3 Project Planning of Bucket Elevator Gear Units

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Clyde Reeves
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1 Additional documentation Project Planning of Bucket Elevator Gear Units.1 Additional documentation In addition to the information provided in this catalog, SEW-EURODRIVE offers extensive documentation on the complete subject area of electrical drive technology. This is primarily documentation from the "Drive Engineering Practical Implementation" series. The current SEW documentation can be ordered or downloaded from the SEW- EURODRIVE homepage ( Drive Engineering Practical Implementation The publication "Drive Engineering Practical Implementation Drive Arrangements with SEW Gearmotors" features extensive information on characteristics, differentiating features and application areas of SEW drives. A comprehensive collection and assignment of the most important formulas for drive calculation and detailed examples for the most frequently used applications make this documentation an important tool for the project planner and an essential addition to the SEW product catalogs. Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 17

2 Data for drive dimensioning.2 Data for drive dimensioning Certain data are required for a definite specification of your drive. These are: Data for drive dimensioning n 2 Output speed [1/min] P K2 Output power [kw] M K2 Output torque [Nm] M K2max Maximum output torque [Nm] M K Output torque for driving power from auxiliary drive [Nm] Frequency of maximum output torque [1/h] F R2 Overhung load at gear unit output [N] F A2 Axial load at gear unit output [N] J load Mass moment of inertia to be driven [10-4 kgm 2 ] n 1 Input speed [1/min] P m at n 1 Motor power at input speed [kw] P K1 at n 1 Operating power at input speed [kw] P K1max Maximum operating power [kw] F R1 Overhung load at gear unit input [N] F A1 Axial load at gear unit input [N] Type of driving motor e.g. electric motor - S..,..%ED Operating mode and cyclic duration factor CDF or exact load cycle can be entered - ϑ amb Ambient temperature [ C] H Standard, dusty, abrasive, chemically aggressive S, H Altitude Installation site [m above sea level] Ambient conditions - Required gear unit version: S Output shaft as solid shaft H Output shaft as hollow shaft ( selection tables and dimension drawings) V A, f A Operating voltage and frequency of auxiliary drive [V], [Hz] IP.. Required enclosure of auxiliary drive - V speed monitor Operating voltage of speed monitor [V] - Your entry 18 Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

3 Project planning process. Project planning process The following flow chart schematically shows the procedure for project planning of a bucket elevator gear unit. Required informationen on the driven machine Technical data and ambient conditions Calculation of effective application data reduction ratio i = n 1 /n 2 Operating power P K1 = M K2 x n 2 / (9550 x η) selection Specify gear unit size, gear unit reduction ratio i and gear unit design with F S = Calculate permitted operating power: P K1perm = 2 x P N1 / F F Check maximum operating power: P K1max P K1perm Calculate permitted output torque: M K2perm = 2 x M N2 / F F Check maximum output torque: M K2max M K2perm Calculate thermal power: P T = P TH x f 1 x f n1 x f V Check thermal power: P K1 P T Check the occurring external radial and axial shaft loads please contact SEW-EURODRIVE Selecting components on the input side Specify component and design Specify component size Check component load Selecting accessories Monitoring functions (units, systems) NEMA adapter for auxiliary drives Swing base, optionally with torque arm Check whether all defined requirements are being met. Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 19

4 Calculation factors.4 Calculation factors The following calculation factors are important for project planning of bucket elevator gear units: Service factor F S The service factor F S = takes into account the load impacts generated by the driving motor and the driven machine. Factor F F The factor F F takes into account how often the maximum output torque occurs per hour. MCR MR Frequency of maximum load per hour > Altitude factor f 1 Altitude H [m above sea level] MCR ) MR ) ) Intermediate values must be interpolated. Input speed factor f n1 MCR MR Input speed n 1 [1/min] Factor f n1 ϑ amb = 20 C ϑ amb = 0 C ϑ amb = 40 C ϑ amb = 50 C w/o with w/o with w/o with w/o with Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

5 Additional project planning notes Factor f V for installation site The thermal limit rating P TH was established based on an installation in large rooms or halls. The following values can be used without operation if there are air velocities > 4 ms -1 at the installation site: f V = 1.29 for MCR f V = 1.0 for MR With operation, the air velocity is determined by means of the speed and is already taken account in the P TH values in sections.7 and.8 "Thermal limit rating." In this case, fv = 1.0. Please consult SEW-EURODRIVE in case of deviating conditions..5 Additional project planning notes Efficiency The efficiency η is Peak loads External radial and axial shaft load The bucket elevator gear units may only be overloaded for a short period of time. Individual peak loads must not last for more than ten seconds. Please consult SEW-EURODRIVE in case of external radial or axial shaft loads. Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 21

