Appendix 5. Mechanical Subsystem

Appendix 5. Mechanical Subsystem 5.1 Mass Budget 5.2 Stability Analysis5.3 Stress Analysis 5.4 Thermal Analysis5.5 Pictures 5.6 Test Plan and Results5.7 Component Specifications5.8 Technical Drawings

Appendix 5. Mechanical Subsystem

Stability Analysis

Thermal Analysis

Results Component Specifications Technical Drawings

5.1 MASS BUDGET The following table summarizes the mass budget for the mechanical components of the design.

PartName Description Mass (g) Material Qty

MAIN Complete Assembly

The complete assembly of all the components of the MAIN payload. Excluding the FISH. 15657.98 N/A 184

Line Guide AssemblySafety mechanism to brake the line, reel up and reel down 139.04 N/A 1

Line Guide Side BlockBlocks that make up the sides of the line guide's cage 13.37 Aluminium 2

Line Guide PinPins that make up the struts of the line guide's cage 10.57 Aluminium 2

Line Guide Shaft

Shafts to fit inside the supporting bearings of the line guide as well as the shaft coupling to the motor 32.35 Steel 2

M6 20mm Flat Head ScrewM6-1mm machine screw with flat head and 20mm length 4.41 Steel 6

Line Guide MountingMounting parts for the Line Guide Assembly 684.6 N/A 1

Line Guide Bearing

Sleeve bearings used to support the Line Guide AssemblyPdyn = 16.6 kN; Pstat = 52 kN 5.13

Steel with coatings of Bronze and PTFE 2

Line Guide Bearing MountCustom parts to support the Line Guide Bearings 307.81 Aluminium 2

Slide Nut M6Slide nut made for the PU25 profiles 5.91 Steel 4


Line Guide DriveDrive train for the Line Guide Assembly 3322.194 N/A 1

Rigid Shaft CouplerRigid steel parallel shaft coupler for 10mm to 10mm keyed shafts 187.86 Steel 1

Brushless Motor

Brushless DC Geared Motor with 30W output and 1.5 Nm rated torque 3000 N/A 1

Line Guide Motor SupportPlate to mount the Line Guide Motor to the structure 99.39 Aluminium 1



M5 30mm Flat Head ScrewM5-0.8mm machine screw with flat head and 20mm length 4.28 Steel 4

MAIN StructureRigid structure of the MAIN payload 4290.56 N/A 1

PU25 400mm w\ HolesUniversal Profile 25x25x400 with holes at the ends 272.01 Aluminium 2

PU25 350mm Universal Profile 25x25x350 241.63 Aluminium 6

PU25 266.488mm Universal Profile 25x25x266.488 183.98 Aluminium 4

PU25 200mm w\ HolesUniversal Profile 25x25x200 with holes at the ends 133.03 Aluminium 4

PU25 150mm Universal Profile 25x25x150 103.56 Aluminium 4

Angle Adaptor

Piece to join the profiles at an angle; 500 N max loadHinge 6 30x30, heavy-duty 28.86 Aluminium 8

Mount Bracket

Custom corner bracket to mount the MAIN on the gondolaAngle Bracket 6 30x30 Zn, white aluminium, similar to RAL 9006 28.1 Steel 4


M6 10mm Button Head ScrewM6-1mm machine screw with button head and 10mm length 3.12 Steel 8


MAIN InsulationInsulation around the MAIN payload 2435.07 N/A 1

Insulation Frame 775mmAluminium frame to support the insulation panels 79.68 Aluminium 4

Insulation Frame 400mmAluminium frame to support the insulation panels 41.13 Aluminium 4

Insulation Side PanelStyrofoam panel to insulate the sides of the MAIN payload 348.78

Low-Density EPS 4

Insulation Top PanelStyrofoam panel to insulate the top of the MAIN payload 156.71

Low-Density EPS 1

Insulation Bottom Fill

Styrofoam panel to insulate the bottom of the MAIN payload and secure the FISH 400

Low-Density EPS 1

Reel Mount Mounting assembly for the reel 1024.01 N/A 1

Spinning ReelDaiwa Saltiga Surf Spinning Reel 6000 530

Magnesium Alloy Body 1

Reel Mount Plate6mm thick mount plate for the reel and bail-flip stopper 312.71 Aluminium 1

Bail-Flip Stopper

Aluminum block to flip the bail back as a turn of the reel is done when the bail is open 103.8 Aluminium 1


M6 Washer 4mm thick M6 washer 6.85 Steel 4


Reel Drive Drive assembly for the reel 3342.724 N/A 1

Rigid Shaft CouplerRigid steel parallel shaft coupler for 10mm to 10mm keyed shafts 187.86 Steel 1

Reel Shaft

Rigid steel shaft for the reel, with M5 right-handed end and a 10mm keyed end 33.26 Steel 1

Reel Motor MountPlate to mount the Reel Motor to the structure 98.48 Aluminium 1

Brushless Motor

Geared motor with brake or self-lock and rated at 30W output, 150 to 200 RPM, and 1.5 to 2 Nm 3000 N/A 1


M5 30mm Flat Head ScrewM5-0.8mm machine screw with flat head and 20mm length 4.28 Steel 4

Bail ReleaseBail release mechanism for the reel 419.78 N/A 1

Servo Motor

FUTABA S3801 (Segelbåtsservo)with 140 degree motion and 4.8 to 6 V input 107 N/A 2

Bail Release ArmArm which extends across the reel to open the bail 25.92 Aluminium 1

Servo Motor Mount Mount plates for the servos 31.48 Aluminium 3

Bail Release LeverLever which extends to hold the Bail Release Arm 15.62 Aluminium 2



FISH 1849.23External Assembly All external structure 658.87

Nose Skin

0.5 mm Aluminium sheet metal machined to form a cone. Attached to the skin 36.87 Aluminium 1

Skin

1mm thick Aluminium Clad cylinder. 325 mm in length with a 160 mm diameter 622

Aluminium/Steel 1

Insulation MainInsulation of the FISH components 68.32

Nose Insulation160 mm diameter, 75 mm height, cone shaped styrofoam 21.49

Low-Density EPS 1

Body Insulation

Side insulation, approximately 25 mm thickness and height of 50 mm 23.57

Low-Density EPS 1

Top Insulation1160 mm diameter, 25 mm height, semicircle styrofoam 11.63

Low-Density EPS 2

Insulation Tail Insulation fo the radio 93.49

Upper Insulation50mm thick insulation, 160 mm diameter, covers Zigbee 46.45

Low-Density EPS 1

Lower Insulation50mm thick insulation, 160 mm diameter, covers Zigbee 46.44

Low-Density EPS 1

Zigbee Radio UnitRadio Unit to communicate with MAIN 0.6 N/A 1

Internal Structure Internal Structure of the FISH 600.81

Base

160mm diameter base, 1mm thick. Attachs all components to it 46.54 Aluminium 1

Stiffener

1.5 mm thick, 60 mm wide, 160 mm long, 20 mm deep, C-shape. Provide stiffness to base 55.89 Aluminium 1

side

3 mm thick, 50 mm height, 20 mm wide side to hold the top and the bottom together 11.54 Aluminium 2

Top Plate

Attachs to I Beam, holds the parachute up. 160 mm diameter disc, 1mm thick 10.1 Aluminium 1

I-beam1

C-shape, 0.5mm thick, 25 mm height, 20 mm wide, 160 mm long. Attachs to line, parachord and skin 9.1 Aluminium 2

Parachord tubesProtect parachord from I beam, 0.5 mm thick 3 Aluminium 2

Processor Unit

Determines FISH velocity and altitude for parachute deployment 162 N/A 1

Control UnitControls the setting of ground altitude 10 N/A 1

Release UnitCuts line when parachute needs to be activated 10 N/A 1

PCB Houses electronics 55 N/A 1Accelerometer 45 N/A 1

Battery HolderHolds the Batteries, 60mm x 60 mm 15 Plasic 1

Battery Provide power 24 N/A 6

Parachute MechanismThe mechanicsm the deploys the parachute 380

Parachute

Parachute to be used for safetly mechanism. Spring loaded, 150 mm diameter 50mm compressed 370

Steel spring, Parachute material 1

Ring10 mm ring to strengthen hole in parachute 10 Steel 1

ParachordAttachs the Structure to the Parachute 10 Parachord 1

Fasteners All Fasteners 47.74

M4 Screw Button head Joint thick structures together 2 Steel 6M4 Nylon lock nut Attach to screw 0.9 Steel Nylon 6M5 Washer Attach to screw 0.39 Steel 6M4 Aluminium Rivet Light attachments 0.5 Aluminium 48

Epoxy Glue Epoxy 1Cable Tie Attach Cypres unit to base 1 Plastic 4

LINE The complete Line assembly 40

SuperBraid0.5 mm thick braided fishing line, 300 m Dyneema 1

Swivel High strength swivel 20 Steel 2

Line tubesProtect line from I beam, 0.5 mm thick 10 Aluminium 2

5.2 STABILITY ANALYSIS

Static Margin Calculations The static margin requires a two calculations.

1. Calculation of the Aerodynamic Centre 2. Calculation of the Centre of Gravity

Centre of Pressure The Centre of Pressure calculation was conducted using a software called JavaFoil (1). This is a program used to analyse the aerodynamic properties of an aerofoil. Before any calculations could be made a diagram of the FISH aerodynamic surfaces had to be produced so to be inputted in to the program. The overall characteristics of the FISH are summarised below. Once these characteristics were placed into the Java foil a slight rotation was placed on the design to simulate a deviation from the normal position. JavaFoil is able to calculate the pressure on each of the surfaces of the capsule and are shown in Figure XX. These pressures were then used to calculate the centre of Pressure via the static force equations. The equation is stated below.

�� =∑(�/�). �� − ∑(�/�). ��

∑ �� − ∑ ��= 0.66 = 264 ��

Where x/L is the position of the pressure along the x axis.

75mm 325mm

160mm

Figure 0.1: Surface Pressure of Skin of FISH

CoG Calculation The CoG calculation is conducted through the CAD program Solidworks. The result of the CoG produces

�� = 165�� from the nose.

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1-10

-8

-6

-4

-2

0

2

4

6

8Centre of Pressure Calculation

x/length

Pre

ssur

e

5.3 STRESS ANALYSIS

Critical Force for the FISH Structure Calculations Parachute Opening The most critical force that shall be applied to the FISH is when the parachute is deployed. The parachute characteristics have been described in the main document and are summarized below.

Cd 1.5

Diameter 0.66 m

Surface Area 0.342m2

If the parachute opens at a low altitude when the FISH is at terminal velocity it will create a drag force on the FISH which is assessed to be the largest stress produced during the whole mission. The maximum force that is experienced by the parachute is given by the following equation

�� =2��

��1 −

��

��

Ref: (1) Where T = length of time to open chute = 0.5s and g = gravity (1). The initial and finial velocities are calculated using the terminal velocity equation.

� = �2�

��

Thus Where for the initial conditions

Characteristics Initial Final W 1.8x9.81 = 17.66 N Cd 0.2 1.5 ρ 1.2 kg/m3 S 0.082π = 0.02m2 0.332π = 0.342m2 V 85.78 m/s 7.57 m/s

Thus the maximum force on the parachute is

�� = 563.11 � This force will be experienced through the paracord that is attaches the parachute to the FISH’s structure. G’s produced by Gondola One of the design limitations was to make sure the structure can handle 10 g’s . Since the FISH’s total mass is 1.8kg. Thus the maximum force that FISH will experience during typical mission loads is

� = �� = 1.8�� × 10� × 9.81 = 176.58 � This force will be experience through the attachment of the Fishing line to the FISH structure. Summary Thus the critical forces experienced by the FISH is

Force (N) Interface 176.58 Fishing line attached to FISH structure 563.11 Parachord attached to FISH structure

Reel Brake Analysis The brake of the system has been analysed to one of the more important safety components of the system. Thus a larger level of study has gone into this device. In the previous design the reel.SMRT was meant to have a variable brake system with a motor interfacing with the brake and hence being able to control it. Unfortunately due to reel constraints this idea was substituted for a non-variable brake which is preset before launch. This has many advantages and disadvantages, firstly with a variable brake the user is able to control it thus can increase the force if the brake is not strong enough. This is a more adaptive method to unforeseen environmental hazards. The disadvantage with the variable brake is that it increases the complexity of the system and also it is reliant on more systems to work for the brake to function which is a safety risk in itself. Thus it has been decided that a non variable brake is best for the system. The reel brake has a maximum force 300 N which allows for a wide range of braking strength alternatives. In Figure 0.2 it is shown the stopping distances and time for different brake strengths along with the g’s that are experienced by the FISH in Table 1.

Figure 0.2: The FISH's displacement for different Brake Forces

0 0.5 1 1.5 2 2.5-40

-35

-30

-25

-20

-15

-10

-5

0

Time(seconds)

Z D

ispl

acem

ent f

rom

the

poin

t of B

rake

app

lied

(m)

Z Displacement of the FISH at various Brake Forces

Fb = 40Fb = 60Fb = 80Fb = 100Fb = 120Fb = 140Fb = 160

Displacement and G’s Experience by FISH for various Brake Forces

Brake Force (N) 40N 60N 80N 100N 120N 140N 160N G’s 1.27 2.4 3.53 4.66 5.8 6.93 8.06 Max displacement when braking (m)

39.18 20.89 14.34 10.97 8.91 7.53 6.54

Table 1: Characteristics of the FISH at Various Brake Forces

By observation of the G’s experienced by the FISH when the brake is applied, one can see that the larger the brake force, the larger the G’s that are incurred by the FISH. The two defining factors that affect the choice of the brake force is the maximum distance the FISH is allowed to travel before the line is expired and also the maximum number of G’s that the structure or line can withstand. These two values are summarised in the table below Reference Maximum Deceleration Length 50 m Maximum stress 100 N Line Critical Force Appendix 5.3 To satisfy these two conditions a braking force of approximately 100 N has been chosen. To make sure this system is safe and the brake will work every time, the system will be tested under a various mission environmental conditions. How these conditions will affect the brake will be determined in the tests and the brake force will be set accordingly. In conclusion, a non-variable braking system will be used to reduce the velocity of the FISH because it decreases the complexity of the system thus increasing the relative safety of the braking system. This brake shall be pre-set before mission launch to 100 N.

SuperBraid Line Critical Phases It has been assessed that there are two critical phases during the mission that the line has to endure.

• FISH deceleration phase

• Housing of FISH phase

These phases produce critical forces on different sections of the line which need to be analyzed for design purposes. FISH Deceleration Phase The Deceleration Phase starts when the brake is applied to the line and the FISH starts to slow down. The brake force is 100 N (appendix) which is a approximately a 5 g slow down. This will cause the line to experience a 90 N through it.

� = �� = 1.8 × 9.81 × 5 ≅ 90� Since there is only one line that is connected between the FISH and the reel, 100% of this force will be need to be absorbed by it. From the Test M.3 one can see that the braking strength of a single line is 196.2N at its minimum. Thus the FS is 2.6 which is sufficient enough for the flight.

�� =196.2

90= 2.18

A note, if the gondola experiences a vertical motion when the line is being decelerated, these forces will not be experienced by the FISH. The brake of the reel is designed to only place a constant force on the line, when more g’s are experienced by the FISH the brake merely takes longer stop the FISH. Thus the force on the line will never be larger than the braking force. Housing of the FISH Phase During the housing of the FISH the line experiences the largest force during the mission. Stipulated via the BEXUS user manual the FISH needs to withstand 10 g’s (Req.T.M.1) during the mission. Thus the force that will be experience by the line will be 177N.

� = �� = 1.8 × 9.81 × 10 = 176.6� These forces will be taken over the design shown in the figure below.

Thus the maximum force that is placed over the line is

�� =�

2�� + ��

This force is calculated to be F 177N H 400mm b 41.5mm

�� = 88.97 ≅ 90�

For each of the braids that will be attached to the I-beam there will be 5 lines braided thus reducing the risks from any faults in the line, because the stress will be divided across the lines evenly. Thus the maximum force on each of the lines is

�� =��

# ��=

88.875

≅ 18�

Since the maximum strength of the line is 196.2 N, (Test M.3) this is will produce a FS of

�� =196.2

18= 10.9

Thus the FS when the FISH is being housed is 13.9 which is well above the required limits.

F

�2�

�� + ��

b

L

d

H

�2�

�� + ��

Summary of the Critical Phases The critical phases are summarised in table XX. Critical Phases Critical Forces FS FISH deceleration 90 N 2.18 FISH housing 18 N 10.9 These FS are well within the range of the breaking stress of the line

Stress Calculations As shown in the Critical Force Calculations (Appendix 5.3) the maximum stresses the structure will receive is summarized below. Critical Case Force (N) Interface 1 563.11 Parachord attached to FISH

structure 2 176.58 Fishing line attached to FISH

structure Both of these forces will be experienced through the parachord or fishing line, which are both attached to the I-beam situated at the base of the parachute. I Beam Properties and 2nd moment of Inertia The I beam is 160 mm long with a cross sectional area shown in Figure XX. All dimensions are in mm’s.

The 2nd moment of area for this I beam needs to be calculated so the future stress calculations can be made. This has been calculated like such.

