear actuator with a maximum force rating. Its modular design uses an in-line layout of motor, planetary gearing and lead or ballscrew drive to achieve a high force rating in relation to the diameter of the body. It is also available with a wide range of options enabling the actuator to be tailored to the exact requirements of the application. These include a choice of motors, encoders and other customised adaptations including stroke lengths. Various types of mounting and end connections may also be specified.

As standard, LiMax has an all-stainless steel body, piston and end fittings. These qualities, coupled with an IP65 rating, allow it to provide trouble-free actuation in exposed locations and corrosive environments. The designers of this product have also paid particular attention to its aesthetics. Given its all-weather suitability it is therefore ideal for applications such as climate control systems on the facades of buildings.

Simple to fit and operate with a long life expectancy and minimal maintenance needs, LiMax is easily integrated into existing control systems. In-built stroke limit switches are fully adjustable allowing on-site fine-tuning to suit the application. It is reliable in extreme heat and in the presence of dust and moisture so its scope of use is wide. In addition to building engineering, LiMax is already proving popular for use in telecommunications and in the hygiene conscious food and pharmaceutical industries.

LiMax is available in two basic body size diameters of 60mm and 80mm with standard stroke lengths from 200 to 800mm; shorter stroke lengths are available on request. The units provide a stroke force of 5,200N with stroke speeds from 3 to 360mm/s.

DRIVES FOR CLIMATE CONTROL IN COMMERCIAL BUILDINGS

Automated energy management systems are now commonplace as businesses strive to cut their carbon footprint and overheads. External louvres are typical of these new systems. However whether the need is to control air flow, heat or to adjust the positioning of solar panels the drive system chosen for the built environment requires distinct features. In addition to operating quietly and being able to withstand all weather conditions it must be discrete and also look good.

These are qualities synonymous with the Framo Morat linear and rotary drive systems from R. A. Rodriguez and the reason why this range is increasingly being specified by building engineers. For example the Framo LIMAX actuator is now widely used for climate control. It uses a powerful coaxial motor to achieve the required stroke in minimum space.

A number of features ensure the LIMAX offers reliable operation even in extreme conditions such as heat, dust and moisture. These include a thermally protected motor, life time lubrication and integral safety switches. This reliability is complemented by economical operation, low maintenance and a long service life.

The modular concept of the LIMAX actuator offers great design freedom. It can be specified with a choice of mounting and connecting arrangements and is easily interfaced with an existing controller. Special stroke lengths and other custom features are available on request.

As its name implies, the Framo Compacta slip-on geared motor is both space and weight saving but also highly flexible in its application. Models in the range are up to 10kg lighter than alternatives but have the same output torque and speed. The Compacta also provides 22 output speed options and its motor choices offer a wise range of power and duty cycles.

The design’s integral and easily adjustable mechanical limit switches contribute to the product’s exceptional flexibility with a speed range 0.9 to 193 rpm and output torques from 6 to 600 Nm. The range can also be equipped with ESA electronic limit switches with up to 10 set points and 2 end positions. These are easy to programme, provide an absolute encoder signal and therefore ensure precise positioning and repeatability.

Custom drives are also available for building applications whose needs fall outside the standard product programme. R. A. Rodriguez has 40 years of applications knowledge and Framo, 140 years experience in the manufacture of gears, transmissions and actuation devices. Together they are able to design, develop and manufacture drive systems with the exact characteristics to suit the task.

RENEWED FOCUS ON LARGE DIAMETER BEARINGS

For its entire operational life in the UK, R. A. Rodriguez has enjoyed a highly successful relationship with KAYDON®. The result is echoed in year-on-year sales increases of KAYDON® bearing products in the UK, Ireland and Scandinavia and with the names of REALI-SLIM® and ULTRA-SLIM® becoming industry-standards in many sectors.

These brands however form only part of the much wider KAYDON® range. Following KAYDON®’s acquisition of Avon Bearings earlier this year and with the manufacturer’s restructuring programme complete, R. A. Rodriguez is now also responsible for the ‘local’ marketing of one of the world’s most comprehensive ranges of slewing ring, turntable and advanced custom bearings. These products are used in a range of industries but typically in systems for the renewable energy, medical, mining, construction and military sectors.

KAYDON® is now able to produce bearings with an outside diameter of over 6m using the most modern facilities and equipment in the industry. The company’s investment in flexible manufacturing also allows R. A. Rodriguez to supply small quantities at an economical price.

AEROSPACE AND MILITARY ROADSHOW

Throughout September R. A. Rodriguez will be on a nationwide tour of aerospace and defence manufacturing sites as an exhibitor in the Aerospace and Military Roadshow.   The Roadshow takes the exhibitor to the specifier rather than the other way round and in the process will visit most of the UK’s leading manufacturers in this sector.

The focus of the R. A. Rodriguez display will be KAYDON® bearings, a range that has formed the core of its business for more than 40 years.  KAYDON® Reali-Slim bearings are ideal for applications where space is at a premium and weight needs to be minimised. These bearings are available in both Imperial and metric ranges and in different radial sections up to 1m diameter from stock - larger to order.   Turntable bearings are a KAYDON® speciality.  There are models to suit every need from light to extreme heavy duty.   There is also a Reali-Slim® version of this range too offering the benefits of small size and minimum weight.

The success of equipment designed for use in special applications can often rest with one or a combination of bearing features and that’s where KAYDON® custom bearings score highly.  Manufactured and tested to the highest quality standards, special attention is paid to balls, bearing raceway geometry, finish and retainer design resulting in optimum bearing performance.

ANOTHER REALI-SLIM® MISSION TO MARS

The Phoenix Mars Lander that began scooping up samples of Martian soil last month depends on KAYDON® REALI-SLIM® thin-section bearings to position its robotic arm for digging in the permafrost.  This is the second Mars mission for REALI-SLIM® bearings.  They were also used in two 2004 Mars Exploration Rovers which are still sending geological findings back to earth, a distance of 171 million miles away.

The robotic arm is designed to trench the surface, pick up soil and ice samples and deposit them in instrumentation for testing and analysis.  The 2.13m, 17.7 cm arm is attached to the deck of the Lander with a garden-sized trowel on its opposing end. A camera mounted above device sends colour images of the samples to scientists on earth.

The arm has four types of motion: up and down, side to side, backwards and forwards and rotation.  Three of the joints that accomplish these movements feature sets of custom-engineered REALI-SLIM® thin-section bearings from KAYDON®.

The system was designed by Alliance Space Systems in Pasadena and the company’s Mechanical Engineering Group Supervisor advised that KAYDON® bearings were specified for several reasons.  “They gave us plenty of load capacity even though they are lightweight and small enough to fit into a tight space,” Richard Fleischner said. “They are also sufficiently robust to withstand the force and vibration of the launch.”

The bearings take a heavy load during digging as up to 44 kg of force is needed to break through the ice in order to reach a depth of about 50 cm.  They are made from heat-treated 440C stainless steel and mechanically honed to achieve a superior finish and torque.  To enable them to operate in extreme cold down to -108°C the bearings are heated and use a low outgassing lubricant that neither gets too viscous in the cold temperature nor evaporates in the thin atmosphere.

The Phoenix Lander is expected to be on Mars for three months digging for evidence that the planet could sustain life.

In the UK KAYDON® bearings are supplied by long-standing factory representatives R. A. Rodriguez.

NEW BELT TENSIONERS SAVE PLANT DOWN TIME

The tension adjustment of the S2 conveyor at the sinter plant at Corus Redcar was proving increasingly difficult for the maintenance engineers due to harsh environmental conditions and challenging maintenance schedules.

The problem was addressed during a planned plant shutdown but the team encountered considerable problems releasing tension on the tail end in order to replace the conveyor belt.  Not only did the remedial work take excessive time but the poor condition of the adjusters meant that insufficient tension could be applied to the new belt.

The Corus site at Redcar produces circa 3mt of steel per annum facilitated by extensive materials handling systems, which requires regular replacement of conveyor belts. This is an expensive and time-consuming business that is made worse should the tail end adjustment not be released quickly. Investigations into alternative tension adjustment mechanisms led Corus engineers to a product that is widely used on mobile crusher conveyors in the UK and on fixed plant conveyors in the US and Canada, the Bryant Telescoper®, and it was a move that was to prove a big success.

