Gearhead_Catalog

A L T R A

I N D U S T R I A L

M O T I O N

High Precision Planetary Gearheads

Page 1

Applications

Pages 2 - 3

Features

Page 4

Selection Guide

Page 5 - 10

PL2 Series

Boston gearheads provide precise, durable and long-lasting performance The Boston Gear line of servo gearheads has been designed for direct attachment to popular servomotors.

Power is transmitted from the motor to a sun gear which drives three planet gears contained within an

Page 11 - 16

PR2 Series

internal toothed ring gear. The planet gears are mounted in a carrier with double wall supports. The output shaft automatically rotates as the planet gears and carrier rotate.

Due to the load sharing attributes of multiple tooth contacts, planetary gearboxes provide the highest torque and stiffness for any given envelope. Balanced

Page 17 - 22

PL6 Series

planetary kinematics at high speeds combined with the associated load sharing make planetary-type gearheads ideal for servo applications. Other significant advantages include: • True helical technology provides increased tooth to tooth contact ratio by 33% vs spur gearing - 12º helix angle produces smooth and quiet operation

Page 23 - 28

PR6 Series

• One piece planet carrier and output shaft design reduces backlash - Single step machining process - Assures 100% concentricity - Increases tortional rigidity • Efficient lubrication for life

Page 29 - 34

PL5 Series

Boston Planetary Gearheads are designed for a wide variety of applications

Packaging

Semiconductor

Automotive

Machine Tool

Medical

Printing

Paper Converting

Robotics

Assembly

Cut-To-Length

Many applications typically associated with conventional power transmission solutions are beginning to utilize servo control and precision gearheads to meet production requirements. Servo-driven solutions can achieve faster speeds with more precise accuracy while providing greater flexibility and quicker changeover.

P-1603-BG • 3/11

Boston Gear

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1

Boston gearheads... the most robust gearheads available.

Superior engineering and design combined with the latest technology have resulted in the creation of a full line of gearheads loaded with enhanced features. Patented planet carrier design, patented input and output sealing designs and special heat and surface treatments are just a few of the unique features that give Boston gearheads a competitive edge.

11

1 2 7

6

13 10

8

3 14 5

4

9

PL2

PR2

2

Boston Gear

800-825-6544

PL5

P-1603-BG • 3/11

Patented output sealing systems design

7

eliminates friction and heat generation which is accomplished by applying a hi-tech Titanium Carbon Nitride coating to all output contact surfaces. The TiCN coating reaches a hardness of 3000Hv and is ground to Ra 0.2Îźm finish to ensure sealing.

1

Equipped with solid uncaged needle roller bearings, provides maximum contact points to increase stiffness and generates high output torque.

8 Patented planet carrier design places the sun

A high setting gear performance is achieved by using advanced gearing technology, by easing off the tooth profile and crowning the lead of each tooth.

This optimizes the gear mesh alignment and overlap to achieve maximum tooth surface contact.

gear bearing directly into the planet carrier. This ingenious concept eliminates gear misalignment and gains the highest accuracy on the market. Less than 1 arc-minute backlash!

2

9

A special non-electrolysis nickle surface treatment on the output housing and black anodized aluminum input adapter

are provided for the most extreme environmental conditions to achieve an IP65 Rating.

3 Single piece planet carrier with an extended, tapered roller bearing

provides maximum radial load capacity (up to 50,000 NM) and increases system reliability and stiffness.

10

4

Plasma nitriding heat treatment process

maintains the tooth surface hardness at 840Hv for superior wear-resistance and a core hardness at 30HRc for toughness.

True Helical Gear Design

Precision helical gearing increases tooth to tooth contact ratio by over 33% versus spur gearing. The helix angle produces smooth and quiet operation with decreased backlash (less than 1 arc-minute and less than or equal to 56dB).

Solid, single-piece sun gear construction obtains precise concentricity with increased strength and rigidity.

11

The unique motor adapter and bushing module system design allows for quick and easy mounting of any motor.

5

12

Triple split collet with dynamic balanced set collar clamping system provides backlash

free power transmission and eliminates slippage. 100% concentricity allows for smooth rotation and higher input speed capability.

6 Precision tapered roller bearing support to increase radial and axial loading capacity.

13

Patented input sealing system design

eliminates breakaway torque and decreases friction/heat. The TiCN coated bushings (1700 Hv, Ra 0.2Îźm finish) interface with a proprietory seal which decreases wear and erosion of both sealing surfaces. This new design prevents leakage and has a service life of over 30,000 hours.

P-1603-BG • 3/11

Boston Gear

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3

Selection of the Optimum Gearbox Selection Start

S5 Cycle Operation

S1 Continuous Operation YES

ED<60% twork<20mins (Eq.1)

NO

Calculate the Ratio i (Eq.2)

Calculate the Ratio i (Eq.2)

Calculate the Mean Output Torque T2m (Eq.3)

Calculate the Mean Output Torque T2m (Eq.3)

Calculate the max. Acceleration Torque T2max (Eq.4)

NO Select a Larger Gearbox

NO

T2max<T2B T2m<T2N

T2m<T2N

Select a Larger Gearbox

Eq. 1

YES Calculate the Mean Output Speed n2m and the Nominal Output Speed n2N of Gearbox (Eq.5)

Select a Smaller Ratio i in Larger Motor if Needed

YES

Eq. 2

NO n2m<n2N

Eq. 3

YES Calculate the Mean Radial F2m and Axial Loads F2am on Output Shaft of Gearbox (Eq.6)

Eq. 4

Calculate the Permitted Radial F2rB and Axial Loads F2aB on Output Shaft of Gearbox

F2rm<F2rB F2am<F2aB

NO

Select a Larger Gearbox

YES Select the Required Backlash and Shaft Option

Order your Gearbox

Recommended (for S5 Cycle Operation) The general design is given for JL < 4 x Jm i2 The optimal design is given for JL ~Jm i2 JL Load Inertia Jm Motor Inertia

4

Boston Gear

800-825-6544

Eq. 5

Eq. 6

P-1603-BG â&#x20AC;˘ 3/11

PL2 Series

Stainless Steel High Precision Inline Planetary Gearboxes Dimensional drop-in for Bayside Stealth PS Series

Ordering Number System for PL2 Models PL

In-Line/ Right Angle PL: Precision Gearhead In-Line PR: Precision Gearhead Right Angle

Series No. 2, 5, 6

2

060

—

005

Example: PL2060-005-KS-M-0000-00.0

—

KS

—

M

Case Size

Shaft Type

Backlash

042, 060, 090, 115, 142, 180, 220

SS: Smooth Shaft KS: Keyed Shaft

S: Standard 5 arcmin M:: Mid-grade 3 arcmin P: Premium 1 arcmin

Ratios

—

—

0000

Housing Part No. Based on servo motor make and model.

00.0

Input Shaft Inner Diameter Based on servo motor make and model.

Single Reduction: 003, 004, 005, 007, 009, 010 Double Reduction: 015, 020, 025, 030, 035, 040, 045, 050, 070, 090, 100

Note: Other ratios are available upon request

SS Standard output shaft

P-1603-BG • 3/11

KS Output shaft with key (Keyway: Standard DIN 6885)

Boston Gear

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5

PL2 Series Features Stainless steel 416 special non-electrolysis nickle surface treatment

Integrated helical internal ring gear

Patented output sealing systems design

One piece planet carrier with output shaft design

Lubricated with Nyogel 792D (Smart Grease)

Plasma nitriding

True helical gear design

Triple split collet with dynamic balanced set collar clamping sytem.

Unique motor adaptor and bushing module system.

6

Boston Gear

800-825-6544

Deep groove ball bearing Advanced gearing technology crowns lead of each gear tooth

Patented input sealing system design

P-1603-BG â&#x20AC;˘ 3/11

PL2 Series Model No.

