Product Catalog

Author Archives: Shelley Doherty

  1. Python™ Quick Adjust Line: Flange & Flange Mounting Collars

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    Our new Quick Adjust line will optimize your operational efficiency with user-friendly shaft collars, specially designed for easy one-handed installation and quicker, more convenient adjustments. The Python™ Quick Adjust Line redesigns the standard flange collar to make it easier to install and adjust as needed.

    Stafford specializes in developing innovative products built for lasting performance in fast-paced environments, and our premium quick-adjust products are used across a variety of industries. Learn more about our new Python™ Quick Adjust Line and the two collars in this evolving product line.

    Introducing the New Python™ Quick Adjust Line

    Shaft collars frequently need repositioning and changes, but conventional shaft collars can’t keep pace with busy facilities that have strict up-time schedules. When the hardware needs to be disassembled, moved, and reassembled, that cuts into valuable operational hours. The Python™ Quick Adjust Line from Stafford incorporates quick-adjust technology so your technicians can make fast changes. These collars can be adjusted with one hand and minimal disruption so you can maintain quality standards, adjust hardware to meet changing needs, or make repairs. They also require no tools, further simplifying the task. 

    Take a closer look at our two Python™ collars: the Python™ Flange Mounting Collar and Python™ Flange Collar. Operators can quickly adjust the tension and positioning of either collar with a single hand or set up stops for even easier use. The collar is easy to adjust and withstands axial loads of up to 200 pounds, making it a good fit for linear, low-speed RPM systems. Python™ collars are available in different styles based on:

    • Material: Standard is aluminum,  with steel & stainless available on request.
    • Bore shape: Round bore is standard; square, hexagon, and threaded bores on request.
    • Sizes: Imperial and metric size variations are available

    Some of the key advantages quick-adjust components offer include faster adjustments and easier handling, but the benefits go even deeper. By simplifying small adjustments, technicians can more easily fine-tune the performance of the entire system, increasing performance and versatility. Manufacturers can use quick-adjust collars to produce controlled variations, ensure standard production quality, and operate as efficiently as possible with minimal downtime.

    Python™ Flange Mounting Collar

    This mounting collar gets its signature adjustability from its Flip-Lok clamping lever that operators can use to adjust the collar with no tools. Once the level is engaged, technicians can adjust and reclamp the collar without needing a wrench. Every collar has a six-hole bolt pattern so it can be mounted on virtually any system with low, linear RPM rotational power.

    The key advantages of the Python™ Flange Mounting Collar are:

    • Fast, tool-free positioning
    • Six-bolt design for ease of mounting.
    • Ability to set stops

    Python™ Flange Collar

    This collar has a split hub flange design for easy installation. Because of the split design, it can accommodate a variety of shaft sizes. The collar itself does not have mounting hardware but can be used as a mounting surface for other hardware. Manufacturers can use this collar in linear and low-speed rotary motion applications such as managing paper rolls, handling laboratory equipment, and bagging or packaging. The flange collar comes in a range of sizes from  3/8″ to 1-1/4″ in both imperial and metric. Its Flip-Lok Quick Release Clamp makes it easy to reposition the collar, clamp it tightly in position, and ensure it’s properly set up for a variety of manufacturing applications.

    Contact Our Experts for Premium Quick Adjust Products 

    Investing in easily adjustable collars and hardware makes it simpler than ever to fine-tune your facility’s manufacturing and processing systems so you can optimize for quality and performance without compromising on speed and efficiency. 

    At Stafford Manufacturing, we design and develop quick-adjust products and a diverse catalog of shaft collars, coupling, and adapters for virtually every manufacturing application, and we’ve been serving our clients with high-quality products for nearly 50 years. Reach out today to learn more about our new Python™ Quick Adjust Line.

  2. Quick Adjust Products From Stafford

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    When you need to make frequent alterations to the positioning of shaft collars, incorporating quick adjust products allows for faster assembly, disassembly, and adjustment of components for optimal convenience. At Stafford Manufacturing Corp., we deliver a variety of quick adjust products to help simplify and speed up any rapid-change applications. Our quick adjust line includes wrenching collars, clamp-on wrenches, and Grip & Go™ Quick Release products as well as our new Python™ Line Stop Collar and Flange Mount Collar. Read on to learn more about these offerings and their benefits.

    What Does Quick Adjust Mean?

    Quick adjust is a category of products often related to maintenance and repair tools but can be used in any situation where there is a need for rapid or frequent changes in location. These products allow for quick, simple repositioning of collars on a shaft to fine-tune system performance or adjust a component to reflect changes in its environment. Using quick adjust products allows adjustment with minimal or no tools, preventing time lost searching for the right wrench.

    Wrenching Collars

    Shaft Wrenching Collars, two-piece

    A wrenching collar is a shaft collar variety that has wrenching flats, enabling users to quickly and easily use a standard open-end wrench to make adjustments to the part placement. Stafford offers two-piece split and hinge-style wrenching collars in the following types:

    The hinge-style collars utilize a captive screw to facilitate installation. Available in bore sizes ranging from 1/4 inch to as large as 1 1/2 inch, our wrenching collars have wrenching flats on their outer diameter (OD) for compatibility with standard open-end wrenches.

    Clamp-On Wrenches

    adjustable wrench collars, hex

    These adjustable wrench collars offer high versatility and ease of use, quickly clamping around a standard pipe, a shaft, or a hex nut. Tightened with a twist of the wrist, these knurled collars form a strong hold that’s still easily adjustable for your application and positioning needs. They are simple to grip and manually turn to secure, but still allow for conventional wrenches when high torquing is required.

