AS Drives & Services GmbH

product catalogue

Direct Drives
Cooling Units
Flow Control
Gearboxes
Lubrication Units
Engineering
 Content

0. Introduction  5
1. Direct drives  7
2. Cooling Units  19
3. Flow Control  23
4. Gearboxes  29
5. Lubrication Units  37
6. Engineering  41

AS Drives & Services GmbH

Industriestraße 30
48734 Reken (Germany)

www.as-drives.com
info@as-drives.com
Tel.: + 49 2864 9008 0

AS Drives & Services GmbH

All rights reserved
Version 03/2018; Rev. 02

Page 2 AS Drives & Services GmbH AS Drives & Services GmbH Page 3
 0. Introduction

Successful on the market for over 25 years

AS Drives & Services GmbH (AS) considers itself to be an Thanks to our own Engineering department, we are also able
innovative servicing company for industrial gears made by to implement your entire modification projects in the drive
all manufacturers. We inspect, repair, modify, improve or technology sector. From designing the drives and lubrication
reconstruct gears and also offer professional installation and technology to implementing all drive-related modifications, we
removal. can provide everything from a single source.
In addition to servicing, AS also markets its own products in the AS is therefore the only drive specialist that can offer
drive and lubrication technology sectors. We have our own R&D modernisation of all drive systems and the corresponding
department to enable us to continue discovering new solutions lubrication technology from a single source.
to existing problems. All products are designed to the specific
requirements of customers and have received numerous
awards thanks to their innovative design.
The product range comprises all components (motors, thermo
management, inverters, gearboxes, lubrication systems and
flow control for lubricants and coolants) required to modernise
and increase the speed on equipment such as paper-making
machines.

Your machine
is our drive
... with quality
... with safetyness and
... with respect to the environment

Page 4 AS Drives & Services GmbH AS Drives & Services GmbH Page 5
 1. Direct drives

1.1. Motors made by AS  8

1.2. The FlexoDirect® synchronous motor  10
1.3. Motors for the paper-making industry  11
1.3.1. The slip on version of the FlexoDirect®  12
1.3.2. The patented Torque Support  13
1.4. Type code FlexoDirect®  14
1.5. Technical data FlexoDirect®  15
1.6. Request form for special sizes  17

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1.1. Motors made by AS

As a motor manufacturer, AS accompanies every step of the For the construction of electrically powered machines, AS is able The fully equipped range of machine tools makes it possible
design process for a drive unit - whether for modernisation or for to offer the following things on a direct basis: to produce all electrically powered machines at our Reken site.
a new-build. Starting with an analysis of the drive requirements, The skilled employees at Reken manufactures lamination stacks
production of a requirement specification and design on the • non-linear field calculation and coils, and is competent in the handling of highly magnetic
CAD system through to simulation of the drive and integration • production of poly-phase winding systems made of round permanent magnets. Their repertoire also extends to the
of it in commonly used control systems – AS Drives supplies or profile wire maintenance of commonly used kinds of electrically powered
turnkey system solutions with optimum drives manufactured • FEM thermodynamic processes machines.
in-house, or using standard drives from standard-compliant • strength calculations
ranges of motors. Of course, all drives are commissioned, i.e. The test area features a range of high-precision measuring
(static/dynamic, linear/non-linear FEM) equipment that can be used to validate all calculation results
put into service. In addition, AS, based on simulation models
or on measurements from ongoing operation, can also offer • bearing calculation based on DIN/ISO under realistic conditions. The test layout can be extended at any
improvements in feedback control technology. • development of new electrical machines for all applications time to include an air-conditioned room, enabling additional
• specialist development of electrically powered machines heat loads, water spray and high humidity to be included in the
After the commissioning process, AS is available 365 days a (e.g. high-temperature) process in a controlled manner. The in-house Cooliflex® water
year - round the clock - to provide advice and practical support. cooling system provides temperature control for the motors
The service and product portfolio for drive technology primarily • prototype construction for universities and research institutes and inverters with precision adjustment of inlet temperatures.
comprises: • small-scale and volume production of synchronous machines Thermographic recordings, force measurement data and
• performance measurement and system analysis
• software development (e.g. „C“ / „S7“ / „Matlab“ / „LabVIEW“)
• inverter development up to 690 VAC (1000 VDC)
measuring values from vibrational analysis can be transferred
automatically to our CAD systems together with the operating Engine construction
• drive synthesis, design and concept design data of the inverters. This means that all relevant process values
•
•
dynamic simulation of drive components
digital multi-body simulation with Matlab/Simulink
• Motor test bench up to 48 kNm. are available to us directly for analysis and design purposes.
with passion
• controller optimisation
(based on simulation models and/or measurements)
• design and calculation of thermal circuits (e.g. load cycles or
the water cooling of machines and inverters)
• project planning of all activities arising
• measurement of the system in 3D
• design in 2D and 3D

To offer the best possible drives, AS has been conducting

research ever since 2006 into development of its own electric
motors on a variety of motor topologies. As well as the analytical
and digital design of electromagnetic circuits, AS invests its
know-how in the development of low-voltage inverters. This
enables the experts from AS Drives to access a comprehensive
range of drive technology expertise.

