How Does Redex Differential Drive Work

How does a REDEX differential drive system work?
Guideline of Presentation
How Does REDEX Differential Drive System Work?
- Terminology
- Internal Design and kinematic relation
- Speed relation in a REDEX differential unit
- Torque relation in a REDEX differential unit
- REDEX differential drive in TLL
- Precise Elongation Control
- Perfect Torque sharing
- Benefits of using REDEX differential drive
LI Chang Yu / 李长禹
1 – Terminology
A REDEX differential unit

Tq1 is composed of three
Tq2 elements:
- Casing which carries the planets

Rotation speed N1 - Torque Tq1
- Reaction sleeve / sun gear

Rotation speed N2 - Torque Tq2
- Central shaft / sun gear
Tq3 Rotation speed N3 - Torque Tq3
ρ: through ratio between sleeve and shaft

K: reduction ration between casing and shaft
2 – Internal design and kinematic relation
a b Through ratio ρ calculation

A×b
ρ=
a×B
A, a, B and b are the number of teeth of pinions,
for exemple:
A=37, a=26
B=35, b=23
Reduction ratio K calculation

1
K=
1− ρ
We can see that ρ and K are constants defined

A B by its internal mechanical design.
3 – Speed relation in a diffential unit
Speed relationship ( Willis formula )
N 3 − N1
=ρ→
N 2 − N1
N1
N3 = ρ × N2 +
K
REDEX precise elongation control is
Based on the above equation.
4 – Torque relation in a differential unit
Tq1 Torque relationship:

Tq2 Tq1 + Tq 2 + Tq3 = 0 
→
Tq1× N1 + Tq 2 × N 2 = Tq3 × N 3
Tq1 = − (1 − ρ ) × Tq 3

Tq 2 = − ρ × Tq 3
REDEX torque sharing principe is
based on the above equations
Tq3
5 – Applications of REDEX differential unit
Precise elongation control + Torque sharing in REDEX TLL line
Line elongation control

Entry torque sharing control
Exit torque sharing control

6 – Precise elongation control by REDEX differential unit
6.1 Precise elongation control - The theory

Main
motor
Elongation
motor
N1
N3 = ρ × N 2 +
K
1
K=
1− ρ
N1 : Elongation motor speed
N2 : Main motor speed
N3 : Exit speed
For stainless steel tension leveling, REDEX select

ρ = 0.9351, K = 15.4
6.2 Precise elongation control – Demonstration
Main
motor
Elongation
motor
Speed equation
N3 = ρ * N2 + N1*(1-ρ)
Elongation equation
El = (N3-N2)/N2 = (1-ρ )*( N1 /N2 –1 )
N1/N2 = El /(1-ρ)+1
Elongation deviation calculation :

∆El = (1-ρ ) * ∆( N1 / N2 )
= ( 1-ρ ) * (N1 / N2 ) * [ (∆ N1/N1) + (∆ N2/N2) ]
= ( El+1-ρ ) * [ (∆ N1/N1) + (∆ N2/N2) ]
6.3 Precise elongation control – Numerical application
Main
motor
Elongation
motor
Numerical application:
REDEX elongation differential box with ratio ρ = 0.935 1
Case 1: running at low speed or in Acceleraion / Deceleration phase, speed control
precision of each motor at 0.1%
∆El = ( El +1 – 0.9351 ) *( 0.1% + 0.1% )
El = 0.00, ∆El = 0.0649 * 0.2% = 0.013%
El = 0.02, ∆El = 0.0849 * 0.2% = 0.017%
Case 2: running at medium or high speed, speed control precision of each motor at 0.01%
∆El = ( El +1 – 0.9351 ) *( 0.01% + 0.01% )
El = 0.00, ∆El = 0.0649 * 0.02% = 0.0013%
El = 0.02, ∆El = 0.0849 * 0.02% = 0.0016%

6.4 Precise elongation control – Comparison to conventional electrical drive
N1 : Leveler entry speed N2 : Leveler exit speed
Elongation equation:
El = (N2-N1)/N1 = N2 / N1 – 1
Elongation deviation calculation:

