Fill-cotrolled Fluid Coupligs
Voith Our Compay. Voith is the reliable parter for essetial idustries. We set stadards aroud the world i our markets for paper, eergy, mobility ad service. With aual sales over 3.7 billio ad more tha 34,000 employees i early 250 locatios worldwide, Voith is oe of the large family-owed compaies i Europe. Paper Eergy Mobility Service Markets We Are Shapig the Future Our equipmet, compoets ad services allow us to make a major cotributio towards our customers success. The global demad for paper, eergy, mobility ad services will cotiue to grow i the comig years. We will be there to watch these markets of the future develop, ad to play our part i shapig them. People at Voith have writte ad re-writte techical history with their ideas ad developmets. Today, our products set stadards aroud the world. Our egieers will cotiue to shape the future actively i our markets, for the beefit of our customers ad the log-term success of our compay. Customers Everythig we do is cetered aroud the eeds of our customers. Our global presece ad proximity to our customers allow us to create a workig relatioship based o cofidece ad trust. We wat to draw o our iovative stregth, our solidity ad our egieerig skills i order to be a reliable parter for geeratios to come. 2
Fill-cotrolled fluid coupligs from Voith Turbo The getle way of gettig masses goig Be it raw material extractio or process techology wherever large masses eed to be moved, high powers are required. But the higher the power, the heavier the wear. Protect your drive systems ad compoets with fill-cotrolled coupligs from Voith Turbo. They cotrol ad accelerate your machie getly ad protect the drivetrai agaist damage i the evet of a overload. Machies such as shredders, crushers, AFC s or mills ca suddely block as a result of overload. Fill-cotrolled coupligs slip whe a overload occurs ad protect the drivelie effectively. I combiatio with a electroic startup cotrol system, ru-up times of up to several miutes are realized. Tesile forces occurrig durig the startup of belt coveyors are reduced to a miimum. By varyig their fill levels, they cotrol the trasmissio of torque ad cosequetly also the operatig speed, steplessly ad smoothly. 3
Applicatio features ad beefits Characteristics Applicatio Start-up aid (load-free motor start) Acceleratio of heavy masses Overload protectio Speed cotrol Vibratio dampig Multi-motor drive (sequetial start of motors) Limitatio of startig torque Load compesatio betwee drives Break-away of drive machie Crushers + ++ ++ ++ Shredders + ++ +++ ++ + Ball mills +++ + ++ Vertical mills ++ + + ++ Cetrifuges + +++ + Belt coveyors + ++ + ++ +++ ++ + AFC s ++ +++ + +++ ++ ++ +++ Mixers + + + ++ Beaters + + ++ + + ++ Gas turbie start + +++ + + + Fa (retrofit) + ++ ++ + Pump (retrofit) ++ The best solutio for ay requiremet Sigle or as a double-pack : Voith Turbo has the right solutio for your applicatio. Depedig o requiremets, the hydrodyamic circuit cosistig of a sigle set of pump ad turbie wheels (TPK) ca also be combied i pairs ito a double couplig circuit (DTPK). Three differet desigs are described o the followig pages: 7 10 13 Pages with product overview 7 8 9 DTPK exterally supported, compact uit for idustrial applicatios 10 11 12 TPKL self-supported, drive module for above ad below groud belt coveyors 4 13 14 15 DTPKW special desig for miig applicatios, usig water as the operatig medium
