Professional Documents
Culture Documents
Central or Girth Gear Drive For Ball Mills - 1
Central or Girth Gear Drive For Ball Mills - 1
Introduction .
For medium and high capacity cement mills particularly, this question presents itself
to the cement manufacturer again and again.
Alongside the purely economic considerations it is often necessary to also view the
situation deriving from the competitive strenght of the mill builder.
Drive system
Girth gear drive and central drive a r e mechanical systems designed t o reduce the motor
speed to the working speed of the mill. Transmission i s via gears.
Certainly the gear tooth design is probably the most important item. But the pos-
ition of the plant shafts a s governed by the housing design, the kind of connection
between the rotating parts, and the monitoring of the operating conditions a r e of
no mean significance.
Power transmission by the rotating parts can only take place flawlessly if these
a r e held in optimum position by the housing during operation. An inadequate hous-
ing jeopardizes the safety factor of the gearing. The latter is calculated to recog-
nized formulae, and is referred exclusively to the gear teeth.
The plant engineer, on the other hand, must judge the drive system a s a whole.
The difficulty lies in taking all influential factors into account and weighing them
in correct proportion in the overall safety assessment.
Strict difference is to be made between well known factors of influence, and such
others a s a r e discernible in their effect only, but of which the magnitudes a r e
indefinable.
Modern g e a r p a r t s do not wear
k
In contrast to other still widespread contentions, modern engineering can produce
g e a r s and install them in mill drive units such that they a r e not t o be regarded as
wearing parts. But it is essential t o c a s e harden the tooth flanks and grind them
with the appropriate flank oorrections, and a s s u r e that the suitable conditions a r e
attained f o r assembly and operation. Such conditions a r c attained ideally with the
centraI drive planetary gear.
With a girth g e a r drive, on the other hand, these conditions cannot be realized to
a comparable extent.
Then the significance of the efficiency and energy requirements should be revealed.
Example :
Ball mill 9000 H P
Motor speed 990 rpm
Mill speed 14 rpm
R/L ill diameter 5m
Mill bearing 22 m
Project A Project B
-------
-------- ----
------
Two-pinion girth gear drive Fig. 2A Central drive Fig. 2B
1 Annulus, 2 pinions 1 Double planetary gear
2 Reducing gears, each 2-stage 1 Main motor
2 Main motors 1 Turning gear
2 Turning gears
I.
-- SAFETY
--=-
SYSTEM
5. Separate mill
A: Damage to mill cylinder, neck or stub endanger girth gear and pinion.
Repairs entail extra work for girth gear dismantling.
B: Damage to mill cylinder cannot endanger gear teeth. Mill repairs do not
entail gear dismantling.
KAANUFAC T U RE
Pitch e r r o r a t the joints, Fig. 6, causes knocking in the drive train, vibration
and slaclrening of nuts. Tooth bearing contact degenerates and wear increases.
Axial run-out of the teeth around the girth g e a r is frequently the result of de-
formed joint s u r f a c e s of the girth g e a r halves and axial run-out of the girth gear
location surfaces.
Figure 7 :
Machining errors on the w i l l flange.
Run-out e r r o r X on g i r t h g e a r mounting.
INSTA LLA TION
---
Figure 8:
Girth gear deviation a) to f ) during different running conditions.
INSTA LLATION
Figure 8:
G i r t h gear deviation a) to f) during different running conditions.
Some remaining uncertainly is hardly to be avoided.
The exact alignment of two drive units is furthermore a laborious busi-
ness.
Inadequate tooth contact means r i s k of wear.
B: Aligning and re-aligning of the charged mill gives little trouble. There
can be no detrimental effect on the gear teeth.
Table I to Fig. 8:
I Condition
I deviation
Vertical deviation
Radial run-out
1 a) Empty mill
cold
c) Charged mill at
Axial run-out Vertical posit ion X 2
operating tempe-
rature
Y2 Radial run-out D I - D
d) Start - up after
Radial run-out X 3
shift stop Wobble Y 3
Balls warm Radial run-out D 3 - D 2
i
B: Gear teeth not hazarded, even if the mill is not turned at intervals.
