Condition monitoring, industrial powertrain, sortation: Merger, new motion control products

New condition monitoring system, gear drives, industrial powertrain, roller bearings, sortation system and worm gears were among Regal product introductions, at Pack Expo Las Vegas. Days later the motion control company announced it completed its merger with Rexnord PMC, creating Regal Rexnord Corp.

By Regal, Regal Rexnord Corp. January 11, 2022
Courtesy: Regal Rexnord Corp.

 

Learning Objectives

  • Learn details of the completed Regal merger with Rexnord PMC, creating Regal Rexnord Corp.
  • Examine advantages of condition monitoring device, gear drive, industrial powertrain.
  • See new features of roller bearings, a sortation system and IP69K worm drive.

Regal announced on Oct. 5, 2021, that it completed its merger with Rexnord PMC creating Regal Rexnord Corp. Days prior, at Pack Expo Las Vegas, Regal showed new product developments involving condition monitoring, gear drives, industrial powertrain, roller bearings, a sortation system and worm gears. More on each follow.

Regal completes merger with Rexnord PMC, creating Regal Rexnord Corp.

The combined Regal Rexnord Corp., the Oct. 5, 2021, merger of Regal Beloit Corp. and Rexnord Process and Motion Control (PMC) expands the range of product and digital industrial powertrain solutions aimed at helping increase customers’ efficiency and productivity. Regal Rexnord reported combined 2020 sales exceeding $4 billion and has 29,000 associates.

The Beloit, Wis.-based corporation engineers and manufactures industrial power transmission solutions and high-efficiency electric motors and systems. At a time when global supply chains are constrained, the combined company said it will be able to leverage manufacturing facilities on five continents to help increase reliability, quality, response time and product availability.

The new company will be comprised of four distinct business segments: Motion control solutions, climate solutions, commercial systems and industrial systems. Combined markets include air handling and HVAC solutions, agricultural and foodservice equipment, mining and manufacturing operations, and moving and conveying solutions for e-commerce.

The combined portfolio includes Regal’s Browning, Grove Gear, Hub City, Jaure, Kop-Flex, McGill, ModSort, Sealmaster and System Plast brands, as well as PMC’s Berg, Cambridge, Centa, Falk, Rexnord and Stearns brands, among others.

Regal Rexnord offers Industrial Internet of Things (IIoT) and digital solutions by harnessing the combined capabilities of Regal’s Perceptiv and Rexnord’s DiRXN digital platforms. “By integrating hardware, software and human-ware, Regal Rexnord will be well positioned to deliver best-in-class solutions optimized for reliability, performance and efficiency,” the company said in the announcement.

Louis Pinkham, CEO of Regal Rexnord, said, “For over 125 years, Regal has consistently provided our customers with reliable, high quality powertrain products and solutions. Now, with the addition of Rexnord PMC, we are taking a tremendous positive step forward in Regal’s ongoing transformation, positioning the new Regal Rexnord company to create significant value for all our customers. We will provide more robust industrial powertrain solutions — comprised of our motors and critical power transmission components — to enable a range of efficiency and productivity gains for our customers. By providing more energy-efficient solutions, developed with greater intention, especially when it comes to leveraging voice of the customer, Regal Rexnord is also now in a better position to fulfill our business purpose: creating a better tomorrow by energy-efficiently converting power into motion.”

www.regalrexnord.com/regal-rexnord-integration.

Graphic shows the industrial powertrain brands resulting from combination of Regal and Rexnord PMC. Brands include Regal’s Browning, Grove Gear, Hub City, Jaure, Kop-Flex, McGill, ModSort, Sealmaster and System Plast brands, as well as PMC’s Berg, Cambridge, Centa, Falk, Rexnord and Stearns brands, among others. Courtesy: Regal Rexnord Corp.

Graphic shows the industrial powertrain brands resulting from combination of Regal and Rexnord PMC. Brands include Regal’s Browning, Grove Gear, Hub City, Jaure, Kop-Flex, McGill, ModSort, Sealmaster and System Plast brands, as well as PMC’s Berg, Cambridge, Centa, Falk, Rexnord and Stearns brands, among others. Courtesy: Regal Rexnord Corp.

Condition monitoring device for food and beverage conveyor lines

The Regal Beloit Corp. System Plast iCOF condition monitoring device for food and beverage conveyor demonstrated how, for manufacturers running a manufacturing line, especially a dry running line, friction is a key factor for the proper handling and flow of containers. The iCOF condition monitoring device is designed to monitor the condition of a manufacturing line or a part of it by measuring the coefficient of friction (COF) of a chain or belt while it is running. It returns the average value and trend of the COF. The goal is to maintain line efficiency and an optimum cleaning regime.

“The iCOF device can be used in any conveyor, where a stable friction is the critical point. In dry lines, this value can more easily be affected by several factors, including the cleaning conditions of the conveyors,” said Brad Gossard vice president and general manager, PTS Conveying, Regal. “Inliners, feeders or the points where the containers change their speed quickly are the areas to watch. The iCOF condition monitoring device can also be used in mass conveyors to keep the back-line pressure under control.”