Specifications

Stages

1

Nominal Output Torque T2N

Nm

2

Max. Output Torque T2B Nominal Input Speed n1N Max. Input Speed n1B

Nm rpm rpm

Premium Backlash P

arcmin

Mid-grade Backlash M

arcmin

Standard Backlash S Torsional Rigidity Max. Radial Load F21B2 Max. Axial Load F2aB2 Service Life

arcmin Nm/arcmin N N hr

Efficiency n

%

Weight

kg

Operating Temp Lubrication Degree of Gearbox Protection Mounting Position Noise Level (n,= 3000 rpm)

°C

dB

1,2 1,2 1,2 1 2 1 2 1 2 1,2 1,2 1,2 1,2 1 2 1 2 1,2 1,2 1,2 1,2 1,2

Ratio1

PL2042

PL2060

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100 3~100 3~100 3~100 3~10 15~100 3~10 15~100 3~10 15~100 3~100 3~100 3~100 3~100 3~10 15~10 3~10 15~100 3~100 3~100 3~100 3~100 3~100

20 19 22 19 14 14 20 19 22 20 19 17 14 22 19 14 14

55 50 60 50 40 40 55 50 60 55 50 45 40 60 50 40 40

5,000 10,000 – – ≤3 ≤5 ≤5 ≤7 3 780 390

5,000 10,000 – – ≤3 ≤5 ≤5 ≤7 7 1,530 765

0.5 0.8

1.3 1.5

≤56

≤58

PL2090

PL2115

PL2142

130 208 342 140 290 542 160 330 650 140 300 550 100 230 450 100 230 450 130 208 342 140 290 542 160 330 650 150 310 600 140 300 550 120 260 500 100 230 450 160 330 650 140 300 550 100 230 450 100 230 450 3 times of Nominal Output Torque 4,000 4,000 3,000 8,000 8,000 6,000 ≤1 ≤1 ≤1 – ≤3 ≤3 ≤3 ≤3 ≤3 ≤5 ≤5 ≤5 ≤5 ≤5 ≤5 ≤7 ≤7 ≤7 14 25 50 3,250 6,700 9,400 1,625 3,350 4,700 20,000* ≥97% ≥94% 3.7 7.8 14.5 4.1 9 17.5 -10°C ~ + 90°C synthetic gear grease (NYOGEL 792D) IP65 all directions ≤60 ≤63 ≤65

PL2180

PL2220

588 1,050 1,200 1,100 900 900 588 1,050 1,200 1,100 1,100 1,000 900 1,200 1,100 900 900

1,140 1,700 2,000 1,800 1,500 1,500 1,140 1,700 2,000 1,900 1,800 1,600 1,500 2,000 1,800 1,500 1,500

3,000 6,000 ≤1 ≤3 ≤3 ≤5 ≤5 ≤7 145 14,500 7,250

2,000 4,000 ≤1 ≤3 ≤3 ≤5 ≤5 ≤7 225 50,000 25,000

29 33

48 60

≤67

≤70

Model No.

Gearbox Model No.

Inertia

Stages

1

Mass Moments of Inertia J1

kg • cm2

2

1. Ratio (i=Nin/Nout) *S1 service life 10,000 hrs

P-1603-BG • 3/11

Ratio

PL2042

PL2060

PL2090

PL2115

PL2142

PL2180

PL2220

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100

0.05 0.04 0.04 0.03 0.03 0.03 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.03 0.03 0.03 0.03

0.24 0.18 0.17 0.15 0.14 0.14 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.03 0.03 0.03 0.03

1.04 0.71 0.64 0.52 0.48 0.47 0.22 0.21 0.21 0.21 0.21 0.21 0.20 0.15 0.15 0.15 0.15

5.05 3.67 3.34 2.85 2.66 2.62 0.70 0.66 0.66 0.65 0.64 0.64 0.64 0.52 0.52 0.52 0.52

14.61 10.57 9.66 8.24 7.65 7.54 3.50 3.39 3.37 3.34 3.32 3.31 3.30 2.63 2.61 2.61 2.61

46.76 33.53 30.31 25.57 23.63 23.23 10.19 9.84 9.76 9.66 9.62 9.58 9.56 7.56 7.53 7.51 7.51

118.39 81.87 73.00 59.89 54.51 53.40 31.69 30.66 30.43 30.15 30.02 29.92 29.85 23.26 23.16 23.11 23.11

2. F2rB F2aB applied to the output shaft center @ 100 rpm

Boston Gear

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7

PL2 Series Dimensions (1-stage, Ratio i = 3-10)

K Note: Dimensions shown in mm

Dimension

PL2042

PL2060

PL2090

PL2115

PL2142

PL2180

PL2220

D1 D2 D3 j6 D4 g6 D5 D6 D7 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C13 C23 C33 C43 C53 G6 C63 C73 C83 C93 C103 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 56 42 26 5.5 1 16 2 4 31 3.2 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 86.5 8.75 5 15

70 5.5 16 50 30 M5 x 0.8P 80 60 37 7 1.5 25 2 6 35 4 12.5 70 M5 x 0.8P *≤14 / ≤16 30 50 4 60 41.5 113.5 10 5 18

100 6.6 22 80 45 M8 x 1.25P 116 90 48 10 1.5 32 3 8 48 6 19 100 M6 x 1P *≤19 / ≤24 40 80 4 90 48 144 11.25 6 24.5

130 9 32 110 60 M12 x 1.75P 152 115 65 12 2 40 5 10 61 9.5 28 130 M8 x 1.25P ≤32 50 110 5 115 61 187 13.5 10 35

165 11 40 130 75 M16 x 2P 185 142 97 15 3 63 5 12 71.5 12 36 165 M10 x 1.5P ≤38 60 130 6 142 71 239.5 16 12 43

215 13 55 160 95 M20 x 2.5P 240 180 105 20 3 70 6 15 84.5 15 42 215 M12 x 1.75P ≤48 82 180 6 190 96 285.5 18.25 16 59

250 17 75 180 115 M20 x 2.5P 292 220 138 30 3 90 7 20 93 15 42 235 M12 x 1.75P ≤55 82 200 6 220 100 331 20 20 79.5

3. C1~C10 are motor specific dimensions (metric std shown). * PL2060 ratio 5,10 provides C3 ≤ 16 option. * PL2090 ratio 3~10 provides C3 = 24 option.

8

Boston Gear

800-825-6544

P-1603-BG • 3/11

PL2 Series Dimensions (2-stage, Ratio i = 15-100)

K

Note: Dimensions shown in mm

Dimension

PL2042

PL2060

PL2090

PL2115

PL2142

PL2180

PL2220

D1 D2 D3 j6 D4 g6 D5 D6 D7 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C14 C24 C34 C44 C54 G6 C64 C74 C84 C94 C104 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 56 42 26 5.5 1 16 2 4 58.5 3.2 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 114 8.75 5 15

70 5.5 16 50 30 M5 x 0.8P 80 60 37 7 1.5 25 2 6 72 4 12.5 46 M4 x 0.7P *≤11 / ≤12 25 30 3.5 42 29.5 138.5 8.75 5 18

100 6.6 22 80 45 M8 x 1.25P 116 90 48 10 1.5 32 3 8 85.5 6 19 70 M5 x 0.8P *≤14/≤16 30 50 4 60 41.5 175 10 6 24.5

130 9 32 110 60 M12 x 1.75P 152 115 65 12 2 40 5 10 113 9.5 28 100 M6 x 1P *≤19 / ≤24 40 80 4 90 48 226 11.25 10 35

165 11 40 130 75 M16 x 2P 185 142 97 15 3 63 5 12 135 12 36 130 M8 x 1.25P ≤32 50 110 5 115 61 293 13.5 12 43

215 13 55 160 95 M20 x 2.5P 240 180 105 20 3 70 6 15 161.5 15 42 165 M10 x 1.5P ≤38 60 130 6 142 71 337.5 16 16 59

250 17 75 180 115 M20 x 2.5P 292 220 138 30 3 90 7 20 178.5 15 42 215 M12 x 1.75P ≤48 82 180 6 190 96 412.5 18.25 20 79.5

4. C1~C10 are motor specific dimensions (metric std shown). * PL2060 ratio 15-50 provides C3 ≤ 12 option. * PL2090 ratio 15-50 provides C3 ≤ 16 option. * PL2115 ratio 15-100 provides C3 = 24 option.

P-1603-BG • 3/11

Boston Gear

800-825-6544

9

PL2 Series Radial and axial loads allowed on the output shaft

L X

The permitted radial and axial loads on the output shaft of the gearbox is dependent upon the design of the gearbox supporting bearings. The Boston Gear PL2 Series uses an oversized, straddle mount, ball bearing design, which can take heavy loads from both axes.

F2r

F2a2 F2a1

F2r Radial Load F2a Axial Load

If the radial force F2r is exerted on the center of the output shaft, then X=0.5 x L. PL2220

Under these conditions the permitted radial load can be determined from the graph on the left.

