A pump coupling is the element used to connect the rotating pump shaft to the drive shaft of the motor; enabling the motor to efficiently transmit power to the pump.
When a pump is close coupled, a separate coupling is not required as the motor is directly mounted to the pump on a single shaft. Whilst close coupled pumps benefit from a compact, cost effective design, they are less preferable for heavy duty, high power, continuous use as there is more strain put on the common bearings and the size of the motor is usually limited.
For heavier duty applications, long coupled pumps are more suited. As the pump and motor are mounted on their own shafts separated by a coupling, the separate bearings share the strain of operation, therefore extending the lifespan of the mechanical parts.
The coupling of the two shafts would be simple if they remained perfectly aligned and there were no vibrations during operation. However, in reality this isn't the case, and any misalignment can result in the premature wear and failure of the bearings, mechanical seals and even the coupling itself.
Misalignment is when one or both shafts are forced from its desired position, of which there are three main types:
The problem of misalignment is one of the factors that need to be considered when the coupling is selected, as the different types cope with it differently. So, what are the different types of pump coupling and when should they be used?
As their name suggests, rigid couplings connect the pump and motor shafts together very firmly, which allows them to transmit more power to the pump than flexible couplings of a comparable size. They also benefit from a simpler, more cost-effective design. However, rigid couplings don't have the ability to handle any shaft misalignment without high stress on the bearings and seals as are unable to absorb any vibrations from the pump running, or thermal expansion. They are usually used for applications where misalignment is not a concern, for example where the shafts have been precisely positioned in perfect lateral and angular alignment at installation.
Unlike rigid couplings, flexible couplings can accommodate some movement e.g. vibrations and thermal expansion without damage. This makes them ideal for applications where there is a degree of unavoidable misalignment between the drive and pump shafts. As they can absorb vibrations well, they can also be used to reduce excessive operating noise. With these benefits come a more complex, expensive design. However, as flexible couplings protect the shaft and bearings from damage and premature wear, there are maintenance savings to be had in the long run.
Magnetic couplings differ to rigid and flexible as rather than a mechanical shaft, the motor is coupled to the pump by a magnet which offers various benefits. Firstly, with magnetically coupled pumps there is a small air gap between the magnet and the motor and pump. As there is no physical contact, misalignment and thermal expansion is not a problem. The absence of a mechanical seal also eliminates the chance of leakages, making a magnetic drive pump ideal for handling aggressive or hazardous fluids.
However, magnetic couplings are only suited to clean liquids as the presence of any particles can be problematic as they stick to the magnet. They are also sensitive to extreme operating conditions; if excessive torque exceeds the capabilities of a magnetic coupling, the magnetics may decouple, and the pump shaft will slip causing stoppages. Therefore, when selecting a magnetic coupling, you need to be sure that is aligned with the power of the system.
Rigid gear couplings are also known by the name of sleeve or sleeve couplings were an economic even if historically inaccurate for tree-straight tree associations. It is because of them imperfections that were previously not even considered useful for any servo application. However, with the progress of science by leaps and bounds, 6cm aluminum rigid gear coupling are progressively used for motion control applications due to their firmness, zero kickback and high torque limit.
Types of rigid gear couplings
There are three main types of rigid gear couplings that can be chosen by a person depending on your needs:
' Flanged Type: These couplings are used to connect rotating machines if both the trees are already aligned with each other. It takes up much less space than others types for installation and even cheaper.
' Clamp Type: These couplings are used in machines where there are two different machine shafts connected to function as a single tree. They are available in different shapes, sizes and options.
' Sleeve type: these are the simplest types of coupling in terms of installation and maintenance. However, they can only be used in cases where the available tree size of both the equipment is the same in terms of power and torque.
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Advantages of rigid gear couplings
Rigid Gear Coupling 6cm has several advantages over its counterparts that have made them popular choice between different sectors. Some of the key benefits are as follows:
' Low cost of production: the cost of producing standard and custom rigid couplings 6 cm is quite low compared to other types of gear couplings. This helps producers get in producing them at a fairly convenient rate.
' Excellent torque transmission: one of the main advantages of the 6 cm rigid gear coupling is which can effectively transfer torque from one shaft to another connected shaft.
' Torsional stiffness: rigid couplings have a high torsional stiffness. This helps to improve positioning of the same.
' Accuracy: These couplings are now more accurate with almost no play and no winding.
' Simplicity: they are relatively simpler to use and install
' Alignment Capability: Rigid gear couplings can also be used to establish shaft alignment between the components connected to the engine.
' They are quite suitable for various support and push pull applications.
' Easy maintenance: 6 cm rigid gear couplings are easy to assemble, disassemble and maintain for the entire life of the machine.
Disadvantages of rigid gear couplings
Despite their advantages, there are also several disadvantages associated with this type of type of coupling. Let's take a closer look at some of them:
' Rigid gear couplings are difficult to pick up or destroy
' Being rigid or inflexible, they are unsuitable for any kind of misalignment.
' Because there is a lack of adaptable components, rigid gear couplings cannot assimilate vibrations and dizziness.
' They need a progressively pivotal space compared to other different types of mates Depending on your needs and weighs down the pros and cons of the same, one should choose the right 6cm rigid gear coupling for their industry.
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