SPECIAL GEAR ENGINEERING STEEL AND ALUMINIUM INDUSTRY

EISENBEISSLEADING THE WAY IN SPECIAL GEAR ENGINEERING FOR THE MARKETS OF THE WORLD.

EFFICIENTRELIABLEINNOVATIVE GEAR SOLUTIONS

EISENBEISS OFFERS THE BETTER GEAR SOLUTIONS FOR THE STEEL AND ALUMINIUM INDUSTRY.

More efficientThanks to collaboration directly on site with globally operating steel and aluminium works we know the plants and processes and can thus develop optimum gear solutions. Investment costs are one aspect, low costs throughout the entire product lifetime, however, are more important.

More reliable Extreme impacts and load fluctuations together with long-term and also short-term operation place special requirements on a gearbox. Housings made of steel and special design criteria ensure that our gears run smoothly far beyond the warranty period.

More innovativeRealising faster plant speeds, greater rolling precision and higher plant availability means to us innovative solutions, starting with toothing right up to offering electronic gear management.

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OUR DRIVE. YOUR SUCCESS.

A manufacturer of special gear systems concentrating on segments of the steel and metals industry, Eisenbeiss is a family-run business with a flat hierarchy and fast decision- making processes and strong customer focus. The efficient scale of the company allows constant further development, internationalisation and innovation.

On the following pages you will find a selection of gear units designed for highly specialised applications in the steel and aluminium industry. For Eisenbeiss, specialisation is the sign of true problem solving. Not only do products and services meet requirements exactly, they also offer a high degree of operational stability, reliability and a long service life.

Quality and precision always have been and always will be the basis of our company philosophy. As a producer of special gear systems, process-oriented fabrication (from planning to after-sales service) is the foundation for speed and flexibility.

We consider a modern machinery park and investments in future-oriented technologies to be absolutely essential in strengthening our own competitiveness.

CONTENT

P. 6-7 Steelworks

P. 8-9 Cranes

P. 10-11 Continuous casting

P. 12-13 Hot rolling mill

P. 14-15 Cold rolling mill

P. 16-17 Strip processing

P. 18-19 Tension levellers

P. 20 Getriebeservice

P. 21-23 GearControl

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Winch drives for oxygen lances are a particularly demanding gear application. In oxygen metallurgy the water-cooled lances are inserted directly into the converter and have to be removed again once the process is complete.

TWICE AS SAFE.

Grafik: Quelle [FVA]

STEELWORKS

WINCH GEARS This case of application calls for absolute reliability in emergency situations. To ensure this there is also an emergency drive possibility besides the main drive which can be linked via a planetary gear.

TECHNICAL DATA:

Gear torque: 30-150 kNmMain drive: i=30-100Auxiliary drive: i=120-500

STEELWORKS WINCH GEARS:HIGH OPERATIONAL STABILITY IN EMERGENCY OPERATION VIA TWO DRIVE SYSTEMS WHICH ARE INDE-PENDENT OF EACH OTHER.

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MAJOR EXPORT SUCCESSES THANKS TO DECADES OF EXPERIENCE AND KNOW-HOW.

TRAVELLING UNITThe design is either as a vertical standing foot-mount-ed or 3-point suspension gearbox. A series developed specifically for this purpose meets the special oper-ating requirements such as frequent acceleration and slowing down, plus reversing. The toothing is optimised to the static strength which is crucial for wheel slip. This results in smaller and, at the same time, more reliable gears for our customers for this application.

LIFTING MECHANISMWith these gears attention is paid above all to weight optimisation and a narrow design. Eisenbeiss gears have minimal power loss thanks to special efficiency optimi-sations. As a result of this, there is only negligible tem-perature increase and no additional cooling is necessary even in the case of high output.

LIFTING MECHANISM WITH 2 DRIVESEisenbeiss uses superimposed planetary gear systems to help realise two-motor drives for full or half lifting speed. Thanks to this drive redundancy the lifting gear remains operational even if one motor fails.

CRANES

We have the specific know-how in the development, fabrication and supply of special gear systems for cranes in the steel and aluminium industry.