PL2180

The permitted axial load can then be calculated by using the following formulas:

PL2142 PL2115 PL2090 PL2060

F2a1B = 0.2 x F2rB (axial force towards the gearhead) F2a2B = 0.1 x F2rB (axial force away from the gearhead)

PL2042

PL2042 PL2060 PL2090 PL2115 PL2142 PL2180 PL2220

If the radial force F2r is not exerted on the center of the output shaft then X is the distance measured from the output seal.

The position load factor Kb can then be determined by the graph to the left.

Under these conditions the radial and axial loads can be calculated by using the following formulas: Radial Load: F’2rB=Kb x F2rB Axial Load: F’2a1B=0.2 x F’2rB

* Continuous running reduces service life by 50%.

10 Boston Gear

800-825-6544

F’2a2B=0.1 x F’2rB

P-1603-BG • 3/11

PR2 Series

Stainless Steel High Precision Right Angle Planetary Gearboxes Dimensional drop-in for Bayside Stealth RS Right Angle Series

Ordering Number System for PR2 Models PR

In-Line/ Right Angle PL: Precision Gearhead In-Line PR: Precision Gearhead Right Angle

Series No. 2, 5, 6

2

060

—

005

Example: PR2060-005-SS-M-0000-00.0

—

SS

—

M

Case Size

Shaft Type

Backlash

042, 060, 090, 115, 142, 180, 220

SS: Smooth Shaft KS: Keyed Shaft

S: Standard 5 arcmin M:: Mid-grade 3 arcmin P: Premium 1 arcmin

Ratios

—

—

0000

Housing Part No. Based on servo motor make and model.

00.0

Input Shaft Inner Diameter Based on servo motor make and

Single Reduction: 003, 004, 005, 007, 009, 010, 014, 020 Double Reduction: 025, 030, 035, 040, 045, 050, 060, 070, 080,

Note: Other ratios are available upon request

S1 Standard output shaft

P-1603-BG • 3/11

KS Output shaft with key (Keyway: Standard DIN 6885)

Boston Gear

800-825-6544

11

PR2 Series Features • Higher output torque rating by using spiral bevel gear design.

• High tensile low weight single piece aluminum alloy housing for

30% more than straight bevel gear.

highest stiffness.

• Allows input speeds up to 8 times than with straight bevel gearing.

• Maintenance free lifetime lubrication.

• Improved load sharing through precision tooth design and longer

• Patented sealing design for high speed and continuous running.

service life.

• High efficiency up to 95%. Low noise level down to 61dB.

• Ground gears verified with sophisticated software, ensures smooth,

quiet operation with reduced backlash (≤2 arcmin).

Stainless steel 416 special non-electrolysis nickle surface treatment

• Most ratios available from 3~200.

Integrated Helical internal ring gear Oversized Ball Bearing

Patented planet carrier with output shaft design

Advanced gearing technology crowns lead of each gear tooth

Patented output sealing systems design

True helical gear design

Plasma nitriding

12 Boston Gear

800-825-6544

Spiral Bevel gear design

Lubricated with Nyogel 792D (Smart Grease)

Triple split collet with dynamic balanced set collar clamping sytem.

Unique motor adaptor and bushing module system.

P-1603-BG • 3/11

PR2 Series Model No.

Specifications

Stages

1

Nominal Output Torque T2N

Nm

2

Max. Output Torque T2B Nominal Input Speed n1N Max. Input Speed n1B

Nm rpm rpm

Premium Backlash P

arcmin

Mid-grade Backlash M

arcmin

Standard Backlash S

arcmin

Torsional Rigidity Max. Radial Load F2rB Max. Axial Load F2aB Service Life

Nm/arcmin N N hr

Efficiency h

%

Weight

kg

Operating Temp Lubrication Degree of Gearbox Protection Mounting Position Noise Level (n1= 3000 rpm)

C

dB

1,2 1,2 1,2 1 2 1 2 1 2 1,2 1,2 1,2 1,2 1 2 1 2 1,2 1,2 1,2 1,2 1,2

Ratio1

PR2042

PR2060

3 4 5 7 9 10 14 20 25 30 35 40 45 50 70 90 100 140 180 200 3~200 3~200 3~200 3~20 25~200 3~20 25~200 3~20 25~200 3~200 3~200 3~200 3~200 3~20 25~200 3~20 25~200 3~200 3~200 3~200 3~200 3~200

9 12 15 19 14 14 15 20 19 17 14 14 19 14 14 -

36 48 60 50 40 40 42 40 60 55 50 45 40 60 50 40 40 -

5,000 10,000 ≤4 ≤7 ≤6 ≤9 3 780 390

5,000 10,000 ≤4 ≤7 ≤6 ≤9 7 1,530 765

0.9 1.2

2.1 1.5

≤61

≤63

PR2090

PR2115

PR2142

90 195 342 120 195 520 150 260 650 140 310 550 100 260 450 100 230 450 140 300 550 100 230 450 150 325 650 150 310 600 140 300 550 120 260 500 100 230 450 100 230 650 140 300 550 100 230 450 100 230 450 140 300 550 100 230 450 100 230 450 3 times of Nominal Output Torque 4,000 4,000 3,000 8,000 8,000 6,000 ≤2 ≤2 ≤2 ≤4 ≤4 ≤4 ≤4 ≤4 ≤4 ≤7 ≤7 ≤7 ≤6 ≤6 ≤6 ≤9 ≤9 ≤9 14 25 50 3,250 6,700 9,400 1,625 3,350 4,700 20,000* ≥95% ≥92% 6.4 13 24.5 7.8 14.2 27.5 -10°C~+90°C synthetic gear grease (NYOGEL 792D) IP65 all directions ≤65 ≤68 ≤70

PR2180

PR2220

588 1,040 1,200 1,100 900 900 1,100 900 1,200 1,100 1,100 1,000 900 1,200 1,100 900 900 1,100 900 900

1,140 1,680 2,000 1,800 1,500 1,500 1,800 1,500 2,000 1,900 1,800 1,600 1.500 2,000 1,800 1,500 1,500 1,800 1,500 1,500

3,000 6,000 ≤2 ≤4 ≤4 ≤7 ≤6 ≤9 145 14,500 7,250

2,000 4,000 ≤2 ≤4 ≤4 ≤7 ≤6 ≤9 225 50,000 25,000

51 54

83 95

≤72

≤74

Model No.

Gearbox Model No.

Inertia

Stages 1

Mass Moments of Inertia J1

kg • cm2 2

1. Ratio (i=Nin/Nout) *S1 service life 10,000 hrs

P-1603-BG • 3/11

Ratio

PR2042

PR2060

PR2090

PR2115

PR2142

PR2180

PR2220

3~10 14 20 25~100 140~200

0.09 0.09 -

0.35 0.07 0.07 0.09 -

2.25 1.87 1.87 0.35 0.31

6.84 6.25 6.25 2.25 1.87

23.4 21.8 21.8 6.84 6.25

68.9 65.6 65.6 23.4 21.8

135.4 119.8 119.8 66.9 65.6

2. F2rB F2aB applied to the output shaft center @ 100 rpm

Boston Gear

800-825-6544

13

PR2 Series Dimensions (1-stage, Ratio i = 3-20)

K Note: Dimensions shown in mm

Dimension

PR2042

PR2060

PR2090

PR2115

PR2142

PR2180

PR2220

D1 D2 D3 j6 D4 g6 D5 D6 D7 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C13 C23 C33 C43 C53G6 C63 C73 C83 C93 C103 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 56 42 26 5.5 1 16 2 4 111.5 3.2 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 90.5 8.75 5 15

70 5.5 16 50 30 M5 x 0.8P 80 60 37 7 1.5 25 2 6 145 4 12.5 70 M5 x 0.8P ≤14/≤16 30 50 4 60 41.5 108 10 5 18

100 6.6 22 80 45 M8 x 1.25P 116 90 48 10 1.5 32 3 8 203 6 19 100 M6 x 1P *≤19/≤24 40 80 4 90 48 153 11.25 6 24.5

130 9 32 110 60 M12 x 1.75P 152 115 65 12 2 40 5 10 259 9.5 28 130 M8 x 1.25P ≤32 50 110 5 115 61 192 13.5 10 35

165 11 40 130 75 M16 x 2P 185 142 97 15 3 63 5 12 333 12 36 165 M10 x 1.5P ≤38 60 130 6 142 71 236 16 12 43

215 13 55 160 95 M20 x 2.5P 240 180 105 20 3 70 6 15 394 15 42 215 M12 x 1.75P ≤48 82 180 6 190 96 301 18.25 16 59