test bench

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1.2. The FlexoDirect® synchronous motor 1.3. Motors for the paper-making industry

The FlexoDirect® is a permanent-magnet-synchronous-motor The FlexoDirect® motors are characterised by very good The paper-making industry is a core field of activity for the AS offers direct drives for the entire paper production process.
and is included in the standard range of AS Drives products. utilisation of energy. Compared to asynchronous machines, drives manufactured by AS Drives. AS Drives has been supplying
Specifically adapted to suit the requirements of the material web they demonstrate a higher efficiency rating at all operating dryer group drives ever since 1997. In 2006, the challenges • Material winding and unwinding functions
processing industry, it combines quiet operation, high torque, points. By using waste heat from the water cooling system, of this drive concept became the foundation for a range of • Vacuum pumps and compressors
effectiveness and reliability in a single compact component. their effectiveness can be enhanced even further – the coolant specialist motors. A range of motors specifically matched to • Fibre enhancement / mills
This modular design and the winding, with unconstrained temperatures of 60-70°C on the FlexoDirect® make it easier the demanding environmental conditions of the paper-making • Pulpers and mixers
configuration options, makes it possible to provide the benefits to use waste heat in production processes. The substantial industry has subsequently become a standard component of
of this technology to a broad range of customers. This also reduction in operating and maintenance costs compared to a the AS product range. • Wire drives
makes it possible to design the associated peripherals (inverter, comparable system comprising an IEC asynchronous motor and • Direct drive for presses up to 50 kNm and 1.5 MW
supply lines, cooling) in a cost-effective manner. gearbox is further improved through the use of high-quality These drives are ultra-efficient synchronous machines with • Direct drive for smoothing cylinders up to 50000 Nm
and very durable materials. special magnetic circuits. They are based on a robust design
The full scope of production of these machines takes place with fully encapsulated housings and single or multiple seals.
under the roof of AS. Lamination stacks, winding systems A drive solution involving FlexoDirect® offers: Insulated bearings are always used in these machines. This Depending on the application area, we can offer the appropriate
and rotors are inspected exhaustively at the final assembly makes FlexoDirect® motors especially easy to integrate in motor from our powerLINE range:
stage of these drives, then Quality Assurance conducts a • minimal mechanical complexity through a reduction in the applications for the paper-making industry. They are able to
test run. To withstand the unavoidable overvoltage peaks number of components replace IEC drives as well as commonly used gearboxes, usually • FlexoDirect® powerPOPE (0-800rpm / 1000-4000 Nm)
of modern frequency inverters, even at high temperatures, • minimal maintenance overhead on a 1:1 basis. An appropriate drive can be found for every • FlexoDirect® powerWIRE (0-500rpm / 4500-15000 Nm)
AS uses a particularly robust insulation system that can • exceptionally quiet operation task quickly because of the modular range, with its scalable
cope with high loadings. Provided that all machines are performance and torque classes. The compatibility of machines • FlexoDirect® powerPRESS (0-500rpm / 15000–48000 Nm)
• very high torques and power-to-weight ratios • FlexoDirect®powerYANKEE (0-50rpm / 15000-48000 Nm)
at least able to meet the requirements of thermal class with the latest versions of inverter from all the usual providers
H=180°C, all motors can be approved for operation on • great dynamics and maximum precision on this market is therefore assured on the test benches operated
690 VAC inverters with a 1000 VDC intermediate circuit. The • low operating costs by AS Drives.
direct motors made by AS are characterised by extremely long (no gearbox overhauls, no gearbox oil changes)
service life (even on modern, very fast-switching frequency • minimisation of the costs of spare parts and inventory
inverters).
Since the properties of permanent magnets are closely linked
to their operating temperature, all AS machines are classified
for their respective applications. For example, for the drying
of paper in the dryer groups, a type of machine was created
that does not reach the load limit of the material, even when
operating at an ambient temperature of 135°C while directing
hot steam through the quill shaft at a temperature of 180°C.
Direct Drives for the
The machines are connected mechanically either by solid shafts
or by hollow shafts, meaning that they can be adapted to suit
paper production
customer-specific dimensions. All FlexoDirect® motors can be
supplied as foot versions or as slip on versions.
With this direct drive technology, efficiency ratings of more than
97% can be achieved. In contrast to IEC motors, these values
are also achieved across a substantially wider range of speeds.
Here, the synchronous machine offers significant benefits as a
slow-running multi-pole machine.

