CONVEYOR MANUFACTURERS ASSOCIATION

OF SOUTH AFRICA NPC

GENERIC SPECIFICATION FOR GEARED REDUCERS

FOR CONVEYORS

CMA MR01 Rev05 2011

INDEX

ITEM Page

1. SCOPE ............................................................................................................................. 3
2. GEARS ............................................................................................................................. 3
2.1. Gear Ratio..................................................................................................................... 3
2.2 Tooth Profile and Gear Strength .................................................................................... 3
3. GEAR SHAFTING ............................................................................................................ 3
4. GEAR CASINGS .............................................................................................................. 4
4.5 Identification .................................................................................................................. 4
5. LUBRICATION ................................................................................................................. 5
6. TERMINOLOGY ............................................................................................................... 6
7. SERVICE FACTORS ........................................................................................................ 7
8. BEARING SELECTION .................................................................................................... 8
9. MOUNTING AND ALIGNMENT ...................................................................................... 10
10. HOLDBACKS ................................................................................................................. 11
11. ACKNOWLEDGEMENTS .............................................................................................. 12
12. RECORD OF AMENDMENTS ........................................................................................ 12

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1. SCOPE
This specification covers the general technical requirements for gear reducers for use on
belt conveyors. Standard terminology for the specification of reducers is defined. Note
that the standardised requirements for units conforming to the “Euro” standard are not
specifically covered by this specification. Because of their special nature, gear units that
are dependent on external reductions (such as vee drives or chain) to achieve their
speed reduction (the “SMSR” type of reducers) are excluded from this specification.

2. GEARS
The basic requirements for mechanical speed reducers by means of gearing may be
summarised as follows :

2.1. Gear Ratio

In order to achieve the desired output speed, the reduction ratio of the reducer shall be
specified by the user, in accordance with the range of ratios as offered by the supplier.
The exact ratios of the reducer unit shall conform to the standard nominal ranges within a
tolerance of ±5%. Tables 1 and 2 list the standard range of ratios in ISO and AGMA. The
ISO range utilises the R20 number series, while the AGMA range utilises a geometric
progression with 1,5 as the common ratio.

10 11,2 12,5 14 16 18 20
22,4 25 28 31,5 35,5 40 45
50 56 63 71 80 90 100

TABLE 1: SELECTED STANDARD NOMINAL RATIOS

IN ACCORDANCE WITH ISO R20

6,2 7,6 9,3 11,4 14,0 17,1 20,9

23,2 25,6 28,4 31,4 34,7 38,4 42,5
47,1 52,1 57,7 63,8 70,6 86,5 105,9

TABLE 2: SELECTED STANDARD NOMINAL RATIOS

IN ACCORDANCE WITH AGMA

2.2 Tooth Profile and Gear Strength

The gear tooth profile and the load capacity of gear pairs shall be determined in
accordance with the ISO or AGMA group of standards, provided that the allowable
material stresses are comparable. Cognisance shall be taken of advances in material
technology.

3. GEAR SHAFTING
3.1 Gear shaft material shall be appropriately selected and shall be designed to be rigid, in
order to minimise clearances between gear pairs when operating under full load.
Applicable stress concentration factors shall be catered for as required.

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3.2 The surface texture on the protruding shafts and the bore of hollow shafts shall be in the
following ranges
3.2.1 For bore or shaft diameters 100 mm; Ra = 0,8 m (N6).
3.2.2 For bore or shaft diameters >100 mm; Ra = 1,6 m (N7).
3.2.3 For all cases where a rigid coupling is specified, Ra = 0,8 m (N6).

3.3 Keys and keyways for protruding shafts and for hollow shafts (not fitted with keyless
systems) shall conform to BS 4235 and DIN 6885. Tapped holes in shaft ends shall
comply with the requirements of DIN 332/2

3.4 In the case of shaft-hung reducer sets equipped with rigid output couplings, it may be
preferable for the output shaft of the reducer to be increased in diameter and reduced in
protrusion length, in order to reduce the imposed overhung loading component. In this
case, the user should consult the supplier, as appropriate.

