Bonfiglioli EVOX Gearmotor Selection and Configuration Guide

Selection, Configuration, and Engineering Application Practice of Bonfiglioli EVOX Series Reduction Motors

In the field of modern industrial transmission, the selection and configuration of equipment are directly related to the efficiency, reliability, and maintenance costs of the production line. As a global leader in power transmission and drive solutions, Bonfiglioli's EVOX platform, especially the CP series coaxial reduction motor, has become a preferred choice for many engineers in industries such as material handling, food and beverage, packaging, and HVAC due to its modular design, high torque density, and compliance with global energy efficiency standards.

However, in the face of complex working conditions, diverse installation locations, and strict environmental requirements, how to accurately configure an EVOX product that meets performance requirements while maintaining long lifespan and high reliability is a practical challenge faced by every responsible engineer. This article will be based on the technical manual of Bonfiglioli EVOX CP to deeply analyze the key points of the entire process selection from environmental assessment to mechanical verification.

Environmental condition assessment: the influence of temperature and altitude

The starting point of any transmission scheme is a precise judgment of the application environment. Although the design of the EVOX series covers a wide range of industrial scenarios, environmental temperature and installation altitude are two key variables that directly affect its final performance output.

1. Compensation mechanism for environmental temperature

The standard EVOX motor is designed according to CEI EN 60034-1 standard, with a reference ambient temperature of 40 ° C, and is suitable for altitudes below 1000 meters. When the ambient temperature exceeds the standard range of -15 ° C to+40 ° C, correction must be made.

Low temperature environment (-25 ° C to -10 ° C): The viscosity of the lubricating oil in the gearbox will significantly increase. When starting the deceleration motor under these conditions, it is recommended to perform partial load preheating operation first to avoid gear or bearing damage caused by insufficient lubrication. If the ambient temperature is below -25 ° C, Bonfiglioli technical support must be contacted for customization of special shell materials or seals.

High temperature environment (>40 ° C): The available power of the motor will decrease with increasing temperature. According to the coefficient provided in the manual, when the ambient temperature reaches 45 ° C, the motor power needs to be corrected to 95% of the rated value; When reaching 50 ° C, it needs to be corrected to 90%. For gearboxes, if they are exposed to an environment above 50 ° C for a long time, standard lubricating oil may fail. In this case, it is recommended to choose oil-free delivery (SO option) and select special synthetic oil or mineral oil according to the actual temperature range.

2. Correction strategy for altitude

An increase in altitude can lead to a decrease in air density, affecting the heat dissipation efficiency of the motor and the performance of the lubricating oil.

For applications with altitudes between 1000 meters and 3000 meters, the rated power of the motor needs to be reduced by a specific factor.

It is particularly important that when the installation altitude exceeds 1500 meters, if the gearbox has been filled with lubricating oil before leaving the factory, the product must be placed with the oil plug facing upwards during installation, and the oil plug must be opened for pressure balance to offset the additional load on the shaft seal caused by the pressure difference between the inside and outside during transportation or use.

Lubrication scheme and sealing system configuration

Lubrication is the lifeline of the gearbox. Bonfiglioli EVOX CP comes standard with Shell Omala S4 WE320 (PAG) synthetic oil, which has a long lifespan and maintenance free characteristics (subject to regular inspections depending on specific operating conditions). But in specific industries, standard configurations often cannot meet the needs.

1. Food grade lubrication

There is a risk of accidental contact with products in the food and beverage, cosmetics, or pharmaceutical industries. At this point, options such as LA, LB, LC, LD, etc. should be selected. These oils comply with NSF H1 certification, FDA 21 CFR § 178.3570, and ISO 21469 standards to ensure that they will not contaminate the product even with extremely low probability of contact. However, it should be noted that after using food grade oils, it is recommended to conduct additional HACCP risk analysis to verify the feasibility of the overall plan.