The local 2nd moment of inertia for beams 1, 2, and 3 are

�� =��

12= ��, �� =

2��

12

With the local CoG distances from the global CoG as such

Member Local CoG from Global CoG

1 �� = � + �

2

2 �� = 0 3 �� = −

� + �2

1

0.5

0.5

30 160

25

L

T

T

2

1

3

H

2T

Using the parallel axis theorem where

�� = � �� + ��

Thus

�� = �� =��

12+ ��

� + �2 �

�

�� =2��

12

Hence

�� = 2��

12+ 2��

� + �2 �

�+

2��

12

Where Distance (mm) L 30 H 24 T 0.5

Therefore

�� = 4553.8�� Area of Beam The Area of the Beam is

� = 2�� + 2�� = 54�� Bending Moment Analysis For critical case 1 the position of the paracord to the I beam is shown in the diagram along with the forces that are applied The force balance diagram for this beam is Shear Force Balance

�2

F

�2

d d

H

d

�2

�2

�2

�2

d

Shear Stress Bending Moments Thus the maximum bending moment is

�� =��2

Horizontal Force Balance Compressive/ Tensile Force Thus maximum Compressive/ Tensile Force

�� =��2�

The maximum stress for this beam is then

�� =��

��+

��

−�2

�2

−��2

d

��2�

��2�

d

��2�

��2�

−��2�

��2�

http://physics.uwstout.edu/StatStr/statics/Beams/beam41.htm Critical Case 1 For critical case 1 the parameters for calculating the maximum stress is

F 563.11 N d 20 mm H 1000 mm L 160 mm Y 12.5 mm A 54 mm Ix 4553.8 mm4

The maximum axial force is

�� =��2�

= 5.63 �

The maximum bending moment

�� =��2

= 5631.1 ��

The maximum stress calculated

�� =��

��+

��

= 15.46 + 0.10 = 15.56�

�� = 15.56��

The Factor of safety is

�� =110

15.56= 7.07

Critical Case 2

F 176.58 N d 80 mm H 30 mm L 160 mm Y 12.5 mm A 54 mm Ix 4553.8 mm4

Note: that there is only one line attached to this beam, but the bending moments are still the same if d is half the length of the beam. The maximum axial force is

�� = 0 � The maximum bending moment

�� =��2

= 7063.2 ��

The maximum stress calculated

�� =��

��+

��

= 19.39 = 19.39 �

�� = 19.39��

The Factor of safety for the yield tensile strength of aluminum as 110 MPa

�� =110

19.35= 5.67

The Summary table of the Maximum stresses and Factors of Safety for the two critical cases

Critical Case Maximum stress (MPa) FS 1 15.56 7.07 2 19.39 5.67

Base Insert analysis As shown in the Critical Force Calculations (Appendix 5.3) the maximum stresses the structure will receive is summarized below.

Critical Case Force (N) Interface 1 563.11 Connected to I beam

Translating this force into the force the Base will experience will be needed to be done via calculation of the acceleration.

� =�

��=

563.111.8

= 312.9 �/��

This acceleration will be translated to all components on the base which are the battery and holder, the pcb, accelerometer, and the Cypres unit. The forces have been calculated in table XX

Component Mass (kg) Force (N) Cypress unit 0.183 F1 = 57.26 Battery and Holder 0.164 F2 = 51.52 PCB 0.055 F3 = 17.21 Accelerometer 0.045 F4 = 14.08

Thus the force balance equation is Thus the forces equate to

�� + �� = �1 + �2 + �3 + �4 And

Fb Fa

F1 F2

F4

F3

D1

D2

D3

L

�� =�1 × �1 + (�2 + �3) × �2 + �1 × �3

�

Where

F1 57.26 N D1 41 mm F2 51.52 N D2 80 mm F3 17.21 N D3 95 mm F4 14.08 N L 160 mm

Thus Fa 82.67 N Fb 57.4 N

I Beam Properties and 2nd moment of Inertia The I beam is 160 mm long with a cross sectional area shown in the figure below. The length of the stringers are actually 16mm long but for the analysis have been reduced because the corners at the end are smaller. If this beam is able to withstand the bending moments that the forces above produce then the actual beam should as well. All dimensions are in mm’s. The 2nd moment of area for this I beam needs to be calculated so the future stress calculations can be made. This has been calculated like such. CoG, is locate calculated as such

� =�2

� = � × �� + �2

× �� =�� + 1

2 ��

2�� + ��

60 160

10

1

t

L

CoG

d1

d2 1

2

3 H

4

The local 2nd moment of inertia for beams 1, 2, and 3 are

�� =��

12= ��, �� =

��

12

Using the parallel axis theorem where

�� = � �� + ��

Thus

�� = �� =��

12+ ��(�2)�

�� =��

12+ ��(�1)�

Hence

�� =��

12+ ��(�2)� +

��

12+ ��(�1)�

Thus since

t 1.5 mm L 58 mm H 15 mm

Then the centre of gravity is along this the distance to the local CoG’s

X 30 mm Y 3.05 mm from base d1 2.55 d2 4.45

Therefore

�� = 1446.2�� Area of Beam The Area of the Beam is

� = �� + 2�� = 78�� Bending Moment Analysis The force balance diagram for this beam is

Fb Fa

F1 F2

F4

F3

D1

D2

D3

L

Shear Stress Bending Moments Thus the maximum bending moment is

�� = �� × �1 + (�� − �1) × (�2 − �1) The maximum stress for this beam is then

�� =��

��

Critical Case For critical case 1 the parameters for calculating the maximum stress is

Fa 82.67 N F1 57.26 N D1 41 mm N D2 80 mm Y 15 mm

The maximum bending moment

�� = �� × �1 + (�� − �1) × (�2 − �1) = 4340.46 �� The maximum stress calculated

�� =��

��= 45.02

�� = 45.02��

Fa

Fb

Fa-F1

Fa-F1-F2

Fa*D1 + (Fa-F1)*D2)

Fa*D1

The Factor of safety is

�� =110

45.02= 2.44

The Summary table of the Maximum stresses and Factors of Safety for the two critical cases

Critical Case Maximum stress (MPa) FS 1 45.02 2.44

Stress Analysis of the Line Guide Mechanism It was determined through dynamics analysis that the maximum force exerted on the line guide pins will be of 100 N per pin. However, due to the complexity of the analysis, not shown for sake of conciseness, the load is assumed to be of 200 N per pin. By performing a finite-element analysis of the pin, using Cosmos, with the following boundary conditions: - Fixed ends in the middle of the screws - Distributed load of 200 N on the pin’s outer surface The safety factor for aluminium was found to be 35. Figure 0.3 shows the Von Mises stress distribution in the pin on a magnified displacement field.

Figure 0.3 Line Guide Pin's FEA Results - Von Mises Stress

The side blocks, on which the line guide pins are fixed were analysed with the same loading conditions as the pins, i.e. a 100 N force on each end of the block, due to the fact that the reaction load on either side of the pins are half the total load on the pins. The finite-element analysis was performed, using Cosmos, with the following boundary conditions: - Fixed at the fastening point to the line guide shaft, where the screw is attached

- Distributed loads on the fastening points of the pins of 100 N on either side The safety factor for aluminium was found to be 5. Figure 0.4 shows the Von Mises stress distribution in the side block on a magnified displacement field.

Figure 0.4 Line Guide Side Block's FEA Results - Von Mises Stress

Stress Analysis of the Reel Mount Plate In order to analyse the stress on the reel mount plate, the load have been identified to consist of 100 N attributable to a 5 G acceleration given to the FISH of 1.8 kg, rounded up, in addition to a 50 N attributable to 10 G acceleration, inherent to the BEXUS flight, applied on the reel itself of 0.5 kg, rounded up. In total, a force of 150 N is applied to the mount plate, however, it is important to notice that the force is applied through the center-line of the reel, approximately, which is offset from the plate by 10 cm which result in a moment applied to the plate of 15 Nm. Finite-element analysis, using Cosmos, shows that the safety factor is 3 for a 6 mm thick steel plate, see Figure 0.5, loaded under the following conditions: - Fixed at the four mounting screws - Load is applied as distributed inside the mounting slots of the base of the reel Although the factor of safety is not great, one can see that the regions of higher stress are only present near the mounting holes and the slots. The stress concentrations are most probably due to the hard boundary conditions present at those areas which will not be so hard in reality.

Figure 0.5 Reel Mount Plate FEA Results - Factor of Safety > 3

Stress Analysis of the Reel Motor Mount Similar to the analysis of the reel mount plate, the reel motor mount has been analysed for the loading of the 200 N which comes from a 10 G acceleration on the motor. The finite-element analysis, using Cosmos, was performed with the boundary conditions below and a factor of safety of 3 was also obtained for similar reasons as for the reel mount plate, as shown in Figure 0.6. - Fixed at the mounting holes - Distributed load of 200 N applied to the mounting holes of the motor

Figure 0.6 Reel Motor Mount FEA Results - Factor of Safety > 3

Stress Analysis of the Servo Mounts A final critical part in the assembly is the servo motor mount which are subject mainly to the fairly good torque that the servos can produce, i.e. 1.4 Nm. The servos are 70 mm of height, that is, 70 mm between the top and bottom mounting holes. For reacting to a moment of 1.4 Nm with a moment arm of 70 mm one easily obtains a load of about 20 N, sideways. Finite-element analysis, using Cosmos, with the boundary conditions below has given a factor of safety of 32, as shown in Figure 0.7 by the Von Mises stress on a magnified displacement field. - Fixed at the mounting holes - Distributed load of 20 N on the mounting holes of the servos

Figure 0.7 Servo Motor Mount FEA Results - Von Mises Stress

Stress Analysis of the Aluminium Profile Structure The aluminium profiles used for the structure of the MAIN payload are so-called PU25 from Solectro which are specified by the manufacturer and by previous analyses done at the IRV in cooperation with ESRANGE experts to be: � = 70 �� = 270 �� = 14.3 ∙ 10�� = 12.5 �� = 0.0125 � � = �

�= 1.144 ∙ 10��

The above leads to the determination of the maximum axial load on the sections of PU25 which are limited by the yield stress as opposed to buckling loads for lengths under about 40 cm. This is the

case for all the segments of the MAIN payload’s structure. As seen from the MAIN payload structure in Figure 0.8, the main segments under load are the two-force members making up the bottom pyramid structure and their base supporting beams. The middle square of PU25 segments also carried a bending load but it is smaller than the bending load on the bottom segments. Consequently, the only elements that near to be analysed are the two-force members of 266.5 mm length and the bottom long beams of 400 mm length. The maximum axial loading is specified as 68.8 kN and the maximum bending load on the bottom beam can be obtained from Euler-Bernouilli beam theory. The end conditions used here are simple supports although in reality the ends are fixed to some extent, but since the simple supported case is more restrictive on the maximum load it is just an additional factor of safety in case the end are not properly conditioned at assembly time. One can follow these simple calculations to find the maximum load for bending conditions, for a point load applied at the centre of the beam:

�� = ��

� ��,�� = ��

�= �∙�.��∙��∙��∙��

�.��= 3088.8 �

Now that the maximum loading conditions are established, one can identify the expected loads on the MAIN payload.

Figure 0.8 MAIN Payload's Structure

If one assumes that the upper rectangular “cage” is a rigid body which supports all the loads of the structure, consisting of the weight of all components except the bottom segments under 10 G of upward acceleration. First, the weight of the upper “cage” is calculated as �� = �� − �� = 16.2 �� − 4.2 �� = 12 �� 1200 � �� 10 � �� Simple statics analysis will show that the axial load on the two-force members, at an angle of 18.7 degrees from the vertical, will be about of 315 N which is far below the maximal axial load of the PU25 sections, with a factor of safety of 218. However, it must be noticed here that the PU25 attached to the remaining structure via angle adaptor from Item which are specified at a maximum load of 1000 N under fixed conditions. This reduces the factor of safety to 3.17 which is still a good

Pload

figure. Now for the bending loads, it is clear that the axial load of the two-force members have to be reacted upon by the ends, i.e. the beam segments of the lower square structure. As calculated above, the maximum bending load is 3088.8 N which, under 315 N of load, correspond to a factor of safety of 9.8 which is well within reasonable limits. As a final note, one could remark that there are additional components (electronics and batteries) which were not taken into consideration in the analysis as well as the mass of the lower segments of the structure. However, given the obtained factors of safety, one can, with confidence, assume these additional loads not to drive the stresses above the yielding limits and, in fact, still conserve a significant margin of safety. Another final issue, elaborated in the thermal analysis, is the likelihood of adding an insulation section at the interface between the lower angle adaptors and the two-force members which could have repercussions on the loading at those interfaces. However, the structural strength of EPS material is good and most of the load will be taken by the joining screws which are rated at more than 20 kN of axial load (for M6 steel screws of length of 60 mm), as specified by McMaster-Carr’s industrial ratings of ISO 7380 for class 10.9 screws.

5.4 THERMAL ANALYSIS Thermal Analysis of the MAIN Payload The stratospheric environment poses some challenges and some advantages in terms of thermal considerations. The challenge is that the temperature ranges experienced in the BEXUS flight include a passage of the tropopause at temperatures -70 degrees Celsius to a rise in the stratosphere up to temperatures of -30 degrees at the altitude of the BEXUS’ steady flight period. The advantage is that the convective heat transfer can be neglected from the dual effect of extreme low pressure ambient air and the shielding that the gondola provides to an extent from winds or natural convection. The thermal problem can be stated as the problem to maintain inside temperatures to levels at which the components can operate while handling the heat generated by those same components during operations. First to identify thermal loads: Thermal Heat Sources:

• Heat generated from the reel motor, estimated at 30 W

• Heat generated from the line guide motor, estimated at 30 W

• Heat generated from the batteries, estimated at 5 W

• Heat generated from the electronics, estimated at 2 W

Then to identify the heat sinks, one can remark that in the absence of convection, the main heat sink is through the interfaces to the gondola and possibly by radiation. The radiation will first be neglected and the efforts will be concentrated on the interface to the gondola. Assuming the gondola is in thermal equilibrium with the environment and that its size, in terms of thermal capacity, is much larger than the MAIN payload, the gondola can be considered as a heat reservoir, i.e. with constant temperature and infinite heat capacity. The strategy will be to maintain the temperature in a selected portion of the MAIN payload by designing the thermal interfaces to the outside. The goal is to impede the flow of heat to the outside in order to keep the temperature inside within operating ranges without needing too much power during the non-operating phases of the mission. Then during the operating phases of the mission, the heat generated from the sources needs to be evacuated or stored in the bulk of the MAIN payload. Let us first concentrate on the non-operating phases of the mission. As seen in Figure 0.9, the payload bulk is set against the gondola’s heat reservoir via aluminium profiles which will act as heat pipes since all other thermal conduction processes are negligible compared to these heat pipes. Since all components of the MAIN payload are attached to the upper “cage” structure, it is essential to maintain the temperature of this section within operating ranges of the components. Except for the electronics, all components only require temperatures above -20 degrees Celsius in order to guarantee good operations. The electronics for their part can be treated as a separate thermal problem, one which poses no challenge and will not be considered here. A second property of the MAIN payload bulk is the fact that it is almost entirely built of aluminium which is a remarkable heat conductor and makes the temperature quasi uniform in that section.

Figure 0.9 MAIN Payload's Thermal Sections

In the light of the aforementioned assumptions, one can realise that the problem can be reduced to finding how much heat will flow through the heat pipes in order to maintain a temperature of -20 degrees Celsius in the bulk when the reservoir is at -30 degrees at steady state and -70 degrees for a short period. It is clear that aluminium is a good conductor and that much heat will be able to flow from the bulk to the reservoir. For that reason, the heat pipes will be terminated by a layer of insulating polystyrene (EPS). Structurally, EPS is almost as strong as aluminium in compression which may come to a surprise but is a known fact. Nevertheless, the mounting of the ends of those two-force members will be accomplished with M6 steel screws which are by far strong enough to hold the structural loads. And hence, a 50 mm thick section of EPS will be terminating the heat pipes. This leads to the following analysis:

�

��= �

��+ �

��

Where the C stands for thermal conductance in W/K. It remains to obtain the conductance of the aluminium heat pipes, the screw and the EPS section.

�� = ��

=��

�� ∙ �.��

�.�� = 0.2791 �

�

�� = ��

=��

�� ∙ �.��

�.�� = 0.01636 �

�

�� = ��

� = 0.68 ��

∙ 0.000255 �� = 0.000425 ��

From the above, we obtain an overall heat conduction of 0.01583 W/K for one member. As there are four members in the structure, this number is multiplied by 4 and we obtain a thermal conductance between the bulk and the reservoir of 0.06332 W/K. This means effectively, that the thermal insulation provided at the interface to the gondola can keep a temperature difference of almost 16 degrees Celsius with only 1 W of heating power, which is provided by the electronics easily. Of course, during the ascent, the tropopause will impose a temperature difference of 50 degrees Celsius between the bulk and the reservoir which will demand about 3.3 W of power from the heaters and the electronics combined, and only for a fairly short amount of time, less than 1 hour. Additionally, some small heaters will be required from specialised items such as the batteries and the reel if our tests find that these are necessary.

