A style of locking assembly that clamps the equipment by using compressive force over the diameter of the equipment to the shaft.
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TLK603 55X100 Medium-High Torque Shrink Disc
The KTR 603 external clamping set (shrink disk) is a shaft-hollow shaft-connection.This external Add to Inquiry
The shrink disc is a flange-shaped external locking device that uses friction to lock the shaft hub. It is a frictionless backlash free connection, which can be used to replace the gap connection of the keyed connection. This is a relatively advanced mechanical connection method in modern machinery manufacturing activities. The shrink disc consists of one or two thrust rings with tapered bores and a matching tapered inner ring, by tightening the locking screws the thrust rings are pulled together, compressing the inner rings and applying pressure to the outside of the hub, locking them clamped on the shaft. As a result, the shrink disk is not in the load path and operates without torque. The torque can be transmitted directly by static friction through the joint surface between the shaft and the hub without intermediate parts(e.g. keys or splines).
Shrink Discs can be divided into different structural forms according to different uses and structures: Medium-high torque, Very-high torque; Two-part shrink disc, Three-part shrink disc; Standard-Series(3171), Standard-Series strengthened(3181); Heavy Series(3191); Heavy Series strengthened(3193) and any other type.
Assembly 2-part shrink discs (torque-controlled)
What is Shrink Discs
Shrink Discs are flange-shaped, friction-locked shaft-hub connections and the more powerful and reliable alternative to conventional shrink fits, wedge, keyway or polygonal connections. In contrast to internal locking devices, e.g. locking assemblies, the pressure is applied from the outside to the hollow shaft or hub, thus creating an absolutely backlash-free, frictionally engaged connection between shaft and hub. The shrink disc is therefore not in the load path – instead, the torque is transmitted in a force-locking manner at the joining surface between shaft and hub without an intermediate element. Shrink Discs also convince through complete freedom from wear and maintenance, easy assembly and dismantling as well as outstanding resistance to alternating torsion and concentricity properties. Depending on customer-specific requirements, our shrink discs are available in proven standard and specially developed special variants, in two- and three-part designs as well as in stainless steel. In addition to torque and bending loads, axial and radial loads can also be transmitted.
Advantages of Shrink Discs
High strength and abrasion resistance: Shrink discs are made of high-quality materials with excellent impact and abrasion resistance, able to withstand high loads in mixing and processing equipment.
High flexibility: Shrink discs can be customized according to different processing needs, adaptable, can be widely used in a variety of mixing and processing equipment.
Easy to install and maintain: Simple design, easy to install, reduce maintenance costs and time.
Long life: Long life, can reduce the frequency of replacement, improve production efficiency.
Wide range of applications: Shrink discs are widely used in heavy machinery, wind power generation, shipbuilding, petrochemical and other fields, such as heavy machinery to connect the various components, wind turbines Blade and spindle connection of wind turbine, ship structural components and marine equipment connection, as well as petrochemical equipment, pipeline and equipment connection.
The Working Principle of Shrink Discs
The working principle of Shrink Discs is to form a mechanical compression fit between the shaft and the sleeve through the externally applied clamping force, so as to realize the fixed connection between the shaft and the sleeve.
Shrink discs, also known as locking discs, are frictionless couplings between shafts and bushings. This device creates a mechanical compression fit between the shaft and the sleeve by externally applying a clamping force to the sleeve. The clamping disk itself does not transmit any torque or axial load, but rather applies radial forces to the sleeve via the conical inner ring on both sides, creating a forced friction coupling that safely transmits high torques and axial loads. This type of coupling is able to create a high pressure between the mating surfaces, achieving a complete seal and avoiding the problem of corrosion of the mating surfaces. During disassembly, the mating surfaces are automatically relaxed by loosening the screws, and the shaft, sleeve and inner ring of the locking disk automatically return to their original dimensions and clearances, making both disassembly and installation This makes disassembly and installation equally easy.
Hydraulic Shrink Discss are similar in principle to mechanical Shrink Discss, but hydraulic Shrink Discss use hydraulic locking technology, which greatly reduces installation and dismantling time compared to mechanical Shrink Discss and improves work efficiency.