3.5 In the case of shaft-hung reducer sets equipped with rigid output couplings, the tolerance
on the diameter of the reducer output shaft shall be as specified by the rigid coupling
manufacturer. The shaft shall be supplied without a keyway, unless otherwise specified
by the user.

3.6 Where shafts are not required to protrude beyond the reducer casing, they shall be
securely sealed by means of end caps or plates. Protruding shafts shall be sealed
against the ingress of dirt and moisture, using advanced sealing technology, such as
regreasable seals, as appropriate.

4. GEAR CASINGS
4.1 The gear casing shall be designed and constructed to minimise deflection and distortion
under full load and under maximum temperature operating conditions.

4.2 The casing shall be designed to withstand the combined effects of the radial, axial and
overhung loads imposed. The casing shall be provided with lifting facilities, suitably
located and proportioned. Where a reducer casing is split and/or invertible, the lifting
facilities shall be provided on both halves of the casing.

4.3 The gear casing shall be provided with a properly dimensioned drain system and an
easily accessible oil filling port, with an easily accessible oil level monitoring system, by
means of either a dip stick or sight glass (or both), or level plug.

4.4 The filter requirements shall be in accordance with contaminant levels in the
environmental and operational conditions.

4.5 Identification
The gear casing shall be provided with a nameplate, securely attached to the casing and
indicating the following:

4.5.1 The nominal reducer power rating, based on a service factor of 1. In addition, the
reducer torque rating may be indicated.
4.5.2 The reducer ratio. The ratio indicated may be either nominal or exact and shall be
identified accordingly.
4.5.3 The reducer size designation in accordance with the supplier’s convention.
4.5.4 The lubrication specification, with regard to oil type, grade and fill quantity.
4.5.5 A traceable serial number for the gear reducer assembly.

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5. LUBRICATION
5.1 The reducer shall be designed so that all the internal moving parts are adequately
lubricated, by means of splash, scoop, channel or pump forced lubrication, as
appropriate.

5.2 The type and grade of lubricant shall be determined by the supplier, in conjunction with
the user.

5.3 The design of the installation or system shall limit the reducer sump running oil
temperature to a maximum of 90°C when using mineral oils. Higher temperatures could
be obtained with synthetic oils, but that would be subject to agreement between user and
supplier. The addition of fans, cooling coils or external radiators shall be determined in
collaboration with the end user. Other oil temperature limitations may be imposed for
particular applications.

5.4 Should the unit not be supplied with a first fill of oil, then a further label shall be affixed to
the reducer clearly indicating that the reducer has no oil. The label may indicate the oil
grade and quantity for the first fill.

5.5 Normal Ambient Temperature.

For sub-Saharan Africa and particularly for Southern African conditions, the normal
ambient temperature is considered to be in the range 30°C to 40°C. The ambient
operating temperature should be determined in conjunction with the user.

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6. TERMINOLOGY
6.1 The standard definitions relating to power are listed in Table 3.

Term Definition
The power seen by the output shaft of the reducer. This
power is derived from the conveyor itself and is normally
Absorbed Power
given by the effective tension (kN) multiplied by the
conveyor belt speed (m/s). Te x S = Pabs (kW)
The power required at the motor shaft. This power is
Pin
Demand Power derived from Pdemand = (kW) where Pin is the input
cp lg
power and cplg is the input coupling efficiency
The unfactored mechanical capability of the reducer. This
Reducer Rated
is usually available in the power tables published by the
Power
manufacturer.
The electrical power or nameplate power of the motor.
Installed Power Designated Pmot it is normally the next larger size of motor
compared to the Demand Power.
The power derived, including factors, for comparison with
P  SF
Design Power the Reducer Rated Power. Thus Pred = abs (kW),
red
where SF is the appropriate service factor.
The power required at the reducer input shaft. This power
P
Input Power is derived from Pin = abs , where red is the reducer
red
efficiency.
The power derived by the manufacturer and published as
the Thermal Power Rating of the reducer. This rating is
Thermal Power affected by several factors, such as the addition of fans,
external cooling, the radiation coefficients of the reducer
casing and the ambient conditions.