The iCOF device can be mounted on a conveyor and integrated in the line control system. Without any operator intervention, the system will independently measure the friction at regular intervals. With these data, it is possible to calculate an average value and the related trend and set alerts to take corrective action.

The iCOF condition monitoring device is compatible with Profinet protocol and Ethernet. The iCOF design fits with standard 85mm pitch conveyors. Its compact and firm structure, made in high strength steel (AISI 304), is completely closed and waterproof, offering the best resistance to cleaning agents. The easy and quick replacing of wear parts, a low tension and current absorption (24 V, 400 mA, 10 W) ensure reliability and operability.

The iCOF system includes the iCOF device, one slider to imitate product type (PET, CAN or GLASS), one set of screws for the slider, one screwdriver, and one USB drive with graphical user interface (GUI).

The Regal Beloit Corp. System Plast iCOF condition monitoring device for food and beverage conveyor is designed to monitor the condition of a manufacturing line or a part of it by measuring the coefficient of friction (COF) of a chain or belt while it is running. It returns the average value and trend of the COF. The goal is to maintain line efficiency and an optimum cleaning regime. Courtesy: Regal Rexnord Corp.

The Regal Beloit Corp. System Plast iCOF condition monitoring device for food and beverage conveyor is designed to monitor the condition of a manufacturing line or a part of it by measuring the coefficient of friction (COF) of a chain or belt while it is running. It returns the average value and trend of the COF. The goal is to maintain line efficiency and an optimum cleaning regime. Courtesy: Regal Rexnord Corp.

Gear drive up to 40% more efficient than standard worm gearing

The Regal Hub City SS (stainless steel) Hera High Efficiency Right Angle Gear Drive has two new sizes to the IP69K certified SS version of this helical-hypodial gear drive to this product suite with the stainless steel 55 and 75, taking the torque range to 8,500 in-lb. Worm gear drives are generally not as efficient as helical gears and become less efficient the higher the ratio. The SS Hera Gear Drive is 90% efficient regardless of ratio.

“The line extension of the SS Hub City Hera Gear Drive is designed to be a no-hassle replacement of major brands of worm speed reducers and also provides a highly efficient right angle gear solution for new applications,” said Mike Suter, vice president, marketing, Regal. “SS Hera offers four models that can replace up to a dozen sizes of worm reducers. This interchangeability can help with inventory consolidation.”

The SS Hera, with polished 316 stainless steel housings, is IP69K-certified to withstand sustained high-temperature, high-pressure washdown. It is also HACCP-compatible and BISSC-certified.

It can be bundled with Leeson Stainless Washguard all-stainless motors. It is available with the HubLoc keyless bushing system and new stainless steel HubCap bolt-on split covers.

Regal offers online tools and apps for Apple iPhone and Android users to assist with SS Hera selection. Users may select the right product using physical parameters and by entering a competitive worm gear model number. The product search and 3D configurator are user-friendly, quick to navigate and provide native computer-aided design (CAD) files.

Industrial powertrain optimizes efficiencies for bulk and unit material handling, metals, pulp and paper, mining, other critical industrial applications

The Regal electromechanical powertrain offering encompasses a broad range of Regal-produced components (such as motors, speed reducers, gearing, couplings, bearings, belt drives and more) that can be integrated to create complete end-to-end solutions, customized to meet specific application requirements, and optimized to maximize energy efficiency and productivity. In addition to helping customers design, assemble and commission their powertrains, Regal can monitor a solution’s ongoing performance through its cloud-based Perceptiv Internet of Things (IoT) platform. Data collected and analyzed via Perceptiv can support a wide range of diagnostic and prognostic activities, enabling customers to sustain high performance from their assets.

“At Regal, we create a better tomorrow and endless potential for our customers by energy-efficiently converting power into motion,” said Louis Pinkham, Regal’s chief executive officer. “We optimize our engineered mechanical power transmission components and motors to work better together, more efficiently and effectively. The ongoing asset monitoring we offer across the powertrain with Perceptiv intelligence helps to maximize uptime and prevent costly outages, while simplifying the maintenance, repair and operations experience for our customers.”

https://www.regalbeloit.com/products/powertrain.

A Regal Modsort transfer and diverter station exhibit operated in Regal’s booth during Pack Expo Las Vegas 2021. The Regal Beloit Modsort Trident three-way sortation system has a four-zone infeed that gaps a product, reads the package, and sends it down a belt, where it then diverts left, right or straight on a 30-degree spur-curve to one of three sorting locations. Courtesy: Regal Rexnord Corp.

A Regal Modsort transfer and diverter station exhibit operated in Regal’s booth during Pack Expo Las Vegas 2021. The Regal Beloit Modsort Trident three-way sortation system has a four-zone infeed that gaps a product, reads the package, and sends it down a belt, where it then diverts left, right or straight on a 30-degree spur-curve to one of three sorting locations. Courtesy: Regal Rexnord Corp.

Roller bearings reduce total downtime through easier bearing removal

The patented Regal Beloit Time Saving axial groove (TSAG) in the inner ring bore on the Sealmaster Unitized Spherical Roller Bearing (USRB) allows users easy removal and to reuse the shafting with minimal cleanup.