What Are the Types of Shrink Discs
Manual Shrink Tray
This is a device that can be manually operated to realize the shrinkage of objects, usually consists of a rotatable shaft and one or more retractable arms. By rotating the shaft, the telescopic arms can be controlled to achieve the shrinkage of the object. The advantages of manual shrink trays are that they are simple to operate, inexpensive, and suitable for small-scale operations.
Motorized Shrink Tray
This is a highly efficient shrinking device, which is driven by electricity to realize the shrinking of objects. It usually consists of a motor, a speed reducer and a retractable arm. The motor transmits power to the telescopic arm through the speed reducer to realize the shrinking of the object. The advantages of the electric shrink tray are easy operation, high efficiency, and suitability for large-scale operation.
Pneumatic Shrink Tray
This is a safe and reliable shrinking equipment, which realizes the shrinking of objects through pneumatic pressure drive. It usually consists of a cylinder, a control valve and a retractable arm. The cylinder controls the air pressure through the control valve, thus realizing the shrinking of the object. The advantage of pneumatic shrink trays is that they are safe and reliable, and they are suitable for applications with high safety requirements.
Shrink Discs Materials
The materials of shrinkable disk include steel, cast steel, ductile cast iron, 42CrMo4 alloy steel.
Shrink discs should first of all have a sufficient yield strength of at least 360 N/mm² to ensure that they are able to withstand the necessary pressure and torque.
In addition to the basic structural material requirements, the Shrink Discs must also be able to transmit and withstand bending moments, so the material should be selected from heat-treatable steels such as 42CrMo4 or higher quality cast steels to ensure its mechanical properties.
Characteristics of Shrink Discs
Key features of Shrink Discss include removability, high torque transfer capability, and suitability for applications with different torque ratings.
Shrink discs, especially the HSD type, are removable mechanical elements specifically designed for attaching hollow shafts to shafts. This design allows for a high degree of flexibility and maintainability, allowing for easy disassembly and reassembly when required. HSD type Shrink Discss are available in several series, each optimized for different torque requirements, including low torque, medium torque, high torque, very high torque, etc., covering a wide range of torque transmission from 0.02 kNm to over 20,000 kNm, adapted to various application scenarios.
Different types of Shrink Discss, such as HYD type hydraulic Shrink Discss and SDG type heat Shrink Discss, are also available to meet the needs of different applications. Hydraulic shrink trays are hydraulically clamped and have shorter assembly and disassembly times than mechanical shrink trays. The SDG type heat shrink disk, on the other hand, is a four-part heat shrink disk for space-saving shrinking of disk-shaped components such as gears, providing a compact and efficient joining solution.
The structural principle of the Shrink Discs is based on a cylindrical conical interference coupling, which offers the advantages of a simple structure, good centering capability, high load carrying capacity and good performance under shock loads. Applications in wind turbines have shown that Shrink Discss, as a type of coupling, are able to effectively transmit spindle torque. Installation points include ensuring that the contact surfaces are clean and dry and that the axial thrust is correctly applied. The key points of installation include ensuring clean and dry contact surfaces and correct application of axial thrust to ensure effective torque transmission and reliability of the connection.
Application Areas for Shrink Discss
Wind power industry: The HSD series of Shrink Discss is particularly well suited for the wind power industry, with a safe torque transmission of up to 18,000 kNm for shaft diameters ranging from 8 mm to more than 1,000 mm. These Shrink Discss are connected to the rotor shaft in the main drive train by means of a hollow shaft in the gearbox, ensuring that the wind turbine is able to efficiently utilize the wind power. Every year, thousands of Shrink Discss are used to ensure the proper functioning of wind turbines and the generation of electricity1. 2.
Marine or mining equipment: In addition to the wind power industry, Shrink Discss are also used in a wide range of applications such as marine or mining equipment. Shrink discs are designed to take into account the diversity of operating conditions and can be adapted to different applications, providing a reliable connection solution.