6 Project planning example.6 Project planning example Bulk material must be transported from one level to a higher level using a bucket elevator. 5052AXX Technical data and application conditions of bucket elevator gear units Foot-mounted gear unit with hollow shaft Output speed n 2 = 5 1/min Output torque M K2 = 9000 Nm Maximum output torque M K2max = 16 knm Maximum operating power P K1max = 61.4 kw Running time: 16 hours per day The gear unit is started up once per hour (frequency of maximum output torque) The gear unit is to be used without a in a large hall under very dusty conditions and an ambient temperature range ϑ amb = C. Installation altitude: 1000 m Technical data of AC motors Input speed n 1 = /min Motor power P m = 45 kw 22 Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

7 Project planning example Step 1: Calculating gear ratio Calculate the gear unit reduction ratio i using the following formula: n 1 i= n 2 i = /min 5 1/min i = /min This value is used to specify the rated gear ratio i N = 45 ( section 4). Step 2: Calculating operating power The operating power P K1 of the drive is cacluated as follows using the output torque M K2 or output power P K2 as well as output speed n 2 and efficiency η: P K1 = P K2 η P K1 = 9000 Nm x 5 1/min 9550 x M P K2 n 2 K1 = η (where η = for three-stage gear units) P K1 = 4.54 kw Step : Specifying gear unit size and gear unit reduction ratio The required rated power of the gear unit P N1 is calculated using operating power P K1 and service factor F S = by means of the following formula: P N1 P K1 F S P N x P N kw This value is used to select the gear unit size MCRLHF04 from the selection tables ( section 4). The selection of the gear unit provides the following technical data: Rated power P N1 = 55.8 kw Rated gear ratio i N = 45 exact gear ratio i ex = Rated torque of the gear unit M N2 = 15 knm Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 2

8 Project planning example Step 4: Calculating permitted power The permitted operating power P K1perm calculated using rated power P N1 and factor F F ( table factor F F ): 2 P P N1 K1perm = F F P K1 perm = 2 x 55.8 kw 1.0 N P K1perm = kw Step 5: Checking maximum operating power The maximum operating power P K1max must not exceed the permitted operating power P K1perm! P K1max P K1perm 61.4 kw kw This means you can use the selected gear unit size. Step 6: Calculating permitted output torque The permitted output torque M K2perm is calculated using the rated torque M N2 of the gear unit determined in step and factor F F ( table factor F F ). 2 M M N2 K2perm = F F M K2perm = 2 x 15 M 1.0 N N2 M K2perm = 0 knm Step 7: Checking maximum output torque The maximum output torque M K2max must not exceed the permitted output torque M K2perm! M K2max M K2perm 16 knm 0 knm This means you can use the selected gear unit size. 24 Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

9 Project planning example Step 8: Calculating thermal power The thermal power P T of a gear unit is the power that can be transferred with the gear unit without the oil temperature exceeding the calculated maximum value depending on the lubricant used. To determine the thermal power P T of the gear unit, it is necessary to determine the thermal limit rating P TH of the gear unit while taking the ambient temperature into account ( section "Thermal limit rating"). In addition, the altitude factor f 1 ( table altitude factor f 1 ), the factor for the input speed f n1 ( table factor f n1 ) and the factor for the installation site f V ( table factor f V ) are required. P T = P TH f 1 f n1 f V P T = 45.6 kw x 0.95 x 1.0 x 1.29 P T = 4.2 kw Higher thermal powers are possible if synthetic lubricants and special oil seals are used. Please contact SEW-EURODRIVE in such cases. Step 9: Checking thermal power The operating power P K1 must not exceed the thermal power P T (P K1 P T ). If P K1 > P T, additional cooling () is required kw 4.2 kw No additional cooling is required in this case. Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 25

10 Thermal limit rating MCR Thermal limit rating MCR The thermal limit rating P TH is based on installation in large rooms or halls. MCRL..02 MCRL..0 MCRL..04 MCRL..05 MCRL..06 MCRL..07 MCRL..08 MCRL..09 i ex Thermal limit rating P TH [kw] ϑ amb = 20 C ϑ amb = 0 C ϑ amb = 40 C ϑ amb = 50 C w/ with w/o with w/o with w/o with , Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

11 Thermal limit rating MR Thermal limit rating MR The thermal limit rating P TH is based on installation in large rooms or halls. MR..70 MR..80 MR..90 i ex Thermal limit rating P TH [kw] ϑ amb = 20 C ϑ amb = 0 C ϑ amb = 40 C ϑ amb = 50 C w/o with w/o with w/o with w/o with Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 27