Now the remaining issue is the operating phases of the mission in which to much heat is generated and needs to be handled. In classical thermal analysis, it would be advisable to evacuate the heat from the payload at the same rate as it is being generated. However, in this case, the operating phase of the mission is at most 2 hours due to the flight characteristics. The strategy employed to is to hold the heat within the bulk of the MAIN payload. One can calculate the heat capacity of the bulk by summing the aluminium and steel components of the bulk, which comes up to 3654 g of aluminium and 4900 g of steel. One then obtains the thermal capacity: �� = �� ∙ �� + �� ∙ �� = 0.896 �

�� ∙ 3654 � + 0.46 �

�� ∙ 4900 � = 5528 �

�

�� ∙ � = �� ∙ ∆� = 5528 ��

∙ 70 � = 386.96 ��

Where C refer to the total heat capacity. Here, the temperature difference is taken as 70 degrees Celsius because after the non-operating phase, the temperature is kept at -20 degrees and the maximum operating temperature of the limiting components is 50 degrees Celsius, as seen in Figure 0.10. If one considers the operating condition that one motor is operated at full capacity, generating 30 W of heat, along with the heat of the batteries and the electronics of at most 10 W, one obtains the following operating time:

� = ��

= 9674 � = 161 �� = 2 ℎ�� 41 ��

The above clearly shows that the MAIN payload can operate under full duty cycle for the whole time of the experiment without over-heating. Furthermore, some heat evacuation will be done via radiation by simply painting the inside of the MAIN payload in black and leaving the outside surface white, limiting the heat input from radiation while evacuating heat when the inside is hot and not so much when it is cold.

Figure 0.10 Thermal Data Table for MAIN Payload

5.5 PICTURES

Figure 0.11 Showcase of Purchased Hardware

Figure 0.12 Mikael Persson in First Step of Assembly

Figure 0.13 Line Tied to the Reel with Locked Half Blood Knot

Figure 0.14 The Saltiga Surf Spinning Reel 6000 with 200m of Braided Line

5.6 TEST PLAN AND RESULTS The tests are planned according to the table on the following pages.

Test No Test ObjectiveRisks Assessedor Requirements Description

Mechanical Tests

M.1 Reel strength Test - Normal

Confirm that the reel can withstand the accelerations of the gondola and support the FISH Risk.M – M 07

The reel will have to succesfully support an oversized weight with vibrations

M.2 Reel strength Test - Mission temp

Confirm that the reel can withstand the accelerations of the gondola and support the FISH at mission temperature Risk.M – M 07

The reel will have to succesfully support an oversized weight with vibrations at mission temperature

M.3 Line Strength Test - Normal Test the line strength until it breaksRisk.M – M 08Risk.M – M 09

The line will be pulled tension until it breaks

M.4 Line Strength Test - Mission tempTest the line strength until it breaks at mission temperature

Risk.M – M 08Risk.M – M 09

The line will be pulled tension until it breaks at mission temperature

M.5 Brake strength Test - Normal

Confirm that the reel brake can withstand the shock of the braking of the FISH

Risk.M – M 01Risk.M – M 03Risk.M – M 04

The line will be dropped with a mass to various heights and brought to a stop

M.6 Brake strength Test - Mission temp

Confirm that the reel brake can withstand the shock of the braking of the FISH at mission temperature

Risk.M – M 01Risk.M – M 03Risk.M – M 04

The line will be dropped with a mass to various heights and brought to a stop, under cold conditions

M.7 Reliability of Bail Mechanism TestConfirm the repeatability of the bail mechanism under various conditions Req.F.2

The bail release system will be tested under all possible conditions and repeated to obtain confidence in the repeatability of the mechanism

M.8 Parachute deployment Test Test to see if the Parachute deploys Req.O.3The FISH will be dropped from a tall building and the parachute deployed

M.9 Line guide strength test

Test that the line guide is strong enough to withstand the shock of braking the FISH Risk.M – M 06

The line guide will have to succesfully support an oversized weight with vibrations

M.10 Line guide functionality - NormalTest that the line guide's operating principles are appropriate Risk.M – M 06

The line will be dropped with a mass to various heights, brought to a stop and reeled back by the line guide

M.11Line guide functionality - Mission temp

Test that the line guide's operating principles are appropriate under mission temperature Risk.M – M 06

The line will be dropped with a mass to various heights, brought to a stop and reeled back by the line guide at mission temperature

M.12 Line Interface Test - Normal

Test to see the line interface and withstand the mission loads + factor of safety


The Reel line and fish will be placed in tension to test if it can handle mission load with FS

M.13 Line Interface Test - Mission Temp

Test to see the line interface and withstand the mission loads + factor of safety at mission temp


The Reel line and fish will be placed in tension to test if it can handle mission load with FS at mission temperature

M.14 Mounting structure testTest that the structure can withstand all loads and vibrations Risk.M – M 07

The structure will have to succesfully support an oversized weight with vibrations

M.15 Reel functionality - Normal Test the functional principles of the reel Req.F.2

The line will be dropped by the reel with a mass to various heights, brought to a stop and reeled back by the reel

M.16Reel functionality - Mission Temperature

Test the functional principles of the reel under mission temperature Req.F.2

The line will be dropped by the reel with a mass to various heights, brought to a stop and reeled back by the reel under mission temperatures

M.17 Reel functionality - Mission PressureTest the functional principles of the reel under mission pressure Req.F.2

The line will be released to the experimental fixture by the reel with a mass to various heights, brought to a stop and reeled back by the reel under mission pressures

M.18 Center of Gravity TestTo locate the center of Gravity of the Fish Req.F.1

The FISH will be place on multiple weight scales to find the x, y, z center of gravity

M.19 FISH aerodynamic Stability TestTo test the Aerodynamic Stability of the FISH Req.F.1

Place a line at the center of gravity and spin the FISH around in a circle, Observe any major movements of the FISH

M.20FISH insulation Thermal Test - Mission Temp

To test if the internal environment of the FISH is at the correct temperature during mission temperature Req.F.7

Place the outer structure and Thermal insulation in a thermal chamber for the mission length and monior the internal temperature

M.21FISH insulation Thermal Test - Mission Temp and Pressure

To test if the internal environment of the FISH is at the correct temperature during mission conditions Req.F.7

Place the outer structure and Thermal insulation in a thermal chamber for the mission length and monior the internal temperature

M.22 Fish Aerodynamic testTo calculate the Cl and Cd of the FISH with respect to its angle of attack Req.F.1

Place the FISH in the wind tunnel and calculate the Cl's and Cd's at various angles of attach

M.23 Reel tether testTo test the over all functionallity of the reel and tether mechanism Req.F.1

The Reel along with the motors will be attached to the test rig and a complete simulation of the system will be conducted

Test No Test Conditions Test Location Required Resources Dates Reliant on Responsibility Participants

M.1 Sea Level conditions Kiruna Large masses May Reel and line present Mikael Campbell, Mikael

M.2 Mission Temperature KirunaLarge massesThermal Chamber June Reel and line present Mikael Campbell, Mikael

M.3 Sea Level conditions Kiruna Force Gauge May Line present Campbell Campbell, Mikael

M.4 Mission Temperature KirunaThermal Chamber Force Gauge May

Line present and thermal chamber times Campbell Campbell, Mikael

M.5 Sea Level conditions Kiruna

Mounting fixtureForce GaugeSufficient drop heightLarge masses May

Reel and line presentTests M.1 & M.3 completed Mikael Campbell, Mikael

M.6 Mission Temperature Kiruna

Mounting fixtureForce GaugeSufficient drop heightLarge massesThermal Chamber or cooling system June

Reel and line presentTests M.2 & M.4 completed Mikael Campbell, Mikael

M.7 Sea Level conditions KirunaLarge massesSufficient drop height August

Structure and Bail release mechanism built Mikael Campbell, Mikael

M.8 Sea Level conditions Kiruna Tall Building August FISH Constructed Campbell Campbell, Mikael

M.9 Sea Level conditions Kiruna Large masses JuneLine Guide BuiltLine present Mikael Campbell, Mikael


Mounting fixtureForce GaugeSufficient drop heightLarge masses

JulyAugust

Line presentStructure and line guide mechanism builtTest M.3 & M.9 completed Mikael Campbell, Mikael


Mounting fixtureForce GaugeSufficient drop heightLarge massesThermal Chamber or cooling system

JulyAugust

Line presentStructure and line guide mechanism builtTest M.4 & M.9 completed Mikael Campbell, Mikael

M.12 Sea Level conditions Kiruna Force Gauge JuneLine, Reel and Fish interface constructed Campbell Campbell, Mikael

M.13 Mission Temperature KirunaThermal Chamber Force Gauge June

Line, Reel and Fish interface constructed Campbell Campbell, Mikael

M.14 Sea Level conditions Kiruna Large masses June Structure built Mikael Campbell, Mikael


Mounting fixtureForce GaugeSufficient drop heightLarge masses August

Line and Reel presentReel mechanism builtBail mechanism builtTests M.1, M.3, M.5, & M.7 completed Mikael

Campbell, Mikael, Mikulas


Mounting fixtureForce GaugeSufficient drop heightLarge massesThermal Chamber or cooling system August



M.17Mission Temperature and Pressure Kiruna

Mounting fixtureForce GaugeTest fixtureVacuum Chamber August



M.18 Sea Level conditions Kiruna 4 scales, minimum 2 August Fish Constructed Campbell Campbell, Mikael


Line, a place to attach the line to the FISH at the center of Gravity August Fish Constructed Campbell Campbell, Mikael

M.20 Mission Temperature KirunaTemperature sensors, Thermal Chamber June

Structure and Insulation of the FISH constructured Campbell Campbell, Mikael

M.21Mission Temperature and Pressure Kiruna

Temperature sensors, Thermal and presure Chamber June

Structure and Insulation of the FISH constructured Campbell Campbell, Mikael

M.22Mission Temperature and Pressure Lulea Wind Tunnel August Fish Structure Built Campbell Campbell, Mikael

M.23 Sea Level conditionsLeiden Netherlands Delta Utec August

Reel and interfaces are connected Campbell Campbell, Mikael

TEST M.1: Aim Method Results and Discussion Conclusion


TEST M.3 : Line Strength Test at Room Temperature Aim To verify requirement XXX by determining the braking force of the Superbraid line. Method The line was fed through two carabina’s, which were both attached to a weights machine. This machine is designed for the gym but is easy to use and easy to change the weight that can be placed on the line. The carabina’s was attached to two points that will experience the complete force of the weight once the machine is in used. Specific weights can only be used ranging from 5 – 100 kg moving in 5 kg steps. This experiment was repeated on 5 different pieces of Superbraid so the average braking force could be calculated along with the reliability of the results can be increased. Result and Discussion The results of this experiment are shown in Table 2 Weight (kg) Force (N) Line 1 Line 2 Line 3 Line 4 Line 5 5 49.05 No No No No No 10 98.1 No No No No No 15 147.15 No No No No No 20 196.2 No No No No No 25 245.25 Yes Yes Yes Yes Yes 30 294.3 Yes Yes Yes Yes Yes

Table 2: The Results from the room temperature line strength test

As can be seen the line continuously broke when the weight was 25kg and above, thus is can be assumed that the maximum stress the line can withstand is 196.2N Conclusion

The result show that the maximum force the line can withstand is 196.2 N at room temperature. This verifies the breaking force of the line as stipulated by risk M – M08 and M – M09. To improve the lines characteristics the line will have to be tested at different temperatures.





TEST M.8: Aim Method

Results and Discussion Conclusion





TEST M.13: Aim

Method Results and Discussion Conclusion





TEST M.18: Aim

Method Results and Discussion Conclusion





TEST M.23:

Aim Method Results and Discussion Conclusion

5.7 COMPONENT SPECIFICATIONS

Print Page

Built to Saltiga standards, they are specifically designed for optimum surf fishing performance with today’s braided lines. click here for the perfect performance match to Saltiga Surf spinning reels. Saltiga Surf Features:

Lightweight “Air Metal” Magnesium body treated to prevent saltwater corrosion.

Seven ball bearings, including CRBB anti-corrosion bearings, plus roller bearing

Digigear™ digitally designed and machined gears

Dual, selectable Infinite Anti-Reverse

Tubular stainless Air Bail® Ultra-reliable, manual bail closure Bail lock prevents handle and rotor

turning during a cast Washable design with sealed drag

system Dual CRBB ball bearing line roller Silent Oscillation (with worm gear

levelwind) Lifetime™ Bail Spring Machined aluminum spool and

handle

SASURF5000

Digigear® Digital gear design ensures a perfect mesh.

CRBB Super Corrosion Resistant Ball Bearings.

For optimum performance, use Saltiga® Surf braided

Page 1 of 2Daiwa | Saltiga Surf

01/04/2009http://www.daiwa.com/Reel/detail.aspx?ID=199

line.

CRBB = Super Corrosion Resistant Ball Bearing, BB = Stainless Steel Ball Bearing, RB Roller Bearing

Model Number

Action FW/SW Bearings Gear

Ratio Line Per Handle

Turn Wt. (oz.)

Line Capacity (Lb. Test/Yards)

Drag Max

Surf Spinning Reels

SASURF4500 -/M 4CRBB,3BB, 1RB

4.1 : 1 32.7" 18.00

12/350, 14/300, 17/220 BRAID: 15/620, 20/520,30/330

33.0

SASURF5000 -/MH 4CRBB,3BB, 1RB

4.1 : 1 32.7" 18.00

14/400, 17/310, 20/24030/490 BRAID: 15/910, 20/760,30/490

33.0

SASURF5500 -/H 4CRBB,3BB, 1RB 3.6:1 28.0” 18.70

20/290, 25/230, 30/190 BRAID: 15/1080, 20/900,

30/580 33.0

SASURF6000 -/XH 4CRBB,3BB, 1RB 3.6:1 28.0” 18.70

25/280, 30/230, 40/170 BRAID: 15/1350, 20/1130,

30/730 33.0

© 2009 Daiwa Corporation. Daiwa Corporation believes the specifications in this site to be correct. However, Daiwa reserves the right to make changes in specifications without prior notice. Daiwa prices and programs are subject to change without prior notice. Daiwa reserves the right to make changes without obligation. Site designed and maintained by Dean Mitchell Design

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Page 2 of 2Daiwa | Saltiga Surf

01/04/2009http://www.daiwa.com/Reel/detail.aspx?ID=199

Measurements are in millimeters. To convert millimeters to inches, insert specs below:

Millimeters: Inches: Convert

Page 1 of 1Futaba® Servo Specs

19/05/2009http://www.futabarc.com/servos/specs-lineart/specs-futm0038.html

Hinge 6 30x30, heavy-duty // Order No.: 0.0.419.80

For connecting profiles at various angles up to 180° and for use as heavy-duty hinges (adjustment range ± 90°). When used in conjunction with the spacer rings, they can be used as freely movable hinges. If the spacer rings are removed, they can be used as rigid angle elements, e.g. bracing, and can also be pinned. The Hinges with Clamp Lever can be locked in position or released. Particularly suitable for adjustable holders, swivel-type arms for Parts Containers and other similar equipment.

Page 1 of 5Hinge 6 30x30, heavy-duty

24/05/2009http://catalog.item-international.com/Onlinekatalog/web/EN/print/artikelinfo/Hinges_hea...

Calculation of the strut length L:



of 5Hinge 6 30x30, heavy-duty


Click here to find our CAD data.

Extensive product descriptions and/or fitting instructions are available for this product



Print this page for your records or for later reference.



Oriental Motor U.S.A. Corp.1001 Knox St.Torrance, CA 90502Tel: 800-418-7903 Fax: 800-309-7999www.orientalmotor.com

Item # AXH230KC-15, Brushless Speed Control System$336.00

Brushless Speed Control SystemBrushless speed control system provides space savings and high power output in an easy to use solution.● Compact board-level driver● Compact, high power motor● Superior speed stability● Constant torque over a wide speed range

SPECIFICATIONS · FEATURES · MULTI-SPEED SETTING METHOD

SPECIFICATIONS

Product Line VEXTA ®

Motor Type Brushless

Motor Frame Size 2.36 in. sq.

Output Power HP (W) 1/25 HP (30W)

Power Supply 24 VDC

Gear Ratio (X:1) 15 :1

Gear/ Shaft Type Parallel Shaft

Rated Torque (lb-in) 14.1

Variable Speed Range (r/min) 6.7 ~ 167

Permissible Load Inertia 77 oz-in2

Type Cable

Available to Ship Same Day (if ordered by 12pm PST) (1-10 pcs)

Components GFH2G15 (Gearhead)AXHM230KC-GFH (Motor)

AXHD30K (Driver)

RoHS Compliant No

Safety Standards ULCSACE

3/7/2009 | Page 1 of 2

http://www.orientalmotor.com

CE Marking EMC Directives

Control System Any one of the following methods: 1. By built in potentiometer (1 piece) 2. By externalpotentiometer (20 k Ω 1/4 W) 3. By DC voltage control (0 ~ 5 VDC)

Insulation Class Class E [248°F (120°C)]

Insulation Resistance [Motor] 100 M Ω or more when 500 VDC megger is applied between the windings and theframe after rated motor operation under normal ambient temperature and humidity.

[Driver] 100 M Ω or more when 500 VDC megger between the power supply input terminaland the frame after 1 minute continuous operation under normal ambient temperature and

humidity.