TABLE 3: COMMON TERMINOLOGY RELATING TO REDUCERS FOR CONVEYORS

6.2 The mechanical power ratings shall be at least based on 2-pole, 4-pole and 6-pole
synchronous motor speeds. For variable speed drives, the mechanical power rating shall
be based on the most arduous power/speed condition.

6.3 The thermal power rating of the reducer shall be determined in order to limit the
temperature rise of the oil to a maximum of 60°C above ambient conditions, as defined in
5.5 above, with a maximum of 90°C. The thermal power shall be at least equal to or
greater than the absorbed power.

6.4 Mineral oils subject to temperatures above 90°C tend to break down more rapidly and
will require more stringent oil condition monitoring and more frequent oil changes. For
variable speed drives, the thermal power rating shall be based on the most arduous
power/speed condition.

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7. SERVICE FACTORS
7.1 The power rating of the reducer is normally determined by the lowest rating for any
bearing or gear pair for either bending or pitting. These criteria shall be covered when
determining the service factor.

7.2 The service factors (SF) shown in Table 4 would apply as the general case and are
based on 24 hours operation. Other service factors could be applied by individual users,
but these would have to be ratified by the supplier.

Loading Description Service Factor

Pred
SF = 1,25 = or
Up to 24 h/day. Uniform loading. Pabs
Uniform Light/medium duty plant conveyors,
Normally single drive options only. Pred
SF = 1,00 =
Pmot
24 h/day. Cyclic or moderate shock P
loads. Bucket wheel reclaimer SF = 1,50 = red or
Pabs
conveyors. Heavy duty plant or
Moderate
overland conveyors and conveyors
Pred
with multiple drives. All underground SF = 1,25 =
conveyors. Pmot
Pred
24 h/day. Dual independent drives SF = 1,80 = or
Pabs
Load- for conveyors other than variable
sharing frequency driven units. Increase
Pred
factor 1,20 SF = 1,50 =
Pmot

TABLE 4: TYPICAL STANDARD SERVICE FACTORS

7.3 Where conveyors are equipped with 2, 3 or 4 power packs in a 1/1 or 2/1 dual
independent drive arrangement with fluid couplings, the Service Factors may be
increased by a factor of 1,2 to cater for uncertain load-sharing. In this case, the SF for
moderate loading may be altered as shown in table 4. It must be noted that the increase
in service factor will result in a higher specification of reducer and the application of the
increased SF should be subject to agreement between the user and the supplier.

7.4 Care must be exercised when specifying the Service Factor with respect to the motor
nameplate power, since an oversized motor (as a result of rationalisation or other
aspects) may result in a significantly oversized reducer. Alternatively, should the reducer
be selected on the basis of design power with the relevant SF, then an oversized motor
may prove destructive.

7.5 When the value of the service factor approaches or exceeds 3, the reducer bearing life
could be adversely affected and the final reducer selection should be referred to the
supplier.

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7.6 The service factor has traditionally been related to the wear life, or the useful service life
of the whole reducer, with due cognisance taken of the individual component life. The
service factors are therefore largely empirical and have been compiled by experience.
Tables for service factors are available from several sources and there is little difference
in the service factor for machine categories and operating periods as determined by ISO,
AGMA and other authorities.

8. BEARING SELECTION
8.1 The minimum basic rating life of the bearings used in conveyor reducer drives calculated
according to the ISO 281:2007 standard shall exceed 40,000 hrs.

8.2 The equation used to determine the basic rating life of a bearing according to the ISO
281:2007 standard is as follows:

L10h = 1000000 (C/P)p

60n

where

L10h - basic rating life (operating hours)

C - basic dynamic load rating of bearing (N)
P - equivalent dynamic bearing load (N)
n - rotational speed (rpm)
p - exponent of the life equation
= 3 for ball bearings
= 10/3 for roller bearings

8.3 For modern high quality bearings, the basic rating life can deviate significantly from the actual
service life for specific operating conditions. ISO 281:1990/Amd 2:2000 contains an adjusted life
equation which includes life adjustment factors for reliability, lubrication and the fatigue limit of the
bearing material. ISO 281:2007 contains a modified rating life equation which includes
modification factors for reliability, bearing material, lubrication (type of lubricant, viscosity, bearing
speed, bearing size), environment (contamination level, seals), contaminant particles (hardness
and particle size in relation to bearing size, lubrication method, filtration) and mounting
(cleanliness during mounting).

