Vendor Spotlight: Regal Rexnord

Regal Rexnord, an industrial manufacturing company with roots dating back to 1955, specializes in components and systems to transmit and control motion within the power transmission market. Headquartered in Milwaukee, WI, the company is known for its Kop-Flex diaphragm and disc couplings and Powerlign torque monitoring system.

Regal Rexnord doesn’t stop its work at the manufacturing stage—its customers and components are supported through its recertification program that offers maintenance and emergency labor for lifecycle extension.

COUPLINGS

A coupling in turbomachinery applications connects the driver to driven machinery while accommodating axial and radial misalignment caused by machine movement and thermal growth. Regal Rexnord manufactures a range of flexible couplings designed to accommodate this torque, including the Kop-Flex, Bibby Turboflex, Ameridrive, and Euroflex models.

The Kop-Flex couplings are available in a diaphragm or disc format and are suitable for high-performance turbomachinery, with variations that suit the application requirements. Regal Rexnord implemented a compact, low-weight, high-power density design into its Kop-Flex couplings as gas turbines and compressors evolve toward smaller footprints and higher speeds. It comes in two styles: the RM and RZ.

Kop-Flex Diaphragm Coupling. Credit: Regal Rexnord

“The RM is a full-featured disc coupling, providing a reduced windage design and interlocking flanges for additional protection in the event of a disc pack failure. The RZ coupling provides a more cost-effective solution and lowest overhung moment with non-interlocking flanges,” said Oliver Doidge, Global Product & Business Development Manager, Regal Rexnord.

The Ameriflex diaphragm coupling tolerates large misalignments with low stiffness through its soft, multi-convoluted design. Regal Rexnord supplies Ameriflex couplings for mobile power-generation packages that require exceptional amounts of misalignment capabilities during transport and operation.

“In recent years, the development of mobile power-generation packages for grid expansion, power for fracking, and even disaster relief require larger amounts of misalignment than normal industrial applications and have been accommodated by the Ameridrives engineers through detailed analysis and optimization to suit,” said Doidge.

Bibby Turboflex Disc Coupling. Credit: Regal Rexnord

Euroflex disc couplings are designed for numerous applications within oil and gas—such as test benches, compressors, and steam and gas turbine power generation. Bibby Turboflex is a brand wholly owned by Regal Rexnord producing customized couplings for oil and gas industries and other markets, including marine propulsion, aerospace and defense, mining, and more.

POWERLIGN MONITORING SYSTEM

Powerlign is a monitoring system that measures the coupling’s torque, power, and speed, offering real-time data on a customer’s critical rotating machinery. This data allows operators to conduct proactive maintenance and cost-effectively diagnose issues before the complete failure of a system. Powerlign tracks performance differentials and over-torque for driving and driven machinery, identifying issues such as blade fouling, coupling shaft failure, or overall equipment failure.

According to Doidge, immediate data feedback gives customers a significant advantage. “Because the system provides real-time monitoring, our customers can tell when to shut down rather than just doing so on a monthly or 90-day schedule. Customers save money by following this process because they are cleaning less or more often, which improves overall efficiency and uptime while reducing the need for the expensive and environmentally harmful cleaning fluids used.”

Rendering of the Powerlign Monitoring System. Credit: Regal Rexnord

Powerlign can integrate with distributed control systems, PCs, and laptops for flexible system data analysis. It also works within a closed-loop system, as it can establish thresholds that, once reached, trigger an alert or alarm for end-users. Regal Rexnord implemented a feature so Powerlign acts as a control system, shutting down equipment or directing equipment in the flow of gas or fuel to secure load and efficiency.

CUSTOMER SUPPORT

Regal Rexnord offers comprehensive customer support through its recertification program, focusing on maintaining couplings that have endured extended operational life and increased misalignment. The program represents a proactive maintenance strategy that restores couplings to a newer condition at a lower cost than outright replacement, reinforcing the reliable operation of rotating equipment.

“With this program, our customers can ensure that their power equipment stays in peak operating condition and minimizes the costs of unplanned downtime, replacement parts, and emergency labor,” said Doidge. “We created the program for Kop-Flex couplings, but it has been expanded to include all Regal Rexnord brands. The company continues to develop its service and commitment to its installed base and user community with a larger global footprint and by increasing the number of facilities across five continents.”

INDUSTRY TRENDS

LNG continues as a primary market for Regal Rexnord’s portfolio of coupling brands, with market growth demonstrated by large-scale projects across the United States, Asia, the Middle East, and Australia. The company’s engineers continue to develop customized systems and solutions for larger, higher-speed turbomachinery applications.

As an emerging fuel for power generation and other industries, hydrogen requires engineers to take a second look at current equipment to assess how it can be adapted to meet the fuel’s demands and develop newer technology. Regal Rexnord is applying this new perspective to its own portfolio.

“Within the industry there is an increased demand for hydrogen compression, meaning that the speeds of the compressors are getting faster and faster,” said Doidge. “Our research and development teams are working closely with our customer base to ensure that we are aligned with this demand, have products that are suitable for these applications, and support them in prototype testing.”