8 6 3 5 1 7 10 9 4 2 The basic fuctio priciple Via a operatig fluid, the pump wheel drive by the motor trasmits power wear-free to the turbie wheel which, i tur, drives the drive machie. 1 Workig circuit 2 Collectig rig 3 Pump chael 4 Dyamic pressure pump 5 Nozzles 6 Temperature moitorig 7 100% Fill level sesor (optioal) 8 Cooler 9 Soleoid valves 10 Tak Wear-free power trasmissio i compact desig Voith Turbo hydrodyamic coupligs combie, i the smallest of spaces, a circular pump (pump wheel) ad a turbie (turbie wheel) which drives a drive machie. Torque emitted from the motor is coverted ito flow eergy by the pump wheel. The turbie wheel trasmits this eergy as mechaical eergy to the drive machie. Cotiuously variable betwee completely full ad completely empty By chagig the fill level i the workig circuit, the trasmissio of torque, ad cosequetly the operatig speed of the drive machie, is adjusted smoothly ad steplessly: the fillig medium flows freely ito the couplig s catchig rig, ad the ito the workig circuit by cetrifugal force. The fluid betwee the pump ad turbie wheels trasmits torque via hydrodyamic actio. To allow for fillig cotrol ad heat dissipatio, the fluid exits the workig circuit via ozzles ito a rotatig pump shell. There, it is take up by a dyamic pressure pump, which poits ito rotatig fluid rig ad, via the cooler, redirected back to the collectig rig. Two soleoid valves cotrol (etirely without exteral movig parts) the active fluid volume i the workig circuit betwee completely full ad completely empty by addig or removig fluid from the coupligs workig circuit. 5
Belt coveyor start-up Costat load torque Drive Parabolic load torque M Coveyor Couplig Fillig Draiig Oil system Trasmissio Cotroller Torque Nomial torque 1.5 30 % 1.25 1 0.75 20 % 0.5 10 % 0.25 5 % Fillig Nomial load Acceleratio torque Idlig load 95 % 90 % 100 % 50 % 60 % 70 % 80 % Torque Nomial torque 1.25 1 0.75 0.5 0.25 30 % 20 % 10 % Fillig 40 % 50 % 60 % 70 % 80 % parabolic load torque 95 % 90 % 100 % 0 0 0.1 0.5 1 Output speed Motor speed 0 0 0.1 0.5 Operatig poit Output speed Motor speed 1 Smooth start-up The smoother a machie accelerates, the more it is protected. This is especially importat for the belt itself, typically the most expesive compoet i the system. To eable this, a electroic cotrol processes the values of motor power ad belt speed. Correspodigly, it actuates the fill ad drai valve to achieve cotrolled acceleratio of the coveyor, miimizig the tesile forces i the belt durig start-up. Parameters for acceleratio periods of up to several miutes ca be set. Speed cotrol Fill-cotrolled coupligs, by modifyig the fill level, ca provide accurate speed cotrol uder full load for parabolic load machies, e.g. cetrifugal pumps ad fas ad ca also provide partial speed cotrol for empty coveyor systems for ispectio ad maiteace. Advatages which impress Wear-free trasmissio of power Smooth build-up of break-away torque Cotrolled acceleratio of heaviest masses Overload protectio i the evet of a blockage Dampig of torsioal vibratios ad jolts Variable speed adjustmet of the drive machie Clutchig ad declutchig of drive machie while motor is ruig High efficiecy at omial operatio owig to low slip Load-free motor start-up; therefore possibility of frequet starts, eve with motors with lower service factors I the case of multi-motor drives, the electric grid is protected owig to sequetial starts of idividual motors Available i specific desigs for water as the operatig medium Isesitive to extreme ambiet coditios such as dust, heat ad cold Robust desig with log service life ad high availability Available i explosio-proof desig Torque Motor torque 2.5 2.0 1.0 2.5 times torque limitatio Nomial torque 0 1 Protectig the drivelie Machies such as shredders, crushers or AFC s are subject to blockage as a result of overload. Here, the couplig protects the drivelie effectively: slip icreases as a result of higher load util a maximum hydrodyamic torque limit is reached. This level ca be factory set withi the rage of approximately 1.8 3.0 times. Output speed Motor speed 6
Iput power P 1 [kw] Iput speed 1 [rpm] Desig DTPK couplig Nomial operatio Performace graph DTPK the compact couplig variatio The highly compact fluid coupligs of type DTPK are primarily used i drives i mills, shredders, pumps ad fas. They are extremely maiteace-friedly ad ca operate at partial speeds. DTPK coupligs are exterally supported. Their ruer parts are directly istalled with the hub to the shafts of the motor ad drive machie, which must accommodate the axial forces created by hydrodyamics as well as the couplig s weight forces. I order to miimize these values, the ruers are made from alumium ad desiged as a double circuit. The shafts are sealed usig cotact-free labyriths ad therefore do ot cotai ay wearig parts. Coectig coupligs are ot required. 7