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1.3.1. The slip on version of the FlexoDirect® 1.3.2. The patented Torque Support

A special feature of the FlexoDirect® is the disconnected hollow As a drive specialist for dryer groups, AS recognised back in the On single drives, zero-backlash ball joint heads are used.
shaft. Steam and condensate can be routed through it. In this late Nineties that rigid torque supports cause torsional stresses. When connecting AS motors, great emphasis is placed on the
process, the reaction forces of the steam head on stationary As early as 1997, AS therefore developed a flexible torque connection being as rigid as possible, with zero-backlash while
siphons can be absorbed by the motor mounting. Its unusually support for the FlexoGear® dryer group gearbox and applied also being movable – this enables the feedback control system
short design and the ability to operate up to an ambient for a patent for it in the same year. Ideally, this torque support on the drives to adapt perfectly to the needs of production.
temperature of 140°C enables the FlexoDirect® to be installed enables two drives to be braced against each other. There is no Often, a substantial reduction in the tendency of web breaks
directly inside the dryer hood. As a consequence, even when need for a connection to the machine framing - any movements can be observed. This in turn leads to significant improvement
retro-fitted to a paper-making machine, no adjustments need of the drives, e.g. due to alignment errors, are absorbed without in productivity.
to be made to the dryer hood. A loss of heat through apertures load by the torque supports.
in the insulation is avoided safely. FlexoDirect® drives can be
installed on the tending side and on the drive side of a machine.
Adapters are used to connect the FlexoDirect® to the cylinder
journal. These are designed individually to suit each project,
based on the material of the journal, the external as well as
internal dimension of the connection surface, and taking
account of the level of external force applied (weight of the
FlexoDirect®, impact of forces from the steam and condensate
system, etc…). Under normal circumstances, AS uses adapter
bushes and shrink discs to achieve a rigid (zero-backlash)
connection to the dryer cylinder journal.

red: adapter
yellow: shrink disc
blue: journal extension
for the steam and condensate system
Torque support horizontal Torque support diagonal

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1.4. Type code FlexoDirect® 1.5. Technical data FlexoDirect®
Ø 315 mm L

FlexoDirect® FD07 -6 -15 -W 846 -4 3 1 0 0 FlexoDirect® FD03

Type axle height 0-200 rpm
0-1000 Nm
FD12 690 = 1380/2
0-209 kW
FD07 349 = 698/2
FD05 263 = 526/2
FD03 160 = 320/2 Size Type Nominal Poles Nominal Nominal Nominal Nominal Efficiency [%] RPM Torque Current kT kE Phase Res. Lenght Weight
speed Torque PowerOut Current In-Voltage 400/690 max [Nm] max [Nm/A] [Vs/ rad] [mOhm] [mm] [kg]
Lenght [rpm] [Nm] [kW] [A rms] [V rms] [A rms]
400/690 400/690 400/690
6
FD03 210W401 400 20 100 4,2 7,1 361 94,0 450 200 15 14,4 8,5 550 219 90
Pool pairs
FD03 605V522 700 10 397 28,9 53,1 367 96,0 828 600 96 7,5 4,6 85 364 136
15
FD03 805V382 700 10 564 41,3 77,8 372 96,0 849 860 140 7,3 4,5 50 459 156
Voltage max
FD03 A05V402 510 10 770 41,2 81,6 369 95,5 645 1160 146 9,5 5,9 46 539 180
690 VAC W
FD03 710W302 650 20 650 45 85 620 96,8 449 1100 92 7,6 5,8 127 404 217
480 VAC V
Winding type
846
Encoder system
without encoder 0 Ø 526 mm L

MHAXY00 SSI, TTL, (HTL, SinCos on request) 1 FlexoDirect® FD05

AS-Resolver 1 pool pairs 2 0-900 rpm
AS-Resolver 3 pool pairs Resolver** 4
0-4200 Nm
0-260 kW
Single-Turn-absolute resolver SSI 5V + SinCos SIL (90°C) 8
More on request A
(**Resolver: X+1 = Tandemresolver)
(**Resolver: X+2 = incl. analysis module SIL2/SIL3)
Rotor shaft
Standard version with hollow shaft according to size 0 Size Type Nominal Poles Nominal Nominal Nominal Nominal Efficiency RPM Torque Current kT kE Phase Res. Lenght Weight
speed Torque PowerOut Current In-Voltage [%] 400/690 max [Nm] max [Nm/A] [Vs/ rad] [mOhm] [mm] [kg]
hollow shaft with special dimensions 1 [rpm] [Nm] [kW] [A rms] [V rms] [A rms]
400/690 400/690 400/690
Solid shaft even 2
FD05 220V901 60 40 560 3,7 8 382 90,5 68 980 22 93 56 3,2 250 280
Solid shaft with feather key 3
FD05 320W401 85/115 40 820 7/19 13,4 351/622 93,0 103/179 1500 25 62,3 37,2 975 287 300
Motor assembly
FD05 320W461 85/155 40 848 7,5/13,1 15,1 351/622 89,3 103/179 1485 30 57,1 36,1 885 287 286
Standard version with assemly LK on output side 0
FD05 420V601 40 40 1000 3,8 9 344 90,0 51 2000 25 125 74,7 2,3 339 340
Feet version according to size 1 FD05 610W472 170/295 20 1600 28,5/49,3 60,1 359/621 94,0 242/420 3400 110 27,3 15,9 131 429 400
Sealing FD05 620W452 80 40 1780 14,9 26,1 369 94,0 90 3200 60 69,9 42 282 429 400
FKM Sealing 0 FD05 610W552 145/250 20 1850 28,5/49,3 60,1 370/641 94,0 206/354 3400 110 30,9 18,6 173 429 400
PTFE Sealing 1 FD05 610W702 110/187 20 1960 22,5/38,4 49,5 374/624 92,0 163/282 2800 85 39,6 23,6 283 429 400

