MAAG TM LGD lateral gear drive for horizontal mills

MAAG TM LGD lateral gear drive for horizontal mills

2 Our Quality Policy FLSmidth MAAG Gear is committed to creating long lasting relationships that establish us as a trustworthy, reliable and professional partner for customers, suppliers and employees. This commitment includes providing high-quality and high-value solutions, products and services that result in satisfied and loyal customers. Certified to ISO 9001 standards With a clear focus on process management, we endeavour not only to meet but exceed international quality standards while providing appropriate resources to support and develop our purpose-designed quality system. Our quality policies reflect the importance of meeting our customers requirements. Our management regularly defines and reviews quality goals. Our employees are committed to the company s management system and to continuously improving not only the system but our entire organization. Also, each employee is aware of the company vision and strategy and works to maintain a culture of opportunity. With our suppliers and external partners, we cultivate open communication and focus on performance-based results.

3 A pioneer of modern gear technology FLSmidth MAAG Gear was founded in 1913 and quickly expanded into an international group that now has almost 100 years of experience in manufacturing gear units. Since introducing the technology of mill gear units to the cement industry with great success in 1966, we have sold over 6000 MAAG gear units and 1000 girth gears. The company At the FLSmidth MAAG Gear headquarters in Winterthur, Switzerland, more than 100 employees work in development, design, finance, project management, sales, customer service and marketing. Production and assembly takes place in three modern plants equipped with high-performance machines. In Elblag/Poland, Milano/Italy and Bawal/India more than 200 employees manufacture gear units, drive systems and components which satisfy the most demanding quality standards. The company belongs to the successful FLSmidth Group, a listed Danish firm. A constant willingness to innovate, and close collaboration with our customers have helped to ensure that MAAG gear units continue to operate reliably throughout the world under the toughest conditions. Product range Today, the product range includes various gear units for mills, complete drive systems, gear solutions for bucket wheel excavators and belt conveyors, as well as maintenance systems for all types of plant. In addition FLSmidth MAAG Gear manufactures components such as bevel sets, girth gears and various replacement parts. All MAAG gear units are available as standard solutions or are customized to the required needs. Our strength The combination of unique precision, accuracy and modularized solutions with compact design are leading to high efficiency products and therefore low maintenance cost for the customer. Experience, new technical solutions and the latest manufacturing techniques are regularly incorporated into the production process. Intensive development and training of our engineers assure best understanding of how to operate a gear unit and lengthen its life cycle.

4 Integrated side drive system Innovative technology The LGD integrated side drive system is based on FLSmidth MAAG Gear s high-quality gear manufacturing expertise acquired during the last 100 years and its experience in operating existing integrated side drives. FLSmidth MAAG Gear is able to deliver the complete drive system out of one source. This ensures optimized adjustment between gear unit and girth gear and allows specific customer requests to be carried out more efficiently. The success of the LGD is based on its design using state-of-the-art technology, i.e. torque split pinions and self-aligning pinions. It is positioned 40 under the mill, allowing a compact type of construction and involving less building and foundation costs. A lot of space and costs are saved as only a very low and simple foundation is needed for the LGD gear unit, auxiliary drive and motor. Design The MAAG TM LGD unit is a three-stage spur gear with torque split. It drives the ball mill directly via the pinions of the two output shafts and reduces the speed of the mill drive motor to the pre-determined speed of the mill. The casing is of cast iron and horizontally divided into three sections. In contrast to other lateral drive equipment suppliers, no separate oil tank is needed. For the lubrication of all the teeth and bearings, the LGD has an integrated lube oil system in the lower casing part. The pinions of the upper and lower output shaft as well as the girth gear of the ball mill are direct lubricated. With the LGD gear unit positioned partly below the mill, it is possible to return the lubrication oil directly from the girth gear guard to the gear unit. The torque split between the two pinions ensures that the total torque to the mill is always equally distributed between both pinions. Any torque imbalances between the two pinions will automatically be equalized by the axial adjustment of the intermediate shaft caused by the deviations in the axial forces. Self-alignment of the pinions is achieved by a crowned toothing between the pinion and the pinion shaft. This ensures full tooth contact even subject to a small run-out failure at the girth gear. Selection chart for a lateral gear drive system Formula: n2p = n2 x (Z2 : Z2p) Example: 127,62 rpm = 14,13 rpm x (280:31) n2p = Pinion speed n2 = Mill speed Z2 = Teeth girth gear Z2p = Teeth pinion Type P/n2p LGD 18 19.3 LGD 32 33.2 LGD 50 51.6 LGD 80 81.4 Mill Power (kw) 9000 8500 8000 7500 7000 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 LGD-80 LGD-50 LGD-32 LGD-18 100 120 140 160 180 Pinion Speed (rpm)

