36 KGD Presentation en APCAC2011

7/28/2019 36 KGD Presentation en APCAC2011

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BOGIFLEX KGD

January 2010

http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD Self Aligning and FloatingKiln Gear Drive


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BOGIFLEX KGD

January 2010


Cement Kiln operationInfluence parameters on Gear Meshing

Meshing of the kiln girth gear depends on the thermal condition of the kilnThe kiln has variable thermal expansion due to condition and type of its refractory and coating

Change in center distance between pinion and kiln axis

Wobbling of girth gear

The sustainability of the meshing of the kiln girth gear is major concern


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BOGIFLEX KGD

January 2010


Cement KilnInfluence parameters on Gear Meshing

Occurs due to variation in kiln operation - uneven coating formation

leading to shell temperature differences and thermal cranks

=> Proper meshing of the teeth no longer assured contact area is

reduced and changing from one side to the other

Wobbling of Girth Gear

Center distance changeLack of tip to root clearance

Overloadingdue to wobbling


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BOGIFLEX KGD

January 2010


BOGIFLEX KGD is solving these issues


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BOGIFLEX KGD

January 2010


BOGIFLEXConcept

Floating drive + Self aligning principle applied for Gear Meshing= BOGIFLEX

Spherical

plain

bearings

Pillow block

Self aligning is achieved because the pinion can move freely

onto the wheel

The rotation shaft of the pinion is free from the rotation shaft of

the wheel

The 2 contacting surfaces or gear meshing between pinion

and girth gear will permanently adapt to each other


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BOGIFLEX KGD

January 2010


BOGIFLEXContact pattern and Advantages

Floating drive + Self aligning principle applied for Gear Meshing= BOGIFLEX

The 2 contacting surfaces or gear meshing between pinion and girth gear will permanently adapt to each

other

The Hertz contact pressure will be uniformized and, therefore, be minimized allong the complete tooth

ofgear meshing. No more stress concentration

Increased life of gear

Coefficient used for Wear and Breakage calculation according in applicable norms (DIN; ISO)

are effectively applied

Safety factor results are corresponding to effective condition of meshing

BOGIFLEX meshing CONVENTIONAL meshing


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BOGIFLEX KGD

January 2010


BOGIFLEX KGDGeneral Principle

General Design:

cardan

KGD

Spring platesKILN SHELL

Girth gear

ERmaster

1 gearbox ERmasterstandard

1 cardan with fixed length

1 BOGIFLEX drive KGD with main pinion 23 teeth

1 Girth gear - in two halves cast steel

1 Set of tangential plates Y shape with shoes


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BOGIFLEX KGD

January 2010



General Design:

max

min

Length of spring plates are adjusted to enable

the mounting onto each kind of shell diameter

considered with the drive range


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BOGIFLEX KGD

January 2010



Pinion rollers: Roll on Girth gear

Adjust permanently the center

distance ; Keep the tip to root

clearance constant

Meshing adjustment not performed

in plant: Workshop machining

Kiln backlash always adjusted

No post adjustment requiredbetween pinion and girth gear

Contact teeth meshing calculated

coefficient always right

Floating on pinion

Relative rotation with pinion

Low speed

Floating fitting

Oil lubrication

Injection and bath lubrication


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BOGIFLEX KGD

January 2010



Inner rollers:

To keep BOGI-Pinion

in position at kiln stop

To enable driving during kiln

backward

Roll on inner track

of the girth gear

Made up with Glicodur

bearings

(standard calculation)

Global clearance with the girth gearAre not in contact with girth gear at

normal kiln driving

Grease lubrication for complete life


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BOGIFLEX KGD

January 2010



Main Bearings:

Over designed

Dimension from pinion

dimension, not from loads

Standard calculation L10h

gives 100000 hrs minimum

Oil lubrication

Oil injection + splash

Higher life time

Securities on lubricated

equipment (flow, pressure)

Thermal monitoring

of the bearings


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BOGIFLEX KGD

January 2010



Reaction BarMovement possibilities:

Reaction bar with one shaft on top side

and one spherical plain bearing at bottom

side

Allowing axial and radial displacement ofthe BOGI-pinion by allowing rotation

movements

BOGI-pinion casing independent from girth

gear casing for self alignment and

permanently good positioning onto girth

gear

OG G


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BOGIFLEX KGD

January 2010

FR b/w

FN w/p

RN b/w

FP b/w

Pushing effect



Reaction BarLoad distribution:

Reaction arm positioning gives

Pushing load effect

Pinion always right positioned onto the

Girth gear

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010


BOGIFLEX KGDRange guide line

General definition of KGD range:Gear drive depends on

kiln torque value and

shell diameter.