250 17 75 180 115 M20 x 2.5P 292 220 138 30 3 90 7 20 484 15 42 235 M12 x 1.75P ≤55 82 200 6 220 100 345 20 20 79.5

3. C1~C10 are motor specific dimensions (metric std shown). * PR2090 C3 option = 24 option.

14

Boston Gear

800-825-6544

P-1603-BG • 3/11

PR2 Series Dimensions (2-stage, Ratio i = 25-200)

K Note: Dimensions shown in mm

Dimension

PR2042

PR2060

PR2090

PR2115

PR2142

PR2180

PR2220

D1 D2 D3 j6 D4 g6 D5 D6 D7 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C14 C24 C34 C44 C54G6 C64 C74 C84 C94 C104 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 56 42 26 5.5 1 16 2 4 139 3.2 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 90.5 8.75 5 15

70 5.5 16 50 30 M5 x 0.8P 80 60 37 7 1.5 25 2 6 163.5 4 12.5 70 M4 x 0.7P *≤11/≤12 25 30 3.5 42 29.5 99.5 8.75 5 18

100 6.6 22 80 45 M8 x 1.25P 116 90 48 10 1.5 32 3 8 206.5 6 19 70 M5 x 0.8P *≤14/≤16 30 50 4 60 41.5 123 10 6 24.5

130 9 32 110 60 M12 x 1.75P 152 115 65 12 2 40 5 10 285 9.5 28 100 M6 x 1P *≤19 / ≤24 40 80 4 90 48 165.5 11.25 10 35

165 11 40 130 75 M16 x 2P 185 142 97 15 3 63 5 12 365 12 36 130 M8 x 1.25P ≤32 50 110 5 115 61 205.5 13.5 12 43

215 13 55 160 95 M20 x 2.5P 240 180 105 20 3 70 6 15 431 15 42 165 M10 x 1. 5P ≤38 60 130 6 142 71 255 16 16 59

250 17 75 180 115 M20 x 2.5P 292 220 138 30 3 90 7 20 521 15 42 215 M12 x 1.75P ≤48 82 180 6 190 96 321 18.25 20 79.5

4. C1~C10 are motor specific dimensions (metric std shown). * PR2115 C3 option = 24 option.

P-1603-BG • 3/11

Boston Gear

800-825-6544

15

PR2 Series Radial and axial loads allowed on the output shaft

L X

The permitted radial and axial loads on the output shaft of the gearbox is dependent upon the design of the gearbox supporting bearings. The Boston Gear PR2 series uses an oversized, straddle mount, ball bearing design, which can take heavy loads from both axes.

F2r

F2a2 F2a1

F2r Radial Load F2a Axial Load

If the radial force F2r is exerted on the center of the output shaft, then X=0.5 x L. PR2220

PR2180 PR2142 PR2115 PR2090 PR2060

Under these conditions the permitted radial load can be determined from the graph on the left.

The permitted axial load can then be calculated by using the following formulas: F2a1B = 0.2 x F2rB (axial force towards the gearhead) F2a2B = 0.1 x F2rB (axial force away from the gearhead)

PR2042

PR2042 PR2060 PR2090 PR2115 PR2142 PR2180 PR2220

If the radial force F2r is not exerted on the center of the output shaft, then X is the distance measured from the output seal.

The position load factor Kb can then be determined by the graph to the left.

Under these conditions the radial and axial loads can be calculated by using the following formulas: Radial Load: F’2rB=Kb x F2rB Axial Load: F’2a1B=0.2 x F’2rB

* Continuous running reduces service life by 50%.

16

Boston Gear

800-825-6544

F’2a2B=0.1 x F’2rB

P-1603-BG • 3/11

PL6 Series

Stainless Steel High Precision Inline Planetary Gearboxes Dimensional drop-in for Alpha SP, Alpha SP+, Stober Servofit P and Micron UltraTrue Series

Ordering Number System for PL6 Models PL

In-Line/ Right Angle PL: Precision Gearhead In-Line PR: Precision Gearhead Right Angle

Series No. 2, 5, 6

6

180

—

009

Example: PL6180-009-KS-P-0000-00.0

—

KS

—

P

Case Size

Shaft Type

Backlash

042, 060, 075, 100, 140, 180, 220

SS: Smooth Shaft KS: Keyed Shaft

S: Standard 5 arcmin M:: Mid-grade 3 arcmin P: Premium 1 arcmin

Ratios

—

—

0000

Housing Part No. Based on servo motor make and model.

00.0

Input Shaft Inner Diameter Based on servo motor make and model.

Single Reduction: 003, 004, 005, 007, 009, 010 Double Reduction: 015, 020, 025, 030, 035, 040, 045 050, 070, 090, 100

Note: Other ratios are available upon request

SS Standard output shaft

P-1603-BG • 3/11

KS Output shaft with key (Keyway: Standard DIN 6885)

Boston Gear

800-825-6544

17

PL6 Series Features

Stainless steel 416 special non-electrolysis nickle surface treatment

Integrated helical internal ring gear

Patented output sealing systems design

One piece planet carrier with output shaft

True helical gear design

Lubricated with Nyogel 792D (Smart Grease) Precision tapered roller bearing

Plasma nitriding

Advanced gearing technology crowns lead of each gear tooth

Unique motor adaptor and bushing module system.

18

Boston Gear

800-825-6544

Triple split collet with dynamic balanced set collar clamping sytem.

Precision tapered roller bearing support for increased radial and axial loading capacity P-1603-BG â&#x20AC;˘ 3/11

PL6 Series Model No.

Specifications

Stages

1

Nominal Output Torque T2N

Nm

2

Max. Output Torque T2B Nominal Input Speed n1N Max. Input Speed n1B

Nm rpm rpm

Premium Backlash P

arcmin

Mid-grade Backlash M

arcmin

Standard Backlash S

arcmin

Torsional Rigidity Max. Radial Load F 2rB Max. Axial Load F2aB Service Life

Nm/arcmin N N hr

Efficiency h

%

Weight

kg

Operating Temp Lubrication Degree of Gearbox Protection Mounting Position Noise Level (n1= 3000 rpm)

°C

dB

1,2 1,2 1,2 1 2 1 2 1 2 1,2 1,2 1,2 1,2 1 2 1 2 1,2 1,2 1,2 1,2 1,2

Ratio1

PL6042

PL6060

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100 3~100 3~100 3~100 3~10 15~100 3~10 15~100 3~10 15~100 3~100 3~100 3~100 3~100 3~10 15~100 3~10 15~100 3~100 3~100 3~100 3~100 3~100

20 19 22 19 14 14 20 19 22 20 19 17 14 22 19 14 14

55 50 60 50 40 40 55 50 60 55 50 45 40 60 50 40 40

5,000 10,000 ≤3 ≤5 ≤5 ≤7 3 610 302

5,000 10,000 ≤3 ≤5 ≤5 ≤7 7 1,400 605

0.6 0.8

1.3 1.5

≤56

≤58

PL6075

PL6100

PL6140

130 208 342 140 290 542 160 330 650 140 300 550 100 230 450 100 230 450 130 208 342 140 290 542 160 330 650 150 310 600 140 300 550 120 260 500 100 230 450 160 330 650 140 300 550 100 230 450 100 230 450 3 times of Nominal Output Torque 4,000 4,000 3,000 8,000 8,000 6,000 ≤1 ≤1 ≤1 ≤3 ≤3 ≤3 ≤3 ≤3 ≤5 ≤5 ≤5 ≤5 ≤5 ≤5 ≤7 ≤7 ≤7 14 25 50 4,100 9,200 14,000 3,700 5,800 11,400 30,000* ≥97% ≥94% 3.7 6.9 13.7 4.1 8.1 16.6 -10°C~+90°C synthetic gear grease (NYOGEL 792D) IP65 all directions ≤60 ≤63 ≤65

PL6180

PL6220

588 1,050 1,200 1,100 900 900 588 1050 1,200 1,100 1,100 1,000 900 1,200 1,100 900 900

1,140 1,700 2,000 1,800 1,500 1,500 1,140 1,700 2,000 1,900 1,800 1,600 1.500 2,000 1,800 1,500 1,500

3,000 6,000 ≤1 ≤3 ≤3 ≤5 ≤5 ≤7 145 18,000 19,500

2,000 4,000 ≤1 ≤3 ≤3 ≤5 ≤5 ≤7 225 49,000 13,200

28 33

48 59

≤67

≤70

Model No.

