Bonfiglioli VF-W IE2/IE3 Worm Gear Reducer: Energy Efficiency Selection and Application Practice Guide

Energy efficiency compliance inspection (S1 continuous working system):

For continuous working system (S1), directly select IE2 or IE3 motors that meet Pn ≥ Pr1 and comply with EC 640/2009 regulations.

Non continuous working system (S2, S3,...):

For intermittent working systems (such as S2 short-term operation and S3 periodic operation), the motor can output greater power in a short period of time. This requires the introduction of a power adjustment coefficient fm.

Condition: Pn ≥ (Pr1/fm)

For example, for the S3 working system (cycle factor I=40%), the adjustment factor fm=1.15 means that a motor with a rated power slightly lower than the required power can be selected while still meeting the working requirements.

Step 3: Select the reducer and verify it

Determine the reduction ratio (i): i=n1/n2 (input speed/output speed)

Choose the machine base number for the gearbox:

In the Speed reducer rating charts, find the minimum machine base number that meets the speed ratio (i) requirements and has a rated torque (Mn2) greater than or equal to the calculated torque (Mc2).

Formula: Mc2=Mr2 * fs

Installation position and lubrication:

The VF-W series reducer supports multiple installation methods (B3, B6, B7, B8, V5, V6). Installation must be strictly carried out in accordance with the installation position specified on the order and nameplate. The different installation positions determine the amount of lubricating oil added to the gearbox when it leaves the factory. Please note that the W110 machine base number does not contain lubricating oil when installed in the V5/V6 installation position or when paired with B14 flange motors at the factory, and needs to be refilled by oneself before debugging.

Motor availability check:

Confirm that the interface (flange, shaft extension) between the selected motor and gearbox is geometrically compatible. Bonfiglioli's Motor availability chart provides detailed compatibility guidelines. For example, for the VF 30 frame size, the maximum installed motor power is 0.55 kW.

Temperature management: allowable temperature limits

Temperature is a key factor affecting the lifespan and performance of reducers. The Bonfiglioli catalog specifies temperature limits for different types of lubricants and seals.

Parameter conditions synthetic oil mineral oil

Environmental temperature (ta) Minimum operating temperature -30 ° C -10 ° C

Maximum operating temperature+50 ° C+40 ° C

Surface temperature (ts) Continuous operation maximum temperature+100 ° C+100 ° C

Oil temperature (to) Continuous operation maximum temperature+95 ° C+95 ° C

Key guidance:

If the expected surface temperature is close to the upper limit (such as 80 ° C to 95 ° C), it is recommended to specify a fluororubber oil seal (Option PV) when ordering to ensure the long-term reliability of the seal.

For applications with ambient temperatures below -20 ° C or surface temperatures consistently above 80 ° C, special selection should be made by contacting Bonfiglioli's technical department.

Braking system configuration and selection

For applications that require quick stopping, precise positioning, or safe parking, the VF-W series can be equipped with two high-performance brake motors.

5.1 DC brake motor (FD option)

Working principle: Spring compression, power-off braking. When the coil is energized, a magnetic field is generated to overcome the spring force and release the brake disc; When the power is cut off, the spring pushes the armature to press the brake disc, achieving braking.

Core advantages:

High braking torque: Typically, the braking torque (Mb) is approximately 2 times the rated torque of the motor (Mn).

Adjustable braking torque: can be adjusted by changing the number and type of springs.

Multiple rectifier options:

NB (half wave rectifier): standard configuration.

SB (Half wave rectifier with electronic excitation): Fast response time for brake release, suitable for applications with high start stop frequency.

NBR/SBR (rectifier with quick turn off): A static switch has been added to NB/SB, which can quickly cut off the power supply to the brake when the power is cut off, achieving extremely short braking response time.

5.2 AC brake motor (FA option)

Working principle: Adopting a three-phase AC electromagnetic brake, directly powered by a power source.

Core advantages:

High dynamic performance: very suitable for applications with heavy loads and high start stop frequencies.

Fast response time: with extremely fast brake release and holding time.

Adjustable torque: The stepless braking torque adjustment can be achieved by adjusting the spring pre tightening screw (adjustment range is 30% MbMAX<Mb<MbMAX).

5.3 Brake release and power supply

Manual release: Provides two manual release lever options, R (automatic reset) and RM (lockable in release position), for easy equipment maintenance during power outages.

Independent Power Supply (SA/SD): For special applications, the brake can be powered by an independent power supply to ensure that it can operate as needed even if the motor main power is cut off.