WITTENSTEIN alpha LP+/LPB+low backlash planetary gear reducer

WITTENSTEIN alpha LP+/LPB+low backlash planetary gear reducer

In the field of modern industrial automation, precision reducers are key components for achieving high-precision motion control. WITTENSTEIN alpha GmbH, with its profound technical accumulation in the field of planetary gearboxes, has launched the LP+and LPB+series products, which are widely used in robots, machine tools, packaging machinery, automated production lines and other applications due to their low backlash, high rigidity and excellent dynamic performance. This operation manual aims to provide users with comprehensive technical guidance to ensure the correct installation, safe operation, and long-term maintenance of the equipment.

Product Overview and Technical Features

The LP+and LPB+series are single-stage or multi-stage low backlash planetary gearboxes designed specifically for industrial applications that require high-precision positioning and dynamic response. The standard version is "M" type (motor installation), and the output shaft bearing is designed to withstand high overturning moment and axial force. The LPB+model is equipped with an output flange, which facilitates the installation of synchronous pulleys and further expands application flexibility.

Core features:

Low backlash design: ensures high-precision transmission and meets precision control requirements.

Clamping hub positioning: The motor is centered by clamping the hub, rather than through an adapter plate, to avoid radial deformation of the motor.

Flexible motor adaptation: Multiple brands and models of servo motors can be adapted through adapter plates and bushings.

High load capacity: The output bearing can withstand large axial and radial forces, adapting to complex load conditions.

Maintenance free lubrication: It is filled with long-lasting grease at the factory and can achieve lifelong lubrication under normal use conditions.

Safety Guidelines and Responsibility Statement

Safety is a prerequisite for operating any industrial equipment. Before using the LP+/LPB+reducer, it is necessary to carefully read and understand the safety instructions in this manual.

Compliance with EC Machinery Directive: As a "machine component", gearboxes are not directly subject to the constraints of EC Machinery Directive 2006/42/EC. But the final machine for installing the reducer must comply with the provisions of this directive and cannot be put into operation until confirmed.

Expected use: The gearbox is only used for converting torque and speed, suitable for industrial environments. The motor must comply with the B5 design standard, with radial and axial runout tolerances of at least Class "N" in DIN 42955, and the motor shaft should be smooth.

Anticipated misuse: It is strictly prohibited to exceed the maximum allowable speed, torque, and temperature range. Any use beyond technical specifications is considered misuse and may result in warranty failure and safety accidents.

Exemption from liability: The manufacturer shall not be liable for any losses caused by failure to comply with transportation, storage, installation, and maintenance instructions, or unauthorized modification, operation without lubricating oil, or severe pollution.

Transportation and Storage

Delivery inspection: Upon receipt of the gearbox, the integrity should be checked immediately according to the delivery note. Any missing or damaged items must be notified in writing to the carrier or WITTENSTEIN alpha GmbH.

Packaging: The product is packaged in film and cardboard boxes, and the packaging materials should be sent to the recycling point for processing.

Transportation: Avoid hard impacts, use lifting equipment with sufficient load-bearing capacity, lift slowly, and strictly prohibit standing under suspended loads.

Storage: Store horizontally in a dry environment at a temperature of 0 ° C to+40 ° C, preferably in its original packaging. It is recommended to store for no more than 2 years and follow the "first in, first out" principle.

Assembly Guide

Assembly work must be completed by trained personnel and follow the following steps. The assembly sequence may vary slightly depending on the model (see manual table Tbl-5).

1. Preparation work

Clean all mating surfaces, centering rings, motor shafts, clamping hub inner diameters, and liner inner and outer surfaces using clean, lint free cloth and grease soluble non corrosive cleaning agents.

Check the mating surface for damage and impurities.

Do not use compressed air for cleaning to avoid damaging the seals.

2. Installation of LPB+reducer and machine

LPB+has an output flange, please pay attention to the following during installation:

Depending on the on-site situation, it may be necessary to use a spacer (E) for precise positioning.

Thoroughly clean the output flange, centering ring, mating surface, spacer, and synchronous pulley. The anti-corrosion agent on the synchronous belt pulley must be removed (acetone or Loctite 7063 can be used).

The fixing bolts need to be provided by the customer, and the size and tightening torque can be found in Table Tbl-17 of the manual.

If using a hollow shaft (C), first place the synchronous pulley (D) inside the hollow shaft, and then install the reducer.

Apply thread sealant (such as Loctite 243) to the bolts and secure the gearbox to the machine through the through-hole.

Ensure that the nameplate is readable and do not use gaskets.

3. Motor installation (LP+/LPB+)

The motor is usually not included in the standard delivery and needs to be installed by oneself.

Confirm that the motor meets the B5 flange standard, the shaft extension runout tolerance meets the requirements, and the shaft extension is as smooth as possible.

For LPB+, if the adapter plate is not pre installed, the adapter plate (B) needs to be fixed with four bolts (A) first, and the tightening torque is shown in Table Tbl-7 of the manual.