Maintenance of Shrink Discss
01/
Cleaning: Regularly clean the surface of the clamping device of dust and debris to maintain a clean state. At the same time, check whether the fixing screws are loose to ensure its stability.
02/
Check the wear and tear: Regularly check the clamping device of the clamping jaws, springs and other wear parts are not seriously worn. If wear is found, it should be replaced in time to ensure the normal use of the clamping device.
03/
Lubricate: Lubricate the sliding parts of the clamping device to reduce friction and wear. It is recommended to use special lubricant or grease for lubrication.
04/
Adjustment: If the clamping force of the clamping device is found to be uneven or not in accordance with the requirements, it needs to be adjusted. Adjustment should be made by gently prying the clamping jaws with a suitable tool, taking care not to damage the jaws or springs.
05/
Replacement of wearing parts: The wearing parts of the clamping device, such as jaws, springs, etc., should be inspected and replaced periodically. It is recommended that a replacement program be established based on actual use.
06/
Storage: When the clamping device is not used for a long period of time, it should be stored in a dry and ventilated place, avoiding direct sunlight and humid environment. At the same time, storage should be checked periodically to ensure that the clamping device is in good condition.
Selection Criteria of Shrink Discs
Load capacity: Ensure that the selected shrink tray can withstand the expected load to avoid problems caused by insufficient load.
Use environment: Select the appropriate material and design according to the specific use environment to ensure that the shrink trays can work properly under the specific conditions.
Size specification: Choose the right size according to the actual needs, both to consider the space constraints, but also to consider the ease of operation.
Durability: Choose a shrink tray with good durability, which can reduce the frequency of replacement and lower maintenance costs.
Cost-effectiveness: Based on the consideration of cost-effectiveness, choose products with reasonable price and excellent performance to ensure the economy of long-term use.
Notes on the Use of Shrink Discs
1
Designed for Use: Shrink disc HSDs are designed for friction type, fixed, non-switchable, removable shaft-hub connections for cylindrical shafts.
2
Temperature range: The standard product is suitable for temperatures ranging from -20°C to +100°C. The standard product is suitable for temperatures ranging from -20°C to +100°C.
3
Material properties: The system used for shafts and hubs must have the required yield strength, the surface roughness (Ra) of the shaft and the hub system should be lower than 3.2 meters.
4
Environmental conditions: Standard products cannot be used in corrosive liquid or gaseous environments.
5
Re-tensioning: Re-lubrication of the tapered surfaces between the exteriors is not required before re-tensioning, but the inner ring of the shrink disc needs to be cleaned and re-lubricated, and the locking bolts must be replaced if there is dirt before reassembly.
6
Maximum Transmissible Torque: The transmissible torque or transmissible axial load depends on the coefficient of friction, the load transmitted by the crimp, the fit tolerance clamping length and the shaft diameter.
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Hub material: Steel, cast steel or ductile iron with a yield strength of at least 360 N/mm can be used as a hub material.
8
Locking bolts: All units are equipped with commercial hexagonal bolts, quality 10.9 or 12.9, size M16 locking bolts up to the high-strength washers for additional use.
Our Factory
SUN AUTOMATION GROUP LIMITED nearly 40 years of bearing support and industrial service experience. We have a stock warehouse and provide a variety of stock bearings. For special and rare ones, we can distribute the goods to the agents in the country of origin of each brand, and the MOQ is as low as 1 set. SUN AUTOMATION GROUP LIMITED has the ability to provide customers with professional bearing solutions. Quality, value and service are the industry that our company is based on.
Our warehouse has one of the largest stocks. We can guarantee direct delivery, and timely delivery and ensure the primary source. If special bearings are not stocked, we can allocate cargo from the agents of original countries such as Sweden, Germany, the U.S.A., and Japan.
FAQ
We're well-known as one of the leading shrink discs manufacturers and suppliers in China. If you're going to buy high quality shrink discs with competitive price, welcome to get more information from our factory.
Ultra Precision Bearing, Bearing Weight B7200 E T P4S, CRB 15025