Connection Couplings HyCon, HyLoc and HyGrip

Voith Turbo Safeset

We are the experts in torque-limiting and connection couplings at Voith Turbo. Voith Turbo, the specialist for hydrodynamic drive, coupling and braking systems for road, rail and industrial applications, as well as for ship propulsion systems, is a Group Division of Voith AG. Voith is one of the largest family-owned companies in Europe with a workforce of around 39,000, EUR 5.1 billion in sales in the 2008/2009 fiscal year and 280 sites worldwide. The company is active in the energy, oil and gas, paper and raw materials as well as transportation and automotive markets around the world.

Principle HyCon, HyLoc and HyGrip

Voith connection couplings provide a backlash-free, frictional, quick setting/releasing shaft-hub connections. The setting or releasing occurs hydraulically. Depending on the application, various operating principles are available, all of which offer the advantage of a backlash-free pressure connection.

HyCon

HyLoc

HyGrip

Mechanical shaft-shaft/shaft-flange connection n Hydraulically set and released n Oil pressure is not required for transmitting torque
n

Mechanical shaft-hub connection Hydraulically set and released n Oil pressure is not required for transmitting torque
n n

Hydraulic hollow sleeve-shaft-hub connection n Pumped up hydraulically n Oil pressure is required for transmitting torque
n

By hydraulically pushing a tapered outer sleeve upon a tapered inner sleeve, a radial force is created. Subsequently a frictional connection is created between shaft, coupling and shaft/flange. During setting and releasing, the shaft hub remains static, only the tapered outer sleeve is moved.

By hydraulically pushing a tapered sleeve inside a coupling unit, a radial force is created. Subsequently a frictional connection is created between shaft, coupling and hub. During setting and releasing, the shaft hub remains static, only the tapered conical sleeve inside the coupling moves.

By hydraulically expanding a coupling unit, a radial force is created. Subsequently a frictional connection is created between shaft, coupling and hub.

During setting and releasing, the shaft hub remains static.

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Connecting applications HyCon, HyLoc and HyGrip

Marine: propulsion shafts and drive line components

Navy: propulsion shafts and drive line components

Metal processing: roll connections, slitting equipment, grinding shafts and drive train components

Power generation: driveline components

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Mining: driveline components

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

HyCon A breakthrough in connection technology

HyCon-F and HyCon-S with high friction coating (HFC), approved by DNV and ABS

The coupling friction surfaces are treated with a unique process, which more than doubles the friction factor. This gives the corresponding increase of the transmittable torque. After a careful investigation DNV and ABS has type approved the HyCon coupling for marine applications using a calculation value of m = 0.3 on the friction coefficient. The corresponding value for conventional friction joints is m = 0.14.

0.5 x L 100 Torque in kNm

with HFC

50

wi

FC th H
with

coa

m ting

=0

.3
= 0.14

C coa out HF
50

ting m

100

without HFC
L

Pressure in MPa

Comparison of HyCon with and without HFC coating: 50% reduction of friction length or pressure

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Setting and releasing

1. Depressurized

Pump P1 P2

R M

Pump P1 P2

R M

4. Release

2. Pressurising

3. Ready for operation

1. Shaft is removed or pushed into correct axial position. 2. Connect both hydraulic hoses to hydraulic fittings P1 and P2. Activate the pump. With increasing pressure, the hub moves in the direction of the arrow. Once the set pressure is reached (approximately 1000 bar) open the valve R and the relief valve at the pump. It is now safe to remove the hydraulic hoses.