TATA STEEL, the world's fifth largest steel producer, decided to use Eisenbeiss hoist gear systems for the 500 tonne casting cranes at their new steelworks in Orissa. A major export success for Eisenbeiss.

LIFTING MECHANISM TRAVELLING UNIT

TECHNICAL DATA:

Torque: 5-35 kNmWheel slip torque: 15-110 kNmTransmission ratio: 12.5-110

TECHNICAL DATA:

Torque: 30-1,000 kNmTransmission ratio: 20-350

TECHNICAL DATA:

Torque: 100-1,000 kNmTransmission ratio: two motors: 50-100 one motor: 100-200

Suitable for heavy loads Maximum tooth foot safety

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STABILITY AND RELIABILITY WITHOUT IFS AND BUTS!

CONTINUOUS CASTING

LADLE TURRETThe particularly robust design with a separate superimposed drive ensures optimum operational stability even in emergency situations such as power cuts, for example. Additionally the gear features inte-grated protection against shock loads through impre-cise positioning. A modular system enables the rapid realisation of a variety of sizes depending on ladle weight and with various drive forms (electric, pneumatic, hydraulic).

CONTINUOUS CASTING DRIVER Temperatures up to 160°C and large amounts of cooling water, dust and strong vibrations represent extreme challenges. These requirements are met through an integrated cooling system and a special seal. The internal lubrication is handled by pumps built especially for this purpose which can withstand these tough conditions and the extreme fluctuations in temperature.

LADLE TURRET

CONTINUOUS CASTING DRIVER

TRANSPORT SYSTEMS

TECHNICAL DATA:

Torque: 15-140 kNmGear: main motor approx. 1 rpm auxiliary motor approx. 0.5 rpm

TECHNICAL DATA:

Torque: 10-125 kNmTransmission ratio: 200-1,350

TRANSPORT SYSTEMSThese gear solutions stand out through their compact design and high performance. Special seals are used to protect against the high amounts of scale and ensure the gear does not develop leaks as a result of contami-nation. Even the configuration of the toothing geometry takes into account this high-impact operation.

TECHNICAL DATA:

Torque: 10-800 kNmTransmission ratio: 5-355

LADLE TURRET:OPERATIONAL STABILITY DESPITE EXTREME IMPACTS.

CONTINUOUS CASTING DRIVER:TIGHT EVEN IN EXTREME HEAT.

Gears for cross and longitudinal motion

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PINION GEAR

FINE ROLLING MILL

PLANT AVAILABILITY AROUND THE CLOCK.

HOT ROLLING MILL

FINE ROLLING MILLSSpecial applications call for special solutions. In this case the big challenge is the power distribution to three rolls which are far apart from each other. Conical toothing developed especially for such applications make it possible to use a compact, space-saving gearbox.

TECHNICAL DATA:

Torque: 20-180 kNmTransmission ratio: 2-12

PINION GEARSThe horizontal and vertical drives of wire and profile lines are subject to a number of highly specific requirements. The ambient conditions, for example, are more than harsh. This ranges from the cooling water that flows over the gear to the extreme amounts of dust and scale that occur. These conditions have been accounted for down to the very last detail in an Eisenbeiss gear programme developed especially for this purpose.

Complete technical data and gear specification sheets help your development engineers to find the right gear fast for it to be planned for use in your plant. Thanks to these existing concepts we are able to offer you fast delivery times and, following on from this, rapid implementation of your project.

TECHNICAL DATA:

Torque: 20-1,500 kNmTransmission ratio: 2.5-400

PINION GEARS:HIGH RELIABILITY DESPITE HARSH CONDITIONS.

FINE ROLLING MILLS:COMPACT AND HIGH-PERFORMING.

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FAST AND SMOOTHLY RUNNING NEVERTHELESS.

COLD ROLLING MILL

TWIN-DRIVE MILL STAND GEARSModern calculation methods for toothing and shafts, combined with state-of-the-art processing machines for corrected toothing, enable short work roll gaps. In connection with the high strength of the casing and low-vibration design of the bevel gears, rolling flaw-less strip is secured.