Sold in the UK by sole European factory representatives, R. A. Rodriguez, the extensive Bryant Telescoper® range has important design and performance benefits.  The adjustment thread in these units is fully enclosed and protected.  Also, unlike alternatives, they feature an Acme thread which is more robust and less prone to ‘picking up’, a problem that can result in damage or seizure.

Having inspected the conveyors deemed to be the most critical at the time, the R. A. Rodriguez application engineer was easily able to select the appropriate Telescopers® based on bearing bore dimension or shaft diameter.  Confirmation of the bearing bolt hole distance was all that was needed to ensure a good fit.  For five conveyors ‘top mount’ models were selected in preference to the ‘bearing plate’ alternative and a standard 36” stroke specified.

The S2 conveyor was fitted with a similar Telescoper® model but called for a non-standard 48” stroke; longer strokes are also available.  This request was easily accommodated by the manufacturer Bryant who is also able to supply to suit larger bearings than its 6” standard highest. In less than two hours the Telescopers® were installed and S2 was ready to run.

All the Corus Telescopers® have been installed to ensure easy access to the adjustment points enabling the conveyors to be tracked whilst running.  Recently a belt was changed on one of the original conveyors to receive a Bryant Telescoper® and the saving in plant down time was significant.  One of the Sinter Plant Engineers responsible confirmed, “The work was carried out far quicker than normal, resulting in a quicker return time.  The whole team is very pleased with the performance of these units.”

FORTY YEARS OF ENGINEERING EXCELLENCE

Precision engineering component specialist, R. A. Rodriguez, has reached another milestone in its long commercial success.  The company is now in its fortieth year of trading and is the British arm of an international organisation that was founded in the USA in 1929.

Whilst the R. A. Rodriguez product programme has grown substantially in recent years KAYDON® bearings remain the corner stone of the business.  Right from the very start the company’s name has been synonymous with precision bearing products and expert application engineering.

For its entire operational life in the UK, R. A. Rodriguez has enjoyed a high successful relationship with KAYDON®.  The result is echoed in a sales record that has seen year on year growth in the UK, Ireland and Scandinavia, with the brands REALI-SLIM® and ULTRA-SLIM® becoming industry standards in many sectors.

Although still a key strand in the business KAYDON® is one of many product brands for which R. A. Rodriguez is now responsible.  The most recent addition is drive specialist Framo Morat for whom R. A. Rodriguez is already proving a highly successful representative.  Sales are booming for these drives in the UK taking the company into new application sectors such as theatre engineering and window actuation.

Today, the R. A. Rodriguez products programme falls into five distinct product divisions, Bearing Products, Linear Products, Aerospace Products, Conveyor Products and Gears & Allied Products.  Naturally over the years staff numbers have increased in line with growth in all these sectors.  Currently the team is eleven strong.

LOW PROFILE SATELLITE DEPLOYMENT

By their very nature mobile satellite uplink systems have to ultra-reliable and be ready for action at a moment’s notice.  Holkirk Communications is a respected specialist in this field.  Its products are characterised by their compact nature, light weight and ease of use.  A recent decision to include a Framo Morat Compacta slip-on geared motor from R. A. Rodriguez has certainly enhanced this reputation.

Holkirk manufactures systems for a broad range of organisations from government departments to the international media.  Each project is individually tailored for broadcast, internet-over-satellite and data applications but the company uses several standard elements to achieve this.  One is the mechanism by which the satellite dish is raised, lowered and positioned on its vehicle-based systems. 

In the latest generation of these mobile systems Holkirk was determined that the satellite deployment mechanism on the vehicle roof should be as low-profile and discrete as possible.  Whilst a traditional geared motor for the specification required could be quite a cumbersome item the Compacta MR6, as its name suggests, packs quality performance into a small design envelope. 

This geared motor rotary actuator has been designed specifically for applications where space is at a premium and for those calling for repeatable positioning.  Models in the range are up to 10kg lighter than their nearest competitors with the same output torque and speed and for Holkirk Communications this represents a significant saving on the payload of the vehicle.

The small dimensions and low weight of the Compacta are achieved by the use of a spur and worm gear transmission combined with performance-optimised motors.  The transmission is also exceptionally quiet, an important factor if the system is being used in sensitive environments.

Satellite uplink technology is used in all weathers and often in hostile environments by many of Holkirk’s customers.  This is another area where the Compacta scores highly as it is designed for reliable operation under extreme heat and in dusty and moist atmospheres.  To enhance the suitability of Compacta for all environments Holkirk specified the unit sealed to an IP65 rating.

Another important benefit is how Compacta is immune to the effects of wind.  When the satellite dish is raised it’s like a sail that catches the wind.  This will cause most geared motors to back drive but not Compacta as self-locking is a feature of its gearing.

These discrete, mobile satellite uplink systems from Holkirk Communications have proved immensely popular.  Indeed, such is the demand for the systems that R. A. Rodriguez will soon be supplying consignments of Compacta MR6 for export so that the mechanisms can be assembled abroad for international markets..

EXTENSIVE CUSTOM DRIVE CAPABILITY

The Framo Morat range of drive systems from R. A. Rodriguez includes compact slip-on geared motors, linear actuators and push-pull linear chains, all based on modular design principles and customised to suit each application. 

Custom capabilities extend way beyond these standard product ranges however.    R. A. Rodriguez has 40 years of applications knowledge and Framo, 140 years experience in the manufacture of gears, transmissions and actuation devices.  This rich heritage puts the partnership in a unique position to design, develop and manufacture special custom drive assemblies to suit specific application needs.

At its 15,000 m2 manufacturing plant in Eisenbach, Germany, Framo has every facility for cost-effective design, prototyping and production. Drive systems can be manufactured in virtually any material required, both metallic and non-metallic.  The company also provides heat treatment of metals to specification.

Examples of successful custom drive projects are many and various.  They include lawn mower gearboxes, gear train drives for floor polishing machines, actuator units for tractor implements, caravan manoeuvring devices and complete drive systems for stairlifts.

AWARD FOR CONSISTENT, HIGH-QUALITY BEARING SUPPLY

In recognition of its quality products, processes and supply the KAYDON® Bearings Division has just received the prestigious Bell Helicopter Premier Supplier Award.   Only AS9100 certified suppliers can qualify for this award and the winner must have maintained the consistent delivery of quality-assured products at a minimum frequency rate of 98%. 

The helicopter sector is a prime market for the KAYDON® custom-engineering and performance critical bearings.   In the UK these products are supplied by R. A. Rodriguez; typical examples are rotor mast and swashplate bearings.  The swashplate is a device that translates the pilot's commands via the helicopter flight controls into motion of the main rotor blades.

For more than 30 years, R. A. Rodriguez worldwide has been providing full engineering support to aircraft companies.  Indeed its aircraft products are fitted to a large number of military and civil aircraft in the Western World including many spacecraft.  They are also used in many other leading edge technologies such as optical sighting systems and laser range finding.

R. A. Rodriguez also supply a wide range of aerospace bearings from a number of leading manufacturers including Thin Section bearings, spherical joint bearings and airframe control bearings.

SPECIAL TURNTABLE BEARINGS

The news that the KAYDON® Corporation has recently acquired the Avon Bearings Corporation brings important advantages to the customers of R. A. Rodriguez.  This Letchworth-based supplier of precision engineering components is the longstanding sole distributor for KAYDON® bearings in the UK and this corporate development certainly extends its product scope.

With its headquarters in Ohio, Avon is a leading designer and manufacturer of custom, large diameter turntable bearings.  Indeed it is one of the most respected manufacturers in this field with customers in a diverse set of markets. Avon also re-manufactures bearings and is known globally for its focus on engineering support.

This acquisition complements manufacturing capabilities at KAYDON® and, in combination with ongoing capital investment programmes, has set the company on course to be the largest manufacturer of slewing ring bearings in North America.

“From our perspective in the UK this news gives our customers instant access to Avon’s flexible manufacturing capabilities for low volume, large diameter slewing ring bearings up to 240 inches (6m) in diameter,” concluded David Hey, Sales Manager at R. A. Rodriguez. “The arrangement also allows us to provide a re-work service for large diameter slewing ring bearings.”

