A star is born

A cross-functional team for a new flexible coupling made in Varvel, of still higher quality and product reliability, but at a highly competitive price.

In order to consolidate and to improve the flexible coupling, a worldwide identification element of Varvel gearboxes for over a decade, the Bologna-based enterprise specialized in power transmission equipment and symbol of Italian excellence entrepreneurship, presents a new flexible element in a revised and optimized star-like design.

The Varvel boost to this reengineering was due to the desire to fill some existing gaps, in order to guarantee its customers full and safe replacement of conventional motor key/keyway connection, no more limits of heavy duty service factors, extreme temperatures in compliance also with ATEX standard.

This action has involved all Varvel departments in a cross-functional team work, which handled every aspect of the new flexible element, from the definition of a new optimized geometry by FEM simulation, to the choice of a right polymer, up to an injection moulding partner selection with the right qualities to ensure an upgraded quality and an added value within the injection moulding process.

The polymer chosen is a powerful step ahead compared with traditional TPU and TPE thermoplastic elastomers, as made of an enhanced polyamide with a special elastomeric insert, that makes it shock and vibration resistant, usable in a wide range of extreme temperatures and resistant to fatigue effects.

The new spider geometry was directly studied for the new material and designed with the finite element aid, to obtain the best combination of enhancement of current critical areas and weight reduction. The latter, a significant costs saving, able to offer customers higher quality and reliability standards at a competitive price.

Finally, the tests carried out so far, show the new flexible coupling is usable in environments subjected to ATEX regulations. The next step will certainly be to extend ATEX certification also to all the gearboxes with flexible coupling.

"Also this new element is the witness of the great R&D work carried out in the company - say Francesco Berselli and Mauro Cominoli, Chairman and CEO of Varvel SpA - showing the constant commitment in satisfying any type of requirement and ensuring continuous attention to acquired and prospect customers, proving the great innovation that features all the products made in Varvel".