Dielectric Strength [Motor] Sufficient to withstand 0.5 kVAC at 50 Hz applied between the windings and theframe for 1 minute after continuous operation under normal ambient temperature and

humidity.[Driver] Sufficient to withstand 0.5 kVAC at 50 Hz applied between the power supply input

terminal and the frame for 1 minute after continuous operation under normal ambienttemperature and humidity.

Ambient Temperature Range [Motor] 14°F ~ 104°F (-10°C ~ 40°C)14°F ~ 122°F (-10°C ~ 50°C) for 100/200 VAC, nonfreezing

[Driver] 32°F ~ 122°F (0°C ~ 50°C), nonfreezing

Ambient Humidity 85% maximum (noncondensing)

Operating Atmosphere No corrosive gases or dust

Degree of Protection [Driver] IP00[Motor] IP65

FEATURES

Speed Control Method (Select one of the following) Internal potentiometerExternal DC Voltage (0~5VDC)

External potentiometer (20kΩ, 1/4W)

Number of Speed Settings 2

Multi-Speed Setting Method Switching between 2 speedsOne speed is set by the internal potentiometer (1 pc), while another speed is set by an

external potentiometer (optional PAVR-20KZ) or by external DC voltage (0~5 VDC).

Instantaneous Stop Yes

Multi-Axes Control Yes

Alarm Output Yes

Position Control Mode No

Torque Limit Control No

Vertical Drive (Gravitational Operation) No

Max. Extension Length (m) 2

MULTI-SPEED SETTING METHODSwitching between 2 speedsOne speed is set by the internal potentiometer (1 pc), while another speed is set by an external potentiometer (optional PAVR-20KZ) or by external DCvoltage (0~5 VDC).

3/7/2009 | Page 2 of 2

mec

han

ics

MECHANICS Aluminium Profiles

Aluminium Profiles

Universal Profiles PU-Profiles

Features

• for fast and easy assembly of hou-sings, tables and frames

• aluminium, anodized• made according to DIN 17615• light, compact, solid• universally applicable• high stress-resistance• with our fast-clamped connections

very firm, stress, reversion and ben-ding resistant profile connections areproduced by means of profile bore holes and clamping pieces

• cut to size on request

Technical Data

Dimension Drawings

B8

PU 25 PU 50

dimensions (W x H) 25 x 25 mm 50 x 25 mm

length up to 3 m (special lenghts upon request)

weight 690 g/m 1,270 g/m

4 T-groove indentions for slide nuts M6hollow indention, Ø 5.5 mm for M6

4 T-groove indentions for slide nuts M62 hollow indentions, Ø 5.5 mm for M6

inertia moment IX 1.43 cm4 10.99 cm4

inertia moment IY 1.43 cm4 2.81 cm4

moment of resistance WX 1.14 cm3 4.40 cm3

moment of resistance WY 1.14 cm3 2.25 cm3

1725

6.5

10.5

28

R 5

R 7.

5

5.5

4

PU 25

6.5

10.5

1725 5.5

4

28

R 5254250

Ø 15

10.5

PU 50

profile designationArt. No: L = 1000Art. No: L = 3000

PU 25W 25 x H 25 mm

200 001 1000200 001 3000

PU 50W 50 x H 25 mm

200 002 1000200 002 3000

Ordering Data

mec

han

ics


Aluminium Profiles

B14

Accessory

Threaded Strips

Slide Nuts

Threaded Strip M6• 13 x 6 mm• galvanized• M6 grid 50 • 3 pieces à 1 m • suitable for PT / RE 40, 65 / PGItem no.: 209 010

Threaded Strip M6• 10 x 4 mm• galvanized• M6 grid 50• 3 pieces à 1 m • suitable for PT / RE 40, 65 / SP / PGItem no.: 209 011

Slide Nut M6 (fig. 1)• L 25 x W 10 x H 3,5 • galvanized• 100 pieces• for all except PT / RE 40, 65 / PS 50 / SP / PG

Item no.: 209 001 0005

Slide Nut M6 (fig. 1)• L 25 x W 13 x H 5• galvanized• 50 pieces • suitable for PT / RE 40, 65 / PGItem no.: 209 004 0001

Slide Nut 2 x M6 (fig. 2)• L 45 x W 10 x H 3,5 • galvanized• 50 pieces• for all except PT / RE 40, 65 / SP / PGItem no.: 209 002 0004

Slide Nut 2 x M6 (fig. 2)• L 45 x W 13 x H 6• galvanized• 2 x M6 grid 25 mm • 25 pieces• suitable for PT / RE 40, 65 / PGItem no.: 209 005 0001

Slide Nut M5• L 25 x W 10 x H 3,5• galvanized• 20 piecesItem no.: 209 006 0001

Angular Slide Nut 2 x M6 (fig. 3)

•galvanized• 25 pieces• for all except PT / RE 40, 65 / SP / PGItem no.: 209 021 0003

Special Slide Nut3 x M6 (fig. 4)

•galvanized• 25 pieces• for all except PT / RE 40, 65 / SP / PGItem no.: 209 022 0003

T-Groove Blocks

T-Groove Block M6•DIN 508• hardened• 20 pieces• suitable for PT / RE 40, 65 / PGItem no.: 209 119 0003

Clamping Vices

Clamping Vice 1 (see figure)

•L 152 x W 130 x H 45 mm • grid 100 •suitable for RE / PTItem no.: 290 055

Clamping Vice 2 (without figure)

•L 215 x W 175 x H 75 mm• grid 125 • suitable for RE / PTItem no.: 290 056

Clamping Blocks

Clamping Block SE•with adjustable screw M6• 2 pieces• suitable for all except PP / PT / PM / SPitem no.: 290 051

Clamping Devices

Hand Lever Clamping Device SH 1• for all except PP / PT / RE 40, 65 / SP / PGItem no.: 290 001

Hand Lever Clamping Device SH 2

• for all except SPItem no.: 290 002

Pneumatic Clamping Device SP 1•lift 10 mm• L 65 x W 10 x H 10 mm• grid 50• suitable for PT / REItem no.: 290 010

Pneumatic Clamping Device SP 2• lift 5 mm• L 65 x W 12 x H 50 mm• grid 50 • suitable for PT / REItem no.: 290 011

Stop Rails

Stop Rail • W 20 x H 10• grid 50• 2 pieces + mounting material • suitable for all except SP

L 125 mmItem no.: 290 021 0125

L 175 mmItem no.: 290 021 0175

L 225 mmItem no.: 290 021 0225

mech

anics

MECHANICSAluminium Profiles

Aluminium Profiles

B15

Accessory

Panel Guide Strips/Profiles

Panel Guide Strip black1-part• for Plates 3 - 6 mm• 1 piece à 10 m • suitable for all except PT / SP / PGItem no.: 209 202 0001

Panel Guide Profile black2-part • for Plates 3 - 6 mm• 1 piece à 3 m • suitable for all exceptPT / SP / PGItem no.: 209 212 3000

Profile Connecting Cubes

Profile Connecting Cubeblack•10 pieces + mounting material• suitable for PU 252-fold

Item no.: 209 104 00023-fold

Item no.: 209 103 0002


Item no.: 209 106 00024-fold

Item no.: 209 107 0002


Item no.: 209 108 00025-fold

Item no.: 209 109 0002

Profile Coverings

Profile Coveringsblack•PU 25 - 25 x

Item no.: 209 105 0003•PU 50 - 25 x

Item no.: 209 126 0003•PL 40 - 20 x

Item no.: 209 127 0003•PL 80 - 20 x

Item no.: 209 128 0003•PS 50 - 25 x

Item no.: 209 129 0003•PS 80 - 20 x

Item no.: 209 130 0003•PS 140 - 10 x

Item no.: 209 130 1001•PG 200 - 10 x

Item no.: 209 130 2000

Aluminium Cast Pedestals• 2 pieces + mounting material • suitable for PGanthracite

Item no.: 248 700 1000light grey

Item no.: 248 700 2000

Aluminium Cast Pedestals

Plastic Rollers

Plastic Rollers Ø 50black (M6)• 4 pieces• 2 with and 2 without locks for PU 25

Item no.: 209 040 0012for PU 50

Item no.: 209 040 0011

Ruberized Steering Rollers Ø 75(M10)• 4 pieces• 2 with and 2 without locks • for PL 40 / PS 50Item no.: 209 043 0011

Steering Rollers

mec

han

ics


Aluminium Profiles

Accessory

B16

Plastic Pedestals

Plastic Pedestals with rubber plate• 4 pieces + adjusting screws• black

for PU 25• Ø 40• adjusting screws M6 x 15 mm

Item no.: 209 029 0003

for PL 40 / PS 50• Ø 60• adjusting screws M10 x 45

Item no.: 209 032 0003


Item no.: 209 031 0013


Item no.: 209 034 0001


Item no.: 209 033 0003

Aluminium Pedestals

Aluminium Pedestals with rubber plate•4 pieces + adjusting screws

for PU 50• Ø 50• adjusting screws M16 x 30• natural

Art.-Nr.: 209 030 0000

for PS 100 / 140• Ø 170• adjusting screws M16 x 100• black

Art.-Nr.: 209 035 0001

T-Groove Coverings

T-Groove Covering• 30 m • (turquoise = similar RAL 5018)• for all except PT / RE 40, 65 / SP / PG

black

Item no.: 209 201 0004turquoise

Item no.: 209 201 0003

AluminiumCorner Connection

Aluminium Corner Connection• L 25 x W 25 x H 15• 10 pieces + mounting material • suitable for RE / PU / PS 50

natural

Item no.: 209 114 0101black

Item no.: 209 114 0111

Aluminium Corner Connection• L 40 x W 40 x H 22• 10 pieces + mounting material • suitable for PP / PL / PS 80 / PS 140

natural


Item no.: 209 115 0111

Aluminium Corner Connection• L 50 x W 50 x H 15• 10 pieces + mounting material • suitable for RE / PM / PU / PS 50

naturalItem no.: 209 116 0101

black

Item no.: 209 116 0111

Aluminium Corner Connection• L 80 x W 80 x H 22• 10 pieces + mounting material • suitable for PP / PL / PM / PS

natural


Item no.: 209 117 0111

AluminiumFloor Mounting

Aluminium Floor Mounting• L 120 x W 40 x H 75 • 2 bore holes Ø 11, grid 90 mm • suitable for PL / PGItem no.: 209 300 0002

Cross Member out of PP 50

Cross Member out of PP 50• L 490 mm• miter sawed• bore holes M6• for all except PT / RE 40, 65 / SP / PGItem no.: 209 300 0000

Plastic Strap Hinge• L 65 x W 40• 10 pieces + mounting material• grid 43 x 20• suitable for PLItem no.: 209 050 0012

Aluminium Strap Hinge• L 40 x W 40 mm• 10 pieces + mounting material• grid 25 x 25• for all except PT / RE 40, 65 / SP / PGItem no.: 209 050 0011

Strap Hinge

mech

anics

MECHANICSAluminium Profiles

Aluminium Profiles

Accessory

B17

Strap Hinge• L 80 x W 40 mm• zinc diecast• 2 pieces• grid 24 x 53 mm• for all except PT / RE 40, 65 / SP / PGItem no.: 209 050 0021

AluminiumMounting Angle

Aluminium Mounting Angle•2 pieces• Angle of gradient adjustable• suitable for RE / PGItem no.: 209 300 0004

Mounting Bracket

Mounting Bracket for pedestal / rollers • steel galvanized• 2 pieces• H 33 mm• suitable for all except SPItem no.: 209 300 0003

Application Sample

Clamping set

mm

X

ru

dilgi

®X

4.1

Inch

iglidur® X – The High TechProblem Solver

Temperature resistant from -100°C to+250°C in continuous operation

Universal resistance to chemicals

High compressive strength

Very low moisture absorption

Great wear resistance through the entiretemperature range

Colly Components AB. Box 76, 164 94 Kista. Tel 08-703 01 00. Fax 08-703 98 41. www.colly.se

X

+ 250º

- 100º

ru

dilgi

®X

4.2

When to use iglidur® X plain bearings:

•when especially high temperature

resistance is necessary

•For pressure loads

up to 150 MPa

•For linear movements with stainless steel

•For linear movements, especially at

high temperatures

•when universal resistance to

chemicals is required

When not to use the iglidur® X plain bearings:

•For very low wear at high loads

iglidur® Q, Z

•For underwater applications

iglidur® H, H370

•For edge pressure

iglidur® Z

Price Index

3 Styles

> 566 Dimensions

Ø 2 - 75 mm

High Tech Problem Solver

temperature resistant from -100°C to +250°C (short term to + 315°C)

universal resitance to chemicals

high compressive strength

very low moisture absorption

high wear resistance over the entire temperature range

Picture 4.1: Intake control device

Picture 4.2: Battery decanting

mm

X

4.3

0,001 0,01 0,1 1 1 00,1

1

10

100

1000

Inch

Material Table

Table 4.1: Material Data

General Properties Unit iglidur® X Testing Method

Density g/cm3 1,44

Colour black

Max. moisture absorption at 23°C / 50% r.F. % weight 0.1 DIN 53495

Max. moisture absorption % weight 0.5

Coefficient of sliding friction, dynamic against steel µ 0.09 - 0.27

p x v-value, max. (dry) MPa x m/s 1.32

Mechanical Properties

Modulus of elasticity MPa 8,100 DIN 53457

Tensile strength at 20°C MPa 170 DIN 53452

Compressive strength MPa 100

Permissible static surface pressure (20°C) MPa 150

Shore D hardness 85 DIN 53505

Physical and Thermal Properties

Max. long term application temperature °C 250

Max. short term application temperature °C 315

Min. application temperature °C -100

Thermal conductivity W/m x K 0.6 ASTM C 177

Coefficient of thermal expansion (to 23°C) K-1 x 10-5 5 DIN 53752

Electrical Properties

Specific volume resistance ? cm < 105 DIN IEC 93

Surface resistance ? < 103 DIN 53482

Graph. 4.1: Permissible p x v - values for iglidur® X running dry against a steel shaft, at 20°C

Surface Speed [m/s]

]aP

M[ da

oL

Picture 4.3: Flaps, valves

Picture 4.4: Catering equipment

X

ru

dilgi

®X

4.4

0 25 50 75 100

0

1

2

3

4

5

6

7

8

0 25 50 75 100 125 150 175 200 225 2500

30

60

90

120

150

180

23 °C60 °C

m/sec Rotaring Oscilating Linear

Continuous 1.5 3 5

Short term 3.5 4 6

iglidur® X Application Temperature

Minimum - 100 °C

Max., long term + 250 °C

Max., short term + 315 °C

Table 4.2: Maximum surface speeds

Table 4.3: Temperature limits for iglidur® X

Picture 4.5: Application on an

outboard engine

Graph 4.3: Recommended maximum permissible static sur-

face pressure of iglidur® X as a function of temperature

Temperature in °C

]aP

M[ da

oL

iglidur® X is defined by its combination of

high temperature resistance with com-

pressive strength, along with high resistance

to chemicals.

Compressive Strength

Graph 4.2 shows how iglidur® X plain bea-

rings deform elastically under load. Graph

4.1 on the preceding page shows the maxi-

mum p x v values at room temperature. In

this case, the compressive strength of igli-

dur® X even measures up to that of steel.

Graph 4.3 shows the special compression

resistance of iglidur® X at very high tempe-

ratures. Even at the highest long term appli-

cation temperature of 250°C iglidur® X plain

bearings still withstand a static surface pres-

sure of approximately 30 MPa.

Graph 4.2

Compressive Strength, Page 1.12

Permissible Surface Speeds

iglidur® X is designed for higher speeds than

other iglidur® bearings. This is due to its high

temperature resistance and excellent heat

conductivity. These benefits are readily

apparent in the pxv values of max.

1.32 MPa x m/s.

However, only the smallest radial loads may

act on the bearings. At the given speeds,

friction can cause a temperature increase

to maximum permissible levels.

Surface Speed, Page 1.14

p x v Value, Page 1.16

Temperature

In terms of temperature resistance iglidur®

X has also taken on a leading position.

Having a permissible long term application

temperature of 250°C iglidur® X will even

withstand 315°C for the short term.

As in all thermoplastics, the compression

resistance of iglidur® X decreases with

increasing temperature. However, the wear

drops considerably when used within the

observed temperature range of 23°C to

150°C In certain cases, relaxation of the

Graph 4.2: Deformation under load and temperature

% ni

noita

mrofe

D

Load [MPa]

e

X

mm

ru

dilgi

®X

4.5

0

1

2

3

4

5

6

7

87,1

2,2

0,05 0,10 0,15 0,20 0,25 0,30 0,35

0,1

0,2

0,3

0,4

0 10 20 30 40 50 60 70 80 900,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

23 °C 150 °C

Inch

Table 4.4: Coefficient of friction for igli-

dur® X against steel (Ra = 1µm, 50 HRC)

iglidur®X Dry Grease Oil Water

C.o.f. [µ] 0.09 - 0.27 0.09 0.04 0.04

Graph 4.4: Wear of iglidur® X, Rotation with p = 0.75 MPa,

v = 0.5 m/s, shaft made of Cold Rolled Steel

Graph 4.6: Coefficient of friction for iglidur® X as a function of

the load, v = 0.01 m/s

Graph 4.5: Coefficient of friction for iglidur® X as a function of

the surface speed; p = 0.75 MPa, shaft Cold Rolled Steel

Temperature in °C

Surface Speed [m/s]

µ n

oitcirf fo t

neiciff eo

Cµ

noi tc ir f f

o tneiciffe

oC

Load [MPa]

W]

mk/m

µ[ rae

bearing can even occur at temperatures of

greater than 170°C. This leads, after re-

cooling, to the bearing moving out of the

housing. At temperatures over 170°C the

axial security of the bearing in the housing

needs to be tested. If necessary, secondary

measures must be taken to mechanically

secure the bearing. Please contact us if you

have questions on bearing use.