TECHNICAL DATA:

Power: 400-6,000 kWTransmission ratio: 1-20

SINGLE-DRIVE MILL STAND GEARSOur single-drive gears stand out through their compact horizontal or vertical designs. The high power density of the double helical gearing enables the transmission of up to 6 MW with pinion distances of only 400 mm in parts. The use of open-die forging shafts means that no shaft/hub collar connection is required in the gear unit. No feather key can be squashed and no gear shaft connection can be damaged even in the event of the strip tearing.

Thanks to the additional use of proprietary brand bearings with solid cages we are able to supply long-lasting, robust stand drives for tandem mills or reversing mills up to a service life of 100,000 hours.

Thanks to ultramodern methods Eisenbeiss can calculate the mass inertia and natural frequencies of components early on in the design phase and, as a result, optimise complex drive systems with regard to vibration behaviour.

TECHNICAL DATA:

Power: 400-6,000 kWTransmission ratio: 1-20

TWIN-DRIVESINGLE-DRIVE

SINGLE-DRIVE GEARS:NO MARKS IN THE METAL THANKS TO EXTREMELY SMOOTH RUNNING.

TWIN-DRIVE GEARS:FOR MAXIMUM SHEET METAL STRENGTHS DUE TO SMALL AXIS DISTANCES.

Robust thanks to simple designTransmissions for new opportunities the rolling process

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ALL GEARS FROM A SINGLE SOURCE.

STRIP PROCESSING

BRIDLE ROLL DRIVEThanks to optimised toothing, bearing assembly and lubri-cation, power loss with this application is reduced by about 30% compared to conventional solutions.Not only are energy costs reduced as a result but in almost all cases no additional cooling is required. This in turn re-duces service work to an absolute minimum. The gearboxes remain straightforward and stable in operation. Combined with the built-in quality brand bearings, this gives our cus-tomers a high level of plant availability.

TECHNICAL DATA:

Torque: 5-280 kNmTransmission ratio: 3.5-315

TECHNICAL DATA:

Torque: 80-280 kNmTransmission ratio: 90-350

ACCUMULATOR WINCHThis application stands out through high stress while in a stationary state which is why these units are designed to withstand high static loads. The result is specially developed toothing in connection with a spe-cial type of immersion lubrication system. This means that sizes smaller than comparable standard gears can be realised, saving both time and money.

Eisenbeiss industrial gearboxes for strip processing lines stand out in particular due to the high robustness and strength of the welded housing and a compact design which is realised through load-optimised toothing design.

ACCUMULATOR WINCH

BRIDLE ROLL DRIVE

BRIDLE ROLL DRIVE:NO ADDITIONAL COOLING THANKS TO OUTSTANDING EFFICIENCY.

Compact and cost-effective

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QUALITY IS ON THE LEVEL.

TENSION LEVELLERS

LEVELLING MACHINESSophisticated distribution systems combined with ex-pert plant knowledge about the development of torque in the levelling process enable us to produce gears with a typical 4 to 17 output shafts.

High toothing quality with the possibility of a wide range of corrections, plus modern calculation pro-cesses, are the basis for extremely small drive shaft distances with a long bearing service life up to 50,000 hours.

TECHNICAL DATA:

Motor rating: to 500 kWShaft space: 80-300 mm

LEVELLING MACHINESMaximum torque with minimum centre distance

TENSION LEVELLER DRIVE SYSTEMSOur tension leveller drive systems stand out through top energy efficiency with control accuracy that is up to 20 times higher. This is realised with the help of a mechanical tension system based on superim-posed planetary gears. The mechanical power rating required is reduced by more than 80% through the mechanical interlocking of the drive and brake rollers.

An additional degree of freedom for control means that varying roll diameters are no longer an issue. As a result, this Eisenbeiss gear solution reduces the operating costs of the entire system.

TECHNICAL DATA:

Roll torque: 30-300 kNmStrip speed: max. 90-350 m/min

LEVELLING MACHINES:CORRECTED TOOTHING FOR NARROW CENTRE DIS-TANCES ON SMALL ROLLS.

TENSION LEVELLER DRIVE SYSTEMS:HIGH CONTROL PRECISION FOR ULTRATHIN STRIP.