Double rotor sealing FKM (approx. size +40 mm) 8 FD05 610W852 85/150 20 2160 19,5/34 46 367/636 94,0 133/230 3800 90 47 28,7 428 429 400

Double rotor sealing PTFE (approx. size +40 mm) 9 FD05 810W352 170/295 20 2600 46,3/80,3 99,2 381/643 94,0 242/420 4800 190 26,4 15,8 95 504 480

Position junction box FD05 810W402 145/250 20 2750 42,1/72,0 92,2 374/643 94,0 214/367 4800 170 29,9 18,0 127 504 480
FD05 A10W545 250 20 3000 78,5 148,5 438 94,0 332 5200 300 20,2 12,7 50 550 580
Standard sidewise 0
FZ05 E15W303 140/240 30 4200 62/107 120 377/652 96,6 165/286 6200 210 35 23 65 554 560

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FlexoDirect® FD07
0-600 rpm
Ø 698 mm L
1.6. Request form for special sizes
0-15000 Nm
0-560 kW
Contact data
Company:
Name:
Phone:
Email:
Size Type Nominal Poles Nominal Nominal Nominal- Nominal Efficiency RPM Torque Current kT kE Phase Res. Lenght Weight
speed Torque PowerOut Current In-Voltage [%] 400/690 max [Nm] max [Nm/A] [Vs/ rad] [mOhm] [mm] [kg] Project name:
[rpm] [Nm] [kW] [A rms] [V rms] [A rms]
400/690 400/690 400/690
FD07 312V603 250 12 1600 44 91 371 94,0 351 3000 180 18,47 10,9 92 325 460
System specification
FD07 612W606 250/430 24 3000 79/134 190 360/602 94,0 352/610 6060 436 18,5 10,9 42 442 760
Application range
FD07 612V606 230/- 24 3200 69/- 179 378/- 94,0 345/- 5500 380 18,5 11,1 42 442 660
Function of the motors
FD07 615W846 150/250 30 3250 48/84 108 360/602 94,0 230/399 6060 242 29 17,8 88 442 760
Positioning accuracy [°]
FD07 815W696 145/250 30 4100 63/108 128 386/660 95,0 195/328 7950 288 32,6 19,5 1400 517 760
FD07 830W251 27/48 60 3900 12/19 20 367/615 88,0 33/57 5800 30 193 116 1400 517 760 speed rating [U/min]
FD07 630W436 135/233 60 4500 64/110 106 390/674 96,0 230/399 6060 242 29 17,8 88 447 760
Required nominal torque
FD07 A15W476 150/250 30 5600 88/147 208 347/602 95,0 226/390 10400 460 28 16,6 1400 592 860
FD07 830W21C 400/- 60 5600 235/- 408 373/- 96,9 438/- 8500 800 13,9 8,67 5,7 517 860
Nominal torque [Nm]
FD07 A30W256 135/233 60 7300 104/177 180 394/664 96,0 147/254 12100 360 41,3 25,9 43 597 760 Max. torque [Nm]
FD07 A30W256 135/233 60 7500 107/182 180 394/646 96,0 147/254 12100 360 41,3 25,9 43 592 760
Connected load
FD07 A30W206 156/270 60 7800 127/220 230 384/637 96,8 179/310 14400 400 34,3 21,7 26,7 592 780
intermediate circuit voltage
FD07 C15W343 81/140 30 8014 67,9/117,5 142 392/680 94,0 113,7/197 11400 285 57,3 33,59 101 667 960
[VDC]
FZ07 K20W158 277/480 40 11500 323/560 586 351/608 97,6 326/565 21500 1189 19,2 11,65 6,5 717 1058
Max. power [Aeff ]
Available space
L Length x width [mm]
FlexoDirect® FD12
0-500 rpm Ø 1340 mm Acceptable weight max. [kg]
0-48000 Nm Design
0-1800 kW Housing Air-cooled Water-cooled Without cooling
Ambienece conditions
Ambienece temperature [C°]
Protection class
Cable design
Design Cable Single conductor Industrial plug
Winding shield
Sensor KTY84-130 PTC (Thermistor) Bi-metal-plug
Remarks

Size Type Nominal Poles Nominal Nominal Nomi- Nominal Efficiency RPM Torque Current kT kE Phase Res. Lenght Weight
speed Torque PowerOut nal- In-Voltage [%] 400/690 max [Nm] max [Nm/A] [Vs/ rad] [mOhm] [mm] [kg]
[rpm] [Nm] [kW] Current [V rms] [A rms]
400/690 400/690 [A rms] 400/690

