Gear Couplings

Gear couplings are torsionally rigid and are supplied in two designs – completely flexible and flexible/rigid. A completely flexible coupling comprises two hubs with an external gear and two outer sleeves with an internal gear. It’s a universal coupling for all sorts of applications and accommodates all possible misalignments (angular, offset, and combined) as well as large axial moments. Machines, bearings, seals, and shafts are therefore not subjected to the additional forces, sometimes of considerable magnitude, which arise from unavoidable misalignment usually associated with rigid shaft couplings.

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Gear couplings are torsionally rigid and are supplied in two designs – completely flexible and flexible/rigid. A completely flexible coupling comprises two hubs with an external gear and two outer sleeves with an internal gear. It's a universal coupling for all sorts of applications and accommodates all possible misalignments (angular, offset, and combined) as well as large axial moments. Machines, bearings, seals, and shafts are therefore not subjected to the additional forces, sometimes of considerable magnitude, which arise from unavoidable misalignment usually associated with rigid shaft couplings.

Gear Coupling

Gear Coupling Size Chart

GD Type Gear Coupling

Size	Coupling Rating		Maximum Speed rpm	Bore Dia OD mm		Dimensions mm							Solid Hub
Size	kW at 100 rpm	Rated Torque Nm	Maximum Speed rpm	Min. Bore	Max. Bore	ØA	TL	L	ØB	ØF	M	Gap	Mass kg	M.I. (WR²) kg-m²
GD-10	14	1337	8000	14	52	116	89	43	69	84	51	3	4.4	0.0052
GD-15	30	2865	6500	22	65	152	103	50	86	105	61	3	9	0.0192
GD-20	53	5061	5600	27	80	178	127	62	105	127	76	3	15	0.041
GD-25	105	10027	5000	32	98	213	159	77	131	155	92	5	27	0.105
GD-30	168	16043	4400	42	115	240	187	91	152	181	106	5	40	0.195
GD-35	231	22059	3900	47	135	279	220	107	178	211	130	6	65	0.454
GD-40	336	32086	3600	47	160	318	248	121	210	250	145	6	96	0.86
GD-45	472	45073	3200	52	180	346	278	135	235	274	165	8	131	1.39
GD-50	650	62070	2900	72	195	389	314	153	254	306	183	8	186	2.53
GD-55	880	84034	2650	72	215	425	344	168	279	334	203	8	247	3.83
GD-60	1205	115069	2450	77	235	457	384	188	305	366	228	8	299	5.21
GD-70	1823	174084	2150	92	280	527	451	221	356	425	266	9	473	11
GD-80	2639	252006	1750	95	285	590	508	249	385	485	300	10	682	20.72
GD-90	3037	290012	1550	100	300	660	565	276	420	535	325	13	898	34.95
GD-100	4100	391521	1450	120	330	711	623	305	470	595	355	13	1242	55.95

BGS Type Gear Coupling

Size	Coupling Rating		Max Speed rpm	Min. Bore Dia mm		Max. Bore Dia mm		Dimensions mm									Solid Hub
Size	kW at 100 rpm	Rated Torque kNm	Max Speed rpm	Flex Hub	Rigid Hub	Flex Hub	Rigid Hub	ØA	TL1	L	ØB1	ØF	ØB2	L2	M	Gap	Mass kg	M.I. (WR²) Kg-m²
BGS-10	14	1337	8000	14	18	52	60	116	87	43	69	84	84	40	51	4	4.5	0.0055
BGS-15	30	2865	6500	22	26	65	80	152	101	50	86	105	107	47	61	4	9.5	0.0204
BGS-20	53	5061	5600	27	30	80	90	178	125	62	105	127	130	59	76	4	15.5	0.0436
BGS-25	105	10027	5000	32	37	98	110	213	156	77	131	155	157	74	92	5	27.5	0.111
BGS-30	168	16043	4400	42	44	115	130	240	184	91	152	181	182	88	106	5	41.5	0.210
BGS-35	231	22059	3900	47	52	135	150	279	215	107	178	211	212	102	130	6	67	0.477
BGS-40	336	32086	3600	47	52	160	180	318	245	121	210	246	250	116	145	8	100	0.92
BGS-45	472	45073	3200	52	57	180	200	346	274	135	235	274	276	131	165	8	135	1.468
BGS-50	650	62070	2900	72	77	195	220	389	310	153	254	306	309	148	183	9	195	2.73
BGS-55	880	84034	2650	72	77	215	240	425	350	168	279	334	334	173	203	9	261	4.20
BGS-60	1205	115069	2450	77	82	235	260	457	384	188	305	366	366	186	228	10	316	5.70
BGS-70	1823	174084	2150	92	102	280	300	527	452	221	356	425	425	218	266	13	500	12.05
BGS-80	2639	252006	1750	95	105	285	335	590	511	249	385	485	470	249	300	13	715	21.77
BGS-90	3037	290012	1550	100	-	300	370	660	567	276	420	535	518	276	325	15	969	36.60
BGS-100	4100	391521	1450	120	-	330	405	711	626	305	470	595	572	305	355	16	1259	56.27