    Made of anodized aluminum to give them a finish that’s both durable and aesthetically pleasing, Stafford’s selection of clamp-on wrenches includes:

    Grip & Go Quick Release Handle

    Grip & Go™ Quick Release Clamping Handle

    Stafford’s Grip & Go Quick Release line consists of multiple handle options for convenient, rapid linear adjustments. A single Grip & Go Handle replaces a clamp screw and a wrench. The product line is advantageous for its:


    • Fast repositioning capabilities.       With Grip & Go Quick Release products, you’ll use the product handles rather than a wrench to easily make clamping collar adjustments, enabling rapid linear repositioning along the shaft as often as necessary.
    • Diversity. This product line offers high versatility in positioning capabilities and applications in a variety of material options. Grip & Go Quick Release handles are ideal for tasks such as adjusting for table height or stroke length, enabling linear alterations to feed components, or holding test instruments. They’re available in aluminum, steel, and stainless steel.
    • Simplified design. Utilizing a single-handle design for faster modifications, these products also eliminate the need for a separate standard wrench and clamp screw.
    • Easy-to-grip handles. The knurled grip along the OD ensures a firm grasp for fast adjustments without slippage, even in the presence of oil and related substances.
    • Metric thread and high torque product varieties. Both metric thread and high torque versions of our products are available in the Grip & Go Quick Release line, each uniquely tailored to meet your application’s requirements. The metric thread variety is compatible with metric clamp-style shaft collars and comes in a variety of thread sizes. The handle of the high torque version has both a hole for a screwdriver shaft or rod to increase tightening force and wrench flats for tightening with a standard wrench.

    Examples from the Grip & Go Quick Release product line include:

    Python Quick Adjust Line

    Python Flange Mounting Collar

    The Python™ Flange Mounting Collar utilizes a lever-operated clamp featuring a thumbscrew tension nut to quickly make manual adjustments to collar positioning without requiring tools. It consists of black-anodized aluminum – and stainless steel or steel, upon request – and is designed with a keyway and six-hole bolt pattern. While it allows for fast alterations, it delivers a tight clamp able to withstand up to 200 lbs. of axial load. Its applications include:

    • Fast repositioning without tools
    • Setting stops
    • Driving rotating parts at low and linear RPMs

    These quick adjust collars are available in square, hexagon, and threaded bores and come in an array of sizes based on imperial or metric measurements. Stafford also offers the Python™ Shaft Collar, a similar flange collar but with a split hub. 

    Choose Stafford Manufacturing for Quick Adjust Products

    Quick adjust products from Stafford allow frequent linear adjustments quickly and easily while maintaining a secure hold. We offer high-performance, problem-solving components and custom capabilities to ensure you receive the right shaft collar, coupling, clamp, or related precision product for the job. 

    Contact us to purchase any of our quick adjust maintenance, repair, retrofit, and accessory products, or request a quote today.

  3. Advantages of Accu-Clamp™ Precision Products

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    Stafford Manufacturing produces high-quality rigid shaft couplings, clamping shaft collars, and specialty components with experience dating back half a century. Stafford’s Accu-Clamp ™ products feature both a non-clamping section and a clamping section. The non-clamping section consists of a rigid bore capable of maintaining shape during use without flexing or distorting. The cantilevered clamping section offers flexible, proportionally distributed, non-marring holding power.

    Our patented Accu-Clamp ™ products take the benefits of clamping collars to the next level. They feature a unique construction, offering several functional advantages not possible with standard clamping collars. The close-tolerance, highly precise design of these products makes them suitable for a diverse range of applications.

    Benefits of the Accu-Clamp™ Precision Product Line

    The Accu-Clamp ™ design contains a non-clamping section and a clamping section and is available on a wide range of  Stafford catalog items as well as specialty parts designed to a customer’s unique needs . 

    Featuring a unique construction, Stafford’s Accu-Clamp ™ products have a precision machined face that is flat to the shaft within 0.001 TIR. They feature a slotless design, allowing for an uninterrupted outside diameter surface that can be machined, knurled, or profiled to meet the demands of any application. The slotless design also means that the face offers a full 360° surface that can be hardened, ground, flanged, or machined to meet various mounting and tolerance requirements or to be outfitted with features such as:

    • Springs
    • Mounting holes
    • Slotted mounting holes
    • Dowel pins
    • O-ring grooves for sealing
    • Sensor holes
    • Face cams

    Accu-Clamp™ Precision Product Line

    One-Piece and Two-Piece Split ACCU-CLAMP™ Collars

    Accu-Clamp™ Collars combine a non-marring clamp with a solid working face that is either fully machineable or hardened and ground. The machineable Accu-Clamp™ Collar can be used as is, or modified by drilling, tapping, threading, turning, knurling, etc. The precision machined face of the clamp is flat to the shaft within 0.001 TIR and has a slotless design, providing a full 360° surface that can be knurled, profiled, or machined to meet various mounting and tolerance requirements. The hardened and ground Accu-Clamp™ Collar provides an ultra-precise bearing surface for applications that require extreme squareness and flatness. 

    The one-piece split version is ideal when the user has access to the shaft end. The two-piece split version can be completely disassembled and placed anywhere on a shaft and does not require access to the shaft-end.

    ACCU-CLAMP™ Threaded Split Shaft Collars

    ACCU-CLAMP™ Threaded Shaft Collars are available in one-piece and two-piece designs to provide a square and rigid method for mounting components on a UNF/UNC threaded shaft. The one-piece design is suitable for applications where there is access to the shaft end. The unique clamp design distributes holding power evenly for superior performance. The two-piece split shaft collar features a clamp-style design that enables easy installation and adjustment without disassembling the shaft. 