FD12 830W42C 116 / 200 60 14500 182 / 316 360 342 / 603 97,0 154 / 266 24000 720 42,6 24,8 13,8 618 1270
FD12 G30W25C 86 / 150 60 41900 375 / 650 848 342/614 97,0 131 / 226 67000 1580 49,4 29,1 8,2 938 3820
FD12 G30W403 23 60 41900 101 134 649 88 35,3 75000 220 315 186 8,2 938 4075

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 2. Cooling Units

2.1. The Cooliflex®  20

2.2. Type of Cooliflex®  21
2.3. Integrated heat recovery function  21

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2.1. The Cooliflex® 2.2. Type of Cooliflex®

The Cooliflex® was specially developed for the temperature The components of the system are always corrosion-resistant. Installation size Q200 Q 360
control of water-cooled components (motors, inverters, plant All of the important pipework in the Cooliflex® is equipped Flow rate (max.) 200 l/min 400 l/min
components). The coolant water circulates in a closed circuit with by-pass lines. This makes it possible to maintain individual Thermal output (max.) 2 x 12 = 24 kW 2 x 18 = 36 kW
between the cooling points and the Cooliflex® unit. Of course, components even during normal operation. Redundancies in
Cooling efficiency (max.) 0-100 kW 0-200 kW
several consumers can be connected up to each Cooliflex® unit the control unit and in the pumps secure operation in the event
- distribution to them can either be directly on the Cooliflex - or of a malfunction. This means that components such as pumps Pump capacity 2 x 4 kW 2 x 7,5 kW
in the field with our FlexoFlow® registers (see Chapter 3f). or the heat exchanger (optionally available as a water-air or Pipe union
DN 42 DN 50
a water-water system) can be replaced while the system is in (supply and drain)
The Cooliflex is designed as a Plug-and-Play system: set it up, operation. Medium Water, Condensate, Glycol Water, Condensate, Glycol
plug it in, and fill it with coolant. All control unit components System interface PROFIBUS PROFIBUS
are fully fitted, tested and ready to use. No external control The Cooliflex® has automatic monitoring of the flow rate and Electr. Supply 400VAC / 63A / 50Hz 400VAC / 100 A / 50Hz
unit is required. Various tried and tested feedback control feedback control of the cooling points via FlexoFlow® (see (Depend on electr. heating etc.) 500VAC / 50A / 50Hz 500VAC / 80A / 50Hz
algorithms are available for immediate use. These can be used Chapter 3). This reduces the cost and complexity of pipework Size (L/W/H) 2000/800/1400 mm 2200/800/1860
to implement functions such as constant temperature, constant and installation to a minimum and improves operational safety.
flow rate or adaptive checking of fresh water temperature. With the FlexoFlow® units, it is possible at any time to adapt
Incorporation in a PLC is of course possible via PROFIBUS or flow rate values to suit plant conditions - entirely automatically.
PROFINET, or digitally if only a simple feedback message is
needed. This enables a higher-level master to visualise or If there is a need to scale down defined operating conditions
control the system remotely, as desired. by applying heat, additional electrical heating elements can be
configured in the Cooliflex. This ensures that target-controlled
energy input is possible automatically, e.g. by preventing the
system from falling below the dewpoint.

2.3. Integrated heat recovery function

reliable To further improve the overall energy balance of the system, it is

motor cooling advisable to use the waste heat for downstream processes (pre-
heating, spray tubes, hot water). This use of energy is only really
effective if the temperature of the medium is high enough.
On systems from AS, the motors can be cooled as a function of
their respective loading point. The temperature difference of a
cooling point contains all the information needed for a status
analysis – an adjustment of mass flow rate as a function of this
information assures a consistently high return flow temperature
that can be utilised effectively. The average coolant temperature
on the plate-type heat exchanger of an AS drive system with
FlexoDirect (Chapter X) for the dryer group of a paper-making
machine is therefore always within the range of 60-70°Celsius.

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 3. Flow Control

3.1. The FlexoFlow®  24

3.2. Type of FlexoFlow®  25
3.3. The FlexoFlow®Terminal  26
3.3.1. FlexoFlow® Terminal (Type Q 4-12-24)  27
3.3.2. FlexoFlow® Terminal (Type Q 40-60)  27

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3.1. The FlexoFlow® 3.2. Type of FlexoFlow®

