impressively compact double planetary gear unit | flsmidth

impressively compact double planetary gear unit | flsmidth

Current cement producers are also seeking optimum grinding table speeds, which determines the output drive speed of the gear unit. Increasing total gear ratios are the consequences of slower table rotation at the same gear unit input speed. Our MAAG GEAR WPV with its masterful three-stage gear arrangement achieves all these aims without compromising on reliability or ease of maintenance.

Introduced in 2007, the three-stage concept of this bevel-planetary gear unit is FLSmidths answer to ever-increasing mill sizes and our MAAG GEAR WPV has gone from strength to strength since its first implementation.

Unlike conventional two-stage gear units that require larger bevel wheel dimensions to increase power output, our WPV uses two planetary stages to move gear ratio from the bevel to the planetary stage. This adaptation reduces the size of the bevel wheel, keeping the gear unit compact and delivering the high-power output you need for your vertical roller mill.

The unique double-planetary gear with torque split in the WPV Gear Unit allows the unparalleled performance range upwards of 8,000 kW. The first gear stage passes about 25% of the torque directly to the output flange. With the remaining 75% in the second stage we accomplish the reduction in both tooth length and losses. The four planets in the second stage all use smaller gear wheels than typical gearboxes with two planetary stages in serial arrangement, allowing for high drive output in less space.

Easy maintenance and compact design are normally competing interests, but we have managed to combine both in our MAAG GEAR WPV Gear Unit. The double planetary gear stage provides impressive compactness, together with a loss reduction in relation to the torque split.

The thrust bearing arranged around the first planetary stage supports the mill table and absorbs static and dynamic loads from the grinding process. Each bearing pad is lubricated with high- and low-pressure oil and the pads are lined with Babbitt metal at the contact surface. The bevel and the planetary gears are equipped with slide bearings. These bearings not only provide unlimited lifespan, but also deliver smoother operation because of the higher damping compared to anti-friction bearings increasing the overall availability of your vertical roller mill.

Large manholes in the lower casing part provide direct access to the bevel gear, letting the WPV gear unit remain in place under the mill during inspections and servicing and reducing any related downtime. Our WPV Gear Unit also simplifies maintenance by allowing you to easily adjust the tooth contact from the outside and quickly removing or adjusting the bevel pinion from outside the gear unit.

Despite the varying requirements of different mills and applications, the parts used in our MAAG GEAR WPV have a high degree of standardisation. This consistency makes it an optimum gear unit solution for operating safety and reliability in the cement industry. Our WPV Gear Unit is available as standard solution or can be customised to suit your unique operational needs. The combination of the WPVs high-grade bevel gear, innovative double-planetary gear and our unparalleled online condition monitoring lets you rely on common drive technology even in high-power applications. With the WPV, you can implement new drive solutions without the need for complex control systems.

Through carefully considering the power ranges and table diameters of various vertical roller mills, the design of our standardised MAAG GEAR WPV fits with every process and under every mill. Customise your gear unit installation by taking advantage of our variety of auxiliary systems

The flexible coupling that comes standard with the MAAG GEAR WPV Gear Unit is almost maintenance free, as it requires no lubrication. It also keeps vibratory loads low in the drive train and allows relatively wide ranges for axial and radial misalignment. These features combine to give you reliable function, with low operating costs.

A maintenance or auxiliary drive that is tailored to your requirements rounds out the scope of supply for your WPV Gear Unit. The maintenance drive is placed between the motor and gear unit and allows you to rotate the mill table very slowly. This simplifies maintenance work at your vertical roller mill, including replacing lining plates or rebuilding surfaces through welding.The auxiliary unit is mostly used to start the mill when the breakaway torque is too substantial to start the motor directly. The fluid coupling of the auxiliary unit guarantees smooth acceleration and the overrunning clutch automatically disengages the auxiliary drive after the main motor starts.

The oil supply units for our vertical roller mill gear units and drive systems includes low-pressure pumps to feed bearings and toothings with filtered and cooled lubrication oil. If required, high-pressure pumps supply the oil for the thrust bearing from a separated compartment of the tank filled with filtered oil from the low-pressure part. Using only clean oil on the high-pressure side allows us to improve the lifespan of the pumps.

All of our gear units and drive systems are equipped with unparalleled condition monitoring sensors. Normally, these types of sensors keep an eye on critical operating parameters like bearing temperatures, casing vibrations, etc. and trigger a mill shutdown in the case of exceedances.

Our condition monitoring system does much more. It lets you set up condition-based preventive maintenance that uses continuous monitoring and data analysis to detect wear and tear at an early stage. With this enhanced information, we help you plan maintenance and servicing in advance reducing downtime and keeping your plant running smoothly.

FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.

understanding motor and gearbox design : 10 steps (with pictures) - instructables

understanding motor and gearbox design : 10 steps (with pictures) - instructables

Why Spend Time Choosing the Right Motor and Gearbox? Choosing the correct combination of a motor and a gearbox for a given application is very important, both in the FIRST Robotics Competition (FRC) and in actual engineering projects. Without appropriate motor-gearbox combos, your team will find that your robot does not function as quickly and effectively as intended, and may have a tendency to burn out motors. This tutorial will teach you the fundamentals of gearbox design and implementation. First, I will teach you about motor characteristics. Next, I will discuss how to choose a motor and gear ratio given application requirements. I will then provide information about choosing a gearbox, followed by an overview of the motors and gearboxes available in FRC. Finally, I will demonstrate how to use what you learn in this tutorial in an example problem and point out extra tools and resources if you want to learn more. This tutorial was made through the Autodesk FIRST High School Intern program.Prerequisites A basic understanding of physics e.g. force, torque, power, and gear systems A willingness to learn

A motors speed, current draw, power, and efficiency are often plotted against the output torque to make their values easier to visualize. The equations for these curves are all derived from the four specifications discussed above using equations 1 through 4 of the previous few pages. The graph on this page shows the motor curves for a CIM motor, one that is very common in FRC.

Now that you have a motor and gear ratio chosen, you need to choose a gearbox. The first requirement for choosing a gearbox is that the chosen motor must fit on the gearbox. Though most motors have unique bolt patterns, the BaneBots RS-550 motor, Fisher Price motors, and AndyMark 9015 motor all belong to the RS-500 series of motors and therefore have the same mounting pattern. Next, the gearbox must have the gear ratio you have chosen. However, there is more leeway in this requirement. Some gearboxes can be stacked together, creating greater reductions. In addition, not all reduction needs to happen in the gearbox and can instead be achieved through power transmission systems such as sprockets and chain. It is also possible that the exact gear reduction that you want is not available, in which case close enough is usually good enough. Finally, the gearbox must have an output shaft that you can use. Though various sizes of keyed shafts are most common, hexagonal shafts are becoming more and more popular in FRC. There are also many different hubs to accommodate the various styles of output shafts. Ultimately, this is the least restrictive requirement when choosing a gearbox.

Now I will work through an example problem to demonstrate how to go through the process of designing a gearbox. The drawing above shows a picture of a two stage elevator, an element of a manipulator commonly found in FRC. The challenge is to design a gearbox that is capable of driving the 3 inch diameter winch and lifting the elevator to its maximum height of 84 inches high in a time of 1.5 seconds. For the purpose of the problem, we will make two major simplifications: first, we will assume that the 18 pound load is applied for the entirety of the elevators travel, when in reality the winch must lift the weight of the first stage for only half of the distance. Second, we will ignore acceleration and deceleration time, as these calculations are beyond the scope of this tutorial. First we will convert all units to metric because metric units are much easier to work with. Next we must turn our end goals into requirements that can be used to choose a motor and gear ratio. Calculating the required rotational velocity of the winch: Number of rotations to raise elevator: Calculating the load on the winch:

Now we must choose a motor and gear ratio. Well start by looking at the specifications of the available motors and make a guess about which motor may work well for the job. Well try using a single BaneBots RS-550 as our starting point because of its high power, meaning it will be able to get the job done faster. In addition, it is commonly used in applications such as this, meaning that it is probably a good fit for the job in general. To make estimations easier, I made a motor curve graph for the RS-550. First, we want to make sure that the motor wont draw more than 40 A and blow a circuit breaker. Looking at the graph, we can visually see that it takes a load of .23 Nm for the RS-550 to draw 40 A. To ensure that the motor wont reach this, even under heavy load, we will try designing for a current draw of 20 A. Looking at the graph again, we see that this corresponds to a torque of .115 Nm. Now, we can calculate the reduction we would need to achieve the necessary torque of 3.05 Nm. Gear Reduction: We have now chosen a gear reduction of 26:1, which means we can calculate the exact load our elevator motor should encounter. Load at Motor: Now, we can use equation (1) from Motor Characteristics to calculate the current we would expect the RS-550 to draw at this load: Current Draw: Our estimated current draw, 21.0 A, is well within our acceptable bound of 40 A. Next, we will determine the rotational velocity of the gearbox output shaft using equation (2). We will account for the 75% gearbox efficiency at this stage in the calculations. Motor Speed: Now we can check to see if our chosen gear ratio will allow us to achieve our desired output speed, 357rpm. Gearbox Speed: Finally, now that we have verified that our gear ratio satisfies our requirement, we can calculate how long it should take for the motor to raise the elevator. Lift Time: We have now completely verified that our RS-550 motor and 26:1 gearbox will achieve or exceed our original goals. Because real world performance is often worse than the theoretical performance, it is wise to overdesign these systems. Doing so also ensures that our simplifications do not cause our system to perform much worse than expected. When you first go through this process, you may have to go through the calculations multiple times as you try different motors and gear ratios. As you gain experience, you will gain an intuition of which motors and ratios will work well for a job. The final step in this process is to choose a gearbox. In this example, choosing the RS-550 version of Banebots P60 gearbox with a 26:1 reduction makes a lot of sense. Not only is it compatible with our motor, but it also has the right gear reduction and a common .5 inch keyed output shaft. Hopefully this example problem has helped you understand the process of choosing a motor and gearbox. In addition, I hope that it has shown you how to properly apply the theory you learned earlier in this tutorial.