If t h e t w o d r i v e s y s t e m s a r e d e s i g n e d w i t h t h e s a m e s a f e t y
f a c t o r s t o r e c o g n i z e d f o r m u l a e , t h e e f f e c t i v e s a f e t y in t h e
two s y s t e m s n e v e r t h e l e s s differ widely. With the g i r t h gea
d r i v e , Fig. 10 and ZA, the numerically non-definable facto
of i n f l u e n c e a r e n u m e r o u s , w h e r e a s w i t h t h e p l a n e t a r y g e a l
drive, Fig. 11 a n d 2 B , t h e y a r e n e g l i g a b l e f e w .
A realistic, c o m p a r a b l e s a f e t y f a c t o r c a l c u l a t i o n i s not
p o s s i b l e i n t h e c a s e of s y s t e m A .
Figure 11:
Cement mill with MAAG Heavy-Duty Planetary g e a r , Type P2U3-70/110 for max.
input power of 6500 HP a t 985/14 RPNl.
Efficiency
A) Energy losses :
Note:
- With the energy loss difference, 1 mill of 6 . 4 blW and 26.3 kWh/t (2700~ r n ~ / ~ )
2 million Sfr. can be covered, assumiug an interest of 7%.
- The significance of the safety factor becomes manifest in the form of production
loss in the event of a mill stoppage.
t
months in tons
--
(at 8 . Fr. 80. per t)
in S. F r .
1 135'000 11 Mio.
6 810'000 66 Mio.
Depending on the overall quality, the girth gear drive system can be priced
at 5 - 20% less than the planetary central drive.
If the spare parts a r e included and an equivalent manufacturing quality is
assumed, the difference in investment costs is usually about 6% (see also
lecture by Herrn TiggesbSiurnker ZKG 8/1974).
Usually the overall costs can be divided into three partially overlapping groups,
Fig. 12
- Initial capital expenditure
- Spare parts costs
- Cumulative costs throughout a number of years of service.
-
0
1 4
I I ,
I
1
O 140- 0 140.-
t
.-C ma ntenance,
C
.-ln I r maintenance
ln +.' L
I I
C1
8 120-- A 8 120--
11
I
1
i 100 7
0 5 W
1
4
15 0 5 K)
L spare parts
15
-years--, -years-+
Figure 12:
Total costs f o r operation (energy, maintenance, spare parts) in function of the
operating gears ; based on 8000 h p e r year and S. F r s . 0.09 p e r kwh.
It would appear most obvious to make decision chiefly on the basis of the cumu-
lative costs, Fig. 12, which also includes energy consumption. For various
reasons this is very often not the case.
The primary factor for judgement of the various proposals is often the initial
purchasing price alone.
Whilst the cement manufacturer wisheta to make the utmost use of his available
resources, the plant builders prime aim is sales.
If, on the purchasing slde, there a r e more o r less independent temas for plan-
ning and purchasing on the one hand, and for lator operation on the other hand,
an overhead team should keep a healthy balance between the two spheres. This
team must doubtless base its decisions on the cumulative oosts over a certain
period of service. The entities "safety" and lleconomyHa r e to play a realistic
part in the considerations.
B o t t o m p r i c e s a t t a i n e d b y c l e v e r m a n i p u l a t i o n on t h e p a r t
of t h e b u y e r c a n d e v e l o p i n t o a n e x p e n s i v e m a t t e r w i t h t h e
p a s s i n g of t h e y e a r s .
Spare parts costs and the cumulative costs of say 10 years are often not men-
tioned until a seoond transactton phase begins after signing of contract. Above
all, under the influence of an inexpensive purchase, the running costs a r e
quitely transferred to the later finite running costs calculations. In reality it
is beyond all doubt that production r e ~ u l t sa r e painfully dependent on the
quality oi the plant. This above all, in those oases where there is no surplus
of manufacturing energy, and where skilled labour ia expensive.
Bibliography
2) Ackle, W.:
-
Heavy Duty Planetary Gears for Driving Large Ball Mills.
Zement-Kalk-Gips 22 (1969) 125
3) Ackle, W. :
Economical Dr tve System for Large Ball Mills with Heavy-Duty Planetary
Gears
Zement-Kalk-Gips 1 (1975)43