The FlexoFlow® is the intelligent flow rate controller, made by The input and output of data on the FlexoFlow®s is performed Family (FlexoFlowController) FFC FFCM FFCL
AS. The FlexoFlow® is used wherever precise distribution of using the system‘s own touch panel, or directly from the process
Type Q4 Q12 Q24 Q40 Q60 Q100
liquid media is required. control system (e.g. via PROFIBUS). In addition, an optical
display on each individual FlexoFlow® signals the operating Measurement range [l/min] 0,07-4 0,25-12 1-24 5-40 7,5-60 10-100
Depending on the version, it can adapt entirely automatically status to the user, even over a considerable distance. Recommendet application area [l/min]* 0,07-1,5 1-9 6-16 10-30 15-45 20-75
to suit different quantities of oil or water. This takes place
independently of the pressure, temperature and viscosity of Every FlexoFlow® has a mechanical by-pass function. This makes FlexoFlow® per terminal ≤ 24 ≤ 12 1
the medium. By way of example, the FlexoFlow® can supply it possible to clear up impurities on the measuring and control Inlet [mm] 40 or 60,3
each individual lubrication point with a defined quantity of unit of the FlexoFlow® during runtime operation, or to carry out Outlet [mm] 18 28
oil. The flow rate quantities are adjusted individually by each maintenance work on the FlexoFlow®. There is no need to shut
Medium Oil or water
FlexoFlow® unit. down the entire system to do this. Which in turn increases the
availability of the system by reducing downtime. Interface digital I/O or PROFIBUS
Equipped with a measuring and feedback control unit, the
Electr. supply FlexoFlow® via FlexoBus (12VDC)
FlexoFlow® can monitor the flow rate continuously. The
FlexoFlow® responds within seconds to deviations between the Electr. supply Terminal 230V / 16A / 50 Hz
measured actual value and the pre-programmed nominal value.
To enable it to do this, an integrated actuator unit controls the
oil quantity in a fully automatic way. This dispenses completely
with the need for manual setting of the flow rate controller.

Precision
made in Germany
FFC Q4 FFC Q12 FFC Q24 FFCM Q40 FFCM Q60 FFCL Q100

The FlexoFlow® is based on a modular design which means that

the same basic housing is able to cover a very wide range of
different measuring ranges. This is achieved through the use
of various sizes of oval wheel and corresponding adapters,
reducing the inventory level of spare parts for the various
different areas of application.

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3.3. The FlexoFlow®Terminal 3.3.1. FlexoFlow® Terminal (Type Q 4-12-24)
6 5 4 3 2 1

The FlexoFlow® terminal is the central connection station for A FlexoFlow® Terminal (FFT) FFT 08 FFT 16 FFT 24
the FlexoFlow® unit. All components are connected to a central max. number FlexoFlow®/ Terminal 8 16 24
supply unit. Inside the system, the FlexoFlow® units then
Inlet [mm] 42 42 42
adapt their settings simultaneously and independently of one
another. D Outlet [mm] D 18 18 18
Dimensions:
All relevant data can be entered via the so-called FlexoPad A: Width [mm] 580 660 900
for every FlexoFlow® unit (or for entire groups of FlexoFlow® B: Height [mm] 2290 2290 2290
units) and interrogated. For the input and output of data, the
C: Depth [mm] 512 512 512
FlexoFlow® terminal can either be used with the process control 6 5 4 3 2 1

E
B
system via PROFIBUS or via I/O card. D: Width Terminal [mm] 440 440 440
A
E: Height Terminal [mm] 690 970 1250
For the various operating points of a system, individual F: Width Terminal [mm] 160 160 160
specified values can be entered for every FlexoFlow® unit or for
G: Distance to wall [mm] 130 130 130
a complete FlexoFlow® terminal. For example, the amount of oil D D
required in ‚crawler speed‘ is reduced. At the touch of a button, H: Depth without stand [mm] 290 290 290
or controlled automatically by the PLC, the flow rate controller C C

can be adjusted up or down a ramp to the appropriate stored

value. Through progressive adaptation of the oil quantities it is
D G F
possible to avoid bearing overflows after a cold start.
H

E
B
Benefits of the system: C
A
• simultaneous feedback control
of all lubrication points in the system
• no problem to add and expand existing lubrication systems
even possible to convert just one assembly group at a time C C
•
•
pump system pressure can be reduced
power saving B
3.3.2. FlexoFlow® Terminal (Type Q 40-60) B

D G F
• protection of all components (pump, filter) H
• minimal need for pipework. C

B
A

E
FlexoFlow® Terminal Maxi (FFTM) FFTM 04 FFTM 08 FFTM 12
max. number FlexoFlow®/ Terminal 8 16 24
Inlet [mm] 42 42 42*
Outlet [mm] 28 28 28
Dimensions:

B
A: Width [mm] B
580 660 900
B: Height [mm] 2290 2290 2405

Connected A

D
G F
C: Depth [mm]
D: Width Terminal [mm]
A 512
500
512
500
512
500

B
H

E
intelligence
C E: Height Terminal [mm] 690 970 1250
F: Width Terminal [mm] 210 210 210
6 5 4 3 2 G: Distance to 1wall [mm] 160 160 160
H: Depth without stand [mm] 370 370 370
*max. 400 l/min volume stream, flange according to DIN 26,42 (DN 50C)

A A
G F
D
H
C

6 5 4 3 2 1

Page 26 AS Drives & Services GmbH AS Drives & Services GmbH Page 27
 4. Gearboxes

4.1. The FlexoGear® gearbox  30

4.2. The patented Torque Support  31
4.3. Gearbox series  31
4.4. Coupling to a system  32
4.5. Type code FlexoGear®  34

Page 28 AS Drives & Services GmbH AS Drives & Services GmbH Page 29
4.1. The FlexoGear® gearbox 4.2. The patented Torque Support

