shanghai Maud Group
Cross Universal Shaft Coupling
   Universal coupling with spider (SWC, SWP, and SWZ) is mainly made up of a cross pile buildup by flanged jaw, cross shaft and bearing, welded jaw and spline shaft, spline housing jaw subassembly. 
    The holistic length of Universal coupling with spider depends on working condition of live situations (the maximum length we have ever manufactured is 18m), pipe-shaped parts increase machining difficulties in machining process. How to make sure the coaxiality of jaw rotating center and spline housing, and center of bearing holes as well as how to guarantee perpendicularity of rotating center of spline housing are a core problem worthy discussing for long in this line. Common means to make coupling is mainly processed by universal equipment, first finish the machining of main parts of coupling, its last process is to weld the parts and assemble them properly, and its design precision is confirmed by the welding. Its degree of symmetry and coaxiality can not be handled, what’s more, it is impossible to eliminate welding distortion and residual stress of weld, this leads to hidden troubles of quality of products. When coupling is running, it will tremble a lot, seriously affecting the whole transmission system, making much noise, shortening its service life and even distress other rolling equipment.
    Our company has piled up about 20 years experience and techniques of coupling making. Based on the high responsible sense of considering our users, and in order to guarantee machining precision of coupling, we introduced advanced special equipment and techniques and manufacture coupling with typical technique.
Brief introductions of typical machining of main parts are as follows:
Flanged Jaw:
    First finish machine jaw rabbet, fix on CNC end plane keyway miller, mill out its key-way(as picture 2), then put the keyway on keyway grinding bed and grind it to ensure the degree of symmetry of keyway relatives to rotating center, fix the center and direction respectively according rabbet and end plane keyway, then clamp and assemble at one time ,machine jaw bearing earhole and symmetry slot on CNC three-service position boring and milling special united machine tool by multiple service positions.
    After flanged jaw connected by end tooth or tooth block finish machining and being rabbet, end tooth or tooth block of flanged conjunction plane(as Picture 3) will be finished by full automatic numerical professional end plane machine, so it can guarantee the correction of division of end tooth or tooth block. Processing of earhole of jaw bearing and symmetrical trough is as same as that of end plane keyway flange, while processing of bolt jointing hole of end plane flange is also in the numerical vertical machine center controlled by numerical process, and then division and drill are directly operated, in order to ensure the division correction of bolt jointing.
Cross Pile:
    The most important parts of cross pile are cross bearing and bearing shell. In order to guarantee the requirement of tolerance of form and position of every spindle head, first lie cross pile on the center of numerical vertical cross machining which is run completely by machine tool, directly divide and drill the center hole ( as Picture 4), in this way , the positions of four cross shell bearings are fully guaranteed, thus next machining of Russian numerical controlled machine tool and grinding machining are guaranteed too; both roughing and finish machining are operated in numerical central machining tools, so as to guarantee interchangeability and processing accuracy of cross pile.
Weld Assembly of Spline Shaft Yoke:
    Involute spline tooth of spline shaft is machined on numerical horizontal hobbing machine. Because of the generating method of typical machining techniques of involute tooth, the design goal of interchanging of machined parts and self centering of spline supplementary tooth when transmission shaft is running is fully fulfilled.
    First weld jointing jaw and spline shaft together (as picture 5), after that, lie the whole spline parts decumbent on four-service-position (nine shaft interconnection) numerical boring-milling assembled machine tool, and machine the earhole of jaw bearing on jaw, thereby guarantee the verticality of jaw bearing earhole and center of gyration as well as requirement of coaxiality of the whole shaft.
    Machining of spline housing involute tooth is completed on professional long-path gear shaping machine. Producing according to typical gear techniques not only makes the paths longer but also guarantees fitting precision of internal and external tooth.
    Weld assembly of spline shaft yoke is weld jointed of spline housing, bush and spline shaft yoke (as Picture 6). As before put the whole spline housing assembly decumbently on four-service-position (nine shaft interconnection) numerical boring-milling assembled machine tool, and machine out bearing earhole on yoke. In this method, it can guarantee verticality of yoke bearing earhole and center of gyration, over exist disadvantaged of weld jointing , increase axiality and running stationarity of the whole coupling, prolong coupling’s service life, greatly improve driving status of the whole driving chain (including the reducer) and meanwhile prolong its service life.