    The Accu-Clamp™ Threaded Collar combines a non-marring clamp with a solid working face that is fully machineable. It can be used as is, or modified by drilling, tapping, threading, turning, knurling, etc.

    ACCU-MOUNT™ Collars

    The Accu-Mount™ Collar features one solid, square and flat side, with four component mounting holes, along with a centering hub, and a second side that securely clamps to a shaft. Providing a square and rigid method for mounting sprockets, gears, pulleys, lever arms, and related components, they prevent slippage or wobble and can be easily repositioned on the shaft.

    ACCU-FLANGE™ Shaft Mounting Collar and ACCU-FLANGE™ Shaft Collars (English and Metric)

    Accu-Flange™ Mounting Collar is a machineable flange collar that can be configured by the user to perform a wide range of applications such as a pulley, cam, or component mounting device. Featuring an integral clamp incorporating a double-split design and relief groove, this clamping flange collar retains its perpendicularity, will not mar expensive shafts, and is easy to adjust. A standard keyway, along with through holes and three tapped holes are incorporated into the design.

    The user-machineable Accu-Flange™ Shaft Collar also lets designers rapidly develop a custom solution from a standard product line and then order parts machined to specification in production quantities if required. The flange has no holes and allows users to make their own hole patterns if mounting is required

    One-Piece and Two-Piece Split Precision Sleeve Couplings with Keyways (English or Metric)

    Stafford’s exclusive Precision Sleeve Coupling features a solid center section that provides a close tolerance fit on ground shafting, includes a keyway, and the Accu-Clamp™ design which incorporates integral self-centering clamping collars at both ends. They are available in one-and two-piece styles in both English and Metric versions. 

    To assure precise shaft alignment, it maintains <.001″ TIR concentricity while in use and ensures that the shafts can be mated with zero backlash . It is precision machined, non-marring, easy to adjust, with high clamping power.

    Two-Piece Split Precision Sleeve Hex Bore and Square Bore Couplings

    Stafford’s Two-Piece Split Precision Sleeve Hex Bore and Square Bore Couplings are designed to provide accurate and reliable transmission of torque between shafts. They feature a solid center section that provides a close tolerance fit on ground shafting, and the Accu-Clamp™ design which incorporates integral self-centering clamping collars at both ends. These couplings feature a two-piece split design, which facilitates easy installation and removal without disturbing the shaft or other components. They are available with both hex bore and square bore configurations to suit your particular shaft requirements. They maintain <.001″ TIR concentricity while in use, ensuring precise shaft alignment and zero backlash.

    Precision Sleeve Flange Couplings

    The Precision Sleeve Flange coupling allows for mounting components such as gears, motors, brake assemblies etc. to the coupling. The flange includes three through holes and three tapped holes.

    It features a solid center section that provides a close tolerance fit on ground shafting, includes a keyway, and the Accu-Clamp™ design which incorporates integral self-centering clamping collars at both ends.

    To assure precise shaft alignment, it maintains <.001 TIR concentricity while in use. It is precision machined, non-marring, easy to adjust, with high clamping power.

    Flange Adapter Rings

    Designed as an add-on component for the Accu-Flange™ Collars and Precision Sleeve Flange Couplings, the adapter rings extend the outer diameter of the flange on the product. Excellent for adding a mounting flange to a pre-existing collar or coupling.

    Available Customizations 

    Custom solutions, such as modified standard products, offer quick and affordable resolutions to unique problems. Typical modifications can include, but are not limited to:

    • Modified Bores: intermediate sizing, keyways, spherical, non-standard threading
    • Collar Face Modifications: holes (including through, blind, tapped, counterbored, and more), slots, hubs, and ‘O’ ring grooves
    • Modified Outside Diameters: knurling, cam surfaces, flats for mounting or wrenching, notches, pulley grooves, holes
    • Custom Configurations for Shaft-Extender Shat Ends: adding pins, tabs, buttons, bumpers, and balancing
    • Fully Customized Product Designs: extra heavy duty, extra-large shafts, instrument styles, miniature sizes, multi-screw set collars, mounting features, balancing, hinged flange clamps, and more
    • 3D Prototype and Printed Products
    • Composite Parts and Molded Urethane
    • Special Hardware: nut and bolt combos, integral tightening handle, non-standard screws, pins, bumpers, springs, and more

    Special Requests are welcome and handled with expert care. Materials, treatments, holes, slots, and more can be modified easily for customer’s unique needs. Surface treatments, hardening, laser etching,  plating, painting, anodizing, passivating, case hardening, and special materials that can be thru-hardened are all available options with Stafford.

    Precise Clamping Shaft Collars and Rigid Shaft Couplings by Stafford Manufacturing

    For high-quality clamping shaft collars and rigid couplings of all varieties, our experts at  Stafford Manufacturing have the knowledge and equipment to find a solution to your needs quickly. Contact us to order standard catalog coupling or collaring products. Request a quote for custom products, full designs, and machining needs.

  4. Features of Shaft Collars: Three Unique Ways to Use a Shaft Collar

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    Shaft collars attach to shafts and other pieces of hardware to affix components in place. They can grip bearings in the right position, act as mechanical stops to halt rotary motion along the shaft, and ensure internal components don’t shift into misalignment. Because these components are so versatile, they come in a wide range of options for different industrial and commercial applications. 

