Tough couplings for tough industries

BMG’s heavy industrial Rexnord Falk Steelflex couplings are known globally for highly efficient and reliable performance, even in arduous applications. Falk Steelflex couplings have also been proven to minimise downtime – an important factor in determining the total cost of ownership.

BMG’s extensive range of power transmission components encompasses robust products from Regal Rexnord, a leading manufacturer of critical system components that perform efficiently under rigorous demands in diverse applications.

“Plant managers and maintenance teams understand that equipment serviceability is a critical factor in maintaining uptime and efficiency at their facilities- whether it’s in cement, food and beverage, material handling and intralogistics, construction, mining, automotive, agriculture, or forestry,” explains Gavin Kirstein, Business Unit Manager, Power Transmission division, BMG. “The BMG team partners with our customers working closely to find dependable solutions that combat misalignment and contamination, ensuring optimum productivity, minimal downtime and extended service life of components.

“BMG’s Regal Rexnord power transmission components include industrial gear units, low-speed backstops, idlers, couplings, bearings, torque limiters and shaft locking assemblies.

“Critical components in this range are Falk Steelflex grid couplings, which have proven for over 100 years to minimise downtime – an important factor in determining the total cost of ownership. Couplings are subjected to enormous pressure from high impact loads on conveyors, shredders and mixers in harsh operating environments. Vibratory loads on high-speed applications, like pumps or compressors, can also cause the break-down of couplings.

“This range has a modular design, which reduces the number of spare parts required in inventory. For example, it is possible to convert a close coupled design coupling to a full spacer by replacing the standard hubs with shaft and spacer hubs. A standard coupling can also be adapted for high speeds by simply changing the horizontal split cover to a vertical split cover. With a few additional components, it is possible to adapt the Falk Steelflex inventory to a variety of applications.”

BMG’s Falk Steelflex grid couplings have been developed to significantly reduce the negative effects of high impact loads on equipment. These couplings have a unique “replace in place” design, eliminating the need to remove or reposition hubs, or re-align shafts, which is normally required with gear couplings and many elastomer designs. This convenient feature significantly reduces element change out time – an important advantage during maintenance.

Steelflex grid couplings also offer equipment protection against shaft misalignment. The grid, which is quench and tempered, is free to rock, pivot and float within the hub teeth. This means misalignment capacity is provided, without producing detrimental bearing side-loads created by conventional couplings.

When subjected to normal shock or vibratory loads, the grid coupling torsionally deflects. These couplings offer enhanced vibration damping and reduce peak torque by about 30%, also minimising wear on connected equipment components. These couplings act as a shock absorber for rotary motion, relying on the predictable resilience of the steel grid for torsional flexibility.

BMG’s Falk grid range is available in various sizes with different bore, speed and torque capacities. Various models include high speed, spacer, flywheel, brake and controlled torque. These couplings have a maximum bore of 508 mm, a maximum torque capacity of 932 000 Nm and speeds up to 10 000 rpm, depending on the coupling model and size.

Features of Falk Steelflex grid couplings include a tapered T-grid profile that fits smoothly into the hub to ensure easy installation and maintenance. High strength alloy steel grids are tempered to spring-hardness and precision shot-peened for increased fatigue strength to protect equipment against shock and vibratory conditions. Durable, nitrile seals prevent the loss of lubrication and deter the ingress of water, dust and other materials. Grade 5 cap screws ensure secure fastening of the cover which can be powder coated for resistance to chemicals.

This range offers high torque ratings, low operating costs and extended maintenance periods. The application of Falk Long Term Grease (LTG) means lubrication of couplings is not required again for a period of five years.

This grease, which has been developed specifically for couplings, resists the separation of oil and thickening agent that occurs in ‘normal’ greases.

Other important components in BMG’s Regal Rexnord range are Falk True Hold low speed backstops and Rexnord Omega &and Viva elastomeric couplings.

BMG is a complete process solutions provider to all sectors of industry, which means companies can access all essential quality branded engineering components and support services from one supplier. This integrated approach guarantees lower production costs and higher efficiencies.

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