5 Integrated oil system The low LGD foundation minimizes the risk of critical vibrations in the foundation. With the LGD gear unit positioned partly below the mill, it is possible to return the lubrication oil directly from the girth gear guard to the gear unit. This is done so that the LGD drive can be built with the oil sump in the bottom of the gear unit, thus avoiding the need for a separate external lubrication unit with its foundation. Since the oil pump, filter, and cooler etc. are installed directly on the LGD gear unit, external piping between the gear unit and lubrication unit is also avoided. The lubrication oil for the bearings and tooth meshes circulates inside the gear unit only. Girth gear The girth gear is a fabricated design made up of two or four segments. The ring where the toothing is located consists of high-quality alloy steel and is rolled and bent. The rib is made out of ordinary carbon steel and is welded to the ring. Internal stresses are eliminated by heat treatment. With these processes a homogenous crystal structure in the base material of the toothing is ensured, thereby achieving significantly higher fatigue and wear resistance compared to cast girth gears. The connection to the mill is adaptable to customer needs. The T-section of the girth gear gives the system an additional flexibility to absorb misalignment between the mill and the LGD gear unit. Cooling water in- and outlet Oil cooler Lube oil to roller bearing Lube oil to teeth cooling Girth gear guard Oil filter Suction pipe Oil pump Dirt separator for splash oil from girth gear guard

6 Auxiliary drive The auxiliary drive is specially designed for the LGD gear unites. Its components are compactly arranged on a common frame. Therefore the auxiliary drive needs only a small and simple foundation. Also installation and alignment is simple due to the compact design. The auxiliary drive is engaged and disengaged via an overrunning claw-type clutch. A fluid coupling between the auxiliary drive motor and the auxiliary drive gear unit provides a smooth start-up. Overrunning clutch Planetary gear unit Terminal box Disc brake V-belts Hydraulic unit Hand lever Electric motor Hydraulic clutch Base frame Installation and service The low foundation level and the easy access to the measuring points through the inspection covers ensures a high level of serviceability for the entire installation. Furthermore, access is not only improved in relation to the gear but also in relation to the other components such as the auxiliary drive or motor. No special heavy installation equipment is required to install the LGD. The LGD gear unit is installed by sliding or lifting it from a truck on to the foundation, where chain blocks are used to adjust it horizontally to the correct mesh with the girth gear on the mill. No (mobile) crane is needed. The installation of the girth gear is simplified by its design and from the precision and tight tolerances obtained during the manufacturing process. Axial and radial run-out are kept close to zero in order to guarantee a long life of the drive unit and to reduce the level of vibration to a minimum. The junction plate is connected with calibrated screw pins and special bolts in order to reduce the time of assembly. The gear unit is quickly and easily accessible for maintenance. When replacing the rotating parts, no crane is needed to remove the gear unit from the foundation since it can be pulled out using chain blocks.

7 Customer benefits The position of the side drive is combined with many advantages: Simple foundation for gear unit, motor and auxiliary drive Low risk of vibration in the gear unit foundation Easy installation Easy access for service and maintenance Easy replacement of rotating parts Further benefits are: Low foundation design, i.e. compact mill arrangement Integrated oil system Direct lube oil return from the girth gear to the integrated lube oil tank prevents contamination of oil Minimum oil flow in the girth gear guard Minimized overall maintenance cost Girth gear with optimum physical properties in all directions No macro or micro defects in the girth gear base material

Copyright 2012 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth and MAAG are (registered) trademarks of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidthmaaggear.com CM 02-16 500-2-ENG V1 FLSmidth MAAG Gear AG Lagerhausstrasse 11 P.O. Box 8401 Winterthur Switzerland Tel +41 52 260 35 00 Fax +41 52 260 35 35 info@flsmidthmaaggear.com