TENSION LEVELLER DRIVE SYSTEMSComplex drive solutions for exact strip processing

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Eisenbeiss is committed to a forward-thinking approach and not only addresses the market requirements of its customers, it also anticipates them early enough. This has enabled Eisenbeiss to become an acknowledged specialist in gearbox engineering.

The company's own gear service centre repairs and services not only its own products but also 80% non-Eisenbeiss products. At this service centre in Enns, Austria, Eisenbeiss has modern technical equipment at its disposal with a broad range of fabrication possibilities and is able to carry out professional repairs and overhauls of the highest standard in the shortest possible time.

24-HOUR SERVICE – SO EVERYTHING GETS MOVING AGAIN QUICKLY.

GEAR SERVICE

Maintenance work, inspections, service and the removal of any weak points are handled on site at the customer's plant by a rapid deploy-ment team. Diagnosis processes (including vibration measurements, Gearoscopy®/endos-copy) and, wherever possible, any necessary repairs are likewise carried out on site.

Rapid response times prevent lengthy business interruptions.

24h hotline: +43 7223 896-120

One system for many fields of application with sustainable and enormous economical benefits. All eyes are on Industry 4.0 which is associated with the modernisation of plants with new types of supervision possibilities and clear recommendations for action. Cost-efficiency benefits (replacing parts at the right time) and also plant availability (making downtime plannable) are key aspects and considerations in our product development. There are use cases and requirements in virtually every branch of industry where plants and machines with gears are permanently in use without staff.And this always requires more or less 100 per cent plant availability, of course. What does this mean in practice?Service technicians think and act with a view to preventive maintenance, i.e. situations which could occur but should not occur under any circumstances.

Many power stations, plants, cranes or also cable cars in the steel industry can often be operated only "remotely" or, due to environmental conditions and criteria, cannot be accessed, let alone be inspected on the inside of the gearbox – and even if this is possible, there is seldom much to be seen as the oil supply or the parts which come into contact with the lubricant do not allow you to identify damage.

i:GEAR 4.0® from Eisenbeiss is ideal for precisely these places where gearboxes are in use.

i:GEAR 4.0® = EISENBEISS GEAR + GEARCONTROL

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Gear condition and recommended action now also via tablet or smartphone.

i:GEAR 4.0® GEAR MANAGEMENT

Everything from a single sourceYour gear system and supervision from a single source. Our competent experts are at your disposal around the clock.

Know-howTake advantage of the up-to-date know-how concerning condition monitoring and perfective servicing every time.

Service life maximisationThanks to the constant evaluation of the load-carrying capacity of the lubrication film and operating conditions you can directly influence the service life of your components and maximise it.

Withi:GEAR4.0®analarmisgivenautomatically in critical situations and you can avoid routine checks.

Thisenablesyoutospendmoretimeonyourkeytasks(youreconomicalandinnovativeproductionprocesses).

THE GLOBAL INNOVATION IN THE INDUSTRY 4.0

EISENBEISS IS THE FIRST GEAR MANUFACTURER IN THE WORLD TO COMBINE INDUSTRIAL GEARS WITH A COMPREHENSIVE GEAR SUPPORT SYSTEM.

EISENBEISS OFFERS DRIVE SOLUTIONS AND SUPERVISION FROM A SINGLE SOURCE – A GLOBAL FIRST!

EVOLUTION OR REVOLUTION?

GEARCONTROL

THE DIRECT CONTACTTel.:+437223896-737Email:gearcontrol@eisenbeiss.com

❚ AVOID GEAR DAMAGE ❚ EXTEND MAINTENANCE INTERVALS ❚ MAXIMISE OPERATIONAL RELIABILITY ❚ PLAN DOWNTIME

Gears are the most efficient and thus the most cost-effective transmitter of speed and torque. Gears have just one short- coming: bearings and toothing have to be lubricated and require maintenance as a result. The electrification gives the gear a further boost in terms of reliability by means of sensor technology.

By linking gears with intelligent systems you can determine gear status at any time and prevent damage in a proactive way. This also makes gear systems the safest link in the power train even in the toughest of applications. Expensive (gear) substi-tution solutions such as high-pole motors or generators lose their significance as a result of this revolutionary and convinc-ing development.

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