    At Stafford, our experienced team of engineers specializes in creating sturdy, high-performance shaft collars for virtually any configuration. Learn more about the six most common types of shaft collars and their role in food processing, conveyance systems, and heavy-duty machinery.

    Types of Shaft Collars

    Depending on your machinery setup and your mounting needs, there are multiple different shaft collars available. These different varieties are classified based on how accessible the shaft is and the axial hold required. Clamp shaft collars, for example, clamp onto the shaft instead of requiring a set-screw for attaching to the shaft. Some of the most popular options include balanced, hinged, set screw, single split, double split, and threaded shaft collars. Take a deeper look at the different options: 

    • Set Screw Shaft Collars: This collar is solid. It doesn’t have any relief cuts, and it doesn’t split into different sections. Instead, the set screw shaft collar is put into position and then affixed to the shaft by a tightened set screw that runs from the outer to the inner diameter of the collar.
    • Single Split Shaft Collars: This type of collar has one slot opening that allows for sliding the collar onto the shaft and then clamping it down. The slot can be opened and closed with a hex screw. The advantage of this model is that it’s easy to install, however, it doesn’t have the same uniform gripping strength as two-piece clamping collars and cannot be used where the shaft end is inaccessible.
    • Double Split Shaft Collars: These two-piece collars have two halves that are joined together by two socket cap screws. This allows for easy installation, as they can be installed either axially or radially. They also have a more uniform distribution of holding power than one-piece split collars.
    • Threaded Shaft Collars: These collars have an internally threaded clamp so they can be installed over a matching threaded shaft. Not only do the threads ensure the placement is exactly right, but the shaft is designed for supporting heavy axial loads. Threaded shaft collars are available in both single-split and double-split varieties.
    • Balanced Collars: Balanced collars are built to reduce vibration and shaking on a spinning shaft. They also help ensure an even distribution of the load weight. They feature a design similar to a double-split shaft collar, but the attaching screws sit opposite each other to provide even distribution. 
    • Hinged Collars: Hinged collars have a triple-link hinge and a captive clamping mechanism. This allows the collar to open easily, be positioned and then clamped shut. As a self-contained unit, there is never a risk of loose screws.

    Each of these shaft collars can play a critical role in the integrity of your equipment or facility systems.

    Food Processing

    In food processing systems, shaft collars can help at every stage of production and packaging. Shaft collars can help ensure consistent spacing between moving and weight-bearing elements, including supporting weight-bearing components and ensuring gears stay in the correct alignment during operation. Some key applications include:

    • Guiding and stopping parts
    • Mounting, aligning, and spacing components

    At Stafford Manufacturing, we construct all of our shaft collars with a smooth, burr-free finish that mitigates the risk of buildup and bacteria. Our collars are available in several types of stainless steel, making them ideal for situations requiring corrosion resistance or the ability to withstand frequent washdowns.

    • Affordable Cost
    • Wide Variety of Materials
    • Mounting Capabilities
    • Variety of Styles to Suit your Needs
    • Alignment Capabilities
    • Easy Assembly 

    Conveying

    Shaft collars are common in conveyor systems because they ensure all of the moving parts stay in alignment and can handle the weight of different loads. One common application of shaft collars in conveying is to keep the rollers consistently placed and aligned. Shaft collars from Stafford are built with sturdy, long-lasting materials that comply with today’s construction and industrial regulations.

    Heavy-Duty Machinery

    Heavy-duty machinery, like cranes and bulk industrial equipment, needs large, heavy-duty shaft collars that can ensure adequate weight-bearing capabilities. Collars from Stafford are built to secure shafts and axles, support weight, and stop movement as needed for smooth system operation.

    Learn More About Shaft Collars From Stafford

    The team at Stafford Manufacturing is here to help provide the right shaft collars for any application, from food processing centers that need to tightly control the risk of contamination to paper and pulp facilities that manage heavy loads. Contact us today to learn more or request a quote to start your order. 

     

  5. Accommodating Bore Configurations for Your Shaft Collar or Coupling

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    Stafford Manufacturing Corp. designs and manufactures rigid couplings, shaft collars, and specialty mechanical parts used in automation, power transmission, motion control, and other OEM and MRO applications. We have collars and couplings available in square, threaded, hexagonal, keyed, and round bore configurations. In addition, we can add drive slots, press-fits, pulleys, or other special parts to meet your needs.

    Here you’ll learn about each of these bore options and how to decide on the ideal shaft collar or coupling for your application. 

     

    Types of Collar and Coupling Bore Configurations

    Shaft collars and rigid couplings are machine components that slide over a shaft and lock into place with either set-screws or with clamping screws. They have three primary functions:

    • Holding components in place
    • Creating a connection between a shaft and another component
    • Positioning or locating parts along a shaft

    Manufacturers supply variations of collars and couplings in different sizes, designs, and materials to fit a wide range of applications. Some of the common  shaft collar bore configurations include:

    • Round 
    • Threaded
    • Square
    • Hex
    • Keyed

     

    Round Bores

    As one of the most popular bore configurations, round shaft collars and couplings are used in various power transmission, motion control, and mounting applications. Serving as locators, spacers, bearing faces, or stops, they are most often used on shafts, tubing, pipes, and split hubs.

    Round bore configurations are found in the following products:

    • One-piece shaft collars
    • Two-piece shaft collars
    • Hinge shaft collars
    • Threaded shaft collars
    • Heavy-duty shaft collars

    Browse Stafford Manufacturing’s full selection of round bore shaft collars in our catalog

    Browse Stafford Manufacturing’s full selection of round bore rigid couplings in our catalog. 