DRIVE SYSTEMS' CATALOGUE

By turning to pages two and three of the new product range catalogue from Framo Morat readers will be left in no doubt that the company has a rich heritage in manufacture of quality drive systems components.  These products are now available from R. A. Rodriguez in the UK and many offer distinct performance benefits.

The Framo range includes compact slip-on geared motors, linear actuators and push-pull linear chains.  All are based on modular design principles and are customised to suit each application.  Full technical data on all of these products are provided in the catalogue together with extensive application notes.  The publication also includes information on Framo’s ability to design and manufacture custom drives.

The 80-page catalogue is entitled ‘Framo Morat Your Idea – Our Drive’ and is available from the R. A. Rodriguez sales office on 01462 670044 or via email to info@raruk.com

FIRST NEW APPOINTMENT IN MANAGEMENT RE-STRUCTURE

Continued investment in quality people and quality products is certainly paying dividends for precision engineering component specialist, R. A. Rodriguez.  As it records another year of increased sales the company is re-structuring its management team in anticipation of further growth in 2008.

The first confirmed appointment is David Hey to the post of Sales and Marketing Manager.  This is the first time in the company’s forty year history that the need has arisen for a manager to oversee all product divisions.  Until now product managers have reported directly to the MD but with increased sales across the board the need to change the infrastructure has become evident.

For seven years David has been one of those product managers, responsible for bearings.  Before joining R. A. Rodriguez he had spent seventeen years in direct engineering sales and latterly was European Sales Manager for Holroyd Gears.  

“R. A. Rodriguez is based on solid engineering integrity, giving customers’ confidence both in our products and professional support,” David asserts. “Technically superior products and customer service to the highest possible standard – it’s a good combination and one that I am determined to uphold.”

COMPACT GEARED MOTOR ROTARY ACTUATORS

The Framo Morat ‘Compacta’ slip-on geared motor is well named as it is ideal for applications where space is at a premium and they are designed for repeatable positioning and reversing tasks.  Models in the range are up to 10 kg lighter than nearest competitors with the same output torque and speed.  The ‘Compacta’ also provides 22 output speed options by comparison with the maximum of three available on alternatives and its motor choices offer a wide range of power and duty cycles.

The design’s integral and easily adjustable mechanical limit switch contributes to the product’s exceptional flexibility with a speed range 0.9 to 193 rpm and output torques from 6 to 600 Nm.  The range can also be equipped with ESA electronic limit switches with up to 10 set points and 2 end positions. These are easy to programme, provide an absolute encoder signal and therefore ensure precise positioning and repeatability.

The modular design of ‘Compacta’ allows easy customisation from standard parts. Its additional integrated features include choices such as brake, slip clutch, potentiometer, hand crank, encoder etc. This design flexibility differentiates the ‘Compacta’ from other models and greatly extends its scope of application from heavy duty material handling to semi-conductor production equipment in clean room conditions. As each ‘Compacta’ can be optimised for its specific task it is easy to install and there is generally no need for additional drive components.

The smaller dimensions and the low weight of ‘Compacta’ are achieved by the use of a spur and worm gear transmission combined with performance-optimised motors; the transmission is also exceptionally quiet.   Framo is a market leader in the production of worm gears and its products and systems are the preferred choice of many OEMs in the printing and textile machinery sector. 

Four standard models complete the ‘Compacta’ range offering torques up to 600 Nm. Higher torques, IP65 rating and explosion-proof ATEX 95 are also available.  The ‘Compacta’ series is designed for reliable operation under extreme heat, dust and moisture and models in the range are already in use in wider Europe in applications such as sheet metal forming, materials handling, food processing and electronics production. This highly flexible product is now available in the UK via sole UK representative R. A. Rodriguez.

EASY-FIT COMPACT LINEAR GUIDEWAY

The new and compact TMT Power-Line linear guideway T100 from R. A. Rodriguez couldn’t be simpler to assemble.  Just fit a motor and the product can then be used to move light loads with high acceleration and speed.  The self-supporting structure of the rail and its factory applied M6 mounting holes enable quick, easy and economic installation.

This belt-driven, four lubricated wheel design can accommodate direct loads of up to 400N and side loads of 1080N.  Maximum stroke from the single piece construction is up to 7000mm.  It is suitable for speeds up to 4.5m/sec and typical positioning accuracy is ±0.1mm.  The concentric bearing arrangement of the design allows easy adjustment of pre-load. 

Virtually silent in operation this new addition to the R. A. Rodriguez linear motion range is also maintenance-free.  The motor/geared motor can be mounted directly to the guideway or via a coupling. 

The Power-Line linear guideway T100 is the product of TMT, a company that specialises in the design and manufacture of robust rail profiles for automotive lift-and-carry transfer lines.  Its Speedy Rail® system is widely used by the world’s leading car manufacturers.

LINEAR RAIL FOR HOSTILE ENVIRONMENT

Engineering components that are resistant to the ingress of wood dust are crucial to the reliability of a new automated production line being built by project engineering company, 3think Limited.  This Halifax based company has designed, manufactured and is currently installing a bespoke automated line at a large timber engineering company.  This special purpose machine automatically produces frames for timber framed houses and these can be up to 6m long and 3m wide.  The process requires up to 8 nails per second to be fired into the frame to achieve the necessary productivity.

Sections of highly robust and compact TMT Speedy Rail® have been supplied for the bridge across the conveyor that carries the nail gun.  This is a perfect application for this linear motion system that has recently been added to the R. A. Rodriguez product line.  Despite its light weight Speedy Rail® is exceptionally strong and easy to install.  Resistance to weld splatter has made it the preferred choice of most car manufacturers who specify Speedy Rail® for lift-and-carry transfer lines for car body panel welding.

The Speedy Rail® beam is a heat-treated aluminium alloy profile with hollow cross-sections that give it high strength under torsion and deflection stresses.  The profiles are manufactured by a special extrusion process then surface hardened and given a patented finishing treatment.  Quiet operation is assured as the Speedy Rail® rollers are encapsulated in a sintered plastic compound shell that is resistant to pollutants. Resistance to weld splatter has made it the preferred choice of most car manufacturers who specify Speedy Rail® for lift-and-carry transfer lines for car body panel welding.

Given these credentials TMT Speedy Rail® has all the necessary qualities to ensure the reliable running of the nail gun carriage in a hostile environment.   Ease with which the rail could be installed was another plus point for 3think.  Rail sections could be joined end-to-end using standard bolted dovetail clamps to form the required 9m runs on either side of the conveyor.  As standard the rails are provided with a dovetail groove on both sides of the profile to accommodate any fixture attachments without the need for drilling or welding.

MACHINE BUILDING 2008, 13th and 14th February, NEC, Stand no. 2201

Machine Building is an important event for R. A. Rodriguez as it provides the opportunity for the company to showcase its new range of drives to UK industry and also to emphasise its competence in linear motion technology. In addition to the modular Werner systems the company will also be demonstrating examples from its own linear range.

R. A. Rodriguez has recently been appointed the exclusive UK representative for drive manufacturer Framo Morat. Its range of systems includes the Compacta slip-on geared motor with built-in limit switches. This is an ideal actuator for reverse motion and is available in four sizes with torques up to 600Nm.

In a similar vein the MINI is a range of extremely compact linear actuators with acme screws that are sealed to IP65. Minimum space requirement is also the main selling point of LinearChain that is capable of long strokes despite its small size.

COMPACT WHEEL DRIVE

For in-hub applications the new Framo Morat DiscPower electric motor driven gearbox provides a space-saving and economical solution.  The assembly comprises a dynamic, brushless and maintenance-free synchron pancake motor with integrated, low backlash planetary gearbox.

DiscPower models are available from 0.42W up to 1kW with up to 110Nm torque.  The compact planetary gearbox with lifetime lubrication is available in transmission ratios from 5:1 up to 50:1.  It is smaller and lighter than other gear configurations, has a higher efficiency and is exceptionally quiet running.

This latest addition to the R. A. Rodriguez Framo Morat range can be combined with a range of motor feedback systems such as hall effect sensors, encoders or resolvers to suit the application.  DiscPower is the ideal choice for automatic guided vehicles, fork lifts, wheel chairs and indeed any industrial application where minimal space and low noise are important design criteria.