3. HyCon is now set without any internal oil pressure. 4. Connect both hydraulic hoses again to P1 and P2. Open valve A and close valve R. Activate the pump until a pressure of approximately 400 bar is achieved, then close valve A. Carry on pumping until the hub releases which results in a slight pressure increase at the gauge M. Slowly open valve R. The hub returns back to its original position. It is now safe to remove the hydraulic hoses.
Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

HyCon F/FX and S/SX series

HyCon type F/FX

Design and function

Typical applications
n Marine:

The HyCon connection coupling consists mainly of a tapered sleeve and a tapered hub. By means of a sealed piston sleeve, a piston space is created which exerts hydraulic axial forces on the hub when pressure is applied. Consequently, the hub is pushed up the taper of the sleeve, which results in a radial compression. In order to carry out this process at minimum pressure and without wear, the surface of the taper is lubricated with pressurised oil. The surface of the taper is sealed on both sides, thus no leakage can occur. In order to release the connection, oil is pumped in between the tapered surfaces until they are separated and the sleeve is moved down by the axial forces generated.

Connect shaft sections in conventional propulsion drive lines n Marine: Connect drive lines to waterjets, thrusters etc. n Industrial: Connect drive shafts in heavy industry

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Feature High torque capacity due to high friction coating (HFC) Low weight

Benefits
n n n n

Ideally suited for thin hollowed shafts No internal reinforcement sleeves necessary

Reduced system weight Increased effective load especially in ships and boats n Excellent resistance against shock loads in the driveline
n n n

Low mass moment of inertia F/FX: Flange connection on inner sleeve S/SX: Shaft to shaft connection

Reduced system vibrations Simple positioning of the coupling Connection bolts can be tightened before pressurizing of the coupling Low hydrodynamic resistance when located outboard in ships and boats

Industrial application designs

315

Cold rolling mill, HyCon F315 installed between roll and universal joint

Hot plate mill, HyCon SX630 installed between motor and intermediate shaft on a twin drive arrangement (design torque 4200 kNm)

630

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HyLoc

5 1 4 3 2

1 2 3 4 5

Shaft Hub Hollow sleeve Conical ring piston Sealing valve/pump hose connection

HyLoc type HC-B

Design and function

Typical applications
n Industrial:

The HyLoc connection coupling consists of a hollow sleeve, where the internal chamber is a conical ring piston that is moved hydraulically. The ensuing radial expansion produces a backlashfree connection between a shaft and a hub. The pressure required for assembly is normally 1000 bar. A maximum of 1200 bar is usually required for disassembly. After assembly, the oil is drained, so that there is no residual oil pressure in the coupling during operation. The same applies for disassembly. The ring piston is provided with specially arranged lubrication grooves, hence a lubricating film is created when the ring piston moves between the working surfaces.

Fixing of straightening and cutting rolls in the steel industry n Industrial: Fixing of different hubs and runners as flywheels, turbines etc. n Industrial: Knife/blade holders for rotating sitters to cut sheet metal or paper n Industrial: Blade holders for cutting thick sheet metals, e.g. in wide strip hot rolling mills

HyLoc disc knife holder type HC-B

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Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Feature Backlash-free connection

Benefits Improved control of processes Increased service life of all driveline components n No notch effects as the keyways are eliminated
n n n n n n n

Design optimized for simple assembly and disassembly Minimized radial and axial run out Design optimized for withstanding high radial forces Robust design High friction coating (HFC) optional

Rapid and accurate installation Improved control of actual process Ideally suited for roll connections Able to withstand dirty and difficult environments Extremely high torque capacity

ON

OFF

Connection of the hydraulic pump ON: setting/pressurizing OFF: releasing/depresurizing

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

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HyGrip

5 4 1 3

1 2 3 4 5

Shaft Hub Hollow sleeve Pump hose connection Sealing valve

HyGrip type HG-B

Design and function

Typical applications

The HyGrip connection coupling consists of a twin-walled pressure sleeve. It is pressurized with oil to 1200 bar and sealed with a brass valve. This results in a completely backlash-free frictional connection. HyGrip connection couplings can be specifically designed to meet the exact requirements of the application. The torque transmission capacity and the axial forces are proportional to the oil pressure. The connection can be set and released very quickly if a suitable hydraulic pump is used.

