BOGIFLEX KGD. Kiln Gear Drive. Self Aligning and Floating BOGIFLEX KGD. January 2010

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Annabelle Parrish
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1 BOGIFLEX KGD Self Aligning and Floating Kiln Gear Drive

2 Cement Kiln operation Influence parameters on Gear Meshing Meshing of the kiln girth gear depends on the thermal condition of the kiln The kiln has variable thermal expansion due to condition and type of its refractory and coating Change in center distance between pinion and kiln axis Wobbling of girth gear The sustainability of the meshing of the kiln girth gear is major concern

Cement Kiln Influence parameters on Gear Meshing Wobbling of Girth Gear Occurs due to variation in kiln operation - uneven coating formation leading to shell temperature differences and thermal

3 Cement Kiln Influence parameters on Gear Meshing Wobbling of Girth Gear Occurs due to variation in kiln operation - uneven coating formation leading to shell temperature differences and thermal cranks => Proper meshing of the teeth no longer assured contact area is reduced and changing from one side to the other Overloading due to wobbling Center distance change Lack of tip to root clearance

4 BOGIFLEX KGD is solving these issues

5 BOGIFLEX Concept Floating drive + Self aligning principle applied for Gear Meshing = BOGIFLEX Self aligning is achieved because the pinion can move freely onto the wheel The rotation shaft of the pinion is free from the rotation shaft of the wheel The 2 contacting surfaces or gear meshing between pinion and girth gear will permanently adapt to each other Spherical plain bearings Pillow block

BOGIFLEX Contact pattern and Advantages Floating drive + Self aligning principle applied for Gear Meshing = BOGIFLEX The 2 contacting surfaces or gear meshing between pinion and girth gear will

6 BOGIFLEX Contact pattern and Advantages Floating drive + Self aligning principle applied for Gear Meshing = BOGIFLEX The 2 contacting surfaces or gear meshing between pinion and girth gear will permanently adapt to each other The Hertz contact pressure will be uniformized and, therefore, be minimized allong the complete tooth of gear meshing. No more stress concentration Increased life of gear Coefficient used for Wear and Breakage calculation according in applicable norms (DIN; ISO) are effectively applied Safety factor results are corresponding to effective condition of meshing BOGIFLEX meshing CONVENTIONAL meshing

7 BOGIFLEX KGD General Principle General Design: KGD cardan ERmaster 1 gearbox ERmaster standard 1 cardan with fixed length 1 BOGIFLEX drive KGD with main pinion 23 teeth 1 Girth gear - in two halves cast steel 1 Set of tangential plates Y shape with shoes Girth gear KILN SHELL Spring plates

8 BOGIFLEX KGD General Principle General Design: Length of spring plates are adjusted to enable the mounting onto each kind of shell diameter considered with the drive range Ømin Ømax

9 BOGIFLEX KGD General Principle Pinion rollers: Roll on Girth gear Adjust permanently the center distance ; Keep the tip to root clearance constant Meshing adjustment not performed in plant: Workshop machining Kiln backlash always adjusted No post adjustment required between pinion and girth gear Contact teeth meshing calculated coefficient always right Floating on pinion Relative rotation with pinion Low speed Floating fitting Oil lubrication Injection and bath lubrication

BOGIFLEX KGD General Principle Inner rollers: To keep BOGI-Pinion in position at kiln stop To enable driving during kiln backward Roll on inner track of the girth gear Made up

10 BOGIFLEX KGD General Principle Inner rollers: To keep BOGI-Pinion in position at kiln stop To enable driving during kiln backward Roll on inner track of the girth gear Made up with Glicodur bearings (standard calculation) Global clearance with the girth gear Are not in contact with girth gear at normal kiln driving Grease lubrication for complete life

11 BOGIFLEX KGD General Principle Main Bearings: Over designed Dimension from pinion dimension, not from loads Standard calculation L10h gives hrs minimum Oil lubrication Oil injection + splash Higher life time Securities on lubricated equipment (flow, pressure) Thermal monitoring of the bearings

BOGIFLEX KGD General Principle Reaction Bar Movement possibilities: Reaction bar with one shaft on top side and one spherical plain bearing at bottom side Allowing axial and radial

12 BOGIFLEX KGD General Principle Reaction Bar Movement possibilities: Reaction bar with one shaft on top side and one spherical plain bearing at bottom side Allowing axial and radial displacement of the BOGI-pinion by allowing rotation movements BOGI-pinion casing independent from girth gear casing for self alignment and permanently good positioning onto girth gear