Taking full advantage of Framo’s comprehensive manufacturing capabilities R. A. Rodriguez is also able to meet most custom drive requirements. In addition to special worm gear drives Framo has developed, for example, a 2-motor stairlift drive and intelligent actuators for tractors.

The Werner linear motion range of systems, modules and controllers is now one of the most comprehensive available. The products are designed to be freely combined enabling the user to create dedicated, multi-axes handling systems. They offer high load capacity, high rigidity, quiet operation and are complemented by a choice of motors, plug-in positioning systems and controllers.

Examples from the company’s own range of linear components will also be shown at Machine Building 2008. These include linear guideways, ball bushings, bearings housings, shaft supports and shaft blocks. R. A. Rodriguez is far more than just a supplier of linear motion components however. It has many years experience in designing and building bespoke handling systems for a broad spectrum of industries from food processing to automotive part manufacture. Full details will be available on the stand.

HIGH PRECISION SPIRAL BEVEL GEARS

For high speed and high torque applications the new KHK high precision, ground spiral bevel gears from R. A. Rodriguez are an excellent choice.  These strong gears have high load ratings and run at speed with minimal noise and vibration.

KHK have been making a wide range of standard stock gears for over sixty years and are one of the largest and most respected manufacturers in this field.  The company sells more than three million gears annually and invests heavily in new technology to ensure the KHK brand retains its high quality status.  Its entire product range comprising over 3500 gear types in 36 categories is available from sole UK distributor, R. A. Rodriguez (UK) Ltd.

These new spiral bevel gears are available in module sizes 1.5 – 6.  Options include fully hardened keyways and pilot bores that allow additional customer modification.

PUSH-PULL ACTUATION

The design of the precision chain links in the new Framo Morat LinearChain Actuation Device enables the chain to push as well as pull heavy loads.  Their special profile with interlocking fingers at one end enables the chain to roll up for efficient storage in one direction and form a rigid thrust device in the other. 

In the magazine the chain is stored spirally within a narrow chamber making LinearChain ideal for applications calling for long strokes where space is at a premium. The device provides high positioning accuracy, constant stroke speed and shock-free motion with no elastic hysteresis under load.  It has been designed for a long operational life and minimal maintenance.

LinearChain is available in three basic sizes allowing stroke lengths of up to 5m and a maximum push force of up to 35,000N.   Compact drive units for the chain and storage magazines are readily available for all chain sizes from

Framo Morat’s UK distributor,   R. A. Rodriguez. 

COMPACT AND MODULAR LINEAR ACTUATOR

The new Framo Morat MINI linear actuator from R. A. Rodriguez is aptly named as it uses a powerful coaxial motor to achieve the required stroke in minimum space.  The units are manufactured in stainless steel, IP65 rated, ATEX 95 explosion-proof certified and available with a wide range of options to allow them to be tailored to any application from food and pharmaceutical manufacturing to building envelope design.

The MINI range of electric motor driven actuators comprises five basic sizes with body diameters range from 60 to 128mm.  A choice of 3-phase, single phase AC or 24V DC drive motors are available.  Stroke lengths range from 100mm – 800mm, stroke speeds between 0.5 and 181 mm/s and stroke force of up 26,000N. 

A number of features ensure the MINI’s reliable operation even in extreme conditions such as heat, dust and moisture.  These include a thermally protected motor, life time lubrication and integral safety switches. This reliability is complemented by economical operation, low maintenance and a long service life.

The modular concept of the MINI offers great design freedom.  It can be specified with a choice of mounting and connecting arrangements and is easily interfaced with an existing controller.  Special stroke lengths and other custom features are available on request.

QUALITY TURBINE BEARINGS FOR WIND ENERGY

With renewable energy very much a hot topic, R. A. Rodriguez couldn’t be better placed to meet demand for critical drive components.  It is the UK factory representative for KAYDON®, an American bearings specialist whose largest ever order was recently received from an OEM in this application sector.

KAYDON® has been involved in wind energy for more than 20 years and has developed a range of bearing types that best meet critical pitch, yaw and gearbox applications in land-based or offshore systems from 200kW to 5MW and beyond. 

The typical requirement is for a large slewing ring – a large diameter bearing with a large bore – in diameters ranging from 2m – 5m. To combine the function of a bearing and gear, teeth can be cut into the inner or outer race to rotate with the assembly or remain stationary in respect to the ground during operation.

The use of a single larger diameter bearing allows wiring and other services to pass through the bore with ease.  This simplifies the overall system design, improves outward appearance and protects components.

Selecting the right bearing design depends on load, stiffness, speed, size and the smoothness of rotation required. One that has proven to be particularly popular for wind turbines however is the four-point contact ball bearing. 

This bearing accepts combinations of radial, thrust and moment loads.  It uses races shaped like gothic arches on both the inner and outer race ball paths that generate four points of contact on each ball.

To satisfy requirements for maximum load capacity within a given envelope, especially in larger sized bearings, KAYDON® has also developed an eight-point contact bearing that is also widely used in wind turbines.  This is an annular bearing with two rows of balls whose unique feature is its use of the gothic arch internal geometry in both rows.  Tests have confirmed that this additional row increases load capacity by an additional 80%.
 
Naturally corrosion resistance is an important consideration for outdoor use and the KAYDON® wind turbine bearings are therefore available with a range of surface treatments to meet the conditions of the application.  Selection of the most appropriate materials is also critical for operating temperatures that may be as low as -40°C; unique sealing arrangements are available for severe conditions.

While other manufacturers may specialise in one or two specific bearing types KAYDON® has the experience and manufacturing flexibility to match the product to the exact requirement. This includes accommodating special needs without sacrificing system performance or increasing cost. 

Further information on the KAYDON® wind turbine bearings and custom options is available from R. A. Rodriguez at www.rarodriguez.co.uk

NEW PRODUCT MANAGER FOR BEARINGS

KAYDON® is a bearing brand that has global recognition. In particular its Reali-Slim range is the preferred choice of designers seeking space and weight savings without compromising performance. For many years the sales and marketing of the entire KAYDON® range in the UK has been the responsibility of precision component supplier, R. A. Rodriguez.

Recent management changes at R. A. Rodriguez have created a vacancy for a product manager to represent the flagship KAYDON® range and the company is now pleased to confirm that Andrew Tilley has now taken on this role.

Andrew Tilley’s first steps into the world of engineering came with his appointment as prototype toolmaker at Cosworth Engineering. After three years Andrew moved into sales at Benzler (UK), the industrial drive and gearbox specialists. In 1991 came his first external sales job selling capital plant to British Rail and its second tier suppliers for Geismar UK. This was followed by a move to Marconi Data Systems to the post of major account executive for its ink jet and laser coding equipment.

Andrew joins R. A. Rodriguez from Bostik where he was south-east area sales manager for the development and management of key distributors and direct major accounts within the company’s Industrial Sealants Division.

NEW MINIATURE LINEAR GUIDEWAY

Linear motion is a field in which R. A. Rodriguez is able to offer a range of solutions and with the introduction of its own BM linear guideway the company has extended its miniature options. Four sizes complete this series with overall heights of 8mm – 16mm and carriage widths from 17mm – 32mm; basic dynamic loading capacities range from 850 to 6450N.

Compact for discrete installation, this ball-cage based design has high precision, gothic arch raceway profiles for long life, low noise and the accommodation of high loads. The high moment load ratings of the series make them ideal for single rail applications. Minimum vibration is assured by the quality of the raceway surface finish. This also contributes to the guideways long and trouble free working life as does the sealed carriage with lubrication nipple.

Available in five precision grades with a choice of five pre-load specifications, the BM linear guideway series is also available in stainless steel. These products have been proven in Europe in a range of applications including driven and manual positioning and X-Y combinations.

NEW BEARINGS FOR BALLSCREW DRIVES

For several years R. A. Rodriguez has marketed the UNITEC brand of ballscrew support bearings designed for high performance machine tool applications. Now in addition to the high load and exceptional performance capabilities of this needle roller bearing range, the company has introduced a new range of ball bearings to meet more general high precision needs of ballscrews.

Sourced from the R. A. Rodriguez German facility, the DRF/DRN double row ball bearings for screw drives are high precision components with a contact angle of 60°. They can absorb radial as well as axial forces from both directions and guarantee highest running accuracy due to their axial stiffness.  The range is therefore ideal for lighter-load applications that call for precise positioning and good repeatability.