    In fact, our company is religious in management, and produces coupling in flexible machining production line. To ensure the precision of universal coupling with spider, we take excellent equipment as its guarantee, and imported dynamic balance detector from SCHENCK RoTec GmbH in Germany, and tested our shaft coupling under a status without balancing weights. As a result, it is proved that our cross universal shaft coupling can make G16 grade of ISO1940-1985 and G6.3 grade on balance quality

General View of Shaft Coupling Machining Equipment
Long-stroke Gear Shaper 
    Technological Parameter: its gear shaping stroke is 500mm, inner gear shaping diameter is 600mm, maximum modulus of gear shaping is 8m, and machine precision is grade 6. 
    Designation: mainly used to machine inner gear and gear shaping of spline housing which is the key part of involute cross universal shaft coupling, it finishes the history of jointing slip join assistant of shaft coupling products with rectangle spline, found basis for production of involute spline universal shaft coupling. It is just the gear shaper who has the longest gear shaping stroke in China, so Nanjing High speed & Accurate Gear Co., Ltd comes to machine their parts for regarding its reputation.
Semiautomatic Horizontal CNC Crowned Tooth Hobbing Machine 
    Technological Parameter: length of spline hobbing is 3300mm, maximum diameter of hobbing is 320mm, maximum hobbing modulus is 8m, and machine precision is grade 7. 
    Designation: used for machining involute spline shaft hobbing, for CNC machine tool can be used to machine crowned tooth shaft coupling, it machine successfully 5480 spline crowned tooth of German standard for Hangzhou Iron&Steel Co.,Ltd mini type rolling transmission, and it provides great effect in manufacturing shaft coupling products.
CNC End Plane Key seat Milling Machine ( Three-Shaft Motored) 
    Technological Parameter: length of slot mill is 1000mm, width of millrace is 600mm, maximum height of cutting work piece is 800mm, and machine precision is grade 6. 
    Designation: mostly used for cutting machining of flanged jaw, shaft housing, palm end key seat of cross universal shaft coupling. Work pieces are clamped and assembled at one time and machined multiple processes. It has high machining work rate and good rigidity; it can cut an end plane key seat of 120mm wide and 1000mm length.
Semiautomatic End Plane Key seat Grinder 
    Technological Parameter: its millrace is 1600mm long and 200mm, wide, diameter of grinding wheel is 300mm, and machine precision is grade 3. 
    Designation: mainly used for grinding machining of flanged jaw end plane key seat of cross universal shaft coupling, to guarantee central positioning of flanged end plane key seat of cross universal shaft coupling, and to make sure its steady setting and its axiality of shaft coupling.
Dynamic Balance Detector Imported from SCHENCK RoTec GmbH 
    Technological Parameter: rotating diameter for inspecting work piece is 800mm, its length is 3600mm, inspecting precision is grade 0.63. 
    Designation: dynamic balance detector is a necessity for producing shaft coupling products
Three-Service Position (Seven-Shaft Motored) CNC Boring &Milling United Machine Tool 
    Technological Parameter: CNC DTK system, three-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, Seven axes and six machining body, maximum inner diameter is 600mm, maximum cutting length is 7300mm.maximum work piece height is 1200mm. and machine precision is grade 6.It is a machine with multiple functions of boring, drilling, milling and end plane cutting. 
    Designation: It can entirely process spline shaft weld jointing jaw, which is the main part of shaft coupling, and bearing hole of spline housing weld jointing jaw. It is clamped and assembled at one time and machined by multiple positions.
Automatic CNC Professional End Plane Tooth Machining (Four-Shaft Motored) 
    Technological Parameter: CNC DTK system, four-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, maximum gyring diameter is 1600mm, maximum cutting length is 360mm.maximum work piece height is 1200mm. and machine precision is grade 6. 
    Designation: Mainly used for automatic processing of flanged jaw of shaft coupling, semi-catcher end plane tooth, and tooth block end plane jointing parts, precise division makes quality of machined pieces reliable.