Gearbox Inertia

Stages

1

Mass Moments of Inertia J1

kg • cm2

2

1. Ratio (i=Nin/Nout) *S1 service life 15,000 hrs

P-1603-BG • 3/11

Ratio

PL6042

PL6060

PL6075

PL6100

PL6140

PL6180

PL6220

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100

0.05 0.04 0.04 0.03 0.03 0.03 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.03 0.03 0.03 0.03

0.24 0.18 0.16 0.14 0.13 0.13 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.03 0.03 0.03 0.03

1.04 0.70 0.63 0.51 0.46 0.45 0.18 0.17 0.17 0.17 0.17 0.16 0.16 0.13 0.13 0.13 0.13

4.94 3.56 3.24 2.77 2.58 2.54 0.68 0.65 0.64 0.63 0.63 0.62 0.62 0.45 0.45 0.45 0.45

14.35 10.29 9.43 8.00 7.42 7.31 3.39 3.28 3.27 3.24 3.23 3.22 3.21 2.54 2.53 2.53 2.53

46.39 33.02 29.95 25.19 23.26 22.87 9.89 9.57 9.51 9.43 9.39 9.35 9.33 7.33 7.30 7.29 7.29

117.96 87.79 72.06 58.48 53.13 52.05 31.16 30.22 30.03 29.78 29.67 29.57 29.51 22.89 22.80 22.76 22.76

2. F2rB F2aB applied to the output shaft center @ 100 rpm

Boston Gear

800-825-6544

19

PL6 Series Dimensions (1-stage, Ratio i = 3-10)

K Note: Dimensions shown in mm

Dimension

PL6042

PL6060

PL6075

PL6100

PL6140

PL6180

PL6220

D1 D2 D3 j6 D4 g6 D5 D6 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C13 C23 C33 C43 C53 G6 C63 C73 C83 C93 C103 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 42 19.5 6.5 1 16 2 4 31 42 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 86.5 8.75 5 15

68 5.5 16 60 30 M5 x 0.8P 62 28.5 20 1.5 25 2 6 23.5 60 12.5 70 M5 x 0.8P ≤16 30 50 4 60 41.5 113.5 10 5 18

85 6.8 22 70 45 M8 x 1.25P 76 36 20 2 32 3 7 56 90 19 100 M6 x 1P *≤19/≤24 40 80 4 90 48 160 11.25 6 24.5

120 9 32 90 60 M12 x 1.75P 105 58 30 2 40 5 10 48.5 115 28 130 M8 x 1.25P ≤32 50 110 5 115 61 197.5 13.5 10 35

165 11 40 130 75 M16 x 2P 142 82 30 3 63 5 12 62 142 36 165 M10 x 1.5P ≤38 60 130 6 142 71 245 16 12 43

215 13 55 160 95 M20 x 2.5P 180 82 30 3 70 6 15 80.5 180 42 215 M12 x 1. 75P ≤48 82 180 6 190 96 288.5 18.25 16 59

250 17 75 180 115 M20 x 2.5P 220 105 33 3 90 7 20 93 220 42 235 M12 x 1.75P ≤55 82 200 6 220 100 331 20 20 79.5

3. C1~C10 are motor specific dimensions (metric std shown). * PL6075 ratio 3~10 provides C3 = 24 option.

20

Boston Gear

800-825-6544

P-1603-BG • 3/11

PL6 Series Dimensions (2-stage, Ratio i = 15-100)

K Note: Dimensions shown in mm

Dimension

PL6042

PL6060

PL6075

PL6100

PL6140

PL6180

PL6220

D1 D2 D3 j6 D4 g6 D5 D6 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C14 C24 C34 C44 C54 G6 C64 C74 C84 C94 C104 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 42 19.5 6.5 1 16 2 4 58.5 42 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 114 8.75 5 15

68 5.5 16 60 30 M5 x 0.8P 62 28.5 20 1.5 25 2 6 60.5 60 12.5 46 M4 x 0.7P *≤11/≤12 25 30 3.5 42 29.5 138.5 8.75 5 18

85 6.8 22 70 45 M8 x 1.25P 76 36 20 2 32 3 7 93.5 90 19 70 M5 x 0.8P *≤14/≤16 30 50 4 60 41.5 191 10 6 24.5

120 9 32 90 60 M12 x 1.75P 105 58 30 2 40 5 10 100.5 115 28 100 M6 x 1P *≤19 / ≤24 40 80 4 90 48 236.5 11.25 10 35

165 11 40 130 75 M16 x 2P 142 82 30 3 63 5 12 125.5 142 36 130 M8 x 1.25P ≤32 50 110 5 115 61 298.5 13.5 12 43

215 13 55 160 95 M20 x 2.5P 180 82 30 3 70 6 15 157.5 180 42 165 M10 x 1. 5P ≤38 60 130 6 142 71 340.5 16 16 59

250 17 75 180 115 M20 x 2.5P 220 105 33 3 90 7 20 178.5 220 42 215 M12 x 1.75P ≤48 82 180 6 190 96 412.5 18.25 20 79.5

4. C1~C10 are motor specific dimensions (metric std shown). * PL6060 ratio 15-50 provides C3 ≤ 12 option. * PL6075 ratio 15-50 provides C3 ≤ 16 option *PL6100 ratio 15~100 provides C3 = 24 option.

P-1603-BG • 3/11

Boston Gear

800-825-6544

21

PL6 Series Radial and axial loads allowed on the output shaft L The permitted radial and axial loads on the output shaft of the gearbox is dependent upon the design of the gearbox supporting bearings. The oversized, tapered roller bearing, straddle mount design for the PL6 Series accomodates high radial and axial loads with extended life. This design enables a 50% more load capacity than a standard angular contact bearing design.

X F2r

F2a2 F2a1

F2r Radial Load F2a Axial Load

If the radial force F2r is exerted on the center of the output shaft, then X=0.5 x L. PL6220 PL6180 PL6140

Under these conditions the permitted radial load can be determined from the graph on the left.

PL6100

The permitted axial load can then be calculated by using the following formulas:

PL6075

F2a1B = 0.2 x F2rB (axial force towards the gearhead)

PL6060

F2a2B = 0.1 x F2rB (axial force away from the gearhead)

PL6042

PL6042 PL6060

If the radial force F2r is not exerted on the center of the output shaft, then X is the distance measured from the output seal.

PL6075

The position load factor Kb can then be determined by the graph to the left.

PL6100 PL6140

Under these conditions the radial and axial loads can be calculated by using the following formulas:

PL6180 PL6220

Radial Load: F’2rB=Kb x F2rB Axial Load: F’2a1B=0.2 x F’2rB F’2a2B=0.1 x F’2rB

* Continuous running reduces service life by 50%.

22

Boston Gear

800-825-6544

P-1603-BG • 3/11

PR6 Series

Stainless Steel High Precision Right Angle Planetary Gearboxes Dimensional drop-in for Alpha SPK, Stober Servofit PKS and Micron UltraTrue 90 Right Angle Series

Ordering Number System for PR6 Models PR

In-Line/ Right Angle PL: Precision Gearhead In-Line PR: Precision Gearhead Right Angle

Series No. 2, 5, 6

6

220

—

040

Example: PR6220-045-SS-P-0000-00.0

—

SS

—

P

Case Size

Shaft Type

Backlash

042, 060, 075, 100, 142, 180, 220

SS: Smooth Shaft KS: Keyed Shaft

S: Standard 5 arcmin M:: Mid-grade 3 arcmin P: Premium 1 arcmin

Ratios Single Reduction: 003, 004, 005, 007, 009, 010, 014, 020 Double Reduction: 025, 030, 035, 040, 050, 060, 070, 080, 090, 100, 140, 180, 200

—

—

0000

Housing Part No. Based on servo motor make and model.

00.0

Input Shaft Inner Diameter Based on servo motor make and model.

Note: Other ratios are available upon request

SS Standard output shaft

P-1603-BG • 3/11

KS Output shaft with key (Keyway: Standard DIN 6885)

Boston Gear

800-825-6544 23

PR6 Series Features • Higher output torque rating by using spiral bevel gear design.

• High tensile low weight single piece aluminum alloy housing for

30% more than straight bevel gear.

highest stiffness.

• Allows input speeds up to 8 times than with straight bevel gearing.

• Maintenance free lifetime lubrication.

• Improved load sharing through precision tooth design and longer

• Patented sealing design for high speed and continuous running.

service life.

• High efficiency up to 95%. Low noise level down to 61dB.

• Ground gears verified with sophisticated software, ensures smooth,

• Most ratios available from 3~200.

quiet operation with reduced backlash (≤2 arcmin).