The integrated, low-friction seal prevents the ingress of dirt, enhancing reliability and operating life. The bearings are supplied ready-to-fit and lubricated. They may be specified with or without fixing holes and their design ensures swift and easy installation.

Standard precision for the DRF/DRN range is the high accuracy p5/p6 precision class. For lower precision applications a commercial series of the DRF/DRN bearings is also available; this range carries the suffix NP.

Eight types of bearing support units are also introduced in block or flange design.

Full details of the newly extended range of bearings for ballscrew drives from R.A. Rodriguez is contained in a newly published brochure that is available from www.rarodriguez.co.uk.

FRAMO MORAT APPOINT R.A. RODRIGUEZ AS THEIR EXCLUSIVE REPRESENTATIVE IN UK

The parallels between the German drive specialist Framo Morat and precision engineering component supplier R. A. Rodriguez are striking. In addition to having a similar sales support structure and serving similar markets, both companies have common business values and provide a range of engineering services to complement their respective product lines.

This commonality has led a working relationship whereby R. A. Rodriguez is now responsible for Framo product sales in the UK and Ireland. The agreement, signed at the recent Hanover Fair, allows R. A. Rodriguez to market the full Framo range and call upon the company’s extensive manufacturing and assembly capabilities for custom drives.

The Framo range of drive systems includes compact slip-on geared motors; linear actuators and push-pull Linear Chains, all based on modular design principles and customised to suit each application.

The Compacta slip-on geared motor comes with built-in limit switches and is an ideal actuator for reverse motion. The Compacta is available in four sizes with torques up to 600Nm and for speeds from 0.9 to 193 rpm.

In a similar vein the Mini is a range of extremely compact linear actuators with acme screws that are sealed to IP65 and available in stainless steel. Minimum space requirement is also the main selling point of LinearChain that is capable of long strokes despite its small size.

The core competence of Framo is the production of gears and in particular worm gears for which the company is ranked amongst the leading suppliers in Europe. A full range is available including external and internal, spur, helical and spherical in modules from 0.5 to 6 and pitch diameter 15-250mm.

Another of the company’s key products that featured at Hanover is Discpower, a dynamic, brushless and maintenance-free synchronous disc motor with integrated and quiet-running, low backlash planetary gears.

Taking full advantage of Framo’s comprehensive manufacturing capabilities the company is also able to meet most custom drive requirements. In addition to special worm gear drives it has developed, for example, a 2-motor stairlift drive and intelligent actuators for tractors.

Framo Morat products are available from R. A. Rodriguez with immediate effect.

THE BEST BEARING CHOICE FOR ROBOTS

It is difficult to exaggerate the importance of bearing selection in robot performance, particularly in positioning accuracy.  The correct choice is crucial.  A partial list of robot performance elements directly affected by bearing selection includes total robot weight, compactness, cost, payload, reach, power requirements, positioning repeatability and responsiveness.

The inherent design and performance benefits of the KAYDON® REALI-SLIM® thin section bearings makes them a popular choice for robot applications.  Aside from their space and weight saving potential, high bearing stiffness and a large internal diameter to accommodate electrical, hydraulic and pneumatic services are the features that distinguish them.

A single four point contact bearing is ideal for shoulder, elbow and wrist joints.  Also available with integral gears and mounting holes reducing the number of the components and tolerance build-up.  This results in maximum accuracy and a simplified design. 

The 4-point contact bearing can accept combinations of radial, thrust and moment loads.  This is possible due to ‘gothic arch’ geometry of the raceways.  The ball raceway in each race has two radii that are larger than the ball radius and their centres are offset from the centre of the ball radius.  This generates the ‘gothic arch’ configuration in each of the raceways grooves making it possible for the two raceways to contact the ball at four points.

KAYDON® REALI-SLIM® thin section bearings have a radial cross section that remains constant with bore diameter.  They are considerably lighter in weight as bore diameter is increased than bearings with conventional cross sections.

As a rule of thumb every kilo saved by bearing weight is usually accompanied by almost ten kilos less on structural weight.  Such weight reductions in mechanical assemblies provide material and drive power economies that can significantly reduce the cost of a robot.

The bearings are available with bore diameters from 20mm to 1m.  By comparison, conventional bearings are generally limited to bores less than 200mm in standard sizes.  Also, for a given precision class, they are more accurate in large diameter sizes than standard-section bearings because tolerances do not increase as much with diameter.

The KAYDON® REALI-SLIM® range is widely used for light to medium loads at all robot joints, including the waist.  When robot payloads exceed 113 kg a KAYDON® turntable bearing is a good choice as it can handle combined loads at the waist without the need for pairs of standard-section bearings. Turntable bearings are ideal for supporting the intermittent rotating loads occurring at the waist of most robots.

A useful option is the KAYDON® REALI-SLIM® TT Series of miniature thin-section turntable bearings.  They are significantly smaller than conventional alternatives and offer performance advantages. 

DSEI 11th – 14th September 2007, EXCEL London, Stand no. 306

At this year’s DSEI the main focus for KAYDON® and its UK factory representatives R.A. Rodriguez, will be the REALI-SLIM® range of thin-section bearings that are readily available as fit-and-forget military spares and custom aerospace components. The range also benefits from a new and more accurate method of projecting bearing life. This has confirmed that the dynamic capacity rating of many of these bearings exceed previously published figures, by as much as five time in some cases.

The dynamic capacity improvements for REALI-SLIM® vary with type and size. For example for Type X, the four point contact bearing, the improvements range from 31% to 77%. As part of the validation process several competitors’ thin-section bearings were also tested. The actual dynamic capacity of those was found to be up to 72% lower than their published ratings.

Minimum space, very light weight and low torque are the key design credentials synonymous with KAYDON® REALI-SLIM®. This ever-popular range is now available in an expanded range of metric sizes with bores ranging from 20mm to 369mm in diameter in three different cross-sectional sizes of 8mm, 13mm and 20mm square.

Each bore size and cross-section is available in radial contact, angular contact and four-point contact ball construction. In total, R. A. Rodriguez now stocks more than 200 metric types and sizes as well as a comprehensive range of inch sizes.

In addition to the supply and support of aerospace products, R. A. Rodriguez provides a range of engineering services. As well as application engineering, the company is regularly consulted on special bearing design & development. It also undertakes bearing sub-assembly work and self-lube re-lining for military parts. Warehousing and stock supply management, kit-marshalling, labelling and JIT supply are services in which the company is well practised.

CATALOGUE INTRODUCES HIGHER CAPACITY BEARINGS

The higher dynamic ratings capacity of the KAYDON® REALI-SLIM® thin section bearings are detailed in the company’s newly published all-product catalogue. Developed specifically to save space and weight in a broad range of applications the entire REALI-SLIM® range and the new catalogue are available from UK factory representatives, R. A. Rodriguez.

The publication details the seven open and five sealed bearings that comprise the series including type ‘C’ for pure radial loads, ‘A’ for radial and thrust loading and ‘X’ that accommodates radial, thrust and moment loading in a single bearing. The catalogue also introduces seven new sizes and for the first time includes REALI-SLIM® TT™ compact turntable bearings and REALI-SLIM® MM™ metric series bearings.

Sizing charts guide engineers through the preliminary selection of standard, metric or stainless steel REALI-SLIM® bearings. An application worksheet is also included that designers can complete and fax to R. A. Rodriguez for a customised application engineering review and bearing recommendation.

A hard copy of the new catalogue is available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail to info@raruk.com. Alternatively a .pdf version can be downloaded from the company’s website at www.rarodriguez.co.uk. Also downloadable and available on CD is the comprehensive REALI-DESIGN™® software that provides engineers with bearing selection guidance and complete specifications.

THIN BEARING MEETS SPECIAL SEMICONDUCTOR DEMANDS

Without sacrificing bearing accuracy, the KAYDON® Corporation REALI-SLIM® bearings can be optimised to minimise friction, outgassing, contamination and even wear.  Indeed the company specialises in meeting the specific demands of semiconductor manufacturing by offering a range of options to create the optimum characteristics.

These custom REALI-SLIM® bearings were therefore the ideal choice for Applied Materials UK in Horsham for a gripper arm assembly on its Quantum X ion implant machine for the processing of silicon wafers. This is a single wafer, high current implanter using fixed beam technology.