Horizontal Numerical Lathe (Two-Shaft Motored)( Made in Russian) 
    Technological Parameter: CNC KND system, two-shaft motored, advanced ball bearing screw mandrel, maximum gyring diameter is 850mm, maximum cutting length is 1500mm. machine precision is grade 5. 
    Designation: It mainly processes shaft coupling parts.
CNC Vertical Machining Center (Three-Shaft Motored) 
    Technological Parameter: CNC DTK system, three-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, Japanese servo-chief axis, unlimited speed adjustment of cutting chief axis, maximum of whose cutting rotate speed is 4500 r/m, X-axis ‘s stroke is 600mm, that of Y-axis is 800mm, that of Z-axis is 700mm,positioning precision of the three shafts is 0.05um, maximum work piece height is 1200mm. and machine precision is grade 6. 
    Designation: It combines function of drilling, tapping, boring and milling. It is replied mainly to drill, tap, bore and mill various shaft couplings and crowned tooth shaft coupling, and guarantees the position of mounting hole.
CNC Vertical Hobbing Machine 
    Technological Parameter: length of spline hobbing is 330mm, maximum diameter of hobbing is 800mm, maximum hobbing modulus is 8m, and machine precision is grade 7. 
    Designation: Used to process crowned tooth, straight tooth and worm gear.
Horizontal CNC Machining Center 
    Technological Parameter :CNC “FANUC” system, two-shaft motored, advanced slip linearity guide rail, precise bearing ball screw mandrel, maximum lathe rotating diameter is 300 mm, maximum cutting length is 500 mm, maximum of whose cutting rotate speed is 4500 r/m, machine tool precision is grade 4.
    Designation: Mainly used for machining of shaft coupling parts (finish machining of bearing housing), it has a cutting function of keeping even cutting linear velocity, and roughness of surface of cutting work piece.
Four Service Position (Nine-Shaft Motored) CNC Boring&Milling United Machine tool 
    Technological Parameter: CNC DTK system, seven-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, Nine axes and eight machining body, maximum inner diameter is 800mm, maximum cutting length is 3600mm.maximum work piece height is 1200mm. and machine precision is grade 6.
    Designation: combining three-position machine tool plus two shafts, it can give better machining ability and functions of machine tools.
CNC Vertical Cross Shaft Machining Center (Three-Shaft Mechanical, Electrical and Liquid Motored) 
    Technological Parameter: CNC DTK system, three-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, Japanese servo-chief axis, unlimited speed adjustment of cutting chief axis, maximum of whose cutting rotate speed is 4500 r/m, X-axis ‘s stroke is 500mm, that of Y-axis is 300mm, positioning precision of the three shafts is 0.05um, maximum work piece height is 600mm. and machine precision is grade 4. machining roughness of surface are 0.8um.
    Designation: Cross shaft machining center can drill, tap, bore and mill, mostly used to process end plane of cross shaft and center hole which are key parts of cross universal shaft coupling, its positioning precision is 0.02um, that guarantees central positioning accuracy of four cross shaft ends.
Large size CNC Vertical Hobbing Machine ( Made in Russian ) 
    Technological Parameter: length of spline hobbing is 600mm, maximum diameter of hobbing is 1500mm, maximum hobbing modulus is 30m, and machine precision is grade 7. 
    Designation: used for machining crowned tooth, straight tooth, and worm gear (it can process rubber coating worm gear and worm stem with axial feeding) of shaft couplings, and provides guarantee for manufacturing of large crowned tooth.
Largesize CNC Horizontal Hobbing Machine( Made in Russian ) 
    Technological Parameter: length of spline hobbing is 8000mm, maximum diameter of hobbing is 600mm, maximum hobbing modulus is 16m, and machine precision is grade 7.
    Designation: It is used to machine spline major axis of large cross universal shaft coupling. It provides equipment for matching slab band and poling large universal shaft
Large Professional Shaft Coupling Spline Housing Machine Tool ( which mills instead of inserts) 
    Technological Parameter: CNC DTK system, four-shaft motored, advanced rolling guide rail, and ball bearing screw mandrel, maximum inner diameter is 1500mm, maximum cutting length is 1200mm, and machine precision is grade 6.

     Designation: Mostly used to process spline housing of large shaft coupling.