january 2010 bogiflex® kgd · 2011. 12. 6. · – kiln shell from 3,8 to 4,6 m –kgd small •...
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BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGDSelf Aligning and Floating
Kiln Gear Drive
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
Cement Kiln operation – Influence 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
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
Cement Kiln – Influence 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 change
Lack of tip to root clearance
Overloading
due to wobbling
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD is solving these issues
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX – Concept
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
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – General Principle
General Design:
cardan
KGD
Spring platesKILN SHELL
Girth gear
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
1 Set of tangential plates Y shape with shoes
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – General Principle
General Design:
Ømax
Ømin
Length of spring plates are adjusted to enable
the mounting onto each kind of shell diameter
considered with the drive range
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
– Contact teeth meshing calculated
coefficient always right
• Floating on pinion
– Relative rotation with pinion
Low speed
– Floating fitting
• Oil lubrication
– Injection and bath lubrication
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
FR b/w
FN w/p
RN b/w
FP b/w
Pushing effect
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – General Principle
Reaction Bar
Load distribution:
• Reaction arm positioning gives
Pushing load effect
• Pinion always right positioned onto the
Girth gear
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – Range 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
para
mètr
es
SMALL
MEDIUM
LARGE
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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 +/- 80 mm– KGD admissible radial +/- 40 mm
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – Complements
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 µm
ERmaster
Low viscosity
Unit
Oil 460 Cst
filter 40 µm
pump
To HD gear set
To Ermaster
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – Complements 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
January 2010
• Spring plates
• Girth gear
• Bogi-pinion KGD
• Reaction arm
• Cardan shaft
• Primary gearbox
• Baring unit / Inching drive
• Lubrication unit
• Housing & Sealing
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD – Complements
Main Components:
BOGIFLEX® KGD
January 2010
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
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
http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD successful commissioning
Venezuela San Sebastian Plant
Ecuador Holcim Guayaquil
Mexico Apasco Macuspana*
USA Holcim Devil Slide*
Argentina Holcim Capdeville*
Slovaquia Holcim Rohoznik
Azerbaijan Holcim Garadagh