Individual Industry Solutions
2 FLSmidth MAAG Gear s sector solutions The know-how we have gathered over the course of decades allows us to meet all our customers special requirements in many different sectors from plastics via food processing all the way to heavy industry and energy supply in a flexible and customized way. Gear units for many applications When special requests, small series or even individual designs are required, individual solutions are the order of the day and these can only be offered by a medium-sized company with demonstrated flexibility and transparency. FLSmidth MAAG Gear has been demonstrating its efficiency in designing special gear units for several decades and is one of the leading companies in this sector. Renowned machine manufacturers, plant construction firms and end customers all over the world and in every conceivable sector make use of the high product services offered by FLSmidth MAAG Gear. The range of services includes the development, construction and manufacture of special gears and other drive components such as: Helical and bevel helical gears Planetary gear units Power split gears Double-shaft and multi-pinion gears Positioning gears Heavy duty tooth couplings Large axial thrust sleeve bearings Cement & Minerals Iron & Steel Food
3 Production capabilities Our combined production and outsourcing range for gears covers torques from 10 to 15,000 knm and up to 200 t of weight. Girth gears of up to 11 m in diameter and 40 t of weight. Annuluses with internal gears up to 6.5 m. Bevel sets with wheels that are 2.5 m in diameter are manufactured in our production facilities in Poland and Italy. The facility in Poland is equipped with hardening ovens which allow, among other technologies, case carburizing of components up to 2.5 m in diameter and length. Transparent production planning and manufacturing with state-ofthe-art equipment guarantee the fastest and most productive path to high-performance gear systems build by the experts. Design competence Customers in the area of special gears demand a high degree of technical competence at all levels. At FLSmidth MAAG Gear, qualified engineers with many years of experience and expertise are not only responsible for sales consulting but also for drawing up offers and handling projects. Solid engineering competence is combined with real effectiveness in implementing gear solutions; this includes designing with innovative tools. All designs are optimized using state-of-theart design tools and manufacturing machines. Software tools like SOLIDWORKS for 3D modelling; ANSYS for structural analyses and AutoFENA for strength assessment are used to design and optimize components and systems. Standards Known standards, such as ISO 6336 / AGMA 421 / DIN 3991, as well as MAAG Gear standards are applied to size gears and shafts. All gear units run in bearings of many dimensions and designs, such as journal bearings or spherical roller bearings made by well-known brands. Spherical roller bearing durability calculations are based on DIN ISO 281 Standards. Processes at FLSmidth MAAG Gear Regardless of the size of the project, FLSmidth MAAG Gear applies standardized processes for customized developments, and if no detailed customer requirement specifications are available, FLSmidth MAAG Gear works with the customer to analyze data in the plant and its environment. The data that is collected is then passed on to our Technical Department for an initial interpretation and cost calculation. Experienced project engineers deal with the tasks at hand and the fluent communication between our Departments works to ensure that our customers are offered an optimum solution. After agreeing on the technical equipment, requisite quality, delivery dates and investment scope, the Technical Department sets about achieving the agreed-upon goals to the customer s full satisfaction. Quality management FLSmidth MAAG Gear is fully certified in ISO 9001. At FLSmidth MAAG Gear, quality is a goal in all our processes, from sales to customer service, and is not limited only to the production of components. To ensure the absolute precision of our geared components, the latest gear inspection equipment is used at our facilities. Quality plans ensure the traceability of all quality-related documents and certifications. Powergeneration Rubber & Plastic Transport Polymer processing
4 Components (design features) Casings Depending on the design, classical split housings or other designs with a focus on easy maintenance are available. Casings can be made out of ductile cast iron or as manufacture steel constructions. Sturdy constructions ensure high acoustic and dynamic qualities. Shaft seals are designed to resist harsh operating conditions and to protect internal components from contamination. Gears In order to ensure strength, give the teeth the highest wear resistance and allow for compact construction, FLSmidth MAAG Gear uses case-hardened steels only for pinions and wheels. Girth gears are made of quenched and tempered steel. The bevel sets have cyclo-palloid-type gear teeth and the helical stages include all the modifications needed to ensure smooth meshing during operation. Heat treatment and precise teeth machining result in optimal tooth contact under load conditions. This method guarantees optimum tooth flank contact, very long life cycles and, consequently, low noise emissions. Planetary gear stage FLSmidth MAAG Gear has a long tradition in the use of the epicyclical technology. The classical planetary gear train consists in a sun pinion, at least 3 planets and the annulus gear. Planets are mounted on the planet carrier and positioned with shafts (pins). Depending on the size of the gear, the execution of the shaft can vary. Smaller sizes are equipped with shafts made in alloy steel and equipped with spherical roller bearings to support the planet wheels. On larger planetary gears, the entire planetary stage is supported by hydrodynamic sleeve bearings. Both solutions are designed to ensure the best possible positioning of the planet wheels during operations in every load condition.