12 Auxiliary drives.9 Auxiliary drives Bucket elevator gear units are generally equipped with an auxiliary drive. Auxiliary drives are used in maintenance cases to lower the bucket elevator speed. These drives consist of a helical bevel gearmotor that is mounted to the main gear unit via an intermediate flange. An overrunning clutch placed in the intermediate flange is supplied with oil from the main gear unit. The helical bevel gearmotor has its own oil filling. The customer must equip the drive combination with speed monitoring to prevent overspeed at the auxiliary drive in case of a malfunction of the overrunning clutch..10 Auxiliary drives for empty buckets MCR The assignment of auxiliary drive to main gear unit listed in the following table was selected in such a way that a bucket elevator with empty buckets can be operated at low speed in the same direction of rotation. Main gear unit Auxiliary drive MCRL..02 MCRL..0 MCRL..04 MCRL..05 MCRL..06 i ex Gearmotor n 1) KF7 DT80N4 KF47 DT90S4 KF47 DT90S4 KF67 DV100M4 KF67 DV100M4 M K P m I N 400V 50Hz I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] i 28 Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

13 Auxiliary drives for empty buckets MCR Main gear unit Auxiliary drive MCRL..07 MCRL..08 MCRL..09 i ex Gearmotor n 1) M K P m I N 400V 50Hz KF77 DV100L4 KF77 DV112M4 KF77 DV112M4 I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] ) at the output shaft of the main gear unit if driven via auxiliary drive (50 Hz, n 1 = 1,500 1/min; at 60 Hz n increases by approx. 20 %) i Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 29

14 Auxiliary drives for filled buckets MR Auxiliary drives for filled buckets MR The assignment of auxiliary drive to main gear unit listed in the following table was selected in such a way that a bucket elevator with filled buckets can be operated at low speed in the same direction of rotation.. Main gear unit Auxiliary drive MR.. 70 MR.. 80 MR.. 90 i ex Gearmotor n 1) KF 87 DV112M4 KF 87 DV112M4 KF 87 DV112M4 M K P m I N 400V 50Hz I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] ) at the output shaft of the main gear unit if driven via auxiliary drive (50 Hz, n 1 = /min; at 60 Hz n increases by approx. 20 %) i Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

15 Auxiliary drives for filled buckets MCR Auxiliary drives for filled buckets MCR The assignment of auxiliary drive to main gear unit listed in the following table was selected in such a way that a bucket elevator with filled buckets can be operated at low speed in the same direction of rotation. Main gear unit Auxiliary drive MCRL..02 MCRL..0 MCRL..04 MCRL..05 MCRL..06 MCRL..07 MCRL..08 i ex Gearmotor n 1) M K P m I N 400V 50Hz I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] SF 67 DT90L SF 67 DT90S SF77 DV100M4 SF77 DV100M4 SF77 DV100L4 SF87 DV112M4 SF87 DV12S4 SF97 DV12S i Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series 1

16 Auxiliary drives for filled buckets MR Main gear unit Auxiliary drive MCRL..09 i ex Gearmotor n 1) M K P m I N 400V 50Hz SF97 DV12ML4 I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] ) at the output shaft of the main gear unit if driven via auxiliary drive (50 Hz, n 1 = /min; at 60 Hz n increases by approx. 20 %) i.1 Auxiliary drives for filled buckets MR The assignment of auxiliary drive to main gear unit listed in the following table was selected in such a way that a bucket elevator with filled buckets can be operated at low speed in the same direction of rotation. Main gear unit MR..70 MR..80 MR..90 i ex Gearmotor n 1) KF 107 DV160L4 KF 107 DV160L4 KF 107 DV180L4 Auxiliary drive M K P m I N 400V 50Hz I N 460V 60Hz [1/min] [Nm] [kw] [A] [A] ) at the output shaft of the main gear unit if driven via auxiliary drive (50 Hz, n 1 = 1,500 1/min; at 60 Hz n increases by approx. 20 %) i Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

17 Lubrication fill quantities.14 Lubrication fill quantities Refer to the operating instructions for information on lubricants. The indicated filling quantities are recommended values. The exact values vary depending on the gear ratio. The main gear unit is usually supplied without lubricant. The auxiliary drives are supplied from the factory with a lubricant fill in accordance with their mounting position. Empty buckets MCR Main gear unit Filling quantity in liters Auxiliary drive Filling quantity in liters MCRL KF7 1.5 MCRL MCRL KF MCRL MCRL KF67.6 MCRL MCRL KF MCRL Empty buckets MR Main gear unit Filling quantity in liters Auxiliary drive MR MR MR Filling quantity in liters KF Filled buckets MCR Main gear unit Filling quantity in liters Auxiliary drive Filling quantity in liters MCRL SF67.2 MCRL MCRL SF MCRL MCRL MCRL SF87 12 MCRL MCRL SF Filled buckets MR Main gear unit Filling quantity in liters Auxiliary drive MR MR MR Filling quantity in liters KF107 5 Industrial Gear Units: Bucket Elevator Drives of the MC... / M... Series

5 Project Planning for Gear Units

5 Project Planning for Gear Units General information Project Planning for Gear Units.1 General information The planning information provided in this catalog is primarily concerned with the special needs of EBD gear units. For detailed