8.4 The equation (aiso) used to determine the adjusted rating life of a bearing according to the ISO
281:1990/Amd 2:2000 standard is as follows:

Lnah = a1a23 L10h

where

Lnah - adjusted rating life (operating hours)

a1 - life adjustment factor for reliability
a23 - life adjustment factor for material and lubrication
L10h - basic rating life (operating hours)

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8.5 The equation used to determine the modified rating life of a bearing according to the ISO
281:2007 standard is as follows:

Lnm = a1aISO L10h

where

Lnm - modified rating life (operating hours)

a1 - life adjustment factor for reliability
aISO - life modification factor
L10h - basic rating life (operating hours)

8.6 In addition to specifying the calculated basic rating life (L10h) for all of the bearings used
in the conveyor reducer drive gearbox, the gearbox manufacturer can also specify
calculated adjusted (Lnah) and/or modified (Lnm) rating lives to provide an indication of the
effect of additional factors (reliability, lubrication, contaminant particles and mounting
conditions) on bearing service life.

8.7 Should the gearbox manufacturer determine and include adjusted (Lnah) / modified (Lnm)
bearing rating lives in the design specifications, the adjustment factors and resultant
adjusted / modified rating lives shall be specified in the format depicted in Table 5.

L10h 40,000
a1 1
a23 2.5
aiso 2.5
Lnah 100,000
Lnm 100,000

TABLE 5: CALCULATED BEARING LIVES AND ADJUSTMENT / MODIFICATION FACTORS

8.8 Should the gearbox manufacturer determine and include adjusted rating lives or modified
rating lives for the bearings in the design specifications, the operating variables used to
determine the values of the a23 / aISO adjustment / modification factors shall be listed.

8.9 The a1 life adjustment factor for reliability should not exceed 1 which is the reliability
factor for the basic rating life (L10h) calculation. Reliability can be defined as the
percentage of a suitably large group of apparently identical bearings operating under the
same conditions that can be expected to attain or exceed a specified life.

8.10 The a23 life adjustment factor is based on the lubricant film thickness within the bearing
and is a function of the viscosity of the lubricant used and the bearing operating
temperature. Selection of an appropriate lubricant, lubricant delivery system and effective
cooling typically results in an a23 life adjustment factor which is greater than 1.

8.11 The aISO advanced life modification factor represents the relationship between the fatigue
load limit ratio, the lubrication condition and the level of contamination in the bearing.

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8.12 Table 6 below contains guideline values for contamination factors used in the
determination of the aISO advanced life modification factor. The gearbox supplier may use
any value for this factor as long as the value is representative of the actual conditions of
the oil in the gearbox.

Guideline values for factor ŋc for different Typical values for

contamination levels dm<100mm
dm>100mm
Extreme Clean oil – Laboratory conditions 1 1
Highly Clean Oil – Oil filtered through extremely fine filter 0.6 - 0.8 0.8 - 0.9
Normal Cleanliness – Oil filtered through fine filter 0.5 - 0.6 0.6 - 0.8
Slight contamination – Course filtration and no 0.3 - 0.5 0.4 - 0.6
contamination ingress
Normal contamination – Wear particles and environmental 0.1 - 0.3 0.2 - 0.4
particles in oil
Heavy contamination – High environmental particle ingress 0 - 0.1 0- 0.1
and insufficient sealing

TABLE 6: GUIDELINE VALUES FOR CONTAMINATION FACTOR

9. MOUNTING AND ALIGNMENT

9.1 The reducer, motor and coupling assembly shall be mounted on a baseplate that is
designed in a one-piece construction. The baseplate shall be designed to minimise
deflection and twisting while under load. The baseplate may be cast or fabricated, as
required. The baseplate shall be stress-relieved before final machining.

9.1.1 Where the motor is flange-mounted onto the reducer, either directly or by means
of a lantern-ring to house the high speed coupling, the reducer casing shall be
designed to cater for the imposed loads without bending, distortion or twisting.
See also 4.1

9.2 The foundations or support steelwork for the reducer baseplate assembly shall be level
and square, with provision for packing or shimming as necessary during installation, to
achieve proper alignment.