Graph 4.3 and 4.4

Application Temperatures, Page 1.17

Friction and Wear

Similar to wear resistance, the coefficient

of friction also changes with the load.The

coefficient of friction increases with an

increase in surface speed. On the other

hand, an increased load has an inverse

effect: the coefficient of friction decreases

(see Graph 4.5 and 4.6). This explains the

excellent performance of iglidur® X plain

bearings for high loads.

Friction and wear are also, dependent to a

large degree on the shaft material. Shafts

that are too smooth increase the coefficient

of friction of the bearing. Ground surfaces

with an average roughness Ra of 0.6 to 0.8.

are ideal.

Graph 4.5 to 4.7

Coefficients of friction and surfaces,

Page 1.19

Wear resistance, Page 1.20

Shaft Materials

Graph 4.7 and 4.8 show results of testing

different shaft materials with plain bearings

made of iglidur® X. For low loads in rotating

operation, the best wear values are found

with 303 Stainless and HR Carbon Steel

shafts. However, above a load of 2 MPa the

bearing wear greatly increases with these

two shaft materials. For the higher load

range, hard chromed shafts or Cold Rolled

Steel shafts are advantageous. In oscilla-

ting operation at low loads, similar wear

values for cold rolled Steel and 303 stain-

less steel shafts occur The wear is somewhat

higher than during rotational movements.

X

ru

dilgi

®X

4.6

0,1 0,4 0,7 1,0 1,3 1,6

0,20

0,30

0,40

0,50

0,60

0

2,0

4,0

6,0

8,0

10,0

12,0

3,5

5,1

7,0 7,1 7,88,6

9,310,0

0 1 2 3 4 5

0

20

40

60

80

100

120

140

160

180

0

5

10

15

20

25

18,3

21,7

12,8

20,5

If the shaft material you plan to use is not

contained in this list, please contact us.

Graph 4.8 to 4.10

Shaft Materials, Page 1.22

Installation Tolerances

iglidur® X plain bearings are meant to be

oversized before pressfit. After proper instal-

lation into a recommended housing bore,

the inner diameter adjusts to meet our spe-

cified tolerances.

Please adhere to the catalogue specifica-

tions for housing bore and recommended

shaft sizes. This will help to ensure optimal

performance of iglidur® plain bearings.

Please contact an iglidur® technical expert

if you have any question.

Testing Methods, Page 1.27

Chemical Resistance

iglidur® X plain bearings are close to uni-

versally resistant to chemicals.

They are only attacked by concentrated

nitric acid and by sulphuric acid with acidi-

ty levels over 65%. The list at the end of

this catalogue provides more comprehen-

sive detailed information.

Graph 4.11

Chemicals Table, Page 35.1

Graph 4.10: Wear for oscillating and rotating applications with

different shaft materials

Material

W]

mk/m

µ[ rae

Oscillating, p = 2 MPa Rotating, p = 2 MPa

303 Stainless SteelCold Rolled Steel

Graph 4.9: Wear of iglidur® X with different shaft materials

Load [MPa]

W]

mk/m

µ[ rae

Hard chromedCF53 HRCS 303 S. Steel

Graph 4.8: Wear of iglidur® X with different shaft materials,

p = 0.75 MPa, v = 0.5 m/s

Shaft Materials

W]

mk/m

µ[ rae

Drill Rod H. A. Aluminium

304 S. SteelHard chromed

CRS

SS HSS

HRCS

Graph 4.7: Coefficients of friction as a function of the shaft

surface (shaft Cold Rolled Steel)

µ n

oitcirf fo t

neiciffeo

C

Shaft Roughness Ra [µm]

X

mm

ru

dilgi

®X

4.7

0,0 0,1 0,2 0,3 0,4 0,50,00

0,02

0,04

0,06

0,08

0,10

Inch

Table 4.6: Chemical resistance of iglidur® X

iglidur® X

Specificvolume resistance < 105 ? cmSurface resistance < 103 ?

Graph 4.11: Effect of moisture absorption on iglidur®X plain

bearings

Table 4.5: Essential tolerances for igli-

dur® X plain bearings

Table 4.7: Electrical properties of

iglidur® X

Medium Resistance

Alcohols Resistant

Chlorinated hydrocarbons Resistant

Ester Resistant

Greases, oils Resistant

Ketone Resistant

Fuels Resistant

Weak acids Resistant

Strong acids Conditionally resistant

Weak alkalines Resistant

Strong alkalines Resistant

Picture 4.6: iglidur® X plain bearing in

valve applications

Diameter Shaft h9 iglidur® Xd1 [mm] [mm] F10 [mm]

up to 3 0 - 0.025 +0.006 + 0.046

> 3 to 6 0 - 0.030 +0.010 + 0.058

> 6 to 10 0 - 0.036 +0.013 + 0.071

> 10 to 18 0 - 0.043 +0.016 + 0.086

> 18 to 30 0 - 0.052 +0.020 + 0.104

> 30 to 50 0 - 0.062 +0.025 + 0.125

> 50 to 80 0 - 0.074 +0.030 + 0.150

Moisture absorption [weight %]

]%[ rete

maid re

nn i e

h t fo

noitc

ude

R

Radiation Resistance

Plain bearings made from iglidur® X are resi-

stant to radiation up to an intensity of 1x105

Gy iglidur® X is the most radioactive resi-

stant material of the iglidur® product line igli-

dur® X is extremely resistant to hard gamma

radiation and withstands a radiation dose

of 1000 Mrad without detectable change in

its properties. The material also withstands

an alpha or beta radiation of 10,000 Mrad

with practically no damage.

UV Resistance

The excellent material properties of iglidur®

X do not change under UV radiation and

other weathering effects.

Vacuum

In a vacuum environment iglidur® X plain

bearings can be used virtually without

restrictions. Outgassing takes place to a

very limited extent.

Electrical Properties

iglidur® X plain bearings are electrically con-

ductive.

Application Example

X

4.8

XSM-0203-03 2.0 +0.006 +0.046 3.5 3.0XSM-0304-03 3.0 +0.006 +0.046 4.5 3.0XSM-0304-06 3.0 +0.006 +0.046 4.5 6.0XSM-0405-04 4.0 +0.010 +0.058 5.5 4.0XSM-0507-035 5.0 +0.010 +0.058 7.0 3.5XSM-0507-05 5.0 +0.010 +0.058 7.0 5.0XSM-0507-08 5.0 +0.010 +0.058 7.0 8.0XSM-0608-06 6.0 +0.010 +0.058 8.0 6.0XSM-0608-08 6.0 +0.010 +0.058 8.0 8.0XSM-0608-10 6.0 +0.010 +0.058 8.0 10.0XSM-0608-13 6.0 +0.010 +0.058 8.0 13.8XSM-0709-10 7.0 +0.013 +0.071 9.0 10.0XSM-0709-12 7.0 +0.013 +0.071 9.0 12.0XSM-0810-10 8.0 +0.013 +0.071 10.0 10.0XSM-0810-15 8.0 +0.013 +0.071 10.0 15.0XSM-1012-06 10.0 +0.013 +0.071 12.0 6.0XSM-1012-08 10.0 +0.013 +0.071 12.0 8.0XSM-1012-10 10.0 +0.013 +0.071 12.0 10.0XSM-1012-12 10.0 +0.013 +0.071 12.0 12.0XSM-1012-20 10.0 +0.013 +0.071 12.0 20.0XSM-1214-06 12.0 +0.016 +0.086 14.0 6.0XSM-1214-08 12.0 +0.016 +0.086 14.0 8.0XSM-1214-10 12.0 +0.016 +0.086 14.0 10.0XSM-1214-15 12.0 +0.016 +0.086 14.0 15.0XSM-1214-20 12.0 +0.016 +0.086 14.0 20.0XSM-1416-12 14.0 +0.016 +0.086 16.0 12.0XSM-1416-15 14.0 +0.016 +0.086 16.0 15.0XSM-1416-20 14.0 +0.016 +0.086 16.0 20.0XSM-1517-15 15.0 +0.016 +0.086 17.0 15.0XSM-1517-20 15.0 +0.016 +0.086 17.0 20.0XSM-1618-15 16.0 +0.016 +0.086 18.0 15.0XSM-1618-20 16.0 +0.016 +0.086 18.0 20.0XSM-1618-35 16.0 +0.016 +0.086 18.0 35.0XSM-1820-15 18.0 +0.016 +0.086 20.0 15.0XSM-1820-20 18.0 +0.016 +0.086 20.0 20.0

XSM-2022-14 20.0 +0.020 +0.104 22.0 14.0XSM-2022-18 20.0 +0.020 +0.104 22.0 18.0XSM-2022-20 20.0 +0.020 +0.104 22.0 20.0XSM-2023-15 20.0 +0.020 +0.104 23.0 15.0XSM-2023-20 20.0 +0.020 +0.104 23.0 20.0XSM-2023-25 20.0 +0.020 +0.104 23.0 25.0XSM-2023-30 20.0 +0.020 +0.104 23.0 30.0XSM-2225-15 22.0 +0.020 +0.104 25.0 15.0XSM-2225-20 22.0 +0.020 +0.104 25.0 20.0XSM-2427-20 24.0 +0.020 +0.104 27.0 20.0XSM-2528-13 25.0 +0.020 +0.104 28.0 13.0XSM-2528-20 25.0 +0.020 +0.104 28.0 20.0XSM-2528-30 25.0 +0.020 +0.104 28.0 30.0XSM-2730-05 27.0 +0.020 +0.104 30.0 5.7XSM-2832-20 28.0 +0.020 +0.104 32.0 20.0XSM-2832-30 28.0 +0.020 +0.104 32.0 30.0XSM-3034-20 30.0 +0.020 +0.104 34.0 20.0XSM-3034-25 30.0 +0.020 +0.104 34.0 25.0XSM-3034-30 30.0 +0.020 +0.104 34.0 30.0XSM-3034-40 30.0 +0.020 +0.104 34.0 40.0XSM-3236-30 32.0 +0.025 +0.125 36.0 30.0XSM-3539-20 35.0 +0.025 +0.125 39.0 20.0XSM-3539-30 35.0 +0.025 +0.125 39.0 30.0XSM-3539-40 35.0 +0.025 +0.125 39.0 40.0XSM-4044-30 40.0 +0.025 +0.125 44.0 30.0XSM-4044-40 40.0 +0.025 +0.125 44.0 40.0XSM-4044-50 40.0 +0.025 +0.125 44.0 50.0XSM-4550-50 45.0 +0.025 +0.125 50.0 50.0XSM-5055-30 50.0 +0.025 +0.125 55.0 30.0XSM-5055-40 50.0 +0.025 +0.125 55.0 40.0XSM-5055-60 50.0 +0.025 +0.125 55.0 60.0XSM-5560-50 55.0 +0.030 +0.150 60.0 50.0XSM-6065-60 60.0 +0.030 +0.150 65.0 60.0XSM-6570-50 65.0 +0.030 +0.150 70.0 50.0

X S M - 0 2 0 3 - 0 3

d1 d2 b1

Part Number d1 d1-Tolerance d2 b1after Pressfit in Ø H7 h13

Part Number d1 d1-Tolerance d2 b1after Pressfit in Ø H7 h13

Structure of the Part Number:

(Data in mm)

Metric dimension

Type

Material

iglidur® X – Sleeve Bearing, mm

Dimensions according to ISO 3547-1 and special dimensions

mm

ru

d ilg i

®S e

py T – X

X

mm

4.9

XFM-0304-05 3.0 +0.006 +0.046 4.5 7.5 5.0 0.75XFM-0405-04 4.0 +0.010 +0.058 5.5 9.5 4.0 0.75XFM-0405-06 4.0 +0.010 +0.058 5.5 9.5 6.0 0.75XFM-040508-06 4.0 +0.010 +0.058 5.5 8.0 6.0 0.75XFM-0507-05 5.0 +0.010 +0.058 7.0 11.0 5.0 1.0XFM-0608-08 6.0 +0.010 +0.058 8.0 12.0 8.0 1.0XFM-0608-10 6.0 +0.010 +0.058 8.0 12.0 10.0 1.0XFM-0810-075 8.0 +0.013 +0.071 10.0 15.0 7.5 1.0XFM-0810-09 8.0 +0.013 +0.071 10.0 15.0 9.0 1.0XFM-1012-06 10.0 +0.013 +0.071 12.0 18.0 6.0 1.0XFM-1012-08 10.0 +0.013 +0.071 12.0 15.0 8.0 1.0XFM-1012-09 10.0 +0.013 +0.071 12.0 18.0 9.0 1.0XFM-1012-15 10.0 +0.013 +0.071 12.0 18.0 15.0 1.0XFM-1012-18 10.0 +0.013 +0.071 12.0 18.0 18.0 1.0XFM-1214-09 12.0 +0.016 +0.086 14.0 20.0 9.0 1.0XFM-1214-12 12.0 +0.016 +0.086 14.0 20.0 12.0 1.0XFM-1214-15 12.0 +0.016 +0.086 14.0 20.0 15.0 1.0XFM-1416-12 14.0 +0.016 +0.086 16.0 22.0 12.0 1.0XFM-1416-17 14.0 +0.016 +0.086 16.0 22.0 17.0 1.0XFM-1517-12 15.0 +0.016 +0.086 17.0 23.0 12.0 1.0XFM-1517-17 15.0 +0.016 +0.086 17.0 23.0 17.0 1.0XFM-1618-12 16.0 +0.016 +0.086 18.0 24.0 12.0 1.0XFM-1618-17 16.0 +0.016 +0.086 18.0 24.0 17.0 1.0XFM-1820-12 18.0 +0.016 +0.086 20.0 26.0 12.0 1.0XFM-1820-17 18.0 +0.016 +0.086 20.0 26.0 17.0 1.0XFM-2023-11 20.0 +0.020 +0.104 23.0 30.0 11.0 1.5XFM-2023-21 20.0 +0.020 +0.104 23.0 30.0 21.5 1.5XFM-2528-21 25.0 +0.020 +0.104 28.0 35.0 21.0 1.5XFM-2730-20 27.0 +0.020 +0.104 30.0 38.0 20.0 1.5XFM-3034-16 30.0 +0.020 +0.104 34.0 42.0 16.0 2.0XFM-3034-26 30.0 +0.020 +0.104 34.0 42.0 26.0 2.0XFM-3034-40 30.0 +0.020 +0.104 34.0 42.0 40.0 2.0XFM-3236-15 32.0 +0.025 +0.125 36.0 45.0 15.0 2.0XFM-3236-26 32.0 +0.025 +0.125 36.0 45.0 26.0 2.0XFM-3539-26 35.0 +0.025 +0.125 39.0 47.0 26.0 2.0XFM-4044-30 40.0 +0.025 +0.125 44.0 52.0 30.0 2.0XFM-4044-40 40.0 +0.025 +0.125 44.0 52.0 40.0 2.0XFM-4550-50 45.0 +0.025 +0.125 50.0 58.0 50.0 2.0XFM-5055-40 50.0 +0.025 +0.125 55.0 63.0 40.0 2.0

X F M - 0 3 0 4 - 0 5

d1 d2 b1

Inch

Part Number d1 d1-Tolerance d2 d3 b1 b2after Pressfit in Ø H7 d13 h13 -0.14


(Data in mm)

Metric dimension

Type

Material

ru

dilgi

®F e

py T – X

mm

iglidur® X – Flange Bearing, mm


X

4.10

XFM-6065-40 60.0 +0.030 +0.150 65.0 73.0 40.0 2.0XFM-7075-40 70.0 +0.030 +0.150 75.0 83.0 40.0 2.0XFM-7580-50 75.0 +0.030 +0.150 80.0 88.0 50.0 2.0

X F M - 6 0 6 5 - 4 0

d1 d2 b1

Part Number d1 d1-Tolerance d2 d3 b1 b2after Pressfit in Ø H7 d13 h13 -0.14


(Data in mm)