5 Radial and axial bearings With extensive experience in gears, FLSmidth MAAG Gear has just as much experience in hydrostatic and hydrodynamic radial and axial journal bearings lined with Babbitt metal. The high-quality axial thrust pads, for example, are usually used below the grinding table with the purpose of absorbing static and dynamic loads. Depending on the gear size and loads, these bearings are available as pure hydrodynamic bearings, lubricated by low pressure systems, or as hydrostatic bearings, supported by a high pressure oil circuit. Lubrication systems Depending on the environmental conditions and requirements for the gearbox, lubrication can go from splash lubrication to forced lubrication. The gearbox is designed for natural cooling without the use of a water or air cooler. In other cases with extreme environmental conditions and/or higher power losses, a separate lubrication unit with a tank is required. The main components of the lubrication unit include a low and/ or high pressure pump group, a manually switchable by-pass filter and an oil water cooler, a safety valve, a magnetic filter on the pump suction side and a set of heating cartridges to reduce the startup time. MAAG SPU driving a pump in a petrochemical plant.
6 Industries Cement and minerals Large and high-torque planetary and helical gear units are used in mills in the cement and mineral industry, where operational safety and availability are of the utmost importance. Apart from drive units for mills, FLSmidth MAAG Gear also supplies shaftmounted gears, as well as helical and bevel helical gearboxes for driving a wide variety of conveyors and lifting equipment. Careful design and impeccable assembly work guarantee the durability of FLSmidth MAAG Gear units. (See our brochures for the cement and mineral industry) Food High torques and thrust loads, combined with high cleanliness are typical requests for this industry. For several years now, FLSmidth MAAG Gear has been providing the nutritional industry with unique developments and has worked in close cooperation with specialized OEMs to develop a complete series of split torque gearboxes to drive horizontal twin screw presses to extract bulb from sugar beets. In other cases, we have worked in close cooperation with chocolate manufacturers to develop one-off solutions. Iron and steel industry FLSmidth MAAG Gear offers a range of gears for this industry, such as shaft-mounted gears, and helical and bevel helical gearboxes that comply with conventional industry standards. Special attention has been given to tilting drives or steel mills, created for known industry leaders. Power generation FLSmidth MAAG Gear has developed various speed reducers for a wide variety of power generation applications, such as the single-stage or planetary gears for water turbines or combined WPU-type bevel and planetary gears for coal mills. In the area of power generation, water turbines represent a special case, as the speeds are relatively low and the torques and thrust loads are high. FLSmidth MAAG Gear can supply customized solutions for this special application from its own range of parallel shaft or planetary gears. Polymer processing Typically, high torque applications and the absolute tightness of the equipment (and in some cases, deployment in highly hazardous areas) are typical demands for this industry. Differ-
7 ent small series and one-off solutions have been developed to drive kneaders, calenders or melt pumps for the rubber and plastic industry. Also, for the production of glass and carbon fibre mats, FLSmidth MAAG Gear has been asked to develop a special dual pinion gearbox for the production of the fuselage of one of the newest air craft carriers. Other gearboxes and girth gears are used for mixing and homogenizing semi raw materials in the chemical and pharma industry. Test benches A wide variety of gear units have been developed for test benches for the automotive, aviation and defence industries. When it comes to these gear units, there are practically no limits to what FLSmidth MAAG Gear can do. Other industries and special projects The industries mentioned above are just a few of those that we serve. Others include pulp and paper, transportation, telecommunication, the off shore industry, etc. FLSmidth MAAG Gear is also very enthusiastic about special projects associated with other applications. These projects involve close co-operation between FLSmidth MAAG Gear and its customers. Explosion proof protection (ATEX-HAZLOC) Regardless of whether serial or individual production is involved, FLSmidth MAAG Gear supports its customers in analysing the dangers associated with drive groups. Targeted training for employees in each stage of the process allows FLSmidth MAAG Gear to offer tested and certified solutions. Sugar refinery.
Copyright 2015 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. CM 12-15 500-32-ENG www.flsmidthmaaggear.com C 05-12 500-1-ENGssssssss 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