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Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 1 Drive Arrangement Main Motor Hydraulic Coupling Auxiliary Drive Main Gear Unit (Shaft Mounted) Shrink Disc Freewheeler Back Stop Swing Base Slide 2 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 2 Drive Arrangement MC-Series Backstop Freewheeler Adapter Flange Inductive Sensor Auxiliary Drive LSS (Solid or Hollow Shaft) Slide 3 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 3 Drive Arrangement M-Series Auxiliary Drive Adapter Flange Freewheeler Backstop LSS (Solid or Hollow) Foot Mount or Torque Arm HSS (Cooling Fan Optional) Double Lip Seals with Grease Nipple or Au-Taconite Seals Slide 4 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 4 Selection Criteria Main Gearbox Usually a 3-stage bevel-helical gearbox Ratio between 28:1 to 63:1 Fs > 1.5 against Pk1 Selection of cooling fan depends on environment (not for dusty environment) Selection of oil cooler depends on availability of water Backstop optional but often required Auxiliary drive optional but often required Slide 5 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 5 Selection Criteria HSS and LSS Connections HSS connections:- Flexible coupling, gear coupling, hydraulic coupling, etc Solid LSS connections:- Gear coupling, rigid coupling, pin coupling, etc Hollow LSS connections:- Key way or shrink disc Slide 6 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 6 Selection Criteria Oil Seals Regreasable dust protection cover For dirty and dusty environments Dirt will bind onto grease Regreasing interval: 3 - 4 months (To purge dirty grease) Rotate shaft when regreasing (i) Double Lip Seals with Grease Nipple Slide 7 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 7 Selection Criteria Oil Seals (ii) Radial Grease Labyrinth Seal (Australian Taconite Seal) Rotating cover with grease labyrinth For environments with abrasive particles Dirt trapped by grease labyrinth Regreasing interval: 3 - 4 months (To purge dirty grease) Rotate shaft when regreasing Slide 8 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 8 Auxiliary Drive Used to rotate bucket elevator at slow speed (during maintenance or problem) Also called Inching Drive, Maintenance Drive or Sunday Drive SEW-Eurodrive KF unit or SF unit Freewheel coupling or manual clutch isolates gearmotor when main motor is running 2 modes of operation: (a) Maintenance Drive (MD) (b) Operation Under Load (OUL) Slide 9 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 9 Auxiliary Drive Auxiliary drive connected to second shaft (for right angle units) Inductive sensor used to detect failure of freewheel coupling (connected to control panel) Failure of freewheeler is catastrophic!!! - n1 = 1500 rpm, bevel ratio = 3:1 - gear motor ratio = 40 : 1 KF motor speed = 1500 / 3 x 40 = 20 000 rpm !!! SEW Gearmotor (KF or SF unit) Adapter Flange Inductive SensorFreewheeler Slide 10 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 10 Auxiliary Drive - Mode of Operation (a) Maintenance Drive (MD) Used only when buckets are empty (for maintenance purpose only) SEW KF type used Inching torque (at LSS) = 40 to 45% of normal running torque (Mk2) Inching speed (at LSS) = 2 to 5 rpm Gearmotor ratio = 20:1 to 90:1 Slide 11 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 11 Auxiliary Drive - Mode of Operation (b) Operation Under Load (OUL) Used when the buckets are loaded SEW SF or KF type (with brakemotor) Inching torque (at LSS) = 90 to 100% of normal running torque (Mk2) Inching speed (at LSS) = 2 to 5 rpm SF gearmotor ratio = 20:1 to 63:1 KF gearmotor ratio = 20:1 to 90:1 Worm gear more resistant to shock loads and peak loads Slide 12 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 12 Application Examples Typical Arrangement Bevel-helical main gear unit Main motor HSS coupling Coupling guard Backstop Freewheeler Auxiliary drive Solid LSS Slide 13 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 13 Application Examples Bevel-helical main gear unit (M3RHF50) Main motor Hydraulic coupling Backstop Freewheeler Auxiliary drive (KF67 DT100L4) Shrink disk Swing base Typical Arrangement Slide 14 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 14 Application Examples Typical Arrangement - Dual Drive Backstop Arrangement:- 1 backstop on 1 gear unit (Dimensioned for 100% holding load) 2 backstops on 2 gear units (Each backstop dimensioned for 100% holding load. Total holdback capacity = 200%) Slide 15 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 15 Application Examples Atypical Arrangement Helical main gear unit (3C250N) Main motor Hydraulic coupling Manual clutch (Rotex SD 55) Auxiliary drive (R82 DM100S4) Solid LSS Base plate Slide 16 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 16 Application Examples Atypical Arrangement Helical main gear unit (M3PSF60) Main motor Hydraulic coupling Manual clutch (Rotex SD 75) Auxiliary drive (K87 DM132S4) Solid LSS Base plate Slide 17 Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services Driving the worldCCW 27 May 2003 Bucket Elevator Drives II 17