Industrial: Fixing of straightening rolls and cutting rolls where the radial forces are low n Industrial: Fixing of flexible drive shafts and couplings for easy assembly and disassembly n Industrial: Knife/blade holders for rotating slitters to cut sheet metal or paper
n

HyGrip disc knife holder type HG-B

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Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Feature Backlash-free connection

Benefits Improved control of processes Increased service life of all driveline components n No notch effects as the keyways are eliminated
n n n n n n

Design optimized for simple assembly and disassembly Minimized radial and axial run out Robust design High friction coating (HFC) optional

Rapid and accurate installation Improved control of actual process Able to withstand dirty and difficult environments Extremely high torque capacity

Various Applications

HyGrip type HG-N

HyGrip type HG-W

HyGrip type HG-F a) shaft with round journal b) shaft with flat journal
Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

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Technical Data HyCon F and FX series

L1 L2

Df

tolerance h7 or to customer demand

HyCon F Size 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 D2 Df DD1 L1 L2 T D1 [kNm] [mm] [mm] [mm] [mm] [mm] [mm] 14.7 21.4 29.1 38.4 50.5 65.3 82.6 102 126 151 179 211 246 327 424 540 674 830 1000 1200 1430 1680 1960 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 130 147 158 174 191 207 223 240 256 272 288 303 320 351 383 416 448 480 511 544 576 607 639 m: mass 185 210 235 260 285 305 325 345 365 390 415 435 455 495 525 575 605 635 695 730 760 820 855 0.06 113 0.06 125 0.06 135 0.08 149 0.08 166 0.08 176 0.08 194 0.08 205 0.08 216 0.085 226 0.09 236 0.095 247 0.1 257 0.11 278 0.12 302 0.13 322 0.14 344 0.15 365 0.16 385 0.17 407 0.18 427 0.19 447 0.2 469 87 95 103 114 125 132 147 154 161 168 175 183 190 204 220 234 249 264 277 291 305 319 332 m [kg] 8 11 14 19 25 31 40 49 58 69 81 93 108 139 176 224 272 327 398 473 550 651 751 J [kgm2] 0.027 0.050 0.077 0.126 0.205 0.294 0.425 0.597 0.801 1.084 1.441 1.836 2.342 3.612 5.306 8.028 11.056 14.942 21.247 28.282 36.259 48.860 61.957

D1

D2 HyCon FX Size 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 D2 Df DD1 L1 L2 T D1 [kNm] [mm] [mm] [mm] [mm] [mm] [mm] 26.6 39.1 53 69.7 92.3 120 153 191 235 282 335 393 458 610 793 1000 1260 1540 1880 2250 2680 3150 3670 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 145 164 177 194 214 233 252 270 289 307 324 343 362 400 436 470 506 542 578 614 650 685 721 235 285 305 325 345 390 415 455 475 495 525 555 575 620 675 730 810 840 890 955 1000 1040 1115 0.06 0.06 0.06 0.08 0.08 0.08 0.08 0.08 0.08 0.085 0.09 0.095 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2 182 202 222 243 269 289 317 336 358 377 395 416 435 473 512 549 588 626 663 701 738 775 812 139 153 168 185 202 216 237 250 265 278 291 305 318 344 372 398 426 452 478 504 530 556 581 m [kg] 19 29 37 47 62 82 104 130 156 183 214 253 291 380 489 610 777 924 1108 J [kgm2] 0.092 0.201 0.293 0.432 0.657 1.093 1.573 2.344 3.101 4.008 5.269 6.973 8.723 13.439 20.531 30.024 46.345 60.444 81.825