Many methods exist to remove a mounted bearing from a shaft, but the Sealmaster USRB bearing with Time Saving axial groove makes bearing removal easier. Its patented design eliminates interference with the burr created by the setscrew by using axial grooves at setscrew locations that run the length of the inner ring. The axial groove in the inner ring bore is designed to provide clearance from the burr created when the setscrews are properly torqued to lock the bearing to the shaft, and extends the entire length of the inner ring for removal in either direction.

“Time is a valuable commodity in plant operation, and countless hours are spent annually removing setscrew mounted bearings from shafts,” said Ian Rubin, director of customer experience at Regal Beloit. “After the launch of the time-saving axial groove on our large bore mounted ball bearing, we knew implementation on the Sealmaster USRB would provide the same impact to bearing removal simplification and reduction in shaft damage. The design lessens the total downtime required to remove the bearing, saving time and money.”

In addition to the time and costs saved during bearing removal, the design also reduces damage to the shaft compared to other methods of removing the bearing. This lowers the costs associated with repairing the shaft before reuse as compared to normal bearing removal and can eliminate the cost of having to replace the shaft.

The feature is available on all collar-mounted setscrew locking Sealmaster USRB’s.

The Sealmaster USRB bearing with TSAG is perfect for bulk material handling/aggregate industry and industrial blowers to list a few. But it is favored in any industry with the need for easy removal that eliminates shaft damage and speeds up change-out to get operators back up and running quickly.

https://www.regalbeloit.com/brands/Sealmaster/Products/Time-Saving-Axial-Groove

Sortation system: Divert packages left, right or straight on a 30-degree spur-curve to one of three sorting locations

Regal Beloit Modsort Trident three-way sortation system has a four-zone infeed that gaps a product, reads the package, and sends it down a belt, where it then diverts left, right or straight on a 30-degree spur-curve to one of three sorting locations.

The Modsort Trident is a Regal concept and a continuation of its Modsort technologies, which is known for its quiet operation. Modsort technologies include the Modsort Station (individual transfer), Modsort Derivatives (with expanded sort capacity) and Flat Sorter Systems (with a complete mobile and expandable solution). The Modsort Trident three-way sortation system includes additional mechanical variations to this turnkey solution.

“The Modsort Trident is ideal as a secondary sortation station in a fulfillment center and works well with parcel post, e-commerce and warehouse distribution applications,” said Jeremy Fryman, SystemPlast product manager, Regal. “This sortation system can accommodate up to 50 cartons per minute on average, with a weight limit of 50 pounds. It uses a 34-inch wide (between frame) x 66-inch long triple-belt divert for polybags, boxes, flats and some types of totes. Modsort Trident technology uses 24-volt dc power and requires only a simple power drop and Ethernet connection to customer warehouse management solution. Designed to be mobile (the unit comes on heavy duty casters) and can be redeployed if needed to another location.”

The Modsort Trident has:

  • Frame mounted HMI operator control panel with pushbuttons for start/stop, reset, communications fault, and emergency stop
  • Allen-Bradley-based programmable logic controller (PLC)/power panel
  • Compact Logix 5380 processor
  • Allen-Bradley 24-volt dc power supplies
  • Allen-Bradley Stratix network switch
  • Optional NAT
  • Digital/analog input/output backplane array
  • Input/output (I/O) sub panels for MDR motor controller cards.

Worm drive: IP69K provides certified washdown solution for many application

The Regal Beloit Grove Gear Stainless Steel Worm Gear Reducer has achieved third-party IP69K certification. Ingress Protection (IP) Marking rates the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact and water. It is published by the International Electrotechnical Commission (IEC). The IP69K rating is for high-pressure, high-temperature washdown applications. Enclosures conforming to it must not only be dust-tight, but also able to withstand high pressure and steam cleaning.

The Grove Gear Stainless Steel Worm Gear Reducer joins the Hub City Hera Stainless Steel Gear Drive, Sealmaster PN Gold Mounted Bearings and the Leeson Extreme Duck Ultra Motor as third-party IP69K-certified products from Regal. Together, these four products provide a complete washdown solution for food and beverage, pharmaceutical and chemical processing applications.

“Traditionally, IP ratings have been used for electrical components, but the industry is starting to recognize the benefit of IP rating for power transmission components,” said David Silverman, product manager of worm gearing at Regal. “This allows our customers to have a better understanding of the product capabilities for specification purposes. We are pleased that the Grove Gear Stainless Steel Worm Gear Reducer now carries the formal IP69K certification.”

This Grove Gear Stainless Steel Worm Gear Reducer has a 316 stainless steel housing to withstand extreme environments. An O-ring on the face of the motor adapter, poppet-style vent, and v-rings on the output shaft seals provide a system that fights dust and moisture intrusion. A 303 stainless steel output shaft and stainless steel hardware are also included.

This reducer is also available with Leeson motors pre-assembled for a performance-matched and IP69K-certified solution.

Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

KEYWORDS: Motion control, industrial powertrain

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Regal, Regal Rexnord Corp.