MAAG TM WPU two-stage gear unit for vertical mills

MAAG TM WPU two-stage gear unit for vertical 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 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 organisation. Also, each employee is aware of the company vision and strategy and works to maintain a culture of opportunities. 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 Innovative technology Introduction The compact two-stage MAAG TM bevel and planetary gearbox transmits the power from the electric motor to the grinding table. It reduces the speed of the electric motor to the desired speed of the grinding table and changes the horizontal input axis to a vertical output axis. The gearbox also supports the grinding table, mounted on the output disc. An external oil supply unit lubricates and cools the gearbox. Assemblies Thrust bearing for grinding table with associated casing. Planetary gear stage with internally toothed ring gear. Bevel gear stage with its own casing. Gearing The toothed flanks of the sun pinions have both profile and longitudinal modifications to fully compensate for deformations of the sun pinion and planet wheels occuring under load. This method guarantees optimum tooth flank contact and a very long life cycle. Drive The motor drives the bevel gear stage via a flexible coupling. The torque is then transmitted to the planetary gear stage via a toothed coupling. The rotating planet carrier is bolted and pinned to the output disc and drives the grinding table (Figure 1). Thrust bearing The pads of the high-quality tilting-pad thrust bearing for the grinding table are lined with babbitt metal. Their purpose is to absorb the static and dynamic grinding forces. They are lubricated by high- and low-pressure pumps (hydrostatically and hydrodynamically). Their temperature is continuously monitored. Figure 1

5 Casing with internally toothed ring gear The gear casing consists of a robust welded or cast steel structure. The fixed ring gear is bolted to the casing so that reliable torque transmission is guaranteed. The grinding load including grinding table weight is transmitted straight to the foundation via the tilting-pad thrust bearing and the casing wall (Figure 2). Coupling Our standard supply includes a flexible coupling with the following features: durable and reliable low operating costs almost maintenance free (no lubricants to change) low vibratory loads in the drive train relatively wide range for axial and radial misalignment Planet shafts The planet shafts are lined with babbitt metal and scraped. Together they form hydrodynamic bearings with the planet wheels. Lubrication system The gearbox is lubricated by a closed circuit oil system. The oil tank serves as a platform on which all the assemblies and components such as motor pumps (high and low pressure), switchable double oil filter, oil cooler and instrument panel are installed. The design of the lubrication system is standardised thus it is applicable for several gear types. This ensures easy handling, optimal insertion and low costs. Also the components of the lubrication system like instrumentation, filter and cooling/ heating system are consistent. The lubrication system is monitored with digital indication on site. Top priority is given to guarantee operational reliability. Auxiliary drive / maintenance drive Auxiliary or maintenance drives are available to meet your demands. The maintenance drive is placed between the mill motor and the gearbox, whereas the auxiliary drive is located behind the mill motor. The maintenance drive is a low budget drive for build-up welding on the mill table, or for convenient replacing of the lining plates. The auxiliary drive can be used when the mill starting procedure requires a start with its help. It is equipped with a claw type overrunning clutch and a fluid coupling. The fluid coupling provides a smooth start up while the overrunning clutch disengages automatically when the mill motor has started. Figure 2

6 WPU series Type* P/n (kw/rpm) Fa (kn) D (mm) H (mm) Weight (t) min/max min/max min/max min/max 54 42 2650/3800 2200/2700 1750/2100 26/38 64 51 3000/4300 2400/2800 1800/2200 30/42 78 61 3400/5000 2550/2950 1900/2300 36/48 92 72 3750/5600 2650/3100 2000/2400 42/56 107 84 4300/6400 2750/3250 2100/2500 48/62 125 97 4750/6700 2850/3400 2200/2600 56/70 142 110 5200/7000 3000/3550 2300/2700 60/80 161 125 5550/7600 3100/3700 2400/2800 65/86 182 140 6200/8300 3300/3850 2500/2900 78/104 200 155 6800/8800 3450/3950 2600/3000 90/115 222 170 7600/9500 3550/4050 2700/3100 100/125 242 191 8300/10400 3650/4150 2800/3200 105/135 274 212 8900/11000 3800/4250 2900/3300 110/140 302 233 9500/11800 3950/4350 3000/3400 120/150 332 254 10000/12400 4050/4450 3100/3500 135/170 360 275 10500/13000 4150/4650 3200/3600 145/180 *The gearbox will be configured exactly according to specifications Fa D Fa 350 300 Calculation sample P = 2500 kw n = 27.3 rpm P/n = 91.6 250 WPU-125 200 150 H 100 50 0 54 64 78 92 107 125 142 161 182 200 222 242 274 302 332 360 P Mill Power [kw] n Mill Speed [rpm] WPU-Type

7 Customer benefits High operational reliability Proven and robust design Customer-specific design of gear units Very high efficiency Planetary gear stage and thrust bearing for grinding table with a very long service life Short installation time Low-cost maintenance Design The design of the gear unit is optimized to suit the power required, the motor / mill speed and local circumstances. Customer specifications are always taken into full account. Quality Production and all activities are monitored by the internal quality assurance system in strict compliance with ISO 9001. Installation The compact design simplifies shipping and reduces erection time. Delivery time Thanks to continuous monitoring of our production schedule, our clients are provided with the up-to-date status of a project at any time. Maintenance Maintenance work must be performed according to the FLSmidth MAAG Gear instructions. Special service contracts are available upon request. Condition Monitoring Ask us about customised solutions. Customer service Customer care by trained and skilled personnel guarantees professional after sales support. Spare parts Spare parts are available throughout the life of the gear units. Production The latest machines and technical equipment are used for manufacturing. Test running Gear units are tested and logged in detail on our test bed prior to delivery.

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 C 02-16 500-3-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