1333 112.763 1560 145.829 1799 183.807 2121 246.385

T: torque

J: mass moment of inertia

DD1: Assembly clearance shaft-bore

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HyCon S and SX series

L1 L2

HyCon S Size 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 D2 DD1 L1 L2 T D1 [kNm] [mm] [mm] [mm] [mm] [mm] 15.6 22.6 31.3 40.6 53.5 68.9 86.5 107 131 157 187 220 256 341 443 563 704 865 1050 1260 1490 1760 2050 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 125 140 152 166 181 196 212 227 240 0.06 0.06 0.06 0.08 0.08 0.08 0.08 0.08 0.08 142 157 173 189 206 222 244 257 272 285 298 314 327 354 382 409 437 465 491 519 545 571 597 51 58 64 70 76 83 89 95 101 107 113 119 125 137 149 162 174 186 198 211 223 235 247 m [kg] 8 11 14 18 23 29 38 46 54 64 76 89 101 134 170 215 264 323 385 462 544 635 736 J [kgm2] 0.022 0.039 0.058 0.089 0.138 0.204 0.308 0.426 0.558 0.760 1.016 1.304 1.638 2.636 3.968 5.927 8.410 11.792 15.952 21.714 28.660 37.276 47.850

D1 HyCon SX Size 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 D2 DD1 L1 L2 T D1 [kNm] [mm] [mm] [mm] [mm] [mm] 28.7 41.8 58.7 75.5 99.5 129 163 203 248 298 354 415 485 645 838 1060 1330 1630 1980 2380 2830 3320 3870 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 320 340 360 380 400 136 154 165 180 197 214 231 247 264 280 296 314 330 363 394 427 460 492 525 558 590 625 655 0.06 0.06 0.06 0.08 0.08 0.08 0.08 0.08 0.08 0.085 0.09 0.095 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2 253 282 311 342 371 400 435 461 489 515 541 570 596 649 703 757 811 864 916 971 1022 1074 1126 102 116 128 140 152 165 177 189 201 213 225 238 250 274 298 323 348 372 396 421 445 469 493 m [kg] 19 27 33 43 56 71 91 110 133 157 184 220 253 334 423 536 666 810 978 1172 1377 1630 1868 J [kgm2] 0.059 0.108 0.154 0.238 0.371 0.559 0.826 1.143 1.584 2.108 2.763 3.698 4.712 7.513 11.259 16.728 24.143 33.623 46.227 62.548 82.211 109.039 137.510 256 0.085 272 0.09 286 0.095 300 331 360 391 420 450 479 510 540 570 600 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2 T: torque m: mass J: mass moment of inertia DD1: Assembly clearance shaft-bore

D2

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

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HyLoc HC-B series

OFF

D1

L L1

HyLoc Size 50 60 70 80 90 100 110 120 130 140 150 160 180 200 220 T [Nm] 2600 4600 7900 12100 17100 24200 32900 43200 53800 68900 85400 104000 150000 206000 273000 F [kN] 104 153 226 303 380 484 598 720 828 984 1139 1300 1667 2060 2482 d [mm] 50 60 70 80 90 100 110 120 130 140 150 160 180 200 220 D [mm] 77 89 102 115 128 140 154 168 182 196 210 224 252 280 308 D1 [mm] 101 113 122 135 148 160 173 186 200 213 227 240 267 293 320 L [mm] 57 65 75 85 95 105 115 125 135 145 155 165 185 205 225 L1 [mm] 82 90 100 110 120 130 140 150 160 170 180 190 210 230 250 DH [mm] 105 125 145 160 180 200 220 240 260 280 300 320 360 400 435 H M8 M8 M8 M8 M12 M12 M12 M12 M16 M16 M16 M16 M16 M16 M16 J [kgm210-3] 3.3 5.4 8.7 14 23 34 51 76 110 150 210 290 500 830 1300 m [kg] 2.4 3.1 4.1 5.4 7.0 8.6 11 14 17 21 25 30 42 56 73

T: torque (without axial force) m: mass Assembly pressure: 100 MPa

F: axial force (without torque) Hub/shaft tolerances: H7/h7 Disassembly pressure: ~ 120 MPa

2xH

J: mass moment of inertia Oil: Gear oil type 80 W

Different designs are possible on request. Larger model sizes only available as special designs.

