BASIC LINE Pneumatic Motor - the maintenance-friendly drive solution

Time not only brings money, it occasionally costs money too – especially during maintenance work, which can essentially be accelerated through simple solutions. The engineers at DEPRAG SCHULZ GMBH u. CO. have therefore developed the BASIC LINE compressed air lamella motor, which offers an especially attractive price-performance ratio. With the globally unique patented lamella exchange system, significant maintenance time is saved. A few simple steps allow for trouble-free exchange of the lamellae. Longer downtime of the system is excluded, as the lamella change of the service-friendly BASIC LINE air motor can be carried out directly on the machine without disassembly.

Using a screwdriver and tweezers, worn lamellae can be quickly replaced by new ones by untrained personnel. After loosening the cylinder screws on the rear bearing cover and removing the roller, an uncomplicated exchange is possible. The entire maintenance can be completed within a few minutes and is thus even faster than the complete replacement of the motor in the system. The patented lamella exchange system thus not only significantly reduces maintenance effort compared to previously known compressed air motors, but also saves valuable manufacturing time.

The wear of the lamellae mainly results from the motor's working principle: the rotor, which runs around the eccentric cylinder, is set in motion. The lamellae, located in the slots of the rotor, are pressed against the wall of the rotor cylinder by centrifugal force, forming working chambers. The expansion of the compressed intake air converts pressure energy into kinetic energy, causing the motor to rotate. Friction occurs between the lamellae and the wall of the rotor cylinder – over time, the lamellae wear out after prolonged operation.

Oil-mist lubricated operation fundamentally improves the overall lifespan of pneumatic motors. The optimum in terms of performance and durability is achieved with 1-2 drops of oil per cubic meter of air consumption. The quality of the intake air should comply with standard ISO 8573-1 (see illustration). Nevertheless, all BASIC LINE motors can also be operated oil-free. In addition to shorter maintenance intervals, a 10-20% loss of performance must be taken into account when designing the pneumatic motor for oil-free operation.

For applications in explosion-proof areas, the pneumatic motor is particularly suited due to its working principle: the pressure relief of the compressed air cools the friction heat – overheating and thus ignition of gases are excluded. According to Directive 94/9/EC, the suitability of the pneumatic motor for use in explosive environments must still be demonstrated. The type examination certificate from an independent testing authority assures the user of the safe use of the BASIC LINE series according to ATEX II 2 GD c IIC T4 (130°C) X. The air motor is suitable for the "Non-mining" area, Zone 1 (gas- or dust-laden atmosphere), for substances falling under explosion group IIC and up to an surface temperature of 130°C. To better indicate the ATEX certification of the pneumatic motor in the future, the motor's type designation will be changed from 63-… to 63X-….

If the intake air quality is maintained, this robust motor can also be used trouble-free in dusty environments without impairing its function. The internal overpressure prevents the ingress of dust and dirt.

The BASIC LINE motor series is also resistant to heat and can be used in normal operation from -20°C to +110°C. Regarding the ATEX classification ATEX II 2 GD c IIC T4 (130°C) X, an ambient temperature of -20°C to a maximum of +40°C applies.

Compressed air motors are easy to control and find a wide range of applications due to their versatile properties. The BASIC LINE lamella motor is also characterized by the changing rotational speed during load variation. In case of complete relief, the compressed air motor operates in idle mode. When a small load opposes, i.e., a low torque at the motor spindle, the working speed of the motor is close to the idle speed – if the torque increases, the working speed decreases. The maximum power is reached at 50% of the idle speed. In this range, it operates particularly energy-efficiently.

Depending on the application, the rotational speed can be reduced by regulating the amount of air supplied through throttling the intake or exhaust air. Throttling the exhaust air reduces the speed without significantly reducing the performance or torque of the BASIC LINE pneumatic drive. Throttling the intake air, on the other hand, is used to additionally reduce performance or torque besides the speed.

The rotational speed can also be regulated via the operating pressure. The technical data of DEPRAG BASIC LINE pneumatic motors are based on an operating pressure of 6 bar. Each of these motors can be operated arbitrarily between 4 and 6.3 bar to adjust the performance accordingly to the respective application. Reducing the operating pressure by 1 bar results in a torque reduction of 17%. Operating the pneumatic motor at 4 bar reduces the torque by 33%. If the air motor runs too fast or is too powerful, the speed can be adjusted by changing the amount of air, the operating pressure, or a combination of both. If the motor is to be operated at a lower operating pressure, the use of forced start-up lamellae is recommended.

The pneumatic motor of the BASIC LINE series is also reversible and thus suitable for clockwise or counterclockwise rotation.

Unlike an electric motor, the beltless BASIC LINE pneumatic motor can be loaded up to standstill: in case of overload, the motor stops; after reducing the load, it immediately restarts and can do so repeatedly. The BASIC LINE pneumatic motors are equipped with a planetary gear (with a maximum torque of 80 Nm for motors in the power range 200-600 W or 120 Nm for motors in the power range 900-1200 W). If an overload-safe gear motor with higher torque is required, an appropriate gear (planetary gear, spur gear, worm gear, or bevel gear) is selected for the customer's application.

Ultimately, the BASIC LINE air motor can be used anywhere where the manufacturing environment is non-critical and a robust gray cast iron housing is sufficient. The customer thus has access to a broad range of BASIC LINE lamella motors, from which individual applications can be developed and manufactured according to the modular principle. The series is available in power classes of 200 W, 400 W, 600 W, 900 W, and 1.2 kW over a wide speed range. All BASIC LINE pneumatic motors are equipped with a keyway shaft.

For higher demands, such as use in cleanrooms in the food and pharmaceutical industries, the manufacturer offers the product line of ADVANCED LINE stainless steel motors, characterized by their sealed, oil-free, and corrosion-resistant pneumatic lamella motor. The high-quality air motor is extremely space-saving and is the optimal solution for installation in handheld machines or systems. Its power range extends from 20 W to 1.2 kW, from low speeds to high-speed applications. The ADVANCED LINE lamella motor is ATEX certified, reversible, and available with an integrated holding brake.

For the more powerful sector, the manufacturer also offers the versatile POWER LINE product line, with a broad performance spectrum from 1.6 to 18 kW. POWER LINE pneumatic motors achieve high starting torques compared to electric motors with an unmatched low weight-to-power ratio.

With the INDIVIDUAL LINE series of pneumatic motors, DEPRAG completes its range of pneumatic drives. The pneumatic drives of the INDIVIDUAL LINE are characterized by cost-effective and customized manufacturing. The standard program offers numerous variants, from which tailored drive solutions can be developed and manufactured at an attractive price-performance ratio based on the modular principle. DEPRAG's specialists realize a perfect solution for each application, whether it involves custom gear configurations, various drive spindle variants, or customer-specific mounting options. The range also includes air motors made from innovative materials, such as ceramics.