ESCO Flexible Coupling Solution

Introduction: Application Details

• Machine: Wire Drawing / Wire Rope Equipment
• Drive System: Motor – Gearbox – Machine Shaft
• Control System: VFD-based operation

Challenges: Problem Statement

Customer was using locally manufactured couplings in their machines. Over time, they faced repeated issues related to:

• Improper coupling fitment
• Radial and axial misalignment
• Shaft bore and keyway tolerance variation
• Excessive axial movement during operation

The observed shaft bore size was 106.4 mm, and due to DBSE and misalignment, the coupling performance was unsatisfactory.

Initial Engagement & Technical Study

• Site visit conducted for enquiry and application understanding
• Initial offer submitted for FST 110 & EPB 178, however the offer was closed due to pricing
• Second site visit conducted
  • Local make 106 size coupling found installed
  • Customer reported fitment and alignment problems
  • VFD system impact considered during analysis

Proposed Solution (Solutions)

Based on detailed technical evaluation, ESCO Flexible Gear Couplings were recommended due to their:

• High misalignment capacity
• Robust design suitable for VFD applications
• Reliable performance under variable loads

Recommended Models:

• FST 110
• FST 130
• EPB 178

Order & Execution Timeline

• Revised enquiry received; offers submitted for FST 110, FST 130, EPB 162 & EPB 178
• Order finalized and material dispatched
• Alignment visit planned
• Joint visit with technical team for installation and issue analysis

Installation & Observation

During installation of FST 110 Gear Coupling between gearbox and machine shaft:

• Alignment was checked between:
  • Motor to Gearbox
  • Gearbox to Machine
• Axial movement of approx. 8 mm was observed in:
  • Machine–Gearbox connection
  • Gearbox–Motor connection

Root Cause Identified:

Shaft tolerance was found to be in minus, resulting in loose fitment after installation.

Corrective Actions Taken

• Guided customer on proper drilling and tapping procedure
• Ensured adequate lubrication before installation
• Provided on-site technical guidance to stabilize coupling fitment
• Recommended maintaining shaft tolerance in plus for future machines

Project Results & Outcome, Conclusion

• Coupling fitment issue resolved successfully
• Smooth operation achieved after corrective actions
• Customer highly satisfied with ESCO’s technical support

Repeat Order Received:

• Repeat order for FST 110, FST 130 & EPB 178
• Successful installation completed

Visuals of Projects

• Drilling and tapping process
• Lubrication before installation
• FST 130 installed
• EPB 178 installed
• Axial movement observation (~8 mm)

Customer Confidence & Future Business

Based on technical performance and service support:

• Customer has standardized ESCO couplings for their machines
• New enquiry received for:
  • EPB 198
  • FST 155
  • FST 110

ESCO is now the preferred coupling solution provider to customer.