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Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

HyGrip HG-B series

L2 L1

D3

D1

D2

Hydraulic setting sleeve for the connection of a hub with a shaft HyGrip-B Size 30 35 40 45 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 220 T: torque T [kNm] 0.6 0.9 1.3 1.7 2.2 3.6 6.0 7.8 10.0 15.0 20.0 25.0 33.0 40.0 46.0 71.0 78.0 85.0 120.0 130.0 160.0 m: Mass Fax [kN] 40 51 65 75 88 120 171 195 222 300 363 416 507 571 613 887 917 944 1263 1300 1454 D1 [mm] 30 35 40 45 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 220 D2 [mm] 40 45 52 58 65 75 90 100 110 125 140 150 160 170 180 200 210 225 240 250 270 D3 [mm] 85 91 96 103 109 120 135 144 155 170 188 196 205 215 225 233 243 261 273 283 301 L1 [mm] 36 41 47 53 57 65 74 90 102 108 109 133 144 152 162 180 176 176 222 222 222 Fax: Axial force L2 [mm] 66 71 77 83 87 95 104 120 132 146 144 171 182 190 200 225 221 221 270 270 270 m [kg] 1.33 1.5 1.7 2.0 2.4 2.8 3.9 4.7 5.5 8.2 10.0 12.2 13.6 15.0 16.5 24.0 24.9 29.7 40.0 42.0 45.0 J [kgm2] 0.001 0.002 0.002 0.003 0.004 0.005 0.010 0.013 0.018 0.034 0.050 0.068 0.084 0.104 0.128 0.211 0.243 0.330 0.491 0.560 0.710

J: Mass moment of inertia

If torque T and axial force Fax are transmitted simultaneously, a resulting force Fres is to be calculated. ___________ The latter must not exceed the indicated axial force Fax: 2 T 2000 2 Fres = F ax + _____ D1 The maximum operating loads must not exceed the indicated values. An adequate safety factor should be adhered to.

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

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Accessories HyCon, HyLoc and HyGrip

Service Boxes for HyCon

Service Box for HyLoc

Pumps

Service Boxes

Pumps for pressurizing the couplings are available for all couplings. The size of the pump is dependent on the size of the connection coupling. Available pumps: n P115 series for coupling size 30 to 220 n P240 series for coupling size 200 to 360 n P700 series for coupling sizes above 360 The P115 and 240 are manually operated pumps, and the P700 is pneumatically operated. For special demands electrically driven pumps and custom solutions are available.

All operations of the couplings require some additional tools and equipment. The service boxes include all necessary tools to operate any coupling in the connection coupling range. They are also adapted for HyLoc, HyCon or HyGrip connection couplings.

Stroke

HyGrip pressure indicator type 1

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Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

Service Boxes for HyGrip

Pressure indicator and leakage detector

Sealing valves for Hygrip

Additionally, in order to monitor its function, a HyGrip coupling can be fitted with a pressure indicator, or a leakage detector. The pressure indicator reacts to internal pressure, whilst the leakage detector reacts when an oil leak appears at the pressure valve. In the event of oil loss, in both components a plate moves radially which can be sensed externally.

The number of sealing valves is dependent on the coupling size.

Stroke

L 28 25

L 39 36.5

L 63

L 39 B 37.5

L 63 B

M 14 x 1.5 M 14 x 1.5

M 14 x 1.5 M 20 x 1.5 M 20 x 1.5

HyGrip pressure indicator type 2

HyGrip sealing valves

56.5

55

Voith Turbo I Connection Couplings HyCon, HyLoc and HyGrip I G 1578 en

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Voith Turbo Safeset AB Rnningevgen 8 824 34 Hudiksvall, Sweden Tel. +46 650 540-150 Fax +46 650 540-165 info.safeset@voith.com www.voithturbo.com/ safeset-safety-couplings

G1578en, S&F, 09.2010, 0. Dimensions and illustrations without obligation. Subject to modifications.