The AS FlexoGear® series of gearboxes was developed Since all FlexoGear® units are identical in terms of external AS Drives recognised at an early stage that rigid torque supports If only a single gearboxes are used, torque support is provided
specifically for use on dryer cylinders on a paper-making or dimensions, and due to their flexible installation position, can cause torsional stresses in the system, and it therefore through a connection to the machine framing. These flexible
cardboard production machine. On the market since 1996, the it is never any problem to exchange these gearboxes against developed a flexible torque support. properties and compensation for movement are retained.
FlexoGear® gearbox has now been installed more than 600 one another. As a result, only a small number of replacement
times and has become established since that time. gearboxes is needed in order to response flexibly, e.g. as a result Ideally, there are always two FlexoGear® that can provide each
of maintenance work on the gearbox such as the replacement other with this support. This dispenses with the need to have a
The hollow shaft on the FlexoGear® enables it to be mounted of wearing parts. connection to the machine framing. Possible movements of the
directly on the dryer cylinder journal. The FlexoGear® is installed gearboxes, for example as a result of uneven journal movement,
directly on the cylinder journal with shrink discs. Through are absorbed by the torque support. In overall terms, the
the use of adapter sleeves, the FlexoGear® can fit almost any torque support provides three-dimensional compensation for
cylinder journal. If the existing cylinder journal is too short, it is movement.
usually possible to work with journal extensions. This makes the
FlexoGear® ideal for modernising the drives on paper-making
machines.
4.3. Gearbox series
The steam needed for the drying process and the condensate
that occurs can be directed effortlessly through the hollow shaft.

The flexible
To assure optimum supply to gear meshing points and FlexoGear® KS 295 KS 340 KS 400 SZ 300
bearing locations, oil distributor blocks are installed on every
FlexoGear®. From there, oil is directed through pipework to the

gearbox concept
corresponding locations, supplying them with lubrication and/
or cooling oil.

Hollow shaft diameter max. <200 mm* <230 mm* <260mm* <200 mm*
Nominal torque 5.000 Nm 6.400 Nm 7.000 Nm 9.500 Nm
Nominal Output (at 1500 m-1) 135 kW 160 kW 180 kW bis 160 kW
Ratio 5,929 6,261 6,091 2,8 - 20,5
Weight 550 kg 745 kg 900 kg 700 kg
Oil-Supply 7 l/min 8 l/min 8 l/min 6 l/min
Max. coupling of gearboxes 2 4 4 0
Minimum distance between
1.460 mm 1.640 mm 1.900 mm -
two cylinder shafts
Installation position 360° 360° 360° horizontal
*special models are possible on request

When selecting an appropriate gearbox range, due account is by the steam & condensate system. The guide values listed
taken of the distinctive properties of each dryer group structure. above apply to each gearbox at a defined speed, not including
This includes definition of the required level of drive power, the axial forces and gearbox coupling connections. Details of other
number of cylinders to be driven, and the axial forces imposed ratios and power ratings are available on request.

Page 30 AS Drives & Services GmbH AS Drives & Services GmbH Page 31
4.4. Coupling to a system Single drive

Duo drive

Triple drive

Quattro drive

Special solution
The FlexoGear® KS 295 series can be connected to a system
with 2 gearboxes; the series KS 340 and KS 400 can be
connected even up to 4 gearboxes. For each group of
Always combined
gearboxes, it is therefore possible to drive two, three or four
dryer cylinders using one motor and one frequency inverter.
Torque is transmitted between the individual gearboxes by a
perfectly
zero-maintenance solid steel coupling or by a universal shaft.
Therefore, no additional intermediate or transfer gearboxes are
required.

Page 32 AS Drives & Services GmbH AS Drives & Services GmbH Page 33
4.5. Type code FlexoGear® FlexoGear® KS 295

FlexoGear® KS 340 -01 -A -063 -2HL -lo0

Series KS 295 KS 340 KS 400 SZ 300
Bearing
Standard ball bearing x x x x 01
Reinforced bearing x x 02

Version
Crown wheel on the output side x x x A
Crown wheel on the drive side x x B
no crown wheel => no neck journal bearing bush (OHL) x x x x C
FlexoGear® KS 340
Ratio
i=5,33 x 053
i=5,93 x 059
i=6,01 x 060
i=6,26 x 063
i= 20,5* x 205
Number of bearing bushes
0 Neck journal bearing (always at version C) x x x 0HL
1 Neck journal bearing output/drive x x x 1HL
2 Neck journal bearings output x x 2HL
3 Neck journal bearings output x x 3HL
Position neck journal bearing
top x x x o00
left x x l00
right x x r00 FlexoGear® KS 400
left & top x x lo0
right & top x x ro0
left & right x x lr0
left & top & right x x lor

*special models are possible on request

*The series SZ 300 (two staged) can easily be designed in different ratios in the range of i = 2,8 - 20,5

FlexoGear® SZ 300

Page 34 AS Drives & Services GmbH AS Drives & Services GmbH Page 35
 5. Lubrication Units

