A Keyless Locking Solution

<p style="text-align: center;"><img src="/ueditor/php/upload/image/20250614/1749893021569310.png" title="1749893021569310.png" alt="2.png"/></p><p style="text-align: justify;"><span style="font-family: arial, helvetica, sans-serif; font-size: 12px;">Fenner Industrial Motion, through its MAV product line, worked with Rossi, a leader in industrial gearboxes, to provide a keyless locking device for the sugar mill’s power transmission system. Rossi’s gearboxes are used globally in every stage of sugar production, from cane preparation to crystallization. The solution was the MAV Shrink Disc 3009 560 mm x 940 mm Special, which created a rigid, frictional connection between the gearbox’s hollow shaft and the crusher rollers’ solid shaft, eliminating the need for traditional keys/couplings or mechanical fasteners. The shrink disc is a mechanical assembly composed of conical rings and a set of screws. They provide a rigid, backlash-free, frictional keyless connection between an outer hollow shaft (hub) and an inner shaft. This is installed directly onto the hub which is then mounted onto the shaft. They allow the transmission of torque, bending, thrust loads, etc., either alone or in combination. They are suitable for shock and reversing loads. These components provide high contact pressure between the hub and shaft, offering high load capacity in combination with ease of installation and removal.</span></p><p style="text-align: justify;"><span style="font-family: arial, helvetica, sans-serif; font-size: 12px;">“Rossi wants to increase the maximum torque data of several gearboxes including the EP 1500 (from 2150 kNm to 2500 kNm) to be published in their product catalogs to align with the competitors. So, they need a better performing shrink disc. The same request came for the&nbsp; EP1060 (from 1500 kNm to 1800 kNm), EP2120 (from 3.000 kNm to 3.800 kNm), EP3000 (from 4250 kNm to 5400 kNm), the largest models they produce. We did this easily by modifying the geometry of the shrink disc (taper, number of screws, outer diameter, etc.) In this sense, we have improved performance,” Balestrieri said. The shrink disc has provided 40+ years of proven technology for light, normal and heavy-duty applications. Fenner/MAV engineers utilize 3D CAD and calculation software, including FEM Analysis to provide its customer base with the necessary tools to select the proper components. MAV specializes in designing and manufacturing special items according to customer application and design requirements. The company manufactures keyless locking devices, external shrink discs, and rigid couplings for shafts ranging from 5 mm to more than 1 meter. This includes more than 40 series available in both metric and imperial bores. The solution had to handle a significant torque of 2,500 kNm, while keeping the overall system compact and minimizing stress on the components. The MAV-designed shrink disc met these strict requirements, improving both performance and cost-efficiency in the power transmission system. Cost efficiency was gained by not changing the geometry (diameters and lengths) of the output shaft, the material and the production technology of the shaft, according to Balestrieri. “The application of a higher performance shrink disc would have caused the shaft to suffer from excessive stress,” he added. Rossi supplies cost effective, reliable and high-performance solutions for the sugar industry, with expertise in various sugar processes and applications. These gear reducers and gearmotors offer productivity, energy efficiency and great customization capacity. Thanks to the company’s engineering knowhow, they know what is required during every stage of sugar processing.</span></p>