DTPK couplig The ideal couplig for retrofit projects Compact desig ad a separate oil supply system make DTPK coupligs the ideal choice for all retrofit projects, or where there is miimal space i the drive area. Existig plats ca be rebuilt easily ad quickly. Oil supply systems ca be desiged to provide lube oil for other drive compoets. The fial assembly of the couplig is carried out directly o site with the pre-assembled compoets. Areas of applicatio Shredders Mills Retrofits i fas ad pumps Pulpers Desig-specific advatages Extremely maiteace-friedly, o bearigs, o shaft sealig rigs, o coectig coupligs Low istallatio dimesios Speed cotrol Also available for water as the operatig medium Size Type A B F L K H h 1 487 DTPK 670 816 194 290 766 923 485 562 DTPK 720 860 194 340 806 1000 525 B A 650 DTPK 800 1030 204.5 360 980 1108 605 H 750 DTPK 970 1140 223.5 508 1020 1255 650 866 DTPK 1125 1300 380 465 1220 1460 765 h 1 1000 DTPK 1250 1530 354.5 500 1500 1695 920 1150 DTPK 1420 1795 425 570 1700 1903 1055 Dimesios i mm (subject to modificatios) K F L Major dimesios DTPK 8
1. Motor start 2. Acceleratio of drive machie 3. Nomial operatio 4. Operatio at part-load speed Operatig coditios Type with oe couplig circuit (TPK) With this versio, extremely short istallatio spaces ca be realized. Higher axial forces are, however, to be take ito cosideratio. Whe retrofittig existig plats, shiftig of idividual compoets is reduced to a miimum. Type with ope operatig circuit (DTP) The predecessor to the DTPK with the most simple desig. Type with oe couplig circuit (TPK) Type with ope operatig circuit (DTP) Ball mill drive: iput power 5 400 kw at 1 200 rpm 9
Iput power P 1 [kw] Iput speed 1 [rpm] Desig of TPKL couplig Nomial operatio Performace diagram TPKL/DTPKL impressive advatages for belt coveyor startups Fluid couplig types TPKL/DTPKL have bee developed especially for tough belt coveyor applicatios at i miig eviromets. Adapted to the prevailig load coditio, they smoothly cotrol acceleratio processes ad esure eve load distributio with multi-motor drives. But their advatages also prove impressive i other applicatios that are typical of fill-cotrolled coupligs. The exteral cooler makes the drive extremely thermally efficiet. Overloads are effortlessly overcome. Startig times of up to several miutes are mastered without problems. For ispectio rus ad positioig, the empty belt ca be moved at approximately 20 % of its omial speed. Mechaical desig Self-supported, idepedet uit for moutig o foudatios or swig frame Reiforced bearigs ad shafts for heavy miig applicatios Robust welded housig Oil tak itegrated ito housig Fully piped with the exceptio of the separate cooler Coolig provided eve whe plat is at a stadstill No movable exteral parts 10
TPKL couplig Desig-specific advatages Desig optimized for miig applicatios extremely robust ad compact Stadardized uit with little eed for techical clarificatio Easy maiteace of complete drivelie thaks to modular costructio TPKL Size Type A B C D E F G H1 H2 562 TPKL 1000 615 1130 849 230 310 90m6 135 128 562 TPKL-E 814 400 844 766 137 520 90m6 97 98 650 TPKL 1165 710 1480 1055 217 530 120m6 165 165 650 TPKL-E 888 435 985 1055 148 780 120m6 165 165 650 DTPKL 1165 710 1480 1200 217 675 120m6 165 165 650 DTPKL-E 910 455 985 1200 217 675 120m6 165 165 866 TPKL 1530 900 2200 1575 290 883 160m6 240 240 B A A C TPKL-E G G H1 E H1 F D H2 H2 G G 866 DTPKL 1530 900 2200 1750 290 1058 160m6 240 240 Dimesios i mm (subject to modificatios) B C E F D Major dimesios TPKL/TPKL-E 11
