BOGIFLEX® KGD January 2010
BOGIFLEX® KGD
BOGIFLEX® KGD January 2010
Cement Kiln operation – Influence parameters on Gear Meshing Meshing of the kiln girth gear depends on the thermal t hermal condition of the kiln The 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
BOGIFLEX® KGD January 2010
Cement Kiln – Influence parameters on Gear Meshing Wobbling of Girth Gear • 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 Overloading due to wobbling
Center distance change Lack of tip to root clearance
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD is solving these issues
BOGIFLEX® KGD January 2010
BOGIFLEX – Concept Floating drive + Self aligning principle applied for Gear Meshing = BOGIFLEX 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 ⇒
Spherical plain bearings
Pillow block
BOGIFLEX® KGD January 2010
BOGIFLEX – Contact 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 of gear 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
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle General Design: KGD
cardan ERmaster
1 gearbox ERmaster standard 1 cardan with fixed length 1 BOGIFLEX drive KGD with main pinion 23 teeth 1 Girth gear - in two halves – cast steel
Girth gear
1 Set of tangential plates Y shape with shoes
KILN SHELL
Spring plates
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle General Design: Length of spring plates are adjusted to enable the mounting onto each kind of shell diameter considered with the drive range
Ømin
Ømax
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle 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 required between pinion and girth gear
–
•
Floating on pinion – Relative rotation with pinion Low speed –
•
Contact teeth meshing calculated coefficient always right
Floating fitting
Oil lubrication –
Injection and bath lubrication
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle 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 gear Are not in contact with girth gear at normal kiln driving
•
Grease lubrication for complete life
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle Main Bearings: •
Over designed – –
•
Dimension from pinion dimension, not from loads Standard calculation L10h gives 100’000 hrs minimum
Oil lubrication – Oil injection + splash –
Higher life time
•
Securities on lubricated equipment (flow, pressure)
•
Thermal monitoring of the bearings
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle Reaction Bar Movement possibilities: •
Reaction bar with one shaft on top side and one spherical plain bearing at bottom side
•
Allowing axial and radial displacement of the BOGI-pinion by allowing rotation movements
•
BOGI-pinion casing independent from girth gear casing for self alignment and permanently good positioning onto girth gear
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle Reaction Bar Load distribution: •
•
Reaction arm positioning gives Pushing load effect
FN w/p
Pinion always right positioned onto the Girth gear
FR b/w
RN b/w
FP b/w Pushing effect
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – Range guide line General definition of KGD range: Gear drive depends on kiln torque value and shell diameter.
Power transmitted vs diameter on HOLCIM kilns 13,00
LARGE
12,00 11,00 10,00 9,00
3 areas defined SMALL MEDIUM LARGE Similar design for each size
8,00 s e r t è m a r a p
7,00
MEDIUM
6,00 5,00
SMALL
4,00 3,00
Number of teeth and modules are different
2,00 1,00 -
gamme de fours HOLCIM
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – Range 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 1’000’000 Nm corresponding to 470
[email protected] rpm
– Kiln shell from 4,6 to 5,2 m – KGD Medium • Admissible torque value of 2’200’000 Nm corresponding to 1050kW@4,5 rpm
– Kiln shell from 5,3 to 5,3 m _ KGD Large • Admissible torque value of 4’500’000 Nm corresponding to 2’120 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 – KGD admissible radial
+/- 80 mm +/- 40 mm
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – Complements Lubrication system: Separate Lubrication
ERmaster To Ermaster
1) Girth Gear / pinion + Main pinion bearings
To HD gear set
- Forced lubrication of Girth gear & pinion with adequate lubrication unit - Choice of oil lubricant viscosity depends on teeth working temperature
Low viscosity
- Oil viscosity should be higher than 300 Cst at effective working temperature of teeth meshing
Oil 460 Cst
Unit Tank 600 L Tank 200 L pump
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
High viscosity unit pump Oil 3000 Cst
filter 40 µm
Motor filter 80 µm
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – Complements
Natural frequencies:
– K G D S t a n d a r d Y FORM
B A S IC F O R M
9.6
9.9
Hz
Bending Mode
68.3
Torsion
63.6
Hz
Mode
Hz
70.3
Bending Mode
78.1
Hz
Hz
Hz
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – Complements Main Components: •
Spring plates
•
Girth gear
•
Bogi-pinion KGD
•
Reaction arm
•
Cardan shaft
•
Primary gearbox
•
Baring unit / Inching drive
•
Lubrication unit
•
Housing & Sealing
BOGIFLEX® KGD January 2010
BOGIFLEX® KGD – General Principle 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 monitoring
RELIABILITY 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 January 2010
BOGIFLEX® KGD successful commissioning
Venezuela Ecuador Mexico USA
San Sebastian Plant Holcim Guayaquil Apasco Macuspana* Holcim Devil Slide*
Argentina Slovaquia Azerbaijan
Holcim Capdeville* Holcim Rohoznik Holcim Garadagh