Ion implantation is a process where electrically charged atoms are fired into the silicon wafer material to change the electrical properties of the material and can be applied at various points of the wafer process.  The gripper assembly is responsible for loading the wafer into the implant chamber and the role of the KAYDON® bearings is to support the rotation of the gripper.

UK factory representative for KAYDON® Corporation is bearing specialist R. A. Rodriguez with whom Applied Materials UK worked on this project.  The bearing selected was a customised Type X 4-point contact bearing that accepts radial, thrust and moment loading.  It was supplied with a flanged outer race for fixing to the gripper arm plate.

AISI 440C stainless steel races and balls were a must as the application called for contaminant-free, no-lube operation.  This material choice ensures minimum surface degradation and particulate formation that is common in harsh environment applications.  To accommodate the low torque operation under vacuum the bearing was also specified with PTFE cage.

“The gripper arm assembly and therefore the bearings needed to operate in a high vacuum environment of 10-7 Torr.  They also had to be electrically conductive,” explained Applied Materials Senior Design Engineer, Bert Webber. “Another important characteristic for this application was compact design”

Perhaps the best known of the REALI-SLIM® characteristics is the design’s minimum space requirement.  The single 4-point contact REALI-SLIM® effectively replaced the need for Applied Materials to specify two bearings, making the design more compact and simplifying the mounting.  In addition to the obvious cost savings this arrangement also created space for easy installation and maintenance and also saved weight.

The ability of this Type ‘X’ bearing to carry three types of loading simultaneously is thanks to the gothic arch geometry of the inner and outer races. It was also supplied with internal diametral pre-load to ensure zero free-play.  This is accomplished by using balls that are larger than the space provided in the raceways.  The balls and raceways therefore have some elastic deformation in the absence of an external load.

Such is the popularity of these thin section bearings for semiconductor applications that KAYDON® has now produced a dedicated brochure.  This publication and indeed the entire REALI-SLIM® range are available in the UK from R. A. Rodriguez in Letchworth.

KAYDON® BEARINGS SELECTED FOR LOW WEIGHT & HIGH SPEED

In medical diagnostics CAT scanners (computerised axial tomography) produce detailed images of internal body organs by rotating x-ray generators and detectors around the patient. The need for high positioning accuracy is of course paramount in these systems and scanner manufacturers therefore need to be assured of the quality of components such as bearings.

Development is firmly towards the production of faster systems to improve scanning time and reduce the patients’ exposure to radiation. For this reason weight and space are key factors in improving the speed and performance of the moving elements. For this reason KAYDON REALI-SLIM® thin-section bearings have become the choice of all major manufacturers of CAT scan equipment. They are primarily used in the mechanism that carries the x-ray head.

The REALI-SLIM® bearings specified by the leading names in the industry are generally custom made to provide diameters of 1.27m (50 inches). Inherent to the design is its suitability for high-speed rotation, with minimum vibration and ability to run quietly, an important consideration especially for the patient.

These qualities are ensured by KAYDON®'s high quality manufacturing processes. The KAYDON® Corporation has been a leading producer of large diameter custom bearings since its foundation in 1941. It manufactures combination load bearings up to nearly 4.6m and is unique in the breadth of product capabilities offered.

Bearing life is another critical factor as demand for CAT scanners in most hospitals far outweighs availability. Reliability is therefore a critical factor. Already considered to have an exceptional life rating REALI-SLIM® bearings have recently been reassessed using a brand new methodology that integrates theoretical life projections with actual test data. The result is that many KAYDON REALI-SLIM® bearings exceed previously published figures by as much as five times.

HIGHER DYNAMIC CAPACITY RATINGS FOR THIN SECTION BEARINGS

A new, more accurate method of projecting bearing life has confirmed that the ratings of many KAYDON REALI-SLIM® bearings exceed previously published figures, by five times in some cases. KAYDON® Corporation bearings are supplied in the UK by R. A. Rodriguez.

The dynamic capacity improvements for REALI-SLIM® bearings vary with type and size with increases for Type X, the four point contact bearing, ranging from 31% to 77%. As part of the validation process KAYDON® Corporation also tested several competitors’ thin-section bearings. The actual dynamic capacity of those bearings was found to be up to 72% lower than their published ratings.

The revised KAYDON® Corporation ratings are derived from a new method of calculation developed specifically for thin section bearings. It integrates theoretical projections with actual test data instead of simply estimating bearing life as is the practice of other manufacturers. The KAYDON® Corporation Bearings Division is believed to be the first thin-section bearing manufacturer to adopt this methodology.

These ratings have been published by KAYDON® Corporation in a new edition of its product catalogue and are naturally included in the new REALI-DESIGN™ software that is available for download at www.kaydonbearings.com

KAYDON EXTENDS PRODUCTION OF THIN SECTION BEARINGS

Investment in excess of $18.5m has expanded the Kaydon® bearing manufacturing site in Sumter County, USA, prompting the creation of 50 new jobs. Demands for Kaydon® bearing products worldwide has never been greater and this move will ensure the company can easily absorb this growth.

Kaydon® is the acknowledged leader in thin-section bearing technology and its sales and marketing interests are represented in the UK, Ireland and Scandinavia by precision components supplier, R. A. Rodriguez (UK) Ltd. The Kaydon® REALI-SLIM® and ULTRA-SLIM® brands are ideal for applications that call for low weight and compact size but also high performance.

Since opening in 1991, the Sumter County facility has performed at a very high level and Kaydon® has attracted a workforce whose skills are crucial to the continued success of Kaydon® bearing products. "The expansion of this site is good news for our customers," concludes David Hey of R. A. Rodriguez (UK) Ltd. "It ensures our lead times remain good in the face of growing demand and provides greater opportunity for product customisation."

LINEAR MOTION LITERATURE

The Ballscrew and Acmescrew range of components from R.A. Rodriguez is expanding to encompass a wider range of applications in a variety of industries. From slow lift mechanisms to high precision dynamic systems these products are proving to be a highly popular addition to the company’s range of linear motion components.

A new 24-page catalogue provides all the technical information. The publication details the leadscrew options available including the choice of ball transfer system, low backlash nuts and pre-loaded nuts for greater precision. And for less demanding applications it also provides a comprehensive guide to the Acmescrew choices. Both products are available ex-stock and in metric and inch sizes.

Entitled R. A. Rodriguez Ballscrews and Acmescrews, the A4 publication is available from the company’s Letchworth sales office on 01462 670044 or via e-mail to info@raruk.com

NEW STOCK GEAR CATALOGUE INTRODUCES NEW PRODUCTS

As its latest all-product catalogue confirms Japan’s leading manufacturer of gear products, KHK, continues to expand its range. This new publication introduces several new products and reinforces KHK’s status as a comprehensive single source supplier. The full KHK product programme is supplied in the UK by sole distributor R. A. Rodriguez from whom the new KHK 3009 product guide and technical data book is also now available.

The 382-page book has been designed for easy reference and to complement the company’s web-based catalogue. The range now comprises 133 standard gear products and more than 4000 individual items. Several new additions appear in this issue including an expanded range of racks, three types of bevel gearboxes and a new K-clamp for spur gears.

Copies of the 3009 KHK Stock Gear and Order Gear Guide are available from the R. A. Rodriguez sales office on 01462 670044 or by e-mailing info@raruk.com. A good comprehensive introduction to the range can also be found by visiting the company’s website at www.rarodriguez.co.uk

QUALITY, EX-STOCK BEVEL GEARBOXES… includes plastic-housed miniature version

New from KHK, Japan’s leading manufacturer of gear products, are two new ranges of spiral bevel gearboxes that have just been introduced to the UK by precision component supplier, R. A. Rodriguez. These products are ideal for specifiers who need a good quality gearbox available from stock.

Thanks to their plastic resin housing the new PBX miniature bevel gearboxes are lightweight and compact. They have superior chemical and thermal resistance, are maintenance free and have a speed ratio of 1:1. The units have through-holes and counter-bores allowing mounting in any orientation.

For applications involving high duty cycles and high speed the new CBX range of bevel gearboxes is a good, value-for-money choice. The units have a high grade case iron housing and use tapered roller bearings. The spiral bevel gears themselves are made from case-hardened alloy steel and the quality of their manufacture ensures both low noise and highly efficient motion control.