Metric dimension

Type

Material

iglidur® X – Flange Bearing, mm


mm

ru

d ilg i

®F e

pyT – X

mm

X

4.11

XTM-0620-015 6.0 20.0 1.5 13.0 1.5 1.0 20.0XTM-0818-015 8.0 18.0 1.5 13.0 1.5 1.0 18.0XTM-1018-010 10.0 18.0 1.0 * * 0.7 18.0XTM-1224-015 12.0 24.0 1.5 18.0 1.5 1.0 24.0XTM-1426-015 14.0 26.0 1.5 20.0 2.0 1.0 26.0XTM-1524-015 15.0 24.0 1.5 19.5 1.5 1.0 24.0XTM-1630-015 16.0 30.0 1.5 22.0 2.0 1.0 30.0XTM-1832-015 18.0 32.0 1.5 25.0 2.0 1.0 32.0XTM-2036-015 20.0 36.0 1.5 28.0 3.0 1.0 36.0XTM-2238-015 22.0 38.0 1.5 30.0 3.0 1.0 38.0XTM-2442-015 24.0 42.0 1.5 33.0 3.0 1.0 42.0XTM-2644-015 26.0 44.0 1.5 35.0 3.0 1.0 44.0XTM-3254-015 32.0 54.0 1.5 38.0 4.0 1.0 54.0XTM-3862-015 38.0 62.0 1.5 50.0 4.0 1.0 62.0XTM-4266-015 42.0 66.0 1.5 84.0 4.0 1.0 66.0XTM-4874-020 48.0 74.0 2.0 61.0 4.0 1.5 74.0XTM-5278-020 52.0 78.0 2.0 65.0 4.0 1.5 78.0XTM-6290-020 62.0 90.0 2.0 76.0 4.0 1.5 90.0

X T M - 0 6 2 0 - 0 1 5

d1 d2 s

* Design without fixation bore

Inch

Part Number d1 d2 s d4 d5 h d6 +0.25 -0.25 -0.05 -0.12 +0.375 +0.2 +0.12

+0.12 +0.125 -0.2


(Data in mm)

Metric dimension

Type

Material

iglidur® X – Thrust Washer, mm


ru

dilgi

®T e

py T – X

mm

X

4.12

TSI-0203-03 1/8 3/16 3/16 .1269 .1251 .1878 .1873 .1243 .1236TSI-0203-05 1/8 3/16 5/16 .1269 .1251 .1878 .1873 .1243 .1236TSI-0203-06 1/8 3/16 3/8 .1269 .1251 .1878 .1873 .1243 .1236TSI-0304-03 3/16 1/4 3/16 .1892 .1873 .2503 .2497 .1865 .1858TSI-0304-04 3/16 1/4 1/4 .1892 .1873 .2503 .2497 .1865 .1858TSI-0304-06 3/16 1/4 3/8 .1892 .1873 .2503 .2497 .1865 .1858TSI-0304-08 3/16 1/4 1/2 .1892 .1873 .2503 .2497 .1865 .1858TSI-0405-04 1/4 5/16 1/4 .2521 .2498 .3128 .3122 .2490 .2481TSI-0405-06 1/4 5/16 3/8 .2521 .2498 .3128 .3122 .2490 .2481TSI-0405-08 1/4 5/16 1/2 .2521 .2498 .3128 .3122 .2490 .2481TSI-0506-04 5/16 3/8 1/4 .3148 .3125 .3753 .3747 .3115 .3106TSI-0506-06 5/16 3/8 3/8 .3148 .3125 .3753 .3747 .3115 .3106TSI-0506-08 5/16 3/8 1/2 .3148 .3125 .3753 .3747 .3115 .3106TSI-0607-04 3/8 15/32 1/4 .3773 .3750 .4691 .4684 .3740 .3731TSI-0607-05 3/8 15/32 5/16 .3773 .3750 .4691 .4684 .3740 .3731TSI-0607-06 3/8 15/32 3/8 .3773 .3750 .4691 .4684 .3740 .3731TSI-0607-08 3/8 15/32 1/2 .3773 .3750 .4691 .4684 .3740 .3731TSI-0607-10 3/8 15/32 5/8 .3773 .3750 .4691 .4684 .3740 .3731TSI-0708-04 7/16 17/32 1/4 .4406 .4379 .5316 .5309 .4365 .4355TSI-0708-08 7/16 17/32 1/2 .4406 .4379 .5316 .5309 .4365 .4355TSI-0708-10 7/16 17/32 5/8 .4406 .4379 .5316 .5309 .4365 .4355TSI-0708-12 7/16 17/32 3/4 .4406 .4379 .5316 .5309 .4365 .4355TSI-0809-04 1/2 19/32 1/4 .5030 .5003 .5941 .5934 .4990 .4980TSI-0809-06 1/2 19/32 3/8 .5030 .5003 .5941 .5934 .4990 .4980TSI-0809-08 1/2 19/32 1/2 .5030 .5003 .5941 .5934 .4990 .4980TSI-0809-10 1/2 19/32 5/8 .5030 .5003 .5941 .5934 .4990 .4980TSI-0809-12 1/2 19/32 3/4 .5030 .5003 .5941 .5934 .4990 .4980TSI-0809-16 1/2 19/32 1 .5030 .5003 .5941 .5934 .4990 .4980TSI-0910-08 9/16 21/32 1/2 .5655 .5627 .6566 .6559 .5615 .5605TSI-0910-12 9/16 21/32 3/4 .5655 .5627 .6566 .6559 .5615 .5605TSI-1011-04 5/8 23/32 1/4 .6280 .6253 .7192 .7184 .6240 .6230TSI-1011-06 5/8 23/32 3/8 .6280 .6253 .7192 .7184 .6240 .6230TSI-1011-08 5/8 23/32 1/2 .6280 .6253 .7192 .7184 .6240 .6230TSI-1011-10 5/8 23/32 5/8 .6280 .6253 .7192 .7184 .6240 .6230TSI-1011-12 5/8 23/32 3/4 .6280 .6253 .7192 .7184 .6240 .6230TSI-1011-16 5/8 23/32 1 .6280 .6253 .7192 .7184 .6240 .6230TSI-1112-14 11/16 25/32 7/8 .6906 .6879 .7817 .7809 .6865 .6855TSI-1214-06 3/4 7/8 3/8 .7541 .7507 .8755 .8747 .7491 .7479TSI-1214-08 3/4 7/8 1/2 .7541 .7507 .8755 .8747 .7491 .7479

T S I - 0 2 0 3 - 0 3

d1 d2 b1

Part Number d1 d2 b1 I.D.after Pressfit Housing bore Shaft Sizemax. min. max. min. max. min.

iglidur® X – Sleeve Bearing, inch


(Data in inch)

Inch dimension

Type

Material

in mm

hc

ni

ru

dilgi

®S e

pyT – X

X

mm

4.13

TSI-1214-12 3/4 7/8 7/8 .7541 .7507 .8755 .8747 .7491 .7479TSI-1214-16 3/4 7/8 1 .7541 .7507 .8755 .8747 .7491 .7479TSI-1416-12 7/8 1 3/4 .8791 .8757 1.0005 .9997 .8741 .8729TSI-1416-16 7/8 1 1 .8791 .8757 1.0005 .9997 .8741 .8729TSI-1618-08 1 1 1/8 1/2 1.0041 1.0007 1.1255 1.1247 .9991 .9979TSI-1618-12 1 1 1/8 3/4 1.0041 1.0007 1.1255 1.1247 .9991 .9979TSI-1618-16 1 1 1/8 1 1.0041 1.0007 1.1255 1.1247 .9991 .9979TSI-1618-24 1 1 1/8 1 1/2 1.0041 1.0007 1.1255 1.1247 .9991 .9979TSI-1820-12 1 1/8 1 9/32 3/4 1.1288 1.1254 1.2818 1.2808 1.1238 1.1226TSI-2022-10 1 1/4 1 13/32 5/8 1.2548 1.2508 1.4068 1.4058 1.2488 1.2472TSI-2022-20 1 1/4 1 13/32 1 1/4 1.2548 1.2508 1.4068 1.4058 1.2488 1.2472TSI-2426-12 1 1/2 1 21/32 3/4 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TSI-2426-16 1 1/2 1 21/32 1 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TSI-2426-24 1 1/2 1 21/32 1 1/2 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TSI-2629-20 1 25/32 1 13/16 1 1/4 1.6297 1.6258 1.7818 1.7808 1.6238 1.6222TSI-2831-16 1 3/4 1 15/16 1 1.7547 1.7507 1.9381 1.9371 1.7487 1.7471TSI-3235-24 2 2 3/16 1 1/2 2.0057 2.0011 2.1883 2.1871 1.9981 1.9969TSI-3235-32 2 2 3/16 2 2.0057 2.0011 2.1883 2.1871 1.9981 1.9969TSI-3639-32 2 1/4 2 7/16 2 2.2577 2.2531 2.4377 2.4365 2.2507 2.2489TSI-4447-32 2 3/4 2 15/16 2 2.7570 2.7523 2.9370 2.9358 2.7500 2.7490

T S I - 1 2 1 4 - 1 2

d1 d2 b1

Inch

Part Number d1 d2 b1 I.D. after Pressfit Housing Bore Shaft Sizemax. min. max. min. max. min.

iglidur® X – Sleeve Bearing, inch


(Data in inch)

Inch dimension

Type

Material

in mm

ru

d ilg i

®S e

py T – X

hc

ni

X

4.14

TFI-0203-03 1/8 3/16 3/16 .312 .032 .1269 .1251 .1878 .1873 .1243 .1236TFI-0203-06 1/8 3/16 3/8 .312 .032 .1269 .1251 .1878 .1873 .1243 .1236TFI-0304-04 3/16 1/4 1/4 .375 .032 .1892 .1873 .2503 .2497 .1865 .1858TFI-0304-06 3/16 1/4 3/8 .375 .032 .1892 .1873 .2503 .2497 .1865 .1858TFI-0304-08 3/16 1/4 1/2 .375 .032 .1892 .1873 .2503 .2497 .1865 .1858TFI-0405-03 1/4 5/16 3/16 .500 .032 .2521 .2498 .3128 .3122 .2490 .2481TFI-0405-04 1/4 5/16 1/4 .500 .032 .2521 .2498 .3128 .3122 .2490 .2481TFI-0405-06 1/4 5/16 3/8 .500 .032 .2521 .2498 .3128 .3122 .2490 .2481TFI-0405-08 1/4 5/16 1/2 .500 .032 .2521 .2498 .3128 .3122 .2490 .2481TFI-0405-12 1/4 5/16 3/4 .500 .032 .2521 .2498 .3128 .3122 .2490 .2481TFI-0506-04 5/16 3/8 1/4 .562 .032 .3148 .3125 .3753 .3747 .3115 .3106TFI-0506-06 5/16 3/8 3/8 .562 .032 .3148 .3125 .3753 .3747 .3115 .3106TFI-0506-08 5/16 3/8 1/2 .562 .032 .3148 .3125 .3753 .3747 .3115 .3106TFI-0607-04 3/8 15/32 1/4 .687 .046 .3773 .3750 .4691 .4684 .3740 .3731TFI-0607-06 3/8 15/32 3/8 .687 .046 .3773 .3750 .4691 .4684 .3740 .3731TFI-0607-08 3/8 15/32 1/2 .687 .046 .3773 .3750 .4691 .4684 .3740 .3731TFI-0607-12 3/8 15/32 3/4 .687 .046 .3773 .3750 .4691 .4684 .3740 .3731TFI-0708-08 7/16 17/32 1/2 .750 .046 .4406 .4379 .5316 .5309 .4365 .4355TFI-0809-04 1/2 19/32 1/4 .875 .046 .5030 .5003 .5941 .5934 .4990 .4980TFI-0809-06 1/2 19/32 3/8 .875 .046 .5030 .5003 .5941 .5934 .4990 .4980TFI-0809-08 1/2 19/32 1/2 .875 .046 .5030 .5003 .5941 .5934 .4990 .4980TFI-0809-12 1/2 19/32 3/4 .875 .046 .5030 .5003 .5941 .5934 .4990 .4980TFI-0809-16 1/2 19/32 1 .875 .046 .5030 .5003 .5941 .5934 .4990 .4980TFI-1011-08 5/8 23/32 1/2 .937 .046 .6280 .6253 .7192 .7184 .6240 .6230TFI-1011-12 5/8 23/32 3/4 .937 .046 .6280 .6253 .7192 .7184 .6240 .6230TFI-1011-16 5/8 23/32 1 .937 .046 .6280 .6253 .7192 .7184 .6240 .6230TFI-1011-24 5/8 23/32 1 1/2 .937 .046 .6280 .6253 .7192 .7184 .6240 .6230TFI-1214-08 3/4 7/8 1/2 1.125 .062 .7541 .7507 .8755 .8747 .7491 .7479TFI-1214-12 3/4 7/8 3/4 1.125 .062 .7541 .7507 .8755 .8747 .7491 .7479TFI-1214-16 3/4 7/8 1 1.125 .062 .7541 .7507 .8755 .8747 .7491 .7479TFI-1214-28 3/4 7/8 1 3/4 1.125 .062 .7541 .7507 .8755 .8747 .7491 .7479TFI-1416-12 7/8 1 3/4 1.250 .062 .8791 .8757 1.0005 .9997 .8741 .8729TFI-1416-16 7/8 1 1 1.250 .062 .8791 .8757 1.0005 .9997 .8741 .8729TFI-1618-08 1 1 1/8 1/2 1.375 .062 1.0041 1.0007 1.1255 1.1247 .9991 .9979TFI-1618-12 1 1 1/8 3/4 1.375 .062 1.0041 1.0007 1.1255 1.1247 .9991 .9979TFI-1618-16 1 1 1/8 1 1.375 .062 1.0041 1.0007 1.1255 1.1247 .9991 .9979TFI-1618-24 1 1 1/8 1 1/2 1.375 .062 1.0041 1.0007 1.1255 1.1247 .9991 .9979TFI-1820-12 1 1/8 1 9/32 3/4 1.562 .078 1.1288 1.1254 1.2818 1.2808 1.1238 1.1226TFI-2022-20 1 1/4 1 13/32 1 1/4 1.687 .078 1.2548 1.2508 1.4068 1.4058 1.2488 1.2472

T F I - 0 2 0 3 - 0 3

d1 d2 b1

Part Number d1 d2 b1 d3 b2 I.D. after Pressfit Housing Bore Shaft Sizemax. min. max. min. max. min.


(Data in inch)

Inch dimension

Type

Material

iglidur®X – Flange Bearing, inch

in mm hc

ni

ru

dilgi

®F e

pyT – X

mm

X

4.15

Référence d1 d2 b1 d3 b2 d1 après emmanchement Alésage Arbremax. min. max. min. max. min.

TFI-2022-32 1 1/4 1 13/32 2 1.687 .078 1.2548 1.2508 1.4068 1.4058 1.2488 1.2472TFI-2426-12 1 1/2 1 21/32 3/4 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-16 1 1/2 1 21/32 1 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-24 1 1/2 1 21/32 1 1/2 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-26 1 1/2 1 21/32 1 5/8 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2831-16 1 3/4 1 15/16 1 2.375 .093 1.7547 1.7507 1.9381 1.9371 1.7487 1.7471TFI-3235-32 2 2 3/16 2 2.625 .093 2.0057 2.0011 2.1883 2.1871 1.9981 1.9969TFI-4447-32 2 3/4 2 15/16 2 3.375 .093 2.7570 2.7523 2.9370 2.9358 2.7500 2.7490

TFI-2022-32 1 1/4 1 13/32 2 1.687 .078 1.2548 1.2508 1.4068 1.4058 1.2488 1.2472TFI-2426-12 1 1/2 1 21/32 3/4 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-16 1 1/2 1 21/32 1 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-24 1 1/2 1 21/32 1 1/2 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2426-26 1 1/2 1 21/32 1 5/8 2.000 .078 1.5048 1.5008 1.6568 1.6558 1.4988 1.4972TFI-2831-16 1 3/4 1 15/16 1 2.375 .093 1.7547 1.7507 1.9381 1.9371 1.7487 1.7471TFI-3235-32 2 2 3/16 2 2.625 .093 2.0057 2.0011 2.1883 2.1871 1.9981 1.9969TFI-4447-32 2 3/4 2 15/16 2 3.375 .093 2.7570 2.7523 2.9370 2.9358 2.7500 2.7490

T F I - 2 0 2 2 - 3 2

d1 d2 b1

Inch

Part Number d1 d2 b1 d3 b2 I.D.after Pressfit Housing Bore Shaft Sizemax. min. max. min. max. min.

ru

dilgi

®F e

pyT – X

hc

ni


(Data in inch)

Inch dimension

Type

Material

iglidur® X – Flange Bearing, inch

in mm

X

4.16

TTI-0814-01 .500 .875 .0585 .692 .067 .040 .875TTI-1018-01 .625 1.125 .0585 .880 .099 .040 1.125TTI-1220-01 .750 1.250 .0585 1.005 .099 .040 1.250TTI-1424-01 .875 1.500 .0585 1.192 .130 .040 1.500TTI-1628-01 1.000 1.750 .0585 1.380 .130 .040 1.750TTI-1826-01 1.125 1.625 .0585 – – .040 1.625TTI-2034-01 1.250 2.125 .0585 1.692 .161 .040 2.125TTI-2440-01 1.500 2.500 .0585 2.005 .192 .040 2.500TTI-2844-01 1.750 2.750 .0585 2.255 .192 .040 2.750TTI-3248-01 2.000 3.000 .0895 2.505 .192 .070 3.000

T T I - 0 8 1 4 - 0 1

d1 d2 s


(Data in inch)

Inch dimension

Type

Material

Part Number d1 d2 s d4 d5 h d6 +.010 -.010 -.0020 +-.005 .015 +.005 +.008 +.005

iglidur® X – Thrust Washer, inchh

cni

ru

d ilg i

®T e

pyT – X

Colly Components AB. Box 76, 164 94 Kista. Tel 08-703 01 00. Fax 08-703 98 41. www.colly.se

13 21 00/ZERBuyLine 0678www.zeroloc.com

Fiberglass Reinforced Plastic (FRP)

may be factory-bonded to the

steel skins of the Zero-Loc

EPS insulated panels, offering

increased scratch and dent

resistance. FRP protects panels from

the frequent rigorous

cleaning that is required in maintain-

ing a sanitary environment.