∆El = ∆( N2 / N1 )
= (N2 / N1 ) * [ (∆ N2/N2) + (∆ N1/N1) ]
= ( El + 1 ) * [ (∆ N1/N1) + (∆ N2/N2) ]
Numerical application:
Case 1: running at low speed, speed control precision of each motor at 0.1%
∆El = ( El + 1 ) * ( 0.1% + 0.1% )
El = 0.00, ∆El = 1.0 * 0.2% = 0.2%

El = 0.02, ∆El = 1.02 * 0.2% = 0.2%, compared to 0.017% by REDEX
Case 2: running at high speed, speed control precision of each motor at 0.01%
∆El = ( El + 1 ) * ( 0.01% + 0.01% )
El = 0.00, ∆El = 1.0 * 0.02% = 0.02%

El = 0.02, ∆El = 1.02 * 0.02% = 0.02%, compared to 0.0016% by REDEX
Main
motor
Elongation
motor
∆El = (1-ρ ) * ∆( N1 / N2 ) ∆El = ∆( N2 / N1 )
= ( El+1-ρ ) * [ (∆ N1/N1) + (∆ N2/N2) ] = ( El + 1 ) * [ (∆ N1/N1) + (∆ N2/N2) ]
Redex Mechanical differential drive gurantees a much better elongation accuracy than
conventional electrical drive.
Under the same drive configuration and working condition, elongation accuracy is improved by
a factor of 15!!
7 – Perfect torque sharing by REDEX differential unit
7.1 Torque sharing – The theory
Tq2
Tq 1
Tq 3
Tq1 = −(1 − ρ ) × Tq3

Tq 2 = − ρ × Tq3
For stainless steel tension leveling,

REDEX select ρ = 0.6293
7.2 Torque sharing – Torque sharing ratio
According to torque sharing relationship: Tq Input

C2
Tq R 3 ∗ C1 = −(1 − ρ ) × Tq R 4 C1
Tq R 3 1 − ρ 1
= = Tq R4 Tq R3
Tq R 4 C1 A
A is a constant torque sharing ratio which depends on

Amplification capacity of bridle rolls. for stainless steel T1−2
tension leveling, A=1.85
D3 D 
TqR3 = (T1−2 − T1) × = (eµ •α −1) ×T1× 3 
3
2 2 →

D4 −µ •α D4 
TqR4 = (T2 − T1−2 ) × = (1− e 4
) ×T 2 × 
2 2
TqR3 (e µ •α − 1)
3
1 D 1
= µ •α × µ •α × 3 =
TqR 4 (e − 1) e
4 D4 A3
7.2 Torque sharing – Amplification

Tq Input
Amplification factor is a function of wrapping angle 4
C2
and friction coefficient µ:
µ •α
A=e
C1
Tq R4 Tq R3
We note the intermediate tension between R3 and R4 as T1-2:

Apply the above formula:
T1−2
T1−2 µ •α 
= A3 = e 3

T1 T 2 (µ +µ )•α
 → A3−4 = =e 3 4 Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4
T 1
= A4 = eµ •α  Tq input * C 2 = − ρ × Tq R 4
T2 4
T1−2  C1 and C2 are transmission ratios

constants
7.3 Torque sharing – Analysis of behavior of friction coefficient
TqR3 (e µ •α − 1) 1 D3
ρ −1 1 Tq Input
= µ •α × µ •α × 3 = =
TqR 4 (e − 1) e D4
4 C1 A 3
To simplify the analysis, we consider roll 3 and roll 4 have the same diameter.
The mechanical system is designed to work with roll torque sharing ratio of A.
Tq R 3 ( e µ 3
•α
− 1) 1 1 Tq Tq
= × µ •α = → R4 R3
Tq R 4 ( e µ 4 •α
− 1) e3
A
T2 
A+ 
µ 3 •α T1 )
A3 = e =( 
A +1 A +1
 ln Amp • ( )
T2 A +1  A + Amp 2
A4 = e µ •α = 4
•( ) → µ 4 − µ3 = 2 •
T1 A+
T2
 α
T1 
T1−2
T2 
= Amp 2

T1 
Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4
T2 (ln Amp )
e ( µ + µ ) •α =
3 4
→ µ3 + µ4 = 2 •
T1 α Tq input * C 2 = − ρ × Tq R 4
We can see that the friction coefficients are linked to the tension C1 and C2 are transmission ratio
constants
amplification Amp applied between T2 and T1.

