NEMA 34 to Gearbox 80 Flange Adapter

FLANGE ADAPTER MANUFACTURING (NEMA 34 → GEARBOX SN 80) • Material: Steel 40X, Steel 45, or Structural Aerospace Aluminum D16T (Steel is highly preferred due to the minimal flange thickness). 1. Blank Geometry (Turning Stage) The component is designed as a stepped circular flanged sleeve (top-hat configuration): • Flange Overall Outside Diameter: 110.0–115.0 mm (to clear the mounting lugs of the NEMA 34 motor with a pitch circle diameter of 98.0 mm). • Flange Section Thickness: 6.0 mm (strictly according to the drawings). • Centering Spigot ("Skirt") Outside Diameter: Ø60.0 mm. Machining tolerance must adhere strictly to h7 (+0.000 / -0.030 mm) to ensure a precise, zero-play press/slip fit into the gearbox recess. • Centering Spigot Length (Height): 8.0–10.0 mm (Verify the clear depth inside the gearbox flange prior to machining to ensure it does not bottom out against the bearing housing). • Through-Bore (Center Hole): Clean bore to Ø45.0 mm straight through the entire part. This is mandatory for unhindered clearance of the gearbox clamping collar (tsanga) and to maintain access to its tensioning screw. • Motor Pilot Recess (Flange Side): Internal counterbore with a diameter of Ø73.0 mm, machined to tolerance class H7 (+0.030 / +0.000 mm). Recess depth must be strictly 2.5–3.0 mm (engineered for the standard pilot boss of the Hanpose motor). • Machinist’s Note: At the junction of the 6.0 mm flange and the 3.0 mm motor pilot counterbore, a remaining web thickness of 3.0 mm will be left. This is a design requirement; structural steel provides more than adequate shear and bearing strength for this section. 2. Coordinate Milling Stage (Layout and Hole Drilling) Two independent hole patterns must be machined into the 6.0 mm thick flange. The patterns are to be radially offset by 45 degrees relative to each other for assembly tool clearance: • Pattern A (To Gearbox Interface): • 4 through-holes on a Pitch Circle Diameter (PCD) = 75.0 mm. • Drill diameter to match the specific gearbox housing screws (Drill Ø5.5 mm for M5 hardware, or Ø6.5 mm for M6 hardware). • Critical Requirement: On the motor-facing side (inside the Ø73.0 mm recess), these holes must be countersunk for flat-head screws (DIN 7991) or counterbored for low-profile socket head cap screws (DIN 6912). The bolt heads securing the adapter to the gearbox must sit completely flush or sub-flush within the flange body; any protrusion will cause mechanical interference with the Hanpose motor face. • Pattern B (To NEMA 34 Motor Interface): • 4 through-tapped holes on a Pitch Circle Diameter (PCD) = 98.0 mm. • Tap M6×1.0 straight through the remaining thickness of the flange to accept the motor mounting bolts.

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