Stadstill coolig Motor start Machie start Ispectio speed Operatig coditios Couplig types TPKL-R ad TPKL-E All couplig sizes of this type are available as a TPKL/DTPKL stadard versio with a itegrated oil tak. For lower shaft ceterlie heights, the variat (D)TPKL-R has a flatter, but loger tak (dimesios available upo request). The most compact istallatio space is offered by the (D)TPKL-E as it does ot have a oil tak of its ow. The tak is situated exterally or, for example, itegrated ito the swig frame. Start-up of a belt coveyor O belt coveyors with several drives, the motors are started sequetially i order to reduce stress o the electric power supply. Oly the are the coupligs filled, ad the belt tesio is gradually icreased up to break-away. Logitudial tesio waves i the belt are therefore avoided. Cotrolled acceleratio takig up to several miutes miimizes the start-up factor. A exteral cooler offers very high thermal reserves for frequet starts ad ispectio speed. (D)TPKL TPKL-E 12
Iput power P 1 [kw] Iput speed 1 [rpm] Desig of DTPKWL2 couplig Nomial operatio Performace diagram DTPKW breakig away heaviest masses DTPKW fluid coupligs have bee developed for the toughest drive applicatios at the coal face. They use water as the operatig medium, as water offers the highest thermal capacity, is evirometally friedly ad meets the safety stadards for o-flammable operatig media. Owig to their double circuit, DTPKW coupligs are also ideal for miimum headroom. DTPKW coupligs have the most robust desig of the etire series, because they have bee desiged for the most extreme operatig coditios. They are desiged as a tuel versio mout style, elimiatig the eed for aligmet of the drivelie compoets (motor-couplig-reducer). All cotrol compoets ad sesors are itrisically safe. Valves used for cotrollig the water are situated i a block ad directly itegrated ito the uit. A optioal torque limit for overloads is set i the factory. This torque is 2.5 to 3 times the omial torque ad is desiged to protect motor, gearbox, ad chai. 13
562 DTPKWL2 couplig Areas of applicatio DTPKW coupligs have bee developed especially for AFC s, but they ca also be used o other applicatios where oil is ot permitted as a operatig fluid. Desig-specific advatages Almost ulimited frequecy of startups Safe automatic torque limitatio Water-operated (o-flammable, evirometally friedly) Compact desig (tuel desig) No water tak if operated from water supply etwork Easy cotrol ad moitorig DTPKW coupligs are available i exterally or self-supported versios. A outstadig feature of exterally supported models is their short istallatio legth, while self-supported models ca be mouted more quickly. B B Size Type L H B* 487 DTPKWL 1420 860 860 H H 562 DTPKWL 1420 860 860 487 DTPKWL2 1100 860 860 562 DTPKWL2 1100 860 860 DTPKWL B L B L DTPKWL2 562 DTPKWL2-800 1300 950 950 562 DTPKW-TTT 970 950 950 650 DTPKW-TTT 1150 1050 1050 H H Dimesios i mm (subject to modificatios) *Istallatio width L DTPKWL2-800 L DTPKW-TTT Major dimesios Desig variats 14
Motor ru-up ad disposal of excess water Start-up of drive machie Nomial operatio with water exchage for coolig Operatio with partially filled couplig/creep speed Operatig coditios Miimum water requiremets durig operatio At ormal load coditios, the water is oly slightly heated. I omial operatio, it stays i the closed couplig circuit util the thermal limit of 55 C is reached. Oly the is the water exchaged. Maximum frequecy of startups Durig startup attempts agaist the blocked coveyor, the couplig ca heat up to max. 100 C. For each further attempt, cold water from the fresh water supply system is available. The umber of repeat startups is therefore ulimited. Apart from coolig with fresh water, a cooler ca optioally be itegrated ito the couplig circuit, utilizig the coolig water of the motor ad the gearbox. The water requiremets of the couplig ca therefore be eve further reduced. AFC with 562 DTPKWL2, 500 kw power 15
Voith Turbo GmbH & Co. KG Startup Compoets Voithstr. 1 74564 Crailsheim, Germay Tel. +49 7951 32-409 Fax +49 7951 32-480 startup-compoets@voith.com www. voithturbo.com/startup-compoets.com Cr 112 e, 02.2007, 3000, aik/wa. Dimesios ad illustratios without obligatio. Subject to modificatios.