    Round Bore Threaded Coupling
    Round Bore Shaft Collar

     

    Threaded Bores

    Threaded shaft collars have a threaded interior that matches with certain threaded shafts. These provide superior grip, suitable for uses that require precise preload and location settings. Threaded shaft collars act as a stop to position parts or prevent them from moving along the shaft. 

    Threaded bore configurations are found in the following products:

    • One-piece or two-piece split clamp UNF/ UNC Threaded Bore Shaft Collars
    • One-piece or two-piece Accu-Clamp™ Threaded Shaft Collars
    • One-piece or two-piece ACME Threaded Collars
    • One-piece or two-piece UNF/UNC Threaded Split Hub Collars
    • Threaded Hinge collars

    See the threaded shaft collars we provide. 

    Threaded Shaft Collar
    Threaded Hinge Shaft Collar

     

    Square and Hex Bores

    Stafford Manufacturing produces hexagonal and square shaft collars and couplings to fit onto hexagonal and square-shaped shafts. Square and hex shaft couplings and collars are easy to install and customize with mounting capabilities if necessary. They provide high clamping power and are primarily used in food processing and conveyor systems. 

    Square bore configurations are available in:

    • Two-piece split clamp styles collars
    • Mounting two-piece stackable styles collars
    • Precision Sleeve Rigid Couplings

    Hex bore configurations are available in:

    • One-piece split clamp styles
    • Two-piece split clamp styles.
    • Precision Sleeve Rigid Couplings

    Look through our full selection of hex and square shaft collars and couplings here.

    Hex Bore Precision Rigid Coupling
    Hex Bore Shaft Collar
    Square Bore Precision Rigid Coupling
    Square Bore Shaft Collar

     

    Keyway

    Shaft couplings can be configured with keyways, but they are not always required. They should be utilized for couplings designed to support radial alignment and loads with high torque. Determine whether radial alignment or additional torque will affect the system’s overall operation, and then use that analysis to decide whether you need a keyway.

    Keyed Rigid Coupling
    Keyed Shaft Collar

     

    Selecting Your Shaft Collar or Coupling Configuration

    The right shaft collar or coupling is the one that fits your configuration and application.  In some cases, a certain type of configuration may be better than other options (i.e.  square, hex, and keyed shafts can handle more torque). Keyed shafts in particular have a locking position that makes accommodating higher torques possible.

    Standard bores are cost-effective options that fit most basic applications. Stafford Manufacturing carries round, threaded, square, hex, and keyed bores as standard products, so our customers can rely on us to have what they need, when they need it. In addition, Stafford is the only stocking manufacturer of a full line of square and hex bore products.

    While standard bore products serve most applications at the lowest cost, some applications require customized collars or coupling bores. Stafford has been manufacturing custom shaft collars and couplings for over 47 years and we can produce to your exact needs at a fair price with no minimum order quantity.

    Stafford Is Your Custom Shaft Collar and Coupling Manufacturer

    Stafford Manufacturing has nearly 50 years of industry experience. As an ISO 9001:2015-certified business, our staff has the quality control standards in place to produce the highest quality shaft collars and rigid couplings. We have a large selection of products, which enables us to assist you in selecting the ideal bore configuration for your particular needs and price range. If you can’t find a shaft collar or coupling that meets your needs, we will collaborate closely with you to design and produce a custom solution.

    Contact us or request a quote today to learn more about our standard and custom offerings. 

     

  6. What Is the Best Coupling for a Mixer?

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    large industrial batter mixerMixers are common industrial devices that consist of a motor and a propeller or paddle with a coupling acting as the connection point. Mixers are flexible, adaptable pieces of equipment found in a range of industries, from food processing to mining to chemical facilities.

    Choosing the correct coupling for a mixer can be challenging as it needs to have an exact, rigid fit . This blog will highlight how to determine the right coupling for your mixer and how our configurator tool can help you configure your rigid coupling to your needs.

     

    What Is a Rigid Coupling?

    Unlike flexible couplings, a rigid coupling does not allow any radial or axial motion between the driving shaft and the driven unit. It is primarily used for vertical applications. Rigid coupling types include:

    • One-piece split couplings when there is access to both the motor shaft end and the paddle attachment.
    • Two-piece split couplings for easy assembly when in-line installation is needed.
    • Three-piece split couplings when the end of the shaft will remain fixed while the other is moved or changed (very common for mixer situations when paddles would be changed or replaced).
    • Flanged couplings when mounting options are needed.

    On mixers, the motor is bearing-supported, but the shaft on the impeller side is not. Using a flexible coupling would require close bearing support on the paddle, but the sleeve-like design of rigid couplings eliminates the need for a bearing to support the paddle. This makes rigid couplings the only viable option for mixers.

    Rigid couplings have a simple and durable design, allowing greater transmission of power to mixers. They are more cost-effective than other options and offer more design flexibility. While requiring exact alignment between shafts, rigid couplings offer a stronger connection, higher torque, and more precision than flexible couplings.

     

    havey duty rigid shaft coupling wiht a havy duty mixer in the backgroundAdvantages of Rigid Couplings for Mixers

    Rigid couplings provide advantages, such as:

    • Excellent Torque Transmission: They can transfer torque efficiently between connected shafts.
    • Low Production Costs: Manufacturers such as Stafford Manufacturing can produce custom and standard rigid couplings at affordable prices.
    • Torsional Stiffness: Its high torsional stiffness enables better positioning.
    • High Precision: Rigid couplings offer high precision with almost no windup or backlash.
    • Alignment Capabilities: They can establish shaft alignment between the connected parts and the motor.
    • Easy Assembly: Rigid couplings have a simple design, allowing for easy assembly, disassembly, and maintenance operations throughout the coupling’s lifespan. 