Food Processing

The finished Zero-Loc insulated

system is sanitary, energy efficient

and durable.

Cold Storage Warehouses

Ideally suited for low temperature

facilities, Zero-Loc EPS “R” value

performance increases as the

temperature decreases.

Walk-on Suspended Ceiling System

Constructed with Zero-Loc EPS

insulated panels, the finished

Zero-Loc walk-on suspended

ceiling system is energy efficient

and durable and is ideally suited for

low temperature, food processing and

controlled environment applications.

factory applied FRP

Expanded Polystyrene (EPS) Insulated Panel Systems

food processing plants cold storage warehouses walk-on suspended ceiling systems

Technical Specifications

5202-272nd St, Langley, BC Canada V4W 1S3 T: 604-607-1101 F: 604-607-1142

28 Plant Farm Blvd, Brantford, ON Canada N3S 7W3 T: 519-754-4500 F: 519-754-4214

119-9757 Juanita Dr N.E., Kirkland, WA USA 98033 T: 425-823-4588 F: 425-820-9749


9. Gasket: a. Hinged Door and Manual Sliding Door gaskets shall designed for heavy-duty applications, and shall be resistant to oils, grease and/or fats. Door gasket shall create a positive seal at all contact points between door leaf and frame, and door leaf and floor. Level floor surface required for positive gasket seal shall be provided by others. 10. Hinged Door Hardware: a. Overlap-type hinged doors shall be equipped with Kason #1398 Heavy-Duty Cam Rise hinges. b. Infitting-type hinged doors shall be equipped with Kason #1245 Reversible Cam-Rise Hinges. c. Hinged doors shall be equipped with Kason K56 Standard Latches complete with strike assemblies and Kason 481 inside Release Handles. 11. Sliding Door Hardware : a. Sliding door track shall consist of heavy gauge anodized aluminum. Door leaf hanger assembly to be fabricated from: 1) 10 gauge (3.416 mm) 304 2B stainless steel to match door leaf trim finish and faceplate frame finish. 2) G90 galvanized steel to match door leaf trim finish and face plate frame finish. b. Hanger wheels shall be 4 inches (102 mm) in diameter and made from “Delrin” plastic. The 10 gauge (3.416 mm) hanger assembly shall also serve as the cover for the hanger assem bly. 12. Freezer Doors : a. Freezer doors shall be equipped with CSA/UL rated anti-frost heat trace in both door leaf and faceplate frame for heavy-duty hinged and sliding freezer doors and in door leaf or faceplate frame only for hinged and sliding freezer doors in lighter-duty commercial applications. Heat trace shall be factory-wired to a ground-fault circuit interrupter.

2.3 FABRICATION A. Corners: 1. Corner panel connections shall be butt or mitered, flashed, and finished by installation crew on-site. 2. Where specified, corner panel connections shall be a single unit corner panel with a continuous metal skin on the outer bend. B. Offset: Maximum offset from true alignment between two identical members abutting end-to-end: 1/8 inch (3 mm).

PART 3 EXECUTION3.1 EXAMINATION A. Verification of Conditions: Examine areas and conditions under which Work is to be performed and identify conditions detrimental to proper or timely completion. 1. Panel installer to verify that structural steel supports for wall panels are within tolerances in the AISC Code of Standard Practice, Section 7 and supplement modification controlling Section 7.11.3, adjustable items. Limit maximum deviation of steel alignment to plus or minus 3/16 inch(4 mm) from the control with a 1/8 inch (3 mm) maximum change in deviation for any member for any 10 feet (3 m) length of panel. 2. Do not proceed until unsatisfactory conditions have been corrected. B. If support system preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.

3.2 INSTALLATION A. Install in accordance with manufacturer’s instructions.

3.3 TOLERANCES A. Variation: Maximum variation from vertical or horizontal plane, 1/4 inch (6 mm) in 12 feet (3658 mm) length section or 1/2 inch (13 mm) over total length.

B. Offset: Maximum offset from true alignment between two identical members abutting end-to-end: 1/8 inch (3 mm).

3.4 FIELD QUALITY CONTROL A. Manufacturer’s Field Services: Manufacturer shall make periodic inspec tions and issue report to Architect regarding compliance with manufactur ers installation recommendations developed for the Project.

3.5 ADJUSTING A. Repair damage caused during construction. 1. Touch-up mars, scratches, and cut edges to match original finish. 2. If repairs cannot be made to comply with Architect’s requirements, remove damage and install new materials.

Company Profile. Since our establishment in 1969, ZERO-LOC

has grown to become a major worldwide producer of Insulated Panel

and Door Systems. This achievement has been made possible by the

dedication of our employees and the belief that giving greater service

and value to our customers is essential to success.

For design assistance, structural details,

AutoCAD disks, product specifications and

other technical information, please contact

your nearest Zero-Loc representative.

www.zeroloc.com13 21 00/ZERBuyLine 0678

A Wide Range of Applications

• Exterior / Interior EPS insulated build-ing panels for warehouses, and food processing plants

• Standard & specialty insulated doors

• Walk-on suspended ceiling systems

• Storage freezers & coolers

• Blast/Spiral/IQF Freezer Tunnels & Enclosures

• Federally inspected food processing areas

• Environment/atmosphere control rooms

• Factory-Laminated Fiberglass Reinforced Plastic (FRP)

INSULATED PANEL SYSTEMS

PART 1 GENERAL1.1 SECTION INCLUDES

A. Expanded polystyrene (EPS) insulated metal wall and ceiling panels with related accessories.

1.2 RELATED SECTIONS A. Section 03300 - Concrete: Foundations. B. Section 05120 - Structural Steel: Primary structure. C. Section 05500 - Steel Fabrication: Supporting structure.

1.3 REFERENCES

A. American Society for Testing and Materials (ASTM) E96: Standard Test Methods for Water Vapor Transmission of Materials. B. American Society for Testing and Materials (ASTM) E283: Standard Test Method for Rate of Air Leakage through Exterior Windows, Curtain Walls, and Doors. C. Underwriters’ Laboratories of Canada (ULC/ORD-C376-1995): Fire Growth of Foamed Plastic Insulated Building Panels in a Full-Scale Room configuration.

1.4 SYSTEM DESCRIPTION A. General: Construct panel system to provide for expansion and contrac tion of component materials without causing buckling, failure of joint seals, undue stress on fasteners, or other detrimental effects to the panel system or adjacent building systems, or warping of faces of panel system. B. Performance Requirements: Design and construct panels to meet requirements as indicated. 1. Design panel composition to resist wind load mandated by code, with deflection limit of L/180. a. No permanent damage to panels or connections when sub jected to 1.5 times the design wind pressures for both inward and outward. 2. Air leakage: Not greater than .06 cfm per square foot when tested in compliance with ASTM E283 at 1.56 pounds per square foot.

1.5 SUBMITTALS A. Submit under provisions of Section 01300. B. [Product Data]: Manufacturer’s data sheets on each product to be used, including: 1. Preparation instructions and recommendations. 2. Storage and handling requirements and recommendations. 3. Detailed specification of construction and fabrication. 4. Manufacturer’s installation instructions. 5. Certified test reports indicating compliance with specified performance requirements.

C. Shop Drawings: Indicate dimensions, description of materials and fin ishes, general construction, specific modifications, component connections, anchorage methods, hardware, and installation procedures, including specific requirements indicated. 1. Profile and gauge of both exterior and interior sheet. 2. Metal finish. 3. Relationship to other work. 4. Fully show details and connections to and locations of supporting steel indicating control points. D. Selection Samples: For each finish product specified, two complete sets of color chips representing manufacturer’s full range of available colors and patterns. E. Verification Samples: For each finish product specified, two samples, minimum size 6 inches (150 mm) square, representing actual product, color, and patterns. F. Quality Control Submittals: 1. Statement of qualifications. 2. Design data. 3. Test reports.

1.6 QUALITY ASSURANCE A. Manufacturer/installer shall be responsible for fabrication and installation of panel and support framing as specified in this section to comply with the following: 1. Wind load engineering to comply with code requirements. B. Manufacturer’s Qualifications: Not less than 5 years experience in the actual production of specified products. 1. Comply with rigid factory Quality Control program which includes quarterly unannounced inspections from UL, and independent test ing laboratories providing reports directly to code authority. 2. Successfully completed not less than 100 comparable scale projects using this system. C. Installer’s Qualifications: Firm experienced in installation of systems similar in complexity to those required for this Project, including specific requirements indicated. 1. Acceptable to or licensed by manufacturer. 2. Not less than 3 years experience with systems. 3. Successfully completed not less than 5 comparable scale projects using this system. D. Product Requirements: 1. Metal members (prone to rust) and wood or wood by-products (prone to moisture absorption and rot), shall not be permitted within the panel connection system. 2. Panel joints connection system, tested in accordance with ASTM E283 “Air Leakage Rate Testing” and ASTM E96 “Water Vapor Per meance Rate Testing” shall have an air leakage rate at 75 Pa OF 0.00m3/h-m2 (0.00cfm/sq.ft.) and a water vapor permeance rate of 0.00 perms. 3. Insulated panels, related accessories, and construction details shall be in accordance with the following regulatory agencies, where required: a. Canadian Food Inspection Agency (CFIA) b. United States Department of Agriculture (USDA) 4. Wall and ceiling panels, insulated with Type 1 Expanded Polysty- rene (EPS) manufactured to EPS Type 1 standards, shall be listed in accordance with ULC/ORD-C376-1995, “Fire Growth of Foamed Plastic Insulated Building Panels in a Full-Scale Room Configura tion”, in compliance with Part 3.1.5.12 of the 2005 National Build Code of Canada (Combustible Insulation and its Protection). a. ICC-ES Legacy Report No. 96-43.

E. Mock-Up: Provide a mock-up for evaluation of surface preparation tech niques and application workmanship. 1. Finish areas designated by Architect. 2. Do not proceed with remaining work until workmanship, color, and sheen are approved by Architect. 3. Refinish mock-up area as required to produce acceptable work.

1.7 DELIVERY, STORAGE, AND HANDLING A. Store products in per manufacturer’s recommendation until ready for installation. B. Store and dispose of solvent-based materials, and materials used with solvent-based materials, in accordance with requirements of local authorities having jurisdiction.

1.8 PROJECT CONDITIONS A. Maintain environmental conditions (temperature, humidity, and ventila tion) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer’s absolute limits.

1.9 WARRANTY A. Provide manufacturer’s standard limited warranty.

PART 2 PRODUCTS2.1 MANUFACTURERS A. Acceptable Manufacturer: Zero-Loc, Enterprises Ltd.; 5202 272nd Street, Langley, BC, Canada V4W 1S3. ASD. Tel: (604) 607-1101. Fax: (604) 607-1142. Email: [email protected]. Web: www.zeroloc.com. B. Substitutions: Not permitted. C. Requests for substitutions will be considered in accordance with provisions of Section 01600.

2.2 MATERIALS A. Panel General Requirements: Roll-formed exterior and interior steel sheet faces laminated to panel grade type 1 expanded polystyrene (EPS) foam core. EPS foam core shall not contain CFC’s, HCFC’s or HFC’s. Insulated wall and ceiling panels shall be supplied in 46 inches (1168 mm) widths. Panel lengths shall be factory-sized to meet required site dimensions. 1. Panel Thickness: a. 2 inches (50 mm). b. 4 inches (100 mm). c. 6 inches (150 mm). d. 8 inches (200 mm). e. 10 inches (250 mm) 2. Interior wall and ceiling panels shall be clad on all exposed areas with 26 gauge (0.455 mm) pre-painted G90 galvanized steel (USDA & CFIA accepted). a. High gloss white (QC5216 White Appliance Polyester) b. Approved alternate. 3. Exterior insulated panels shall be clad on the weather-exposed side with 26 gauge (0.455 mm) pre-painted stucco embossed G90 galvanized steel. a. 8000 series (QC8317) white. b. USDA white. c. Approved alternate. 4. Concealed areas of panels (ie. top of ceiling panels) shall be clad with 28 gauge (0.378 mm) plain G90 galvanized steel. 5. Metal skins shall be thermal-set to the Type 1 EPS insulation. Insu- lated panels shall be manufactured individually laminated, ensuring uniform adhesion between metal skins and EPS insulation.

6. Panel edges shall be fabricated with a tongue-in groove type panel connection system (sleeve joint). 7. Sleeve-Joints shall be sealed internally by running continuous beads of butyloid caulking (or approved alternate) along the inside edges of the female sides of the panel joints. 8. Sleeve-Joints shall be externally caulked for USDA and Canadian Food Inspection Agency (CFIA) inspected areas only, or as specified, with Tremco Proglaze White silicone (or approved alternate).

B. Wall and Ceiling Panel Insulation: 1. Wall panels and ceiling panels shall consist of Type 1 Expanded Polystyrene (EPS) insulation. 2. Finished panels shall have an R-value of 4.17 per inch at 75 degrees F (23.8 degrees C). Insulation thickness of panels shall be adjusted in accordance with design R-value requirements. 3. Insulation shall not contain CFCs or HCFCs, or other expanding agents. 4. EPS Type 1 shall be manufactured with BASF KF262 bead size (or approved alternate), ensuring uniform densities throughout the insulation. 5. EPS Type 1 panel grade insulation shall meet or exceed federal standards for Type 1 EPS.

C. Panel Protection: 1. Manufacturer shall factory-bond 0.090 inch (2.3 mm) Fiberglass Re inforced Plastic (FRP) a minimum of 4 feet (1219 mm) high on the wall panels or as indicated. Refer to Room Finish Schedule.

D. Insulated Freezer Floor: 1. Insulated freezer floors shall be insulated with Zelsius EPS Type 2 high density insulation, complete with a minimum 10 mil (0.254 mm) polyethylene vapor barrier. a. Type 2 EPS shall meet or exceed federal standards for Type 2 EPS. E. Insulated Doors: 1. Hinged doors. 2. Manually operated horizontal sliding doors. 3. Door leafs shall be insulated with 4 inches (102 mm) of Type 1 expanded polystyrene (EPS) insulation. Type 1 EPS shall meet or exceed federal standards for Type 1 EPS. 4. Door leafs shall be finished as follows: a. FRP 0.090 inch (2.3 mm) thickness fiberglass reinforced plas tic factory-laminated (using a high-pressure heat-bonding process) to 28 gauge (0.378 mm) galvanized metal skins. b. 26 gauge (0.455 mm) stainless steel (304 2B) finish. c. 26 gauge (0.455 mm) prepainted white (QC5216 or approved alternate) G90 galvanized steel. 5. Door finishes shall be factory laminated (using a high-pressure heat-bonding process) to the Type 1 EPS insulation core. 6. Door leafs shall contain no wood or wood by-products. 7. Perimeter of door leafs shall be trimmed as follows: a. 18 gauge (1.214 mm) #304 2B stainless steel channel. b. 18 gauge (1.214 mm) G90 galvanized steel channel. c. 26 gauge (0.455 mm) prepainted white channel to match door leaf. 8. Doorframe Component: The Zero-Loc standard door frame component consists of a faceplate frame to which the door leaf is mounted, door jamb channel up to 8 inches (204 mm) thick for the perimeter of the door opening, and nuts, washers, through-bolts, reverse-side bolt plates and a snap-cap style sheet metal finishing channel to match wall finish. a. The faceplate component shall be fabricated from the following: 1) 16 gauge (1.897 mm) (minimum) #304 2B stainless steel. 2) 16 gauge ( 1.897 mm) (minimum) G90 galvanized steel. 3) 26 gauge (0.455 mm) prepainted white G90 galvanized steel clad overtop 16 gauge G90 galvanized steel. b. Door jambs to be capped with the following: 1) 18 gauge (1.214 mm) 304 2B stainless steel to match stain less steel faceplate. 2) 18 gauge (1.214 mm) G90 galvanized steel to match galvanized steel faceplate. 3) 26 gauge (0.455 mm) prepainted white steel to match white faceplate. c. The frame component supplied by Zero-Loc also includes 3/8 inch (9.5 mm) nuts, washers and through-bolts and for up to an 8 inches (204 mm) thick wall. Reverse side of faceplate shall include 16 gauge (1.519 mm) bolt plates for bolts and sheet metal snap-cap finish flashing to match wall panel finish.