Gear ratios for the CBX range are 1:1 or 1:2 which meet the requirements of most applications. In common with the PBX range, the CBX is available with two or three output shafts and it also offers exceptional design flexibility; 24 permutations of shaft orientation and rotation are standard with the CBX bevel gearboxes.

PLASTIC HOUSED BEARING LITERATURE

Greenlign plastic housed bearings have proven to be a highly popular range of products for R. A. Rodriguez. The choice of types now amount to eight and it is to provide an overview of this extended range that the company has published a dedicated product folder.

Made from tough, precision-moulded thermoplastic that is chemical-resistant, the housed bearings broadly accommodate shaft sizes from 12 – 40mm; pillow block and four bolt flange types suit shafts up to 50mm. All sizes are available from stock and fitted with stainless steel bearings as standard.

The folder provides all the technical data needed for easy specification and holds individual, more-detailed data sheets on each of the product types. The new Greenlign literature is available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail to info@raruk.com

NEW, MACHINE TOOL BEARING ... with superior angle measuring system

A high precision combined radial, thrust bearing designed for machine tool rotary tables and spindle heads has been developed with an integrated angle measuring system by bearing manufacturer UNITEC. Available in the UK from factory representative, R. A. Rodriguez, the new UNITEC RTB AMS bearings use an inductive detecting principle. As a result no magnetic field, nor the presence of lubricating fluid or grease, interferes or influences measurement accuracy and the system is therefore understood to be more accurate than others currently available.

The system includes a graduated stainless steel scale that fits precisely onto the bearing’s washer ring and two sensor heads on the outer ring, sited at 180 ° to the centreline. During rotation, the sensors detect the slots on the scale and generate a 1 V pp output signal to the machine’s CNC enabling the angle to be continuously monitored. The scale slots – set at intervals of 1mm – are protected from dirt ingress by a metal cover.

This new bearing is available in seven sizes with bores from 150mm to 460mm. One reference point is provided as standard but on request several distance-coded reference marks can be specified at any angle from 40 ° to 15 ° depending on bearing size. The absolute position may be determined by detecting during rotation, the single reference point or alternatively two distance-coded marks.

HIGH PERFORMANCE BEARINGS FOR RACE CAR APPLICATIONS

In designing a high performance race car with a competitive edge, the choice of the bearing is critical. Weight and space are key factors in improving speed and fuel economy but this cannot be achieved at the expense of quality performance. For this reason Kaydon thin-section bearings have become the constructor’s choice across the motor racing sector whether it be for Formula 1, Formula 3000 or rally cars. In the UK, the entire Kaydon range is available from factory representative, R. A. Rodriguez.

In Reali-Slim bearings, each series is based on a single cross section that remains constant as the bore diameter is increased. This is in sharp contrast to standard bearings where the cross section increases as the bore diameter increases. Because the radial cross section and race width of Reali-Slim bearings are smaller than comparable diameter bearings from other manufacturers they take up less space. This allows designers to use thinner shafts, housings and other components resulting in not only a more compact design but cost reductions too.

The use of Kaydon Reali-Slim bearings on performance car wheel assemblies provides a good illustration of their technical merits. This is a particularly arduous application due the bearing speeds and the applied loads that are involved. Radial, thrust and moment loads that correspond to the pitch, roll and yaw of the vehicles are simultaneously applied to the wheel bearings.

Controlling pre-load for this type of application is vital. Too much pre-load would increase the loading on the bearings, reducing their life. Too little could lead to lower stiffness and deflections. Many constructors therefore take advantage of the specialist support from Kaydon and R. A. Rodriguez application engineers. Their advice on bearing preload adjustments and mounting arrangements has proved invaluable in achieving optimal bearing performance on the race track.

The Reali-Slim product programme comprises a wide range of choices to accommodate the combined loading that is typical of automotive applications. The range comprises seven open and five sealed series ranging in bore diameters from 20mm to 360mm; R. A. Rodriguez also supplies an Imperial size range.

If required, these bearings can be quickly modified to have special clearances, preloads, lubricants, separators and other features to meet the most demanding application requirements. In addition, the Reali-Slim bearings can be quickly modified to obtain corrosion resistance by applying Endurakote® thin-dense chrome plating. When assembled with 440C stainless steel balls, this modification forms the basis for Endura-Slim series of bearings that provide corrosion protection equal to or better than a full 440C stainless steel.

LINEAR SLIDE MEETS TURBOCHARGER ‘SPEC’

Fundamentally a turbocharger comprises a turbine and a compressor connected by a common shaft supported on a bearing system. It converts waste energy from the exhaust manifold into compressed air that is pushed into the engine. This allows the engine to produce more power and torque improving the overall efficiency of the combustion process.

Proving and measuring the air flow through a turbocharger is a critical process and to assist in this process R.A. Rodriguez has recently supplied the linear motion element for one of Europe’s leading turbocharger manufacturers. The special purpose test rig called for the incorporation of a short stroke, manually operated slide whose accuracy needed to be repeatable in all planes. This was required to ensure the concentricity of positioning two components.

The unit recommended by R. A. Rodriguez is from its IEF Werner range of hand-operated slides. Made from GG25 cast iron to provide greater stability, the slide section is 150mm wide with a 50mm stroke. The unit has 20mm diameter spindle with 1mm pitch and accuracy is ±0.02mm over a 300mm stroke. It was supplied with special fixing holes and a bronze, adjustable pressure plate for establishing a light pre-load in the slide to ensure precision positioning. To identify position, the linear system works in conjunction with a linear digital reader and it is required to carry a load of approximately 20 kg.

This manually operated slide is one of many IEF Werner options available from R. A. Rodriguez. The range can be equipped with dovetail, cross roller or Teflon guides. The latest addition to its slide range is DOMILINE, a variable-combination adjustable system. This visually and technically sound modular system can be specified in a large number of different variants and widths. There are also combinations with and without mechanical locking devices, with a spindle or if desired, a pneumatic or motor drive

NEW MINIATURE PLASTIC-HOUSED BEARINGS... bring even greater choice

Whilst there is nothing ground breaking about the new series of miniature plastic housed bearings from R. A. Rodriguez they perfectly complement the company’s established Greenlign and Redlign ranges. These products are in considerable demand in the hygiene-sensitive food, pharmaceutical and chemical industries where non-corrodible housings and stainless steel bearings are essential.

With the introduction of new Greenlign designs last year R.A. Rodriguez could already boast the widest the choice of plastic housed bearings. The new miniature additions give R. A. Rodriguez even greater scope to provide the right product for the job.

The new range introduces two basic types, the 2N 2-hole flanged bearing and the 4N, its 4-hole counterpart. Each housing type is available in a range of sizes to accommodate a self-aligning stainless steel insert bearing with bore diameters from 3mm to 12mm.

The housings are precision moulded from high-tensile plastic whose strength characteristics can be compared with those of die cast metal alloy. However, unlike cast iron housings, their smooth surface is easily cleaned and will not corrode, chip or scratch.

SMOOTH AND CONSISTENT LINEAR MOTION… for superior inkjet printing

The R. A. Rodriguez linear axis system chosen to carry an inkjet print head across a conveyor-width of food products has brought a range of operational benefits for a major food processing company. It has resulted in consistently high quality printing of ‘best before’ and ‘sell by’ dates, a factor that is all-important for any food processor dealing in the mass market.

Linear motion is now one of five main product sectors for Hertfordshire-based R.A. Rodriguez who represents the sales interests of German handling and automation specialists IEF Werner in the UK. However the company’s role was far more than just a supplier of components. Using elements from the Werner Easyline range of modules, R. A. Rodriguez designed and installed a complete package of equipment complete with programmed controller.

The Easyline axis is integrated into a dessert-packaging machine and used to transport the inkjet print head across a conveyor carrying rows of pots. Each row holds three pots and the conveyor indexes to the next row every three seconds. Smooth operation and consistent speed are vital components in the efficiency of the inkjet printing process and thanks to its controlled acceleration and deceleration the stepper motor controlled Easyline system ensures no disturbance to ink flow.

The IEF Werner linear motion product programme is now a popular programme especially for systems integrators. It has been designed to provide elements that are freely combined to create bespoke, multi-axes handling systems. They offer high loading capacity, high rigidity, quiet operation and are complemented by a wide choice of motors and controllers.