13 BOGIFLEX KGD General Principle Reaction Bar Load distribution: Reaction arm positioning gives Pushing load effect FN w/p Pinion always right positioned onto the Girth gear FR b/w RN b/w FP b/w Pushing effect

14 paramètres BOGIFLEX KGD Range guide line General definition of KGD range: Gear drive depends on kiln torque value and shell diameter. 13,00 12,00 Power transmitted vs diameter on HOLCIM kilns LARGE 11,00 10,00 9,00 3 areas defined SMALL MEDIUM LARGE Similar design for each size 8,00 7,00 6,00 5,00 4,00 SMALL MEDIUM Number of teeth and modules are different 3,00 2,00 1,00 - gamme de fours HOLCIM

15 BOGIFLEX KGD Range guide line General definition of KGD range: Technical data for predefined KGD sizes Kiln shell from 3,8 to 4,6 m KGD Small Admissible torque value of Nm corresponding to 470 KW@4.5 rpm Kiln shell from 4,6 to 5,2 m KGD Medium Admissible torque value of Nm corresponding to 1050kW@4,5 rpm Kiln shell from 5,3 to 5,3 m _ KGD Large Admissible torque value of Nm corresponding to kw@4,5 rpm Service factor acc. ISO 6336 Pitting KB > 1.51 ; Breakage KB > 1.75 Kiln axial and radial displacements usually recorded Kiln Axial +/- 40 mm Kiln Radial displacement + thermal expansion +/- 30 mm BOGIFLEX KGD capacited in displacements KGD admissible axial +/- 80 mm KGD admissible radial +/- 40 mm

BOGIFLEX KGD Complements Lubrication system: Separate Lubrication ERmaster 1) Girth Gear / pinion + Main pinion bearings - Forced lubrication of Girth gear & pinion with adequate lubrication unit To

16 BOGIFLEX KGD Complements Lubrication system: Separate Lubrication ERmaster 1) Girth Gear / pinion + Main pinion bearings - Forced lubrication of Girth gear & pinion with adequate lubrication unit To Ermaster To HD gear set - Choice of oil lubricant viscosity depends on teeth working temperature Low viscosity Unit - Oil viscosity should be higher than 300 Cst at effective working temperature of teeth meshing 2) HD gear set + Ermaster Oil 460 Cst Tank 200 L pump Tank 600 L High viscosity unit - Injection lubrication of intermediate gear set & primary gearbox pump Oil 3000 Cst - Usual lubricant viscosity grade: ISO VG 460 filter 40 µm Motor filter 80 µm 3) All gear stages have a safety splash lubrication with foreseen reservoir

17 BOGIFLEX KGD Complements Y FORM KGD Standard Natural frequencies: BASIC FORM 9.6 Hz Bending Mode 9.9 Hz 68.3 Hz Torsion Mode 63.6 Hz 70.3 Hz Bending Mode 78.1 Hz

18 BOGIFLEX KGD Complements Main Components: Spring plates Girth gear Bogi-pinion KGD Reaction arm Cardan shaft Primary gearbox Baring unit / Inching drive Lubrication unit Housing & Sealing

19 BOGIFLEX KGD General Principle Conclusion: No need of post adjusting of the pinion in front of the girth gear Bogiflex is not sensitive to thermal expansion conditions THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING Optimised meshing and lubrication conditions and High safety factors: Components designed for expected life time Criticality has been studied ; Criticality reduced by monitoring RELIABILITY INCREASED Optimized Maintenance: Maximum number of elements are standard ones KGD studied in standard range in view of having available a set of pool spare parts in addition to plant spare parts Design of KGD has been studied for each part to take care of time required to change it as short as possible: To shorten shut down time of kiln for maintenance has been taken into consideration when design

20 BOGIFLEX KGD successful commissioning Venezuela Ecuador Mexico USA Argentina Slovaquia Azerbaijan San Sebastian Plant Holcim Guayaquil Apasco Macuspana* Holcim Devil Slide* Holcim Capdeville* Holcim Rohoznik Holcim Garadagh

Spur gearing, Helical gearing [mm/iso] Pinion Gear ii Project information? i Calculation without errors.

S Spur gearing, Helical gearing [mm/iso] i Calculation without errors. Pinion Gear ii Project information? Input section 1. Options of basic input parameters 1.1 Transferred power Pw [kw] 9.67 9.63 1.2