     

    Considerations for Selecting a Rigid Coupling for a Mixer

    Choosing the best coupling for a mixer requires precision. Stafford Manufacturing’s configurator tool can help you customize a rigid coupling that suits your exact needs. Configure it by bore diameter, coupling style, coupling material, screw material, finish, and other options available upon request.

    Here are more details about the top considerations for choosing a rigid coupling for a mixer.

    Bore Diameter

    Bore diameter ranges from ¼” to 4”. Choosing the right diameter is key to ensuring a  precise alignment.  

    Coupling Style

    Coupling styles include one-piece, two-piece, and three-piece. One-piece styles have high torque capacities, unlike set screw type couplings. Two-piece styles allow for easy assembly and adjustment. Three-piece styles are used to maintain one shaft’s positioning while the other is adjusted.

    Material Selection

    Material selection is based on the substance your coupling is exposed to. Coupling materials include brass, 303 and 304 stainless steel, weldable steel, carbon steel, and 2024 aluminum.

     

    How to Choose the Best Coupling for a Mixerrigis shaft couplings for mixers

    Consider these factors when deciding on the best coupling for your mixer:

    • Shaft size
    • Keyway size if needed
    • Required torque capacity
    • Bore diameter
    • Material requirements for specialized (i.e. food-grade) applications

    Stafford’s rigid couplings meet these criteria as they are designed with end users’ needs in mind. Our rigid couplings come in different types, from the common one-piece split clamp coupling to precision sleeve couplings.

     

    Choose Stafford as Your Coupling Manufacturer

    Stafford is the leading manufacturer of high-quality shaft couplings and rigid couplings. With the help of our configurator tool, you can determine the right rigid coupling for your needs. Contact us to learn more or request a quote for our products.

  7. Installation Guide for Rigid Shaft Couplings

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    Stafford Manufacturing Corporation is a leading manufacturer and distributor of a variety of shaft collars, specialty mechanical components, and rigid shaft couplings for use in many types of applications. At Stafford Manufacturing Corp., we offer a wide range of rigid couplings to allow two shafts to function as one.

    When deciding on the right coupling for your application, one key factor will be whether you need a one-piece,  two-piece or three-piece coupling. One-piece clamp couplings offer zero backlash and feature high torsional holding power with no damage to the shafts. Two-piece couplings feature the same advantages, with the added benefit of allowing in-place service. Three-piece couplings allow you to keep one shaft in place while the other is changed.

    In this guide, we’ll detail the steps for proper shaft coupling installation for the main types of rigid couplings, along with some factors that determine which couplings to use.

    Materials

    Based on an application’s specific requirements, rigid shaft couplings can consist of a vast array of materials, including 303, 316, and 304 stainless steel, 2024 aluminum, carbon steel or black oxide-finished carbon steel, or brass. The installation steps for rigid couplings will differ depending on the coupling type (one, two or three-piece).

    Installation of a One-Piece Rigid CouplingInstallation of a One-Piece Rigid Coupling

    The steps for installing a one-piece rigid coupling are as follows.

    Alignment

    Rigid couplings are used when an application requires coupling of two aligned shafts (they can be shafts of the same sizes or different sizes). High stress could result if axial or radial misalignment takes place, potentially causing failure so they are only to be used with unsupported or fully aligned shafts. Once connected to two shafts, rigid couplings will prevent any relative motion from occurring. One-piece rigid couplings ensure alignment.

    Installation Process

    When installing a one-piece rigid coupling, take these steps:

    1. Wipe any excess dirt or oil off the shaft as well as the  bore of the coupling.
    2. Slide one end of the coupling over its mating shaft until that shaft is 1/32” short of the cross slot
    3. Adjust the center screw to half of the recommended seating torque.
    4. Adjust the outer screw to half of the recommended seating torque.
    5. Slide the other shaft into the remaining end of the coupling until it is 1/32” short of the cross slot.
    6. Adjust the center screw to half of the recommended seating torque
    7. Adjust the outer screw to half of the recommended seating torque
    8. Use a torque wrench to fully adjust all screws to the recommended seating torque, going from the center screws to the outer screws.
    9. If possible, slowly rotate shafts to ensure proper alignment.

     

    Installation of a Two-Piece Rigid CouplingInstallation of a Two-Piece Rigid Coupling

    The steps for installing a two-piece rigid coupling are:

    Alignment

    Like one-piece rigid couplings, two-piece couplings are used to join two aligned shafts. The use of a two-piece coupling allows installation while both shafts remain in place.

    Installation Process

    The steps for installing a two-piece rigid coupling are:

    1. Wipe any dirt or excess oil off shafts and coupling bore.
    2. Assemble the top and bottom halves of the coupling over the two shafts, making sure that the ends with the face groove are together.
    3. Assemble the two-piece coupling to the point where there is mild resistance in the screws.
    4. Use a torque wrench to adjust the center screws to half of the recommended seating torque.
    5. Use the same wrench to adjust the outer screws to half of the recommended seating torque.
    6. Use the torque wrench to adjust all screws until they’re at the full recommended seating torque, starting with the center screws and completing the process with the outer screws.
    7. Ensure the clamping is even by checking that the slot  gap is the same on both sides
    8. If possible, slowly rotate shafts to ensure proper alignment.