Tq Input
A +1 
ln Amp • ( )
A + Amp 2
µ4 − µ3 = 2 • 
α 
(ln Amp ) 
µ3 + µ 4 = 2.  →
α 
Amp = A 


 Tq Tq
R4 R3
µ4 − µ3 = 0 

ln A  →
µ3 + µ4 = 2.
α 
ln A
µ4 = µ3 =
α T1−2
If Amp is different from A, then we can deduce from the above Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4

equations that the differential gearbox will automatically adapt
to maintain torque balance. Tq input * C 2 = − ρ × Tq R 4
Cst1 and Cst2 are transmission ratio
constants
In this case the working friction coefficients on roll 3 and roll
4 will be changed in its allowable range of µ 3max and µ 4max.
We will do some calculations in the next page to verify this.

A + 1  Tq Input
ln Amp • ( )
A + Amp 2
µ − µ = 2 • 
4 3
α 

µ + µ = 2.
(ln Amp )  →
3 4
α 

A = 1 . 85 
Amp = 1 .5 
Tq Tq
µ − µ = 0 . 02  R4 R3
 →
4 3
µ 3 + µ 4 = 0 . 19 
4 • 3 . 14
0 . 105 •
µ 4 = 0 . 105 , A 4 = e 3 = 1 . 55
4 • 3 . 14
0 . 085 •
µ 3 = 0 . 085 , A 3 = e 3
= 1 . 42
T1−2
In this case have a tension amplification ratio (1.5) smaller than the
predefined torque sharing ratio A(1.85). Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4
We can see that the working friction coefficient on roll 4 is higher Tq input * C 2 = − ρ × Tq R 4
than that of roll 3 which means tension amplification on roll 4 is
higher than roll 3. constants
This adjustement of amplication capacity is done automatically by

the torque sharing box.

A +1 
ln Amp • ( ) Tq Input
A + Amp 2
µ − µ = 2 • 
4 3
α 

µ3 + µ = 2.
(ln Amp )  →
4
α 

A = 1 . 85 
Amp = 2 .5 
µ 4 − µ 3 = − 0 . 06 
 → Tq Tq
µ 3 + µ 4 = 0 . 44  R4 R3
4 • 3 . 14
0 . 19 •
µ 4 = 0 . 19 , A 4 = e 3
= 2 . 21
4 • 3 . 14
0 . 25 •
µ 3 = 0 . 25 , A 3 = e 3 = 2 . 85
In this case have a tension amplication ratio (2.5) bigger than the T1−2
predefined torque sharing ratio A (1.85).
We can see that the working friction coefficient on roll 4 is lower
than that of roll 3 which means tension amplification on roll 4 is Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4
smaller than roll 3. Tq input * C 2 = − ρ × Tq R 4
This adjustement of amplication capacity is done automatically by
the torque sharing box. constants
No matter what the real tension amplification is, the torque sharing box
Can establish automatically torque balance of bridle rolls.
Tension variation is absorbed by the torque sharing unit.
No impact is done to the functioning of leveling process.
Better system stability is achieved.
7.4 Torque sharing – Analysis of influence of roll diameters

Tq R 3 ( e µ 3 •α
− 1) 1 1
= × = → Tq Input
Tq R 4 ( e µ 4
•α
− 1) e µ •α
3 D
A( 3 )
D4
D3 T2 
)+
A( 
µ •α D4 T1 D
A3 = e 3
=( )  A( 3 ) + 1
A +1  D4
ln Amp • ( )
D  D
A( 3 ) + 1  A ( 3 ) + Amp 2
T2 D4  D4
A4 = e µ •α = •( ) → µ4 − µ3 = 2 •
T 2 
4
T1 A(
D3
)+ α
D4 T1 

Tq R4 Tq R3
T2
= Amp 2 
T1 

T2 (ln Amp )
e ( µ + µ ) •α =
3 4
→ µ3 + µ4 = 2 •
T1 α
Influence of roll diameters
Rolls diameters may subject to changes T1−2
Because of strip tension
Because of grinding quality Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4
Because of uneven wear Tq input * C 2 = − ρ × Tq R 4