9.3 In the case of a shaft mounted or shaft hung assembly, the baseplate shall be designed
to withstand the torque developed during starting and stopping cycles of the conveyor.
See also 9.1.1

9.4 Where torque arms are required, the installation tolerance of the torque-arm mounting
bracket shall be within 1,0 mm in any horizontal direction. The torque arm and bracket
assembly shall be designed to be suitably flexible in order to cater for such installation
inaccuracies and to provide cushioning of transient loads and the loads during starting
and stopping of the conveyor.

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9.5 In the case of shaft-hung units equipped with rigid couplings, the installation tolerance on
each coupling flange face shall be limited to 0,03 mm per 100 mm diameter of the
coupling flange. Speed related relaxation of the installation tolerance shall be subject to
negotiation between the user and the supplier. The coupling mounted on the conveyor
drive pulley shaft shall be subject to the same installation tolerance. It must be noted
that the deflection of the conveyor pulley shaft must be considered under full load
conditions and that this shall be catered for in the installation of the shaft hung unit.

(Note. While the installation tolerance recommended by reputable coupling

manufacturers is quoted as 0,01 mm per 100 mm diameter of the coupling flange, the
value suggested in the specification includes an allowance for reducer output shaft
bearing end float and clearances).

9.6 Where rigid couplings are used, the convention is for the coupling half with the female
spigot to be mounted on the reducer output shaft, while the coupling half with the male
spigot is mounted on the conveyor drive pulley shaft.

9.7 Where rigid couplings are used, it is important that the coupling halves are match-marked
upon final assembly and alignment, to facilitate removal and replacement.

9.8 In cases where fluid couplings are specified, the overhung load capability of the reducer
input shaft should be ascertained. In the majority of cases, the couplings should be
arranged such that the greater part of the coupling mass is carried on the motor shaft.

10. HOLDBACKS
10.1 Where a holdback is required to be fitted to the reducer, either internally or externally on
a shaft extension, the system strength (gear tooth strength) shall be capable of the full
holdback rating. Furthermore, the reducer shaft extension where the holdback is to be
fitted shall have adequate strength rating to withstand the full holdback torque capacity.

10.2 Where the conveyor is equipped with multiple drives fitted with internally mounted
holdbacks, either the rating of one holdback shall be adequate for the total run-back
torque (with reference to paragraph 9.1) or the system shall be equipped with load-
sharing type holdback units.

10.3 Holdback lubrication may be incorporated into the reducer system, without the need for
external or separate lubrication systems. The grade of oil specified by the holdback
supplier shall be compatible with the requirements of the reducer.

10.4 It must be noted that externally mounted holdbacks are available which are grease
lubricated. These units can therefore not be lubricated by means of the oil in the gear unit
and shall be clearly marked as such.

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11. ACKNOWLEDGEMENTS
This specification was reviewed by a working group of representatives of
Anglo Technical Division (representing User groups) together with
CMA member companies
Canterbury Mining & Engineering cc.
Bauer, a Division of Hudaco Transmission (Pty) Ltd
David Brown Gear Industries (Pty) Ltd
Flender Power Transmission (Pty) Ltd
Hansen Transmissions (Pty) ltd and
Powerdrives, a division of Bearing Man Ltd
SEW Eurodrive (Pty) Ltd
representing reducer manufacturers, suppliers and bearing suppliers

Further revisions were conducted by CMA member companies:

Bateman
Bauer
Bonfiglioli
David Brown
Hansen
Renold Crofts
SEW
SKF

12. RECORD OF AMENDMENTS

Revision 01 Paragraph 3.2 Surface texture altered and expanded .
Paragraph 4.5.5 added.
Paragraph 5.4 added.
Paragraph 9 expanded and sub paragraphs added.

Revision 02 Index and front cover added.

Revision 03 Table 4 modified to cater for dual independent drives

Paragraph 7.2.1, 8.7 and 9.4 added.

Revision 04 General review

Revision 05 Adjusted Bearing Life

June 2011
Johannesburg.

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