     

    Installation of a Three-Piece Rigid CouplingInstallation of a Three-Piece Rigid Coupling

    The steps for installing a three-piece rigid coupling are:

    Alignment

    Designed for aligned shafts, the three-piece clamp coupling makes two shafts function as one. It can remain fixed to one shaft while the other is moved or changed, or come completely apart to allow the most convenient assembly and adjustment.

    Installation Process

    The following are the steps for installing a three-piece rigid coupling:

    1. Wipe any dirt or excess oil off shafts and coupling bore.
    2. Assemble the ends of the coupling with the matching face groove onto its mating shaft
    3. 3. Use a torque wrench to adjust the center screws to half of the recommended seating torque.
    4. Use the same wrench to adjust the outer screws to half of the recommended seating torque.
    5. Mate the other shaft with the open end of the coupling and loosely assemble the coupling top, making sure that the machined end is towards the outside..
    6. Use the torque wrench to adjust the center screws to half the recommended seating torque
    7. Use the same wrench to adjust the outer screws to half the recommended seating torque.
    8. Use the torque wrench to adjust all screws until they’re at the full recommended seating torque, starting with the center screws and completing the process with the outer screws.
    9. Ensure the clamping is even by checking the saw slot gap.
    10. If possible, slowly rotate shafts to ensure proper alignment.

     

    High-Quality Rigid Shaft Couplings from Stafford Manufacturing Corporation

    If your application requires rigid couplings, please check out our wide variety of couplings, precision couplings, and shaft adaptors at www.staffordmfg.com. Applications include motion control, power transmission, automation, and other types of MRO and OEM applications for consumer or industrial products.

    To find out more about our products and custom capabilities, contact us today with any questions or request a quote for our products.

  8. Overview of Non-Standard Materials

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    Since 1975, Stafford Manufacturing Corp. has been a leading manufacturer and distributor of shaft collars, rigid shaft couplings, and specialty mechanical components. Our products are used for industrial, consumer, OEM, and MRO applications, including automation, power transmission, motion control, and many others. We have unique expertise in designing components with non-standard materials that meet the needs of unique or challenging applications. Some of the non-standard metals we work with include:

    • Titanium
    • Nylon
    • Bronze
    • Brass
    • Delrin
    • High Temp Alloys

    Titanium

    Titanium is a natural element with the highest strength-to-density ratio of any metal and a tensile strength ranging from 30,000 psi to 200,000 psi. This low-density, strong, and lightweight material exhibits a high melting point, low heat-induced dimensional change, good heat transfer, and high electrical resistance. Titanium is commonly used for airplanes, missiles, rockets, and various other applications such as springs and medical manufacturing due to its excellent elasticity, non-toxicity, and biocompatibility.

    Nylon

    Nylon has high abrasion resistance, good thermal resistance, high machinability, good fatigue resistance, and noise dampening capabilities. The different nylon grades include 66, 11, 12, 46, and 6, which are named for the length of their polymeric chains. Key benefits of nylon include low internal stresses, lower water absorption, more crystalline structure equating to higher mechanical strength, and a higher melting temperature.

    Bronze

    This copper and tin alloy is brittle, highly ductile, has low friction, doesn’t produce sparks when struck, expands as it hardens from liquid to solid, and produces a colored patina as it oxidizes. It is used in architectural structures and design elements as well as coins, bearings, electrical contacts, ship propellers, and shaft collars. Bronze can also be made into wool, avoiding some of the problems that steel wool presents, such as rust, broken filaments, and magnetic characteristics that can affect equipment. 

    Brass

    This gold-colored copper and zinc alloy has excellent electrical conductivity, good machinability, and low friction. It is commonly used in architecture and manufacturing of gears, locks, pipe fittings, and musical instruments. There are many subtypes and finishes available, including electroplating, powder coating, painting, and polishing. Tolerances are +/- 125 μm (standard), as well as +/-100 μm and +/- 50 μm (achievable).

    Delrin

    Delrin is a plastic alternative to metal that offers good dimensional stability, excellent machinability, and high fatigue endurance. Natural-grade Delrin is NSF, FDA, and USDA compliant. 

    Other qualities include:

    • Tensile strength of 6,000-22,000 psi
    • Impact strength of  .75-2 ft-lb/in. 
    • Heat deflection of 180-300ºF
    • Chemical resistance to fuels and solvents
    • Low moisture absorption
    • Good wear and abrasion properties
    • Superior impact and creep resistance
    • High strength and stiffness properties

    Common components made from Delrin include gears, bearings, bushings, shaft collars, rollers, fittings, and electrical insulator parts. 

    High-Temperature Alloys

    High-temperature alloys are a mixture of at least one metal and another element that can withstand temperatures above 500º C. High-temperature alloys are used extensively in the military, medical, aerospace, and electronics industries. The alloys were designed for use in conveyors, furnaces, ovens, and oil and gas applications. They are costly and difficult to machine and shape. However, they are necessary for certain conditions. Stafford offers high-temperature alloy shaft collars in one piece, two piece, hinged, and flanged designs.

    Specialty Mechanical Components from Stafford Manufacturing Corp.

    Stafford Manufacturing Corp. is a leading manufacturer specializing in custom-manufactured shaft collars and rigid couplings in non-standard materials. To learn more about our products, please visit our product overview page. For pricing, please request a quote. 

  9. What Is a Threaded Shaft Collar?

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    A shaft collar is a simply-designed machine component composed of a plastic or metal ring fitted around a rod to act as stops, spacers, or for mounting components.  The collar can be loosened or tightened around the shaft using a clamp screw or multiple screws. They are used for tasks ranging from bearing loads to holding components in place along a rod. Among the many types of shaft collars are threaded shaft collars, which offer unique features that make them suitable for various applications. 