Stainless steel 416 special non-electrolysis nickle surface treatment

Integrated helical internal ring gear Advanced gearing technology crowns lead of each gear tooth

Patented output sealing systems design

Patented single piece planet carrier design

Precision tapered roller bearing

Plasma nitriding

Lubricated with Nyogel 792D (Smart Grease) True helical gear design

Triple split collet with dynamic balanced set collar clamping sytem

Unique motor adaptor and bushing module system

24 Boston Gear

800-825-6544

Spiral Bevel gear design

Precision tapered roller bearing support for increased radial and axial loading capacity P-1603-BG • 3/11

PR6 Series Model No.

Specifications

Stages

1

Nominal Output Torque T2N

Nm

2

Max. Output Torque T2B Nominal Input Speed n1N Max. Input Speed n1B

Nm rpm rpm

Premium Backlash P

arcmin

Mid-grade Backlash M

arcmin

Standard Backlash S Torsional Rigidity Max. Radial Load F 2rB2 Max. Axial Load F 2aB2 Service Life

arcmin Nm/arcmin N N hr

Efficiency h

%

Weight

kg

Operating Temp Lubrication Degree of Gearbox Protection Mounting Position Noise Level (n1= 3000 rpm)

°C

dB

1,2 1,2 1,2 1 2 1 2 1 2 1,2 1,2 1,2 1,2 1 2 1 2 1,2 1,2 1,2 1,2 1,2

Ratio1

PR6042

PR6060

3 4 5 7 9 10 14 20 25 30 35 40 45 50 70 90 100 140 180 200 3~200 3~200 3~200 3~20 25~200 3~20 25~200 3~20 25~200 3~200 3~200 3~200 3~200 3~20 25~200 3~20 25~200 3~200 3~200 3~200 3~200 3~200

9 12 15 19 14 14 15 20 19 17 14 14 19 14 14 -

36 48 60 50 40 40 42 40 60 55 50 45 40 60 50 40 40 -

5,000 10,000 ≤4 ≤7 ≤6 ≤9 3 610 302

5,000 10,000 ≤4 ≤7 ≤6 ≤9 7 1,400 605

0.9 1.2

2.1 1.5

≤61

≤63

PR6075

PR6100

PR6140

90 195 342 120 260 520 150 325 650 140 300 550 100 230 450 100 230 450 140 300 550 100 230 450 150 325 650 150 310 600 140 300 550 120 260 500 100 230 450 100 230 650 140 300 550 100 230 450 100 230 450 140 300 550 100 230 450 100 230 450 3 times of Nominal Output Torque 4,000 4,000 3,000 8,000 8,000 6,000 ≤2 ≤2 ≤2 ≤4 ≤4 ≤4 ≤4 ≤4 ≤4 ≤7 ≤7 ≤7 ≤6 ≤6 ≤6 ≤9 ≤9 ≤9 14 25 50 4,100 9,200 14,000 3,700 5,800 11,400 30,000* ≥95% ≥92% 6.4 13.9 23.7 7.8 15.1 26.7 -10°C~+90°C synthetic gear grease (NYOGEL 792D) IP65 all directions ≤65 ≤68 ≤70

PR6180

PR6220

588 1,040 1,200 1,100 900 900 1,100 900 1,200 1,100 1,100 1,000 900 1,200 1,100 900 900 1,100 900 900

1,140 1,680 2,000 1,800 1,500 1,500 1,800 1,500 2,000 1,900 1,800 1,600 1,500 2,000 1,800 1,500 1,500 1,800 1,500 1,500

3,000 6,000 ≤2 ≤4 ≤4 ≤7 ≤6 ≤9 145 18,000 19,500

2,000 4,000 ≤2 ≤4 ≤4 ≤7 ≤6 ≤9 225 49,000 13,200

50 54

83 94

≤72

≤74

Model No.

Gearbox Inertia

Stages 1

Mass Moments of Inertia J1

kg • cm2 2

1. Ratio (i=Nin/Nout) *S1 service life 15,000 hrs

P-1603-BG • 3/11

Ratio

PR6042

PR6060

PR6075

PR6100

PR6140

PR6180

PR6220

3~10 14 20 25~100 140~200

0.09 0.09 -

0.35 0.07 0.07 0.09 -

2.25 1.87 1.87 0.35 0.31

6.84 6.25 6.25 2.25 1.87

23.4 21.8 21.8 6.84 6.25

68.9 65.6 65.6 23.4 21.8

135.4 119.8 119.8 66.9 65.6

2. F2rB F2aB applied to the output shaft center @ 100 rpm

Boston Gear

800-825-6544

25

PR6 Series Dimensions (1-stage, Ratio i = 3-20)

K Note: Dimensions shown in mm

Dimension

PR6042

PR6060

PR6075

PR6100

PR6140

PR6180

PR6220

D1 D2 D3 j6 D4 g6 D5 D6 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C13 C23 C33 C43 C53 G6 C63 C73 C83 C93 C103 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 42 19.5 6.5 1 16 2 4 111.5 42 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 90.5 8.75 5 15

68 5.5 16 60 30 M5 x 0.8P 62 28.5 20 1.5 25 2 6 145 60 12.5 70 M5 x 0.8P ≤16 30 50 4 60 41.5 108 10 5 18

85 6.8 22 70 45 M8 x 1.25P 76 36 20 2 32 3 7 219 90 19 100 M6 x 1P *≤19/≤24 40 80 4 90 48 153 11.25 6 24.5

120 9 32 90 60 M12 x 1.75P 105 58 30 2 40 5 10 269.5 115 28 130 M8 x 1.25P ≤32 50 110 5 115 61 192 13.5 10 35

165 11 40 130 75 M16 x 2P 142 82 30 3 63 5 12 338.5 142 36 165 M10 x 1.25P ≤38 60 130 6 142 71 236 16 12 43

215 13 55 160 95 M20 x 2.5P 180 82 30 3 70 6 15 397 180 42 215 M12 x 1.75P ≤48 82 180 6 190 96 301 18.25 16 59

250 17 75 180 115 M20 x 2.5P 220 105 33 3 90 7 20 484 220 42 235 M12 x 1.75P ≤55 82 200 6 220 100 345 20 20 79.5

3. C1~C10 are motor specific dimensions (metric std shown). * PR6075 C3 option = 24 option.

26 Boston Gear

800-825-6544

P-1603-BG • 3/11

PR6 Series Dimensions (2-stage, Ratio i = 25-200)

K Note: Dimensions shown in mm

Dimension

PR6042

PR6060

PR6075

PR6100

PR6140

PR6180

PR6220

D1 D2 D3 j6 D4 g6 D5 D6 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C14 C24 C34 C44 C54 G6 C64 C74 C84 C94 C104 B1 h9 H1

50 3.4 13 35 22 M4 x 0.7P 42 19.5 6.5 1 16 2 4 139 42 10 46 M4 x 0.7P ≤11 25 30 3.5 42 29.5 90.5 8.75 5 15

68 5.5 16 60 30 M5 x 0.8P 62 28.5 20 1.5 25 2 6 63.5 60 12.5 46 M4 x 0.7P *≤11/≤12 25 30 3.5 42 29.5 99.5 8.75 5 18

85 6.8 22 70 45 M8 x 1.25P 76 36 20 2 32 3 7 222.5 90 19 70 M5 x 0.8P *≤14/≤16 30 50 4 60 41.5 123 10 6 24.5

120 9 32 90 60 M12 x 1.75P 105 58 30 2 40 5 10 295.5 115 28 100 M6 x 1P *≤19/≤24 40 80 4 90 48 165.5 11.25 10 35

165 11 40 130 75 M16 x 2P 142 82 30 3 63 5 12 370.5 142 36 130 M8 x 1.25P ≤32 50 110 5 115 61 205.5 13.5 12 43

215 13 55 160 95 M20 x 2.5P 180 82 30 3 70 6 15 434 180 42 165 M10 x 1.5P ≤38 60 130 6 142 71 255 16 16 59

250 17 75 180 115 M20 x 2.5P 220 105 33 3 90 7 20 521 220 42 215 M12 x 1.75P ≤48 82 180 6 190 96 321 18.25 20 79.5

4. C1~C10 are motor specific dimensions (metric std shown). * PR6075 C3 option ≤ 16. * PR6100 C3 option = 24 option.

P-1603-BG • 3/11

Boston Gear

800-825-6544

27

PR6 Series Radial and axial loads allowed on the output shaft L X The permitted radial and axial loads on the output shaft of the gearbox is dependent upon the design of the gearbox supporting bearings. The oversized, tapered roller bearing, straddle mount design for the PR6 Series accomodates high radial and axial loads with extended life. This design enables a 50% more load capacity than a standard angular contact bearing design.