IP65 rating qualifies the system for the wash down environment required by this dairy application and its controller enables a range of different products and print positions to be accommodated. The freely programmable controller has integrated input/output processing enabling it to control all x-y movements; it has the ability to run a maximum of 32 programmes in parallel.

KAYDON CORPORATE BROCHURE

Although predominantly known in the UK for its rotary bearings and in particular its Reali-Slim thin-section range, the Kaydon Corporation is a manufacturer with diverse business interests. For the first time, details of all of the Kaydon Group companies - several of which are represented in the UK by R.A. Rodriguez – have been brought together in one publication.

Kaydon’s portfolio of products and services now span the metalworking, process and service industries incorporating brands such as Cooper®, Spirolox® ACE®, Purafil®, Tridan® and Canfield®. However leading this new corporate publication is Kaydon’s flagship, the Bearing Division.

In addition to concepts that are synonymous with weight, cost and space savings, the Division is also responsible for the design, manufacture and development of both heavy-duty and lightweight turntable bearings as well as custom miniature bearings for high-speed applications in aerospace, instrumentation and semiconductor manufacture.

LINEAR BEARINGS FOR HARSH ENVIRONMENTS

The fundamental design of the new Schatz Double V linear bearings from R. A. Rodriguez make them ideal for use in harsh environments. Unlike other systems that allow the ingress of dirt, the rolling elements of these components are enclosed and therefore safeguarded from contamination. As a result they provide a longer service life.

The new Schatz HC™ Series builds on these benefits providing a range of guide wheels and tracks that offer superior performance in demanding aerospace, medical, semiconductor, processing and packaging applications. Careful choice of materials is largely responsible for their longevity.

Most of the corrosion resistant bearings on the market use 440C stainless steel as their preferred material of manufacture. Whilst this steel offers better corrosion resistance than non-stainless bearing materials it is prone to wear. The material composition of the HC™ bearings is unusual in that it ensures both corrosion-resistance and long fatigue life.

The inner and outer rings of the HC™ guide wheels are EMS138 stainless steel as is the linear track whose V section hardened to Rc53 min. Ceramic balls are a standard feature of this range. EMS138 has a fatigue life that is at least five times greater than 440C and shows far greater resistance to oxidation especially in salt spray tests lasting 160 hours.

Four wheel-sizes are available in the standard range. Guide wheels can be mounted vertically or horizontally to suit differing space and application requirements and used to support rotary motion. A range of bushings and ancillary products are available for numerous mounting arrangements.

SEMICONDUCTOR THIN SECTION BEARINGS

As well as their compact design, the ability of Kaydon Reali-Slim® bearings to withstand high temperatures, their vacuum and chemical compatibility and low particulate generation make them the ideal choice for semiconductor manufacturing. Such is the popularity of these thin section bearings in this sector that Kaydon has now produced a dedicated brochure. This publication and indeed the entire Reali-Slim range are available in the UK from factory representatives, R. A. Rodriguez.

The brochure covers the three basic configurations, 'C' type for pure radial loads, 'A' for radial and thrust loading and 'X' for any combination or radial, thrust and moment loading on a single bearing. All bearings can be customised to minimise torque, outgassing, contamination, corrosion and wear. The wide selection of ball, race and cage materials that help optimise bearing life and performance are also detailed.

An application worksheet is included in the publication for designers to complete for a free customised engineering review and bearing recommendation. Other free engineering aids are also listed in the catalogue and include the company’s popular Reali-Design™ CD software and the comprehensive Reali-Slim Catalogue 300. All are available from the R. A. Rodriguez sales office on 01462 670044 or via e-mail, info@raruk.com

R. A. RODRIGUEZ IS NOW AS9120 ACCREDITED

Aerospace is a prime market for R. A. Rodriguez. Indeed its products are used on most military and civil aircraft in the Western world. In particular, the company’s Kaydon thin section bearings and Schatz aircraft control bearings are considered by many customers to be industry standards.

It is to ensure its quality management systems are in harmony with the specific needs of the industry that R. A. Rodriguez has sought certification to AS9120. This sector-specific, ISO 9001-based standard focuses on areas with the greatest impact on safety, reliability and regulatory compliance of aerospace products.

R. A. Rodriguez has now received its certificate of registration confirming its compliance with AS9120 Quality Management System Requirements for Stockist Distributors. Developed under the auspices of the International Aerospace Quality Group this standard provides the assurance that all R. A. Rodriguez aerospace products meet this industry’s stringent requirements.

ANOTHER SALES APPOINTMENT FOR R. A. RODRIGUEZ

The second phase of sales team re-structuring at R. A. Rodriguez has been completed with the appointment of Andrew Mason. Working in parallel with Dave Young in the North, Andrew is now responsible for the sale of all product lines in the South. Based in Reading he is supported by four dedicated product managers and the internal sales team.

Having served his engineering apprenticeship with a company specialising in fluid power, Andrew made his first transition into sales in the mid-nineties. He subsequently returned to the factory floor and indeed joins R. A. Rodriguez from Blatchford Products where as manufacturing engineer his role was to bring new artificial limb components from design development to production.

THIN SECTION BEARING WEBSITE

Visitors to the new www.reali-slim.com website can now quickly access a wide range of helpful engineering tools and information to simplify and speed up product design cycles. Kaydon has created this dedicated website for its thin-section bearings to ensure the efficient selection of standard or custom bearings that optimise bearing life and performance in the given application.

Products featured include the company’s space-, weight- and cost-saving Reali-Slim® thin section and turntable bearings and Ultra-Slim bearings. All are available in both imperial and metric sizes. Product descriptions, technical literature, 2D, 3D and CAD drawings can quickly be downloaded. Dimensional drawings are imported directly as native CAD files saving re-drawing time and eliminating compatibility problems.

To save time-consuming manual calculation, the site also includes the Reali-Design™ Engineering Aid. Available calculations include bearing life and load analysis, maximum safe operating speeds and axial play due to internal clearances.
Further information on the Kaydon range is available from factory representatives, R. A. Rodriguez on 01462 670044, www.rarodriguez.co.uk.

R. A. RODRIGUEZ BOOSTS ITS MACHINING CAPABILITY

Thanks to a substantial factory expansion at its sister plant in Germany, R. A. Rodriguez now has far greater capacity to supply UK customers with its own range of linear motion products machined to order. Investment in the facility also includes new CNC production machinery and equipment to enable far greater stock holding.

This next phase of the company’s development extends by a third its purpose-built premises in Eschweiler near Achen. It provides a dedicated machining and assembly shop for the R. A. Rodriguez range that in addition to shafts includes linear guideways, ball bushings, bearing housings, shaft supports, shaft blocks, ballscrews and acmescrews.

1M DIAMETER HYBRID BEARING GOES INTO PRODUCTION

Kaydon’s ability to engineer bearings to suit the individual requirements of a specific application is well exemplified by a unique product that has just gone into production. This special hybrid bearing, used in a three-bearing swivel module on a new fighter jet exhaust system, is the first of its kind to be commercially adopted.

Whilst other companies were initially involved in the project, the Kaydon design proved its outstanding ability to operate well in temperatures up to 600ºC. The bearing has a bore diameter of 1m and its manufacture has required the design of bespoke tooling and the use of special, difficult-to-machine materials.

As well as these bespoke hybrid bearings, R. A. Rodriguez also offers a standard range for general harsh environment applications. These bearings owe their ability to extend the mean time between performance failure to a combination of ceramic balls and hardened steel races. This combination offers several advantages over all-steel bearings and makes hybrid bearings the ideal choice for harsh environments.

Hybrid bearings provide longer life and lower wear than steel bearings because the ceramic rolling elements reduce surface flow induced fatigue. And the higher ball hardness minimises the effects of wear debris tracking. Due to their low friction characteristics, hybrid bearings therefore perform well with minimal lubrication and indeed greatly extend lubricant life.

MULTI AXIS PROGRAMMABLE HANDLING SYSTEM
ensures accuracy and speed in car part production

The economics of the automotive business requires supreme manufacturing efficiency to keep unit costs down. Therefore in designing a timing mark milling machine for a major German second-tier supplier Feasey, the West Midlands based special purpose machine builder, was sure to specify elements that would meet the high productivity needs of the sector.

The role of t