3 areas defined

SMALL

MEDIUM

LARGE

Similar design for each size

Number of teeth and

modules are different

Power transmitted vs diameter on HOLCIM kilns

-

1,00

2,00

3,00

4,00

5,00

6,00

7,00

8,00

9,00

10,00

11,00

12,00

13,00

gamme de fours HOLCIM

paramtres

SMALL

MEDIUM

LARGE

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010


BOGIFLEX KGDRange guide line

General definition of KGD range: Technical data for predefined KGD sizes

Kiln shell from 3,8 to 4,6 m KGD Small Admissible torque value of 1000000 Nm corresponding to 470 [email protected] rpm

Kiln shell from 4,6 to 5,2 m KGD Medium Admissible torque value of 2200000 Nm corresponding to 1050kW@4,5 rpm

Kiln shell from 5,3 to 5,3 m _ KGD Large Admissible torque value of 4500000 Nm corresponding to 2120 kW@4,5 rpm

Service factor acc. ISO 6336 Pitting KB > 1.51 ; Breakage KB > 1.75

Kiln axial and radial displacements usually recorded

Kiln Axial +/- 40 mm Kiln Radial displacement + thermal expansion +/- 30 mm

BOGIFLEX KGD capacited in displacements KGD admissible axial +/- 80 mm KGD admissible radial +/- 40 mm

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010


BOGIFLEX KGDComplements

Lubrication system:Separate Lubrication

1) Girth Gear / pinion + Main pinion

bearings

- Forced lubrication of Girth gear &

pinion with adequate lubrication unit

- Choice of oil lubricant viscosity

depends on teeth working temperature

- Oil viscosity should be higher than 300

Cst at effective working temperature of

teeth meshing

2) HD gear set + Ermaster

- Injection lubrication of intermediate

gear set & primary gearbox

- Usual lubricant viscosity grade: ISO

VG 460

3) All gear stages have a safety splash

lubrication with foreseen reservoir

pump

High viscosity unit

Tank 600 L

Tank 200 L

Oil 3000 Cst

Motor filter 80 m

ERmaster

Low viscosity

Unit

Oil 460 Cst

filter 40 m

pump

To HD gear set

To Ermaster

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010


BOGIFLEX KGDComplements Natural frequencies:

BASIC FORM

9.6

Hz

Bending

Mode

9.9

Hz

68.3

Hz

Torsion

Mode

63.6

Hz

70.3

Hz

Bending

Mode

78.1

Hz

Y FORM KGD Standard

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010

Spring plates

Girth gear

Bogi-pinion KGD

Reaction arm

Cardan shaft

Primary gearbox

Baring unit / Inching drive

Lubrication unit

Housing & Sealing


BOGIFLEX KGDComplements

Main Components:

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010



Conclusion: No need of post adjusting of the pinion in front of the girth gear

Bogiflex is not sensitive to thermal expansion conditions

THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING

Optimised meshing and lubrication conditions and High safety factors: Components designed for expected life time

Criticality has been studied ; Criticality reduced by monitoringRELIABILITY INCREASED

Optimized Maintenance:

Maximum number of elements are standard ones

KGD studied in standard range in view of having available a set of pool spare parts in addition

to plant spare parts

Design of KGD has been studied for each part to take care of time required to change it as

short as possible: To shorten shut down time of kiln for maintenance has been taken into

consideration when design

BOGIFLEX KGD


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BOGIFLEX KGD

January 2010

http://www.cmdgears.com539 d C t 59400 C b i FRANCE

BOGIFLEX KGD successful commissioning

Venezuela San Sebastian Plant

Ecuador Holcim Guayaquil

Mexico Apasco Macuspana*

USA Holcim Devil Slide*

Argentina Holcim Capdeville*

Slovaquia Holcim RohoznikAzerbaijan Holcim Garadagh

36 KGD Presentation en APCAC2011

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Transcript of 36 KGD Presentation en APCAC2011