F2r

F2a2 F2a1

F2r Radial Load F2a Axial Load

If the radial force F2r is exerted on the center of the output shaft, then X=0.5 x L. PR6220 PR6180 PR6140

Under these conditions the permitted radial load can be determined from the graph on the left.

PR6100

The permitted axial load can then be calculated by using the following formulas:

PR6075

F2a1B = 0.2 x F2rB (axial force towards the gearhead)

PR6060

F2a2B = 0.1 x F2rB (axial force away from the gearhead)

PR6042

PR6042 PR6060

If the radial force F2r is not exerted on the center of the output shaft then X is the distance measured from the output seal.

PR6075

The position load factor Kb can then be determined by the graph to the left.

PR6100

Under these conditions the radial and axial loads can be calculated by using the following formulas:

PR6140 PR6180 PR6220

Radial Load: F’2rB=Kb x F2rB Axial Load: F’2a1B=0.2 x F’2rB * Continuous running reduces service life by 50%.

28

Boston Gear

800-825-6544

F’2a2B=0.1 x F’2rB

P-1603-BG • 3/11

PL5 Series

Stainless Steel High Precision Economy Inline Planetary Gearboxes Dimensional drop-in for Alpha LP and Stober PE Series *Can be modified to replace Bayside PX and PV Series, Micron NT & DT Series (Dimensions may not be exact in all cases).

Ordering Number System for PL5 Models PL

5

120—

—

In-Line

Case Size

PL: Precision Gearhead In-Line

050, 070, 090, 120, 155, 205, 235

Series No. 5

070

Ratios

Example: PL5120-070-0000-00.0

—

0000

Housing Part No. Based on servo motor make and model.

—

00.0

Input Shaft Inner Diameter Based on servo motor make and model.

Single Reduction: 003, 004, 005, 007, 009, 010 Double Reduction: 015, 020, 025, 030, 035, 040, 045, 050, 070, 090, 100

Note: Other ratios are available upon request

P-1603-BG • 3/11

Boston Gear

800-825-6544

29

PL5 Series Features

Integrated helical internal ring gear

Stainless steel 416 special non-electrolysis nickle surface treatment

Patented output sealing system design Round, cost effective design

Patented one piece planet carrier with output shaft

Advanced gearing technology crowns lead of each gear tooth True helical gear design Triple split collet with dynamic balanced set collar clamping sytem

Unique motor adaptor and bushing module system

30 Boston Gear

800-825-6544

Plasma nitriding

Lubricated with Nyogel 792D (Smart Grease)

True helical gear design

Patented output sealing system design

Patented input sealing system design

P-1603-BG â&#x20AC;˘ 3/11

PL5 Series Model No.

Specifications

Stages

1

Nominal Output Torque T2N

Nm

2

Max. Output Torque T2B Nominal Input Speed n1N Max. Input Speed n1B Backlash Torsional Rigidity Max. Radial Load F 2rB2 Max. Axial Load F 2aB2 Service Life

Nm rpm rpm arcmin Nm/arcmin N N hr

Efficiency h

%

Weight

kg

Operating Temp Lubrication Degree of Gearbox Protection Mounting Position Noise Level (n1 = 3000 rpm)

°C

dB

1,2 1,2 1,2 1 2 1,2 1,2 1,2 1,2 1 2 1 2 1,2 1,2 1,2 1,2 1,2

Ratio1

PL5050

PL5070

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100 3~100 3~100 3~100 3~10 15~100 3~100 3~100 3~100 3~100 3~10 15~100 3~10 15~100 3~100 3~100 3~100 3~100 3~100

20 19 22 19 14 14 20 19 22 20 19 17 14 22 19 14 14

55 50 60 50 40 40 55 50 60 55 50 45 40 60 50 40 40

5,000 10,000 ≤8 ≤12 3 702 390

5,000 10,000 ≤8 ≤12 7 1,377 765

0.6 0.9

1.4 1.6

≤56

≤58

PL5090

PL5120

PL5155

130 208 342 140 290 542 160 330 650 140 300 550 100 230 450 100 230 450 130 208 342 140 290 542 160 330 650 150 310 600 140 300 550 120 260 500 100 230 450 160 330 650 140 300 550 100 230 450 100 230 450 3 times of Nominal Output Torque 4,000 4,000 3,000 8,000 8,000 6,000 ≤8 ≤8 ≤8 ≤12 ≤12 ≤12 14 25 50 2,985 6,100 8,460 1,625 2,350 4,700 20,000* ≥97% ≥94% 3.3 6.9 13 4.7 8.7 17 -10°C~+90°C synthetic gear grease (NYOGEL 792D) IP65 all directions ≤60 ≤63 ≤65

PL5205

PL5235

588 1,050 1,200 1,100 900 900 588 1,050 1,200 1,100 1,100 1,000 900 1,200 1,100 900 900

1,140 1,700 2,000 1,800 1,500 1,500 1,140 1,700 2,000 1,900 1,800 1,600 1,500 2,000 1,800 1,500 1,500

3,000 6,000 ≤8 ≤12 145 13,050 7,250

2,000 4,000 ≤8 ≤12 225 8,700 4,800

31 35

53 66

≤67

≤70

Model No.

Gearbox Inertia

Stages

1

Mass Moments of Inertia J1

kg • cm2

2

1. Ratio (i=Nin/Nout) *S1 service life 10,000 hrs

P-1603-BG • 3/11

Ratio

PL5050

PL5070

PL5090

PL5120

PL5155

PL5205

PL5235

3 4 5 7 9 10 15 20 25 30 35 40 45 50 70 90 100

0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

0.16 0.14 0.13 0.13 0.13 0.13 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

0.61 0.48 0.47 0.45 0.44 0.44 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13

3.25 2.74 2.71 2.62 2.57 2.57 0.47 0.47 0.47 0.47 0.47 0.47 0.47 0.44 0.44 0.44 0.44

9.21 7.54 7.42 7.14 7.04 7.03 2.71 2.71 2.71 2.71 2.71 2.71 2.71 2.57 2.57 2.57 2.57

28.98 23.67 23.29 22.48 22.53 22.51 7.42 7.42 7.42 7.42 7.42 7.42 7.42 7.03 7.03 7.03 7.03

69.61 54.37 53.27 50.97 50.63 50.56 23.29 23.29 23.29 23.29 23.29 23.29 23.29 22.51 22.51 22.51 22.51

2. F2rB F2aB applied to the output shaft center @ 100 rpm

Boston Gear

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31

PL5 Series Dimensions (1-stage, Ratio i = 3-10)

Note: Dimensions shown in mm

Dimension

PL5050

PL5070

PL5090

PL5120

PL5155

PL5205

PL5235

D1 D2 D3 j6 D4 h6 D5 D6 D7 D8 D9 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C13 C23 C33 C43 C53 G6 C63 C73 C83 C93 C103 C113 B1 h9 H1

44 M4 x 0.7P 12 35 22 M4 x 0.7P 53 50 45.5 34.5 24.5 4 1 14 2 8 47 3.2 10 46 M4 x 0.7P ≤11 30 30 3.5 48 19.5 91 13.25 19.5 4 14

62 M5 X 0.8P 16 52 22 M5 x 0.8P 70 70 53.4 36 6.5 1 25 2 10 62 4 12.5 70 M4 x 0.7P *≤14/≤16 30 50 4 60 15 113 9.5 33 5 18

80 M6 x 1P 22 68 30 M8 x 1.25P 104 90 77 33.5 46 8.5 1 32 3 12 80.5 6 19 100 M6 x 1P ≤19/≤24 40 80 4 90 17 143.5 10.75 35.5 6 24.5

108 M8 x 1.25P 32 90 40 M12 x 1.75P 130 120 102 38 70 17.5 1.5 40 5 16 97 9.5 28 130 M8 x 1.25P ≤32 50 110 5 115 19.5 186.5 13 46 10 35

140 M10 x 1.5P 40 120 75 M16 x 2P 162 155 125 50 97 15 3 63 5 20 119.5 12 36 165 M10 x 1.5P ≤38 60 130 6 142 22.5 239 15.5 53.5 12 43