Technical Data Table

Insulation Tickness of Panels (Zelsius EPS)Inches (mm) 2 (50) 4 (100) 6 (150) 8 (200) 10 (250)

Insulation Type (Zelsius EPS) Type 1 Type 1 Type 1 Type 1 Type 1

Thermal Conductance ASTM C518-19 @ 75ºF (23.8ºC)Imperial Units [BTU/(ft2.hr.ºF) 0.12 0.06 0.04 0.03 0.024SI Units [w/(m2.ºC] 0.68 0.34 0.23 0.17 0.14

Thermal Conductance ASTM C518-19 @ -25ºF (-31.66ºC)*Imperial Units [BTU/(ft2.hr.ºF) 0.096 0.048 0.032 0.024 0.019SI Units [w/(m2.ºC] 0.55 0.27 0.18 0.14 0.11

Total Thermal Resistance ASTM C518-19 @ 75ºF (23.8ºC)RT [(ºF.ft2.hr.)/(BTU.in.)] 8.34 16.68 25.02 33.4 41.7RSI [(m2.ºC)/W] 1.47 2.94 4.4 5.88 7.34

Total Thermal Resistance ASTM C518-19 @ -25ºF (31.66ºC)*RT [(ºF.ft2.hr.)/(BTU.in.)] 10.34 20.68 31.02 41.36 51.7RSI [(m2.ºC)/W] 1.82 3.64 5.46 7.28 9.1

Panel Weight Per Sq.Ft.Foam density Approx. 1#/cu/ft 1#/cu/ft 1#/cu/ft) 1#/cu/ft 1#/cu/ftSheet Steel, 26 gauge,

galvanized & painted 2.16 lb 2.33 lb 2.5 lb 2.66 lb 2.83 lb

Bond Strength Metal to Polystyrene (EPS)When tested to ASTM C-297 Tension test of flat sandwich construction in a flat wise plane

29 psi (200kPa) [Styrene failure]

Max. Girt Spacing for a Max Deflection L/180For exterior wall panels: Interior Skin 26 gauge/Exterior Skin 26 gauge/ Uniform Load = 25PSF**

N/A 16’ 20’ 24’ 27’

Max. Spans in Ceiling Panels (Uniform Load 25PSF**)Walk-on ceiling. Single Span. No ceiling Suspension Hangers.

N/A 16’ 20’ 24’ 27’Walk-on ceiling. Multi Span. With ceiling Suspension Hangers.

N/A 12’ 12’ 12’ 12’Non walk-on ceiling - Single Span

N/A 23’ 28’ 32’ 32’Non walk-on ceiling - Multi Span

N/A 23’ 28’ 30’ 30’

Zero-Loc EPS Insulated Panel System

*Value at -25ºF (-33.66ºC) are for reference only, indicating the increased efficiency of EPS at lower temperature. All design loads should be calculated using the values at 75ºF (23.8ºC).

**Zero-Loc is not responsible for determining the implications of loads applied to a structure by either the wind loading of exterior wall panels or the live and dead of the ceiling system.

13 21 00/ZERBuyLine 0678www.zeroloc.com

Fiberglass Reinforced Plastic (FRP)

may be factory-bonded to the

steel skins of the Zero-Loc

EPS insulated panels, offering

increased scratch and dent

resistance. FRP protects panels from

the frequent rigorous

cleaning that is required in maintain-

ing a sanitary environment.

Food Processing

The finished Zero-Loc insulated

system is sanitary, energy efficient

and durable.

Cold Storage Warehouses

Ideally suited for low temperature

facilities, Zero-Loc EPS “R” value

performance increases as the

temperature decreases.

Walk-on Suspended Ceiling System

Constructed with Zero-Loc EPS

insulated panels, the finished

Zero-Loc walk-on suspended

ceiling system is energy efficient

and durable and is ideally suited for

low temperature, food processing and

controlled environment applications.

factory applied FRP


food processing plants cold storage warehouses walk-on suspended ceiling systems

Technical Specifications

5202-272nd St, Langley, BC Canada V4W 1S3 T: 604-607-1101 F: 604-607-1142

28 Plant Farm Blvd, Brantford, ON Canada N3S 7W3 T: 519-754-4500 F: 519-754-4214

119-9757 Juanita Dr N.E., Kirkland, WA USA 98033 T: 425-823-4588 F: 425-820-9749


9. Gasket: a. Hinged Door and Manual Sliding Door gaskets shall designed for heavy-duty applications, and shall be resistant to oils, grease and/or fats. Door gasket shall create a positive seal at all contact points between door leaf and frame, and door leaf and floor. Level floor surface required for positive gasket seal shall be provided by others. 10. Hinged Door Hardware: a. Overlap-type hinged doors shall be equipped with Kason #1398 Heavy-Duty Cam Rise hinges. b. Infitting-type hinged doors shall be equipped with Kason #1245 Reversible Cam-Rise Hinges. c. Hinged doors shall be equipped with Kason K56 Standard Latches complete with strike assemblies and Kason 481 inside Release Handles. 11. Sliding Door Hardware : a. Sliding door track shall consist of heavy gauge anodized aluminum. Door leaf hanger assembly to be fabricated from: 1) 10 gauge (3.416 mm) 304 2B stainless steel to match door leaf trim finish and faceplate frame finish. 2) G90 galvanized steel to match door leaf trim finish and face plate frame finish. b. Hanger wheels shall be 4 inches (102 mm) in diameter and made from “Delrin” plastic. The 10 gauge (3.416 mm) hanger assembly shall also serve as the cover for the hanger assem bly. 12. Freezer Doors : a. Freezer doors shall be equipped with CSA/UL rated anti-frost heat trace in both door leaf and faceplate frame for heavy-duty hinged and sliding freezer doors and in door leaf or faceplate frame only for hinged and sliding freezer doors in lighter-duty commercial applications. Heat trace shall be factory-wired to a ground-fault circuit interrupter.

2.3 FABRICATION A. Corners: 1. Corner panel connections shall be butt or mitered, flashed, and finished by installation crew on-site. 2. Where specified, corner panel connections shall be a single unit corner panel with a continuous metal skin on the outer bend. B. Offset: Maximum offset from true alignment between two identical members abutting end-to-end: 1/8 inch (3 mm).

PART 3 EXECUTION3.1 EXAMINATION A. Verification of Conditions: Examine areas and conditions under which Work is to be performed and identify conditions detrimental to proper or timely completion. 1. Panel installer to verify that structural steel supports for wall panels are within tolerances in the AISC Code of Standard Practice, Section 7 and supplement modification controlling Section 7.11.3, adjustable items. Limit maximum deviation of steel alignment to plus or minus 3/16 inch(4 mm) from the control with a 1/8 inch (3 mm) maximum change in deviation for any member for any 10 feet (3 m) length of panel. 2. Do not proceed until unsatisfactory conditions have been corrected. B. If support system preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.

3.2 INSTALLATION A. Install in accordance with manufacturer’s instructions.

3.3 TOLERANCES A. Variation: Maximum variation from vertical or horizontal plane, 1/4 inch (6 mm) in 12 feet (3658 mm) length section or 1/2 inch (13 mm) over total length.

B. Offset: Maximum offset from true alignment between two identical members abutting end-to-end: 1/8 inch (3 mm).

3.4 FIELD QUALITY CONTROL A. Manufacturer’s Field Services: Manufacturer shall make periodic inspec tions and issue report to Architect regarding compliance with manufactur ers installation recommendations developed for the Project.

3.5 ADJUSTING A. Repair damage caused during construction. 1. Touch-up mars, scratches, and cut edges to match original finish. 2. If repairs cannot be made to comply with Architect’s requirements, remove damage and install new materials.

5.8 TECHNICAL DRAWINGS

5

6

7

2

1

3

8

4

Line Guide AssemblyLine Guide MountingLine Guide DriveMAIN StructureMAIN InsulationReel MountReel DriveBail Release

12345678

11111111

MAIN Complete Assembly

MCA AD01VARIOUSVARIOUS

QUANTITY: 1

15.7 kg

EXPLODED VIEWSCALE: 1:12

ISOMETRIC VIEWSCALE: 1:16

DO NOT SCALE DRAWING SHEET 1 OF 1

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRICTOLERANCING PER:

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL

PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFLTU and reel.SMRT Design Team. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFLTU and reel.SMRT Design Team IS PROHIBITED.

5 4 3 2 1

FINAL DRAWINGM.P. 21/05/09

NO. PART NAME Qty

3

1

2

1

4

4

4

4

4

4

2

3

1234

LGA01 - Line Guide Side BlockLGA02 - Line Guide PinLGA03 - Line Guide ShaftM6 20mm Flat Head Screw

2226

Line Guide Assembly

LGAxx AD01VARIOUSVARIOUS

QUANTITY: 1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


NO. PART NAME Qty

16

12.50 12.50

20

R1 Filed

90.00°M6 FLAT HEAD

90.00°M6 FLAT HEAD

40

14

6.60M6

CLEAR

6.60M6

CLEAR

6.60M6

CLEAR

3 3

3

Aluminium 6061

0.1

SMOOTH

Line Guide Side Block

Quantity: 2LGA01 MD01

13.37 gDO NOT SCALE DRAWING SHEET 1 OF 1


SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

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DIMENSIONS ARE IN MMTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL


5 4 3 2 1


M6x1.0 Tapped Hole

15 151212

40

12

0.1

Aluminium 6061Polished

Line Guide Pin

LGA02 MD01

10.57 g

QUANTITY: 2



SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

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Q.A.

MFG APPR.

ENG APPR.

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MATERIAL




5 4 3 2 1


14

10

M6x1.0 Tapped Hole

16 26

MD01

42

1512

Steel 4150 QUANTITY: 2SMOOTH

LGA03

Line Guide Shaft0.04



SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

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Q.A.

MFG APPR.

ENG APPR.

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5 4 3 2 1


4

4

4

1

3

3

3

2

2

4

3

4

1

Line Guide Mounting

LGMxx AD01QUANTITY: 1VARIOUSVARIOUS

Line Guide BearingLine Guide Bearing MountSlide Nut M6M6 45mm Flat Head Screw

1234

224



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


NO. PART NAME Qty

200100

16BORE THRU

90.00° 90.00°15

40

17512.50 12.50

6.60M6 FIT THRU

6.60M6 FIT THRU

12.60M6 FLAT HEAD

12.60M6 FLAT HEAD

7.50

Line Guide Bearing Mount

LGM01 MD01QUANTITY: 2Aluminium 6061Rough

0.1

308 gDO NOT SCALE DRAWING SHEET 1 OF 1


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

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DRAWN

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5 4 3 2 1


1

4

4

6

6

6

6

3

2

5

5

Line Guide Drive

LGDxx AD01QUANTITY: 1VARIOUSVARIOUS

Rigid Shaft CouplerBrushless MotorLine Guide Motor SuppoerSlide Nut M6M6 12mm Flat Head ScrewM5 30mm Flat Head Screw

111224

123456



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

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5 4 3 2 1

TENTATIVE DRAWINGM.P. 20/05/09

NO. PART NAME Qty

5.50M5 FIT THRUFOR ALL


12.60M6 FLAT HEADFOR ALL

3517.50 17.50

28DRILL THRU

10.40M5 FLAT HEADFOR ALL

100

90.00°

90.00°

90.00°

20.25

45

55

49.50

30.25

12.50

6

70

49.5035 35

Line Guide Motor Support

LGD01 MD01QUANTITY: 1Aluminium 6061

ROUGH

0.1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

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CHECKED

DRAWN

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MATERIAL




5 4 3 2 1


10

4

4 5

5

2

4510

10

4

53

2

1

1

2

7

7

7

108

9

9

6 6

6

6

6

6

2

MAIN Structure

MSxx AD01QUANTITY: 1VARIOUSVARIOUS

PU25 400mm with HolesPU25 350mmPU25 266.488mmPU25 200mm with HolesPU25 150mmAngle AdaptorMount BracketSlide Nut M6M6 10mm Button Head Scr.M6 20mm Button Head Scr.

12345678910

264448412836



SCALE: 1:8 WEIGHT:

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ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

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CHECKED

DRAWN

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5 4 3 2 1


NO. PART NAME Qty

2525

20

R5.50M6 BUTTON HEAD FIT20 DEEP


400 375

12.50

12.50

MACHINED FROM PU25 SOLECTRO ALUMINIUM PROFILES

AluminiumROUGH

MS01 MD01

PU25 400mm with Holes

QUANTITY: 2

0.1



SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


5M6 BOTTOM TAP20 DEEP

5M6 BOTTOM TAP

20 DEEP

350

PU25 350mm

MS02 MD01QUANTITY: 6AluminiumROUGH

0.1




SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1



5M6 BOTTOM TAP

20 DEEP

266.49

PU25 266.488mm


0.1




SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


25

25



17512.50 12.50

200

R5.50M6 BUTTON HEAD FIT

20 DEEP

R5.50M6 BUTTON HEAD FIT

20 DEEP

175

12.50

12.50

PU25 200mm with Holes


0.1




SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


2525


5M6 BOTTOM TAP

20 DEEP

150


PU25 150mm


0.1



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


31

1

3

3

3

1

1

2

2

2

2

4

MAIN Insulation

MIxx AD01QUANTITY: 1VARIOUSVARIOUS

Insulation Frame 775mmInsulation Frame 400mmInsulation Side PanelInsulation Top PanelInsulation Bottom Fill

1234x

44411



SCALE: 1:12 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1

FINAL PARTIAL DRAWINGM.P. 21/05/09

NO. PART NAME Qty

825

Insulation Frame 775mm

MI01 MD01QUANTITY: 4Aluminium 6061ROUGH

0.1

80 g

MACHINED FROM ALUMINIUM CORNER SECTION OF 20 x 20 mm



SCALE: 1:10 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


400

Insulation Frame 400mm

Mi02 MD01QUANTITY: 4Aluminium 6061

ROUGH

0.1

41 g

MACHINED FROM ALUMINIUM Corner Section 20 x 20 mm



SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


396

823 90.00°

50

90.00°

Insulation Side Panel

MI03 MD01QUANTITY: 4Low-dens. EPSROUGH

350 g

1



SCALE: 1:10 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


396

396 90.00°

50

90.00°

Insulation Top Panel

MI04 MD01

150 g

QUANTITY: 1Low-dens. EPS

ROUGH

1



SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


AD01QUANTITY: 1VARIOUSVARIOUS

12345

4

4

44

4

4

2

5

5

6

6

5

5

6

6

3

1 Reel Mount

RMxx

Spinning ReelReel Mount PlateBail Flip StopperM6 20mm Flat Head ScrewM6 Washer - 4mm thickSlide Nut M66

111644



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


NO. PART NAME Qty

100


12.60M6 FLAT HEAD FITFOR ALL

24

16

16

204

6

90.00°

90.00°75

12.50

32.50

20017545

12.50

77.50

12.50

77.50

Reel Mount Plate

RM01 MD01QUANTITY: 1Aluminium 6061

ROUGH

0.1



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


60

30

M6x1.0 Tapped Hole

7.50

R10POLISHED FINISH

R15

15 DEEPBOTTOM TAP

7.50

50

7.50

15

Bail Flip Stopper

RM02 MD01QUANTITY: 1Aluminium 6061ROUGH

0.1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


123456

2

1

6

6

6

6

3

5

5

4

Reel Drive

RDxx AD01QUANTITY: 1VARIOUSVARIOUS

Rigid Shaft CouplerReel ShaftReel Motor MountBrushless MotorM6 12mm Flat Head ScrewM5 30mm Flat Head Screw

111124



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


NO. PART NAME Qty

10

5M5 THREADED

50 20

70

Reel Shaft

RD01 MD01QUANTITY: 1Steel

SMOOTH

0.05



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


100

70

28 DRILL THRU

5.50M5 FIT THRUFOR FOUR HOLES

5.505.50

5.50

6.60M6 FIT THRUFOR TWO HOLES6.60

12.60M6 FLAT HEAD FIT

10.40M5 FLAT HEAD FIT

6M6 FIT THRU

6M6 FIT THRU

35

49.50

20.25

30.25

12.50

3.30

45

6

90.00°

90.00°

90.00°

10.25

17.5023.10

10.25

17.5029.90

Reel Motor Mount

RD02 MD01QUANTITY: 1Aluminium 6061

ROUGH

0.1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


123456

1

1

2

4

46

6

6

6

6

5

5

3

3

6

5

5

3

55

Bail Release

BRxx AD01QUANTITY: 1VARIOUSVARIOUS

Servo MotorBail Release ArmServo Motor MountBail Release LeverM6 10mm Button Head Scr.Slide Nut M6

213266



SCALE: 1:3 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


NO. PART NAME Qty

3

20160

Bail Release Arm

BR01 MD01QUANTITY: 1Aluminium 6061SMOOTH

0.1



SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


200

20

6M6 FIT THRU

6M6 FIT THRU

6M6 FIT THRU

6M6 FIT THRU

ODD:

20

200

6M6 FIT THRU

6M6 FIT THRU

6M6 FIT THRU

6M6 FIT THRU

4.50

15.50

10

3

12.50 69.80 17 88.20 12.50

12.50 88.20 17 69.80 12.50

4.50

15.50

10

3

EVEN:

Servo Motor Mount

BR02 MD01QUANTITY: 2 EVEN 1 ODD

Aluminium 6061ROUGH

0.1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1


3100

20

3

8.50

8.5024

Bail Release Lever

BR03 MD01QUANTITY: 2Aluminium 6061

ROUGH

0.1



SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL




5 4 3 2 1

INCOMPLETE DRAWINGM.P. 21/05/09

Appendix 5. Mechanical Subsystem

Documents

Transcript of Appendix 5. Mechanical Subsystem