    What Is a Threaded Shaft Collar?

    Threaded Bore Shaft Collars

    A threaded shaft collar is a type of shaft collar defined by the threaded 

    pattern on the inside of the ID. While the standard shaft collar has a smooth interior, threaded shaft collars employ this textured interior to provide superior grip to the rod it is attached to. 

    Threaded shaft collars are paired with a threaded rod, making them fasten together much more securely than a smooth shaft collar on a smooth rod. This provides higher axial holding power with less chance of damaging the rod. Additionally, threaded shaft collars allow for precise positioning and easier adjustments along the rod’s length.

    In terms of variants, threaded shaft collars are typically manufactured in two distinct styles. The one-piece clamp collars are designed as a singular piece of equipment, which are fastened by being pressed together and then tightened once in position. Two-piece split collars consist of two separate halves of a single collar held together by a pair of screws that can be used to loosen and tighten the ring. Threaded shaft collars are typically made from steel or hard plastics. HInged threaded collars are also available for a simple, all-in-one assembly style.

    Applications of Threaded Shaft Collars

    threaded shaft collar

    Due to the various advantages threaded shaft collars have over smooth 

    shaft collars, they are typically used in applications where additional precision or strength are required. In machinery, threaded shaft collars are most frequently used for load-bearing applications and as spring tensioners. Their holding power and durability allow them to survive longer when placed under high stress than other similar parts. They are also used as end stop positioners and as limiters in repetitive operations.

    Hospitals and other medical facilities make use of threaded shaft collars in places ranging from surgical equipment to beds and equipment stands. Other applications include:

    • Automation machinery
    • Mechanical stops
    • Locating components
    • Sprocket hubs
    • Bearing holders
    • Shaft protectors
    • Measuring and testing equipment

    Stafford Manufacturing’s Threaded Shaft Collars

    Stafford Manufacturing produces a variety of threaded shaft collars, all made with quality materials and designed to be non-marring to the rods they attach to. In addition to the previously touched upon UNF/UNC one-piece and two-piece clamps, Stafford also makes hinged collars that combine the ease of use of the one-piece collars with the quick assembly and disassembly of the two-piece collars. Our other offerings include ACME threaded collars featuring left- and right-hand threading as well as custom manufacturing options. 

    Partner with Stafford Manufacturing

    The many beneficial features of threaded shaft collars make them useful in many industries. Their superior grip strength and reliability compared to other types of shaft collars make them the optimal choice for a variety of applications. At Stafford Manufacturing, we manufacture superior threaded shaft collars and other types of shaft collars, and we can work with you to create a custom solution for your needs. For more information, or to get started on your next shaft collar solution, contact us today.

  10. What Is Shaft Coupling Windup and Backlash?

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    Rigid shaft couplings connect two separate shafts by clamping onto their adjacent faces. When installed properly, the shaft coupling connects the shafts in a precise line that transfers rotary motion between the shafts without causing misalignment or breakage. However, there are two main obstacles to the perfect transfer of rotary motion:

    1. This occurs when the application of torque results in greater shaft rotation at one end compared to the other.
    2. Backlash is the unwanted reactive motion between connected mechanical parts that can break couplings or cause mechanical stress.

    This blog explores the causes and effects of windup and backlash in shaft couplings.

    What Is Torsional Rigidity in Shaft Couplings?

    Windup, otherwise known as torsional deflection, occurs when torque is applied and the rotation of one end of the shaft is greater than the other end. This creates unequal torsional deflection that engineers have to consider as they set up feedback mechanisms. The varying load on the gears causes unequal wear. Torsional rigidity can also put stress on the coupling, leading to deformation, breakage, and a more frequent need for parts replacement.

    What Is Backlash in Shaft Couplings?

    Backlash occurs whenever mating parts in a system aren’t precisely aligned. In shaft coupling systems, the coupling may have a poor grip on each of the shafts, resulting in slight angles and unequal wear and stress on the system.

    Shaft couplings can accommodate some degree of backlash, but it’s important to ensure that any backlash is well within the system’s threshold. For example, angular movements greater than 2° past the preferred angle are considered excessive backlash, and this can cause extreme wear, stress, and even breakage. Although not all backlash is bad, when the backlash is too great, it will result in erratic dial indicator and laser alignment readings. Operators should always reduce the backlash to within the 2° threshold before alignment begins.

    There are different types of misalignment based on the resulting misalignment angle. These include:

    • Angular misalignment. When the shafts of two coupled units form a wide ‘V’ or obtuse angle
    • Parallel misalignment. When the shafts are parallel but one is slightly higher than the other
    • Skewed misalignment. Involves both parallel and angular misalignment

    Any type of misalignment can cause backlash on the mechanical parts. It can also reduce the overall efficiency of the rotary motion transfer. It’s important to choose the right type of coupling that can prevent misalignment in the first place. Rigid shaft couplings, along with precise installation and setup, can reduce the risk of parts slippage and skew during operation of the system.

    Choose Stafford Manufacturing for Shaft Couplings and Mechanical Components

    At Stafford Manufacturing, we specialize in manufacturing rigid shaft couplings and other types of specialty mechanical components for energy transfer, motion control, automation, and other systems. Our rigid shaft couplings are designed to optimize the transfer of rotary motion. Browse our selection of one-piece split clamp, two-piece split clamp, three-piece split clamp, and precision sleeve couplings, or contact our team to learn more about our capabilities and inventory.