This section of the tutorial is meant to provide some additional resources for learning about motors and gearboxes, as well as some tools that can expedite the design process. However, DO NOT use the tools in place of understanding the theory. Instead, use them because you have verified them against your own calculations and because you understand how they work.John V-Neuns Design Calculator: This spreadsheet can significantly expedite the process of choosing a motor and gear ratio. However, only use it once you understand the theory behind the calculations.A FIRST Encounter with Physics: This lesson teaches some of the fundamental physics concepts encountered in FRC. I looked at its section on motor and gearbox theory to ensure that I had all of my information right for this tutorial. However, this tutorial goes into a bit more detail than its chapter on motors and gearboxes. Photo Credit:http://aprettybook.com/2011/09/18/future-engineers/

what kind of gearbox will be suitable for motor allowable RPM range: 500-1500RPM. The output shaft having RPM: 1 RPM +/- 5% Torque: 20Nm +/- 1Nm (at 1 RPM) Radial rotating force: Maximum 300N at tip Movement: Bi-directional (open/close of valve) 360O in both directions (no fixed stop) Hysteresis:

Your data ( graph ) for the motor to lift your elevator makes no sense. The numbers quoted are too high: for example the stall current is 85A, but the stall current for a 550 motor is 8A and would burn out very quickly at that. I'm baffled.

I am working on project of making small hydro generation unit. In which I have made hydro turbine of 'Pelton Wheel' type. It rotates at 300 rpm but as rated speed of synchronous generator which is to be connected is 1500 rpm, so to generate electricity I have to step up the speed from 300 rpm to 1500 rpm. For that purpose is it feasible to use gear type arrangement?? Which type of gear to be used?? How will it work?? Explain me in detail......

You can do 2x 2.236:1 or 1 5:1. What is the shaft size of your pelton wheel and what material is it? If it's metal or a shaped (like a square or hexagon beam) you can buy a spur gear (or make one if your pelton wheel is large) and as the main shaft spins you will spin your motor (what sized shaft?) 5 times as fast.

Things to take into consideration:Shaft size helps determine what gear PITCH you use. (The size of the teeth). If you have a really tiny shaft you can't use a large pitch, for power transfer you want a large shaft and large teeth so your gears don't strip themselves.

Gear material is also determined, wood has the potential to expand and contract, plastic probably won't hold up to how much stress you are putting on your wheel. I would go with metal for you. The gears will be really expensive so honestly, I would go old school and use pressure treated wood to make huge gear teeth (like an old fashion water wheel) which is what I think you're using.

So all in all, you need a gear ratio of 5:1 (or close to it, will your wheel always be moving at 300 rpm? if the stream wanes you still want 1500 rpm! If the motor can handle more, think about changing the ratio!)

When I'm saying "huge gear" I'm imagining your wheel to be a foot or two (or more) diameter and you can cut the teeth using a pattern, then another gear. The reason larger is better is because there is less wear, but more importantly the larger the gear the less your human error impacts the gear. (No way you're going to machine a super tiny 188 tooth gear!, but make a 24 tooth gear that's big, you got that!)

If you pelton wheel is rinky dinky and the shaft is only 1 inch diameter or so you can just buy a gear or two from servocity or another gear provider. Make sure the gear pitches match (mod and pitch are the same thing so match 1 mod with 1 mod or 24dp with 24dp, etc.) Then make sure you can attach the pinion gear to your motor, (press fit, glue, welding).

i have a 44 ft long wooden boat that i made it by myself . the boat beam is 15 ft and hull depth 9 ft .Boat displacement is around 22000 lb . the boat is powered by two volvo penta AQAD40 marine diesel engines that produces each 165 hp and a max of 3000 rpm .. i need to install 2 gearboxes could you pls advise about the best ratio suitable for this boat

I posted an Instructable about how I made a gearboxhere- it's kind of the same topic, but doesn't go into quite the detail it sounds like you want. It's definitely a good idea though - I'll put it on my list of ideas for future tutorials.