Motor installation steps:

If there is a key on the motor shaft, the key should be removed; If recommended by the motor manufacturer, a half key can be inserted.

Rotate the threaded pin (B) of the clamping hub (A) until the mounting hole is accessible.

Push the motor shaft into the clamping hub, and do not forcefully push it in. If it is difficult to push in, further loosen the threaded pin. The maximum allowable axial force is shown in Table Tbl-15 of the manual.

Ensure that there is no gap between the motor and the adapter board.

Apply thread sealant to the four bolts (E) and tighten them diagonally in multiple passes to the specified torque.

Tighten the threaded pin (B) of the clamping hub, and the torque value is shown in Table Tbl-15.

Press the accompanying plug into the mounting hole of the adapter plate.

4. Installation of output side components

When installing gears or synchronous pulleys on the output shaft, hammering or forced insertion is strictly prohibited. Suitable tools should be used to ensure that the maximum static axial force of the output bearing (Table Tbl-9) is not exceeded.

Installation of synchronous pulley on LPB+output flange:

Clean the output flange, centering ring, and synchronous pulley.

Place the synchronous belt pulley on the flange.

Apply thread glue to the bolts, manually tighten them first, and then tighten the tolerance bolt (E) and the fixing bolt (F) diagonally in two passes. The torque is shown in Table Tbl-10.

The pre tensioning force of the synchronous belt will affect the service life of the reducer bearings, and should be set reasonably.

5. Installation of LP+reducer and machine

LP+output shaft form, with four threaded holes on the casing for fixing.

Clean the output shaft, centering ring, and mating surface.

The customer provides bolts, specifications, and torque as shown in Table Tbl-16.

Apply thread glue to the bolts and fix the reducer to the machine through the through-hole without using washers.

Startup and Operation

The ambient temperature should be between -15 ° C and+40 ° C, and the operating temperature should not exceed+90 ° C.

Avoid freezing to prevent damage to the seals.

Do not exceed the limit values (speed, torque) in the technical parameter table.

Ensure that the gearbox operates in a clean, dust-free, and dry environment.

Maintenance and upkeep

The LP+/LPB+reducer is designed to be maintenance free, but regular inspections can extend its service life.

Maintenance plan:

After the first 500 hours or 3 months of operation: perform the first inspection.

Every 3 months: Conduct visual inspection and tightening torque check.

Every year: Repeat the above checks.

Visual inspection:

Check for any damage or leakage on the exterior of the gearbox (the radial shaft seal is a vulnerable component).

Check the installation position to ensure that there is no accumulation of foreign media (such as oil) on the output shaft.

Tightening torque inspection:

Check the torque of the casing fixing bolts (Table Tbl-16/17).

LPB+also needs to check the torque of the fixing bolts of the synchronous belt pulley (Table Tbl-10).

Check the torque of the threaded pin installed on the motor (Table Tbl-15).

Lubrication instructions:

All gearboxes are filled with long-lasting lubricating grease (standard is mineral oil-based lithium soap grease, optional food grade synthetic grease, see nameplate) when they leave the factory. The bearings are permanently lubricated and do not require replacement under normal usage conditions.

For additional information, please contact lubricant manufacturers such as Castrol and Kl ü ber.

Start after maintenance:

Clean the exterior of the gearbox, install all safety devices, and conduct a trial run.

Scrap disposal:

Consult customer service for disassembly and disposal advice.

Dispose of at designated recycling points in accordance with local regulations.

Troubleshooting

Chapter 8 of the manual briefly lists possible causes of the malfunction, but does not provide a specific table. Usually, abnormal noise, overheating, leakage, or decreased accuracy may be caused by improper installation, overload, lubrication failure, or seal wear. In case of malfunction, the external installation and operating parameters should be checked first, and if necessary, WITTENSTEIN alpha customer service should be contacted.

Technical specifications and appendices

1. Weight

Gearbox size LP+single-stage [kg] LP+two-stage [kg] LPB+single-stage [kg]

050 0.75 0.95 —

070 2.0 2.4 1.6

090 4.0 5.0 3.3

120 8.6 11.0 7.3

155 17.0 21.0 —

2. Maximum allowable static axial force (Fa max)

Size 050 070 090 120 155

Fa max [N] 1800 4300 5100 11300 18500

3. Parameters related to motor installation

The inner diameter of the clamping hub, the size and tightening torque of the threaded pin wrench, and the maximum axial force are shown in Table Tbl-15.

4. Machine installation threaded hole/through-hole specifications and torque

LP+casing threaded hole: size 050-155, bolt specifications M4~M10, torque 4.5~73.4 Nm (12.9 level).

LPB+through-hole: size 070-120, bolt specification M8~M12, torque 37.3~126 Nm (12.9 level).

5. Torque for general threaded fasteners

The manual provides a commonly used thread torque table (Table Tbl-18) calculated based on VDI 2230 standard, applicable to headless screws and nuts, with a friction coefficient of μ=0.10 and a yield limit utilization rate of 90%.