2. Selection of shaft seal material

The standard EVOX CP output shaft comes standard with a single lip NBR (nitrile rubber) oil seal, and the input shaft comes with a Viton (fluororubber) oil seal. In high temperature or strong chemical corrosion environments, the output shaft oil seal should be upgraded to Viton (PV option) or double lip oil seal (DL option) to enhance the durability and leak resistance of the seal.

Deep analysis of mechanical installation and bearing configuration

A major technological highlight of EVOX CP is its ability to accommodate all installation positions with a single oil level. Thanks to its unique interior design, whether the motor is installed horizontally (B3), vertically (B5/B14), or suspended, its oil level design ensures that all components are fully lubricated. This greatly simplifies inventory management and avoids early failures caused by incorrect installation angles.

However, for specific bearing loads, standard configurations may not be sufficient to cope with harsh transmission methods.

1. Output bearing load optimization

When EVOX CP is used for belt/sprocket transmission (decentralized drive), the output shaft bears a large radial load.

Standard bearings are capable of withstanding high loads.

The Enhanced Radial Bearing Option (OHR) can increase the maximum allowable pure radial load of the CP07 model from 1470 N to 1640N, while the CP47 model can jump from 5240 N to 6580 N, significantly improving its lifespan in heavy-duty belt conveyor applications.

2. Axial load and special working conditions

For screw conveyors or axial piston pumps, they need to withstand significant axial forces. At this point, the option of strengthening axial bearings (OHA) should be selected.

For example, the maximum pure axial load of the CP37 model is 5600N in the standard version, but can be increased to 7650N with the OHA option enabled. If the shaft end is subjected to both radial and axial composite loads, or the load direction is away from the gearbox (Pull direction), it is strongly recommended to conduct detailed life verification through Bonfiglioli's Technical Service.

Performance selection and motor platform integration

Another core competitiveness of the EVOX platform lies in the seamless integration of its efficient motors, particularly the BXN and MXN series.

1. Motor efficiency level

The EVOX platform supports the world's highest energy efficiency standards, including IE3/NEMA Premium. For customers who export to Europe and America or pursue green energy conservation, this is not only a regulatory requirement, but also means lower energy consumption and shorter return cycles. Through a specific "9-PIN" junction box design, a motor can be compatible with power supply networks of 50Hz/60Hz and different voltages (such as 230/400V or 265/460V), greatly simplifying the universality of global equipment.

2. Load characteristics under inverter drive

When configuring EVOX motors with variable frequency drive (PWM control), heat dissipation issues must be considered.

When operating below the fundamental frequency (50Hz), especially below 30Hz, the cooling effect of the standard self ventilated fan motor (IC411) drops sharply, and the torque must be appropriately reduced.

If constant torque is required at low frequencies, it is recommended to choose a servo fan with independent power supply.

When operating above the fundamental frequency, the motor enters the constant power zone, and the torque decreases inversely with increasing frequency, and the maximum torque is approximately inversely proportional to (f/fb) ². At this time, the overload protection threshold must be appropriately lowered. The mechanical limit speed of EVOX motors is usually 4000 rpm.

Special requirements for explosion-proof configuration (ATEX)

For environments with flammable and explosive dust or gases such as chemical, grain processing, or spray painting workshops, EVOX CP provides configuration solutions that comply with ATEX 2014/34/EU-2D/2G T4 levels.

In such configurations, it is important to note the following stringent limitations:

Oil restriction: Synthetic oil must be used.

Sealing restriction: Fluororubber (FKM) seals must be used.

Compatibility limitations: After selecting the ATEX option, many standard mechanical options will be unavailable, including:

Inch output shaft (N-type)

Compact input (S05... S35)

Back stop device (AR/AL)

Reinforced bearings (OHR/OHA)

Stainless steel components (FO) and C3/C4 special coating

Temperature monitoring: This type of gearbox must be equipped with a temperature indicator and come standard with a service plug for regular oil level checks to ensure that the surface temperature does not exceed the 135 ° C limit of T4 grade.