5.1. The Lubriflex®  38

5.2. Model range Lubriflex®  39

Page 36 AS Drives & Services GmbH AS Drives & Services GmbH Page 37
5.1. The Lubriflex® 5.2. Model range Lubriflex®

The Lubriflex® recirculating oil lubrication system was The Lubriflex® system can be used in new systems and as a Type Lubriflex® 300 500 1000 1500 2000 2500 3000 4000 5000 ... 8000
developed specifically for optimum provision of lubricating and replacement for existing recirculating oil lubrication systems. Dimensios:
cooling oil. This simply involves an inspection of the existing pipework Nominal volume [l] 300 500 1000 1500 2000 2500 3000 4000 5000 ... 8000
system. AS can provide any new pipework required, and can
Lubriflex® assures optimum degasification, cleanliness and conduct the concluding leak test. Tank volume [l] 350 625 1250 1875 2500 3100 3600 4800 6000 ... 9600
operating temperature of the lubricant. A special degasification B: Lenght overall [mm] 1300 2500 3500 4000 4500 5000 6000 6500 5000 ... 8500
system minimises the oil dwell time and this halves the A: Width overall [mm] 700 1600 2000 2000 2000 2000 2500 2500 4000 ... 3000
container volume. C: Height overall [mm] 1800 2100 2100 2100 2100 2100 2100 2100 2050 ... 2500
Removable flow direction channels make the complete interior Performance characteristics:
easy to clean. The redundant design of the most important Pump capacity max. [l/min] 30 50 100 150 200 250 300 400 500 ... 800
components (e.g. the pumps) creates a very high level of Connected load pump drives [kW] 0,75 4 7,5 11 15 15 18,5 18,5 30 ... 30
machine availability. Heating capacity [kW] 5 10 16 20 24 40 40 60 80 ... 100

To achieve a long service life, even under adverse ambient Cooling capacity [kW] 27 60 95 135 180 230 280 360 460 ... 720
conditions, the entire tank system is made of stainless steel. Operating pressure max. [bar] 25 25 25 25 25 25 25 25 25 ... 25
*special models are possible on request
The Lubriflex® system is supplied in turnkey condition with all
necessary components, from the degasification tank, the filters
for suspended particulate and the heater used to heat up the
oil. If so desired, the Lubriflex® system can be supplied with
integrated control technology. This means that the Lubriflex®
Oil-conditioning on
system is ready for operation directly after incorporation in the
pipework system. the highest level

Modular divesrity
Page 38 AS Drives & Services GmbH AS Drives & Services GmbH Page 39
 6. Engineering

6.1. Drive projects  42

6.2. Tribology projects / lubrication technology  43

Page 40 AS Drives & Services GmbH AS Drives & Services GmbH Page 41
6.1. Drive projects 6.2. Tribology projects / lubrication technology

AS Drives offers full service for the conversion of drives. The customer benefits from the many years of experience of AS In the tribology sector, AS provides the full package, starting
Depending on the machine, AS can always provide an with all of the commonly used types of drive, such as with project planning, pipework configuration, the selection of
appropriate drive solution, whether that involves increased all components and the installation and commissioning.
speed, modernisation or the renewing of drivelines. • gear boxes
• direct motors To accomplish this, experts from AS tackle all questions in
With its own engineering and design department, AS can devise advance that relate to topics such as central recirculating
• silent felt roll drive and silent dryer drive
customer-specific solutions. The very latest CAD programs make lubrication systems, oil flow rate control and layering units and
perfect planning possible as well as optimum visualisation of • enclosed gearboxes can also assist in the choice of appropriate technology.
all construction components in 2D or 3D. When it comes to the • open gear drive
selection of drives, AS can draw upon its own product ranges • The AS product range includes fully automatic grease
transmission drive
(e.g. FlexoGear®, FlexoDirect®) as well as on standard drive • lubrication systems, 2-line systems and progressive
... distributors.
solutions. Also, if necessary, it can design entirely new drives.
•
When seeking out a solution, our designers can access the AS calculates all lubrication systems and designs these in
many years of experience our AS fitters have in the construction accordance with tribological factors.
and installation of drives. As a primary contractor, AS is therefore able to support the
With its in-house installation team, AS can assure professional
entire course of a project. Starting with pre-engineering, on-
With each customer AS works out the right solution. Then, if installation of its new lubrication technology together with the
site measurement, devising of a solution, project management,
necessary it implements the planned conversion measures with full scope of pipeline construction and pipe-laying. This also
installation management and on to commissioning / initial
its own highly competent installation team. includes inspection (e.g. seal integrity) of all installations prior
start-up.
to commissioning of each system.

Turnkey solutions
for your maschine

Page 42 AS Drives & Services GmbH AS Drives & Services GmbH Page 43
Our services

Gearbox Inspection
Gearbox Repair
Ratio Change
Gearbox Improvement
Gearbox Redesign
Gearbox Assembly

AS Drives & Services GmbH

Industriestraße 30
48734 Reken (Germany)

www.info@as-drives.com
www.as-drives.com
Tel.: + 49 2864 9008 0
Fax: + 49 2864 9008 80