BVG Type Gear Coupling

Standard full flexible gear coupling type BVG accommodates angular & parallel misalignments or a combination of both as well as axial misalignment (end float). Ideal for all horizontal, close coupled applications including fans, overhead cranes, conveyors, steel & paper mill equipment. One or both of the hubs can be easily reversed for more than normal shaft separation applications.

Size	kW at 100 rpm	Rated Torque Nm	Max. rpm	Bore ØD		ØA	ØB	ØF	G	L	M	TL	#
				Bore ØD									wt. kg	M.I.(WR²) kg-m²
				PB	Max.								wt. kg	M.I.(WR²) kg-m²
BVG -100	6	559	7600	13	35	120	50	75	3	45	54	93	4.1	0.006
BVG -101	12	1127	6730	14	50	170	65	110	5	55	67	115	10.6	0.029
BVG -102	29	2804	6150	20	65	185	85	125	5	70	83	145	15.4	0.046
BVG -103	53	5047	5200	30	80	220	105	150	5	85	103	175	26.0	0.110
BVG -104	100	9557	4580	40	100	250	130	175	5	105	124	215	40.0	0.213
BVG -105	152.94	14605	3950	46	115	290	155	200	10	110	136	230	60.0	0.445
BVG -106	235	22444	3550	50	125	320	175	230	10	125	152	260	84.0	0.745
BVG -107	412	39303	3270	60	145	350	205	260	10	140	174	290	113.4	1.21
BVG -108	529	50472	3015	70	165	380	230	290	10	155	187	320	158.0	2.04
BVG -109	658	62821	2650	80	190	430	250	330	10	165	196	340	210.0	3.46
BVG -110	963	91923	2330	100	230	490	310	390	10	180	216	370	290.0	5.55
BVG -111	1289	123065	2100	110	260	545	350	445	10	200	245	410	545.0	15.25
BVG -112	1723	164516	1940	150	300	590	400	490	10	240	289	490	716.0	24.30
BVG -113	2908	277694	1600	160	330	680	440	555	15	260	312	535	984.0	43.21
BVG -114	4019	383786	1500	200	370	730	500	610	15	280	341	575	1219.0	64.84
BVG -115	4812	459515	1400	230	410	780	540	660	15	320	385	655	1566.0	97.30
BVG -116	7028	671165	1200	260	455	900	625	755	20	350	423	720	2246.0	183.66
BVG -117	9997	954665	1100	300	520	1000	720	855	20	400	489	820	3260.0	338.05
BVG -118	13236	1263938	1000	320	620	1100	810	950	20	450	533	920	4680.0	600.41
BVG -119	17454	1666744	900	300	710	1250	910	1050	30	485	559	1000	6283.0	955.96

Advantages of the Gear Couplings

Gear couplings are mechanical devices used to connect two shafts, transmitting torque and accommodating misalignment between them. They are widely used in various industries due to their robust design and performance. Here are the key advantages of gear couplings:

High Torque Transmission: Gear couplings are capable of transmitting high levels of torque, making them ideal for heavy-duty applications such as in steel mills, power plants, and industrial machinery.
Accommodation of Misalignment: They can handle angular, parallel, and axial misalignment between connected shafts, reducing stress on equipment and improving operational reliability.
Durability and Strength: Made from high-quality materials like steel, gear couplings are highly durable and resistant to wear, even under harsh operating conditions.
Compact Design: Despite their strength, gear couplings have a relatively compact size, allowing them to fit into tight spaces in machinery layouts.
Low Maintenance: Their simple design with fewer moving parts means gear couplings require minimal maintenance, reducing downtime and operational costs.
Versatility: Gear couplings can be used in a wide range of applications, from high-speed machinery to low-speed, high-torque systems, making them adaptable to various industries.
Shock Load Absorption: They can absorb and dampen shock loads and vibrations, protecting connected equipment from damage.
High Efficiency: Gear couplings provide efficient power transmission with minimal energy loss, ensuring optimal performance of the system.

Gear Couplings

Typical Applications of Gear Couplings

Gear couplings are widely used in mechanical systems to transmit torque between two shafts that may not be perfectly aligned. Their design, which typically involves two hubs with external gear teeth and a sleeve with internal gear teeth, allows them to accommodate misalignment while delivering power efficiently. Here are some typical applications:

Industrial Machinery: Gear couplings are common in heavy-duty equipment like steel rolling mills, paper mills, and cement mixers. They handle high torque loads and compensate for shaft misalignment caused by thermal expansion or operational stresses.
Power Generation: In turbines, generators, and pumps, gear couplings connect driving and driven shafts. They’re valued for their ability to transmit large amounts of power reliably, even under varying alignment conditions.
Automotive and Marine: They’re used in drivelines of heavy vehicles or ships, where misalignment between the engine and transmission can occur due to vibration or structural flexing.
Mining Equipment: Crushers, conveyors, and hoists often rely on gear couplings. The rugged design withstands harsh environments and the misalignment from uneven loads or wear.
Oil and Gas: Pumps, compressors, and drilling rigs use gear couplings to ensure consistent torque transfer, even when shafts shift slightly due to operational pressures or foundation settling.

Gear Coupling Applications

Common Troubleshooting of Gear Couplings

Gear couplings are widely used in mechanical systems to transmit torque between two shafts while accommodating slight misalignments. However, like any mechanical component, they can encounter issues that require troubleshooting. Here are some common problems associated with gear couplings:

Excessive Vibration: Gear couplings may experience excessive vibration due to misalignment between connected shafts, worn gear teeth, or improper installation. This can lead to uneven load distribution, causing noise and potential damage. Check alignment with precision tools and inspect teeth for wear.
Overheating: Overheating occurs when lubrication is insufficient or degraded, or if the coupling is overloaded beyond its torque capacity. Friction increases, causing heat buildup. Regularly monitor lubricant condition, ensure proper grease levels, and verify the coupling’s load rating matches application demands.
Noise During Operation: Unusual noises, such as grinding or clanking, often indicate misalignment, inadequate lubrication, or worn components. Metal-to-metal contact from insufficient grease can amplify sound. Inspect lubrication quality, re-align shafts, and replace damaged gears if necessary to restore smooth operation.
Premature Wear of Gear Teeth: Gear teeth may wear out quickly due to improper lubrication, contamination in the lubricant, or excessive torque. This reduces efficiency and risks failure. Examine teeth for pitting or scoring, clean the coupling, and use high-quality, uncontaminated lubricant suited to operating conditions.
Lubricant Leakage: Leaks can stem from damaged seals, over-pressurization during greasing, or worn housing components. Loss of lubrication accelerates wear and failure. Inspect seals for cracks, ensure proper greasing techniques, and replace faulty parts to maintain a sealed, lubricated environment.
Shaft Misalignment: Misalignment—angular, parallel, or axial—strains the coupling, leading to vibration, wear, and potential breakdown. It’s often caused by installation errors or foundation settling. Use dial indicators or laser alignment tools to correct shaft positioning and secure mounting bases.