Because of maintenance error, value is badly measured Cst1 and Cst2 are transmission ratio
constants
Based on the above equations, the differential gearbox will
automatically adapt according to the torque sharing rule to get
suitable µ3 and µ4 values in its allowable range
No slip will occur!!
8 – Benefits of using REDEX differential drive
8.1 Installation power saving – the theory

Tq Entry _ Input
Tq Exit _ Input
Tq R4 Tq R3
Tq R6 Tq R5
T1−2
Tq1 + Tq 2 + Tq3 = 0 
→
Tq1× N1 + Tq 2 × N 2 = Tq3 × N 3
PEntry _ Input = P 2 = Tq3 • N 3 − Tq1 × N1  PExit _ Input = P 2 = Tq3 • N 3 − Tq1 × N1 
 
PEntry _ Input = P 2 = Tq R 4 • N R 4 − Tq R 3 × N R 3  PExit _ Input = P 2 = Tq R 5 • N R 5 − Tq R 6 × N R 6 
→ →
N 3 : clockwise, N1 : anti − clockwise  N 3 : clockwise, N1 : counter − clockwise 
N 2 : clockwise, Tq1 = −(1 − ρ ) • Tq 3  
 N 2 : clockwise, Tq1 = −(1 − ρ ) • Tq 3 
PEntry _ Input = Tq3 • N 3 − (1 − ρ ) • Tq 3 × N1 PExit _ Input = Tq3 • N 3 − (1 − ρ ) • Tq 3 × N1
PEntry _ Input = Tq R 4 • N R 4 − TqR3 × N R 3 PExit _ Input = Tq R 5 • N 5 − TqR 6 × N R 6
PInst − Re dex = Tq R 4 • N R 4 + Tq R 5 • N R 5 − Tq R3 • N R 3 − Tq R 6 • N R 6 PInst _ Conv. = Tq R 4 • N R 4 + Tq R5 • N R 5 + Tq R 3 • N R 3 + Tq R 6 • N R 6
Installation power saving: 2 • (TqR3 • N R3 + TqR6 • N R6 )

8.1 Installation power saving – the case analysis
PInst −Conv. = (PR 3 + PR 4 ) + (PR 5 + PR 6 )

PInst −Conv. = (77 + 135) + (175 + 101) = 488kw
PInst − Re dex = (PR 4 + PR 5 ) − (PR 3 + PR 6 )

PInst − Re dex = (135 + 175) − (77 + 101) = 132kw
PInstalled − Re dex = (129 + 19.5) = 150kw
Installation power saving: Psaving = 488kw −150kw = 338kw

8.2 Precise elongation control

∆El = (1-ρ ) * ∆( N1 / N2 )
= ( El+1-ρ ) * [ (∆ N1/N1) + (∆ N2/N2) ]
Absolute precision as high as 0.0016% as previously calculated
REDEX elongation control by differential :
∆El = f ( El , ∆N1, ∆N 2 )
Elongation control by Tension control :
∆El = f ( ∆T )
∆T = f (Tmes , El , ∆N1 , ∆N 2 , ∆Tq1, ∆Tq 2, ∆Th , ∆Wid , ∆σ )
The advantages of precise elongation control:
Reduce the risk of strip breakage when processing strip with low residua elongation
– Small difference of Yield stress and tensil stress, impossible by tension control
REDEX Elongation control are not influenced by the following parameters:
- Tension measurement precision
- Motor torque cotrol precision
- Strip thickness variation
- Strip width variation
- Strip metallurgical properties variation
The influence of motors speed control precision is divided and a factor of K(15.4 for stainless steel)
compared to conventional electrical drive.
8.3 Perfect torque sharing – No slipping
Line elongation control
Entry Exit
Torque sharing Torque sharing
The same linear speed all along the bridles whatever are their actual diameters
8.4 Reliability and easy maintenance
No keyway,
Nylon injection
The unique feature of REDEX differential

The planet gears are connected to shafts via a patented nylon injection instead of keyway !
Patent of REDEX
The advantage of using of REDEX differential drive
- Easy electrical installation and maintenance
- Stability and robustness of mechanical loop
- Better gearbox operation safety

Three levels of overload protection
- Elongation motor torque soft protection against potential setting error
- Torque limitor protection against accidenal tension peaks, shocks, etc.
- The differential internal design safety protection, in case of failure within the
gearbox(bearing …), the nylon injection will disclutch to protect the gears
Thanks for your attention!