What is the difference between torque and stall torque when dealing with an electric motor? As I recall, the highest torque rating of an electric motor is it's stall torque. I thought separating them out was more a function of usable power in an IC engine rather than an electric motor. Or is that formula generic, it's been a dozen plus years since I've even had to look at that stuff. Also, are you going to get into the differences between DC and AC motors? I seem to recall there being a couple of differences when you start talking about what you want the motor to actually do. BTW, not to sound like a jerk, but I do mean differences beyond what source of electricity is handy.

To answer your second question, the reason why I did not discuss AC motors is twofold. First, this tutorial was meant for students who are part of the FIRST Robotics Competition, which only allows brushed DC motors, though the theory is definitely applicable to any project that uses DC motors. Second, I would have no idea what I was talking about if I tried to cover AC motors. I have never used them, so I might be giving unreliable information if I tried to teach about them. If I understand your first question correctly, a brushed DC motor's output torque is not equal to its stall torque. Instead, it applies as much torque as is necessary to rotate the motor's output shaft. In other words, stall torque is a constant that is a characteristic of the motor, while torque is the amount of torque the motor is outputting at a given speed/current.

I'd been waiting for an instructable like this... For a long time I've wanted to attempt building a solar powered plant stand/turntable which would slowly rotate (about 180 in 24 hours) but I never knew where to start. Though it is still daunting, at least now I know where to begin!

high-performing gear unit for your ball mill

high-performing gear unit for your ball mill

Developed in 1966, our two-stage planetary gear unit guarantees optimum power transmission and speed reduction for your ball mill. The standard for central driven ball mills in the cement industry today, our MAAG GEAR CPU Gear Unit drives hundreds of raw and clinker ball mills all around the globe.

The simple design holds the secret to the gear units high efficiency. Two co-axial planetary gear stages are arranged one after the other. Each stage includes three planet wheels mounted in a rotating planet carrier and internal toothed coupling guarantees reaction-free power transmission from the first planetary stage to the second. This setup is the most efficient gear arrangement and guarantees optimum power flow from the main motor to your horizonal mill with the fewest possible rotating parts, tooth contacts and bearings.

Your requirements for the grinding process determine the configuration of this gear unit, which can be tailored to suit many application areas. All installations take into account local circumstances and plant specifications, such as motor and mill speeds. With power ranges from 1,000 to 10,000 kW, the MAAG GEAR CPU Gear Unit has the breadth to adapt output speed to your specifications. We can also add additional features such as water injection or a condition monitoring system.

The space-saving design of our two-stage planetary gear unit means that it takes up less room than traditional, multistage, spur gear units. While it may be smaller, it never compromises on power delivery.

Additionally, the compact size of the CPU Gear Unit simplifies transport. Assembly time is also decreased and, once the foundation is complete, the central drive gear unit is quickly installed and operational.

The design of our MAAG GEAR CPU Gear Unit has been copied many times, but never equalled in efficiency, quality and ease of installation and maintenance. The complete central drive system delivers dependable power for raw and cement grinding allowing your plant to operate with ease.

The toothed couplings installed between the main motor and the gear unit, as well as between the gear unit and the ball mill, transmit pure torque from one component to the next. In addition, they compensate for thermal expansions and mechanical deflections resulting from operating conditions.

During maintenance, the low speed ZCF coupling remains in place between the gear unit and the ball mill, while the dismounted high speed ZEXF coupling provides enough axial space to disassemble the gear unit without moving the main motor.

Ideally located beneath the main motor, the oil supply unit cools and lubricates the toothing and bearings of the CPU Gear Unit. With a high prioritisation on operational reliability, the oil supply unit has all necessary measuring instruments to monitor the correct lubrication of the central drive gear unit.

All of our gear units and drive systems are equipped with unparalleled condition monitoring sensors. Normally, these types of sensors keep an eye on critical operating parameters like bearing temperatures, casing vibrations, etc. and trigger a mill shutdown in the case of exceedances.

Our condition monitoring system does much more. It lets you set up condition-based preventive maintenance that uses continuous monitoring and data analysis to detect wear and tear at an early stage. With this enhanced information, we help you plan maintenance and servicing in advance reducing downtime and keeping your plant running smoothly.

FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.

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