184 M12 x 1.75P 55 160 95 M20 x 2.5P 205 205 160 100 15 3 70 6 22 159 15 42 200 M12 x 1.75P ≤48 113 114.3 6 180 57 316 48.75 107.5 16 59

210 M16 x 2P 75 180 115 M20 x 2.5P 260 235 205 70 126 18 3 90 7 28 175.5 15 42 235 M12 x 1.75P ≤55 116 200 6 220 63 364.5 53.5 106.5 20 79.5

3. C1~C10 are motor specific dimensions (metric std shown). * PL5070 ratio 5.10 provides C3 ≤ 16 option.

32 Boston Gear

800-825-6544

P-1603-BG • 3/11

PL5 Series Dimensions (2-stage, Ratio i = 15-100)

Note: Dimensions shown in mm

Dimension

PL5050

PL5070

PL5090

PL5120

PL5155

PL5205

PL5235

D1 D2 D3 j6 D4 h6 D5 D6 D7 D8 D9 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 C14 C24 C34 C44 C54 G6 C64 C74 C84 C94 C104 C114 B1 h9 H1

44 M4 x 0.7P 12 35 22 M4 x 0.7P 53 50 45.5 61.5 24.5 4 1 14 2 8 74 3.2 10 46 M4 x 0.7P ≤11 30 30 3.5 48 19.5 118 13.25 19.5 4 14

62 M5 X 0.8P 16 52 22 M5 x 0.8P 70 70 45.5 36 6.5 1 25 2 10 87.5 4 12.5 46 M4 x 0.7P *≤11/≤12 30 30 3.5 48 19.5 143 13.25 19.5 5 18

80 M6 x 1P 22 68 30 M8 x 1.25P 104 90 53.4 33.5 46 8.5 1 32 3 12 113.5 6 19 70 M4 x 0.7P *≤14/≤16 30 50 4 60 15 174.5 9.5 33 6 24.5

108 M8 x 1.25P 32 90 40 M12 x 1.75P 130 120 77 38 70 17.5 1.5 40 5 16 138.5 9.5 28 100 M6 x 1P ≤19/≤24 40 80 4 90 17 225.5 10.75 35.5 10 35

140 M10 x 1.5P 40 120 75 M16 x 2P 162 155 102 50 97 15 3 63 5 20 176 12 36 130 M8 x 1.25P ≤32 50 110 5 115 19.5 292.5 13 46 12 43

184 M12 x 1.75P 55 160 95 M20 x 2.5P 205 205 125 100 15 3 70 6 22 214.5 15 42 165 M10 x 1.5P ≤38 60 130 6 142 22.5 337 15.5 53.5 16 59

210 M16 x 2P 75 180 115 M20 x 2.5P 260 235 160 70 126 18 3 90 7 28 260 15 42 200 M12 x 1.75P ≤48 113 114.3 6 180 57 443 48.75 107.5 20 79.5

4. C1~C10 are motor specific dimensions (metric std shown). * PL5070 ratio 15~50 provides C3 ≤ 12 option. * PL5090 ration 15~50 provides C3 ≤ 16 option.

P-1603-BG • 3/11

Boston Gear

800-825-6544

33

PL5 Series Front Plate Option Note: Dimensions shown in mm

Dimension

D1

PL5050-NEMA 23 66.675 PL5050-PX60 70 PL5070-Metric 90 PL5070-NEMA 34 98.425 PL5070-DT90/PX90 100 PL5090-IEC 63D5 B5 115 PL5090-NEMA 42 125.73 PL5120-NEMA 56 149.225 PL5155-B5 175 PL5205-B5 230 PL5235-B5 275

D2

D3

D4h6

L1

L2

L3

L4

6 5.6 6.6 5.6 6.6 9 7 6.6 11 13 17

77 80.5 106 115 120 140 144 170 196 277 317

38.15 50 50 73.08 80 95 55.58 114.3 130 180 235

57.2 60 80 86 90 105 107 127 160 210 240

2 2.5 3 2.5 3 3 4 3 5 5 5

8 8.5 11 8 8 10.5 14.5 17.5 20 23 23

18.5 18.5 28 30.5 31 38.5 35.5 55.5 82 82 108

If the radial force F2r is exerted on the center of the output shaft, then X=0.5 x L. Under these conditions the permitted radial load can be determined from the graph on the left.

PL5205 PL5235 PL5155 PL5120 PL5090 PL5070

The permitted axial load can then be calculated by using the following formulas: F2a1B = 0.2 x F2rB (axial force towards the gearhead) F2a2B = 0.1 x F2rB (axial force away from the gearhead)

PL5050

PL5050 PL5070 PL5090 PL5120 PL5155 PL5205 PL5235

If the radial force F2r is not exerted on the center of the output shaft, then X is the distance measured from the output seal.

The position load factor Kb can then be determined by the graph to the left.

Under these conditions the radial and axial loads can be calculated by using the following formulas: Radial Load: F’2rB=Kb x F2rB Axial Load: F’2a1B=0.2 x F’2rB F’2a2B=0.1 x F’2rB

* Continuous running reduces service life by 50%.

34

Boston Gear

800-825-6544

P-1603-BG • 3/11

Tightening Torque Recommendations For Motor Mounting Bolt Bolt Size

Width Across Flats (mm)

M3 x 0.5P

2.5

Strength 8.8 Tightening Torque (Nm) (In-lbs) 1.3

Strength 10.9 Tightening Torque (Nm) (In-lbs)

12

1.8

16

Strength 12.9 Tightening Torque (Nm) (In-lbs) 2.1

19

M4 x 0.7P

3

3

27

4.1

37

4.9

44

M5 x 0.8P

4

6.1

55

8.2

73

9.8

87

M6 x 1P

5

11

98

14

124

17

151

M8 x 1.25P

6

25

222

34

302

41

364

M10 x 1.5P

8

49

434

67

594

80

709

M12 x 1.75P

10

85

753

116

1028

139

1232

M14 x 2P

12

137

1214

186

1648

223

1976

M16 x 2P

14

210

1860

286

2534

343

3038

Table 1 For Set Collar Bolt Motor Shaft Dia. (mm)

Bolt Size (mm)

Width Across Flats (mm)

1 stage

≤11

M3 x 0.5P x 8L

2.5

2.1

19

2 stage

≤11

M3 x 0.5P x 8L

2.5

2.1

19

PL2060 / PR2060 PL6060 / PR6060

1 stage

≤14

M4 x 0.7 x 12L

3

4.9

44

2 stage

≤11

M3 x 0.5P x 8L

2.5

2.1

19

PL2090 / PR2090 PL6075 / PR6075

1 stage

≤19

M5 x 0.8P x 14L

4

9.8

87

2 stage

≤14

M4 x 0.7P x 12L

3

4.9

44

PL2115 / PR2115 PL6100 / PR6100

1 stage

≤32

M6 x 1P x 16L

5

17

151

2 stage

≤19

M5 x 0.8P x 14L

4

9.8

87

PL2142 / PR2142 PL6140 / PR6140

1 stage

≤38

M8 x 1.25P x 20L

6

41

364

2 stage

≤32

M6 x 1P x 16L

5

17

151

PL2180 / PR2180 PL6180 / PR6180

1 stage

≤48

M10 x 1.5P x 25L

8

80

709

2 stage

≤38

M8 x 1.25P x 20L

6

41

364

PL2220 / PR2220 PL6220 / PR6220

1 stage

≤55

M12 x 1.75P x 30L

10

139

1232

2 stage

≤48

M10 x 1.5P 25L

8

80

709

Gearbox Size

PL2042 / PR2042 PL6042 / PR6042

Tightening Torque (Nm) (In-lbs)

Table 2

P-1603-BG • 3/11

Boston Gear

800-825-6544

35

Motor Mounting Instructions 1.

Double-check the motor and gearbox size.

Clean the mounting surface.

5.

Attach the motor. Tighten to 5% of the recommended torque shown in Table 2 on page 35.

2.

Remove the plug on the adapter plate.

Rotate the set collar until the bolt is aligned with the hole.

6.

Tighten the mounting bolt (including washer) in 1~4 order with torque wrench to specified torque. (See Table 1 on page 35)

3.

Remove motor key.

7.

Tighten the set collar bolt with torque wrench to specified torque. (See Table 2 on page 35)

4.

Check motor shaft size and insert bushing if necessary.

8.

Tighten back the screw plug.

When installing on flatted shafts, be sure to align the collet gap over the flat and the set collar bolt perpendicular to the flat.

36

Boston Gear

800-825-6544

P-1603-BG â&#x20AC;˘ 3/11

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