How Does Redex Differential Drive Work

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How does a REDEX differential drive system work?

How Does REDEX Differential Drive System Work?

A REDEX differential unit

- Casing which carries the planets

- Reaction sleeve / sun gear

- Central shaft / sun gear

Tq3 Rotation speed N3 - Torque Tq3

ρ: through ratio between sleeve and shaft

a b Through ratio ρ calculation

Reduction ratio K calculation

We can see that ρ and K are constants defined

Speed relationship ( Willis formula )

Tq1 Torque relationship:

Precise elongation control + Torque sharing in REDEX TLL line

Line elongation control

Exit torque sharing control

6.1 Precise elongation control - The theory

For stainless steel tension leveling, REDEX select

6.2 Precise elongation control – Demonstration

Elongation deviation calculation :

6.3 Precise elongation control – Numerical application

El = 0.00, ∆El = 0.0649 * 0.2% = 0.013%

El = 0.02, ∆El = 0.0849 * 0.2% = 0.017%

El = 0.00, ∆El = 0.0649 * 0.02% = 0.0013%

El = 0.02, ∆El = 0.0849 * 0.02% = 0.0016%

N1 : Leveler entry speed N2 : Leveler exit speed

Elongation deviation calculation:

= (N2 / N1 ) * [ (∆ N2/N2) + (∆ N1/N1) ]

N1 : Leveler entry speed N2 : Leveler exit speed

El = 0.00, ∆El = 1.0 * 0.2% = 0.2%

∆El = ( El + 1 ) * ( 0.01% + 0.01% )

El = 0.00, ∆El = 1.0 * 0.02% = 0.02%

∆El = (1-ρ ) * ∆( N1 / N2 ) ∆El = ∆( N2 / N1 )

= ( El+1-ρ ) * [ (∆ N1/N1) + (∆ N2/N2) ] = ( El + 1 ) * [ (∆ N1/N1) + (∆ N2/N2) ]

7.1 Torque sharing – The theory

Tq1 = −(1 − ρ ) × Tq3

For stainless steel tension leveling,

7.2 Torque sharing – Torque sharing ratio

According to torque sharing relationship: Tq Input

A is a constant torque sharing ratio which depends on

7.2 Torque sharing – Amplification

We note the intermediate tension between R3 and R4 as T1-2:

T1−2  C1 and C2 are transmission ratios

7.3 Torque sharing – Analysis of behavior of friction coefficient

7.3 Torque sharing – Analysis of behavior of friction coefficient

If Amp is different from A, then we can deduce from the above Tq R 3 ∗ C1 = − (1 − ρ ) × Tq R 4

We will do some calculations in the next page to verify this.

7.3 Torque sharing – Analysis of behavior of friction coefficient

This adjustement of amplication capacity is done automatically by

7.3 Torque sharing – Analysis of behavior of friction coefficient

7.4 Torque sharing – Analysis of influence of roll diameters

Because of uneven wear Tq input * C 2 = − ρ × Tq R 4

8.1 Installation power saving – the theory

PInst − Re dex = Tq R 4 • N R 4 + Tq R 5 • N R 5 − Tq R3 • N R 3 − Tq R 6 • N R 6 PInst _ Conv. = Tq R 4 • N R 4 + Tq R5 • N R 5 + Tq R 3 • N R 3 + Tq R 6 • N R 6

Installation power saving: 2 • (TqR3 • N R3 + TqR6 • N R6 )

8.1 Installation power saving – the case analysis

PInst −Conv. = (PR 3 + PR 4 ) + (PR 5 + PR 6 )

PInst − Re dex = (PR 4 + PR 5 ) − (PR 3 + PR 6 )

Installation power saving: Psaving = 488kw −150kw = 338kw