Topich6hhGeneralhPlanthEquipment

CoursehLBh6.5hhDrivehTechnology

VDZhOnlinehCourses // Cement
Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de/en

Issued: 6th March 2015

Contents
1 Introduction....................................................................................................... 1
2 Basics of Electric Drives ................................................................................... 1
2.1 Three-Phase Low-Voltage Motors ...................................................................... 1
2.2 Three-Phase High-Voltage Motors ..................................................................... 3
2.3 Variable Speed Drives......................................................................................... 4

3 Fields of Application of Electric Drives .......................................................... 5

3.1 Tube Mill Drive .................................................................................................. 6
3.2 Vertical Roller Mill Drive ................................................................................... 8
3.3 High-Pressure Roller Mill Drive......................................................................... 9
3.4 Rotary Kiln Drive ............................................................................................... 9
3.5 Drive Motors for Fans......................................................................................... 10
3.6 Crusher Drives .................................................................................................... 11
4 Special Drive Designs ....................................................................................... 12
i
5 Electro-Hydraulic Drives ................................................................................. 13
5.1 Rotary Kiln Drives.............................................................................................. 14
5.2 Reciprocating Grate Drive of Clinker Coolers ................................................... 16

6 Health and Safety Practices ............................................................................. 17

7 Operation and Quality ..................................................................................... 18

8 Environmental Protection ................................................................................ 18

9 Maintenance and Inspection............................................................................ 18

10 Questions on Course LB 6.5 Drive Technology........................................... 19

Solutions............................................................................................................................... 21
Glossary ............................................................................................................................... 23

Index..................................................................................................................................... 25

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1 Introduction

Modern drive technology is one of the basic elements of almost all production processes.
This is particularly true of the cement production process, where a number of individual
processes (e.g. comminution, burning and comminution) are carried out in succession.
These individual steps are generally carried out in different locations, so conveying equip-
ment is used to connect them. All these components require electric drives.
This course will give an overview of the basic structure and operating principle of drives
and will also discuss the most important types of drive.

Course Summary

2 Basics of Electric Drives

An electric motor is an electro-mechanical converter that converts electricity into me-
chanical energy. The force exerted by a magnetic field on a live conductor (coil) is
1
converted into movement.
The following units will discuss the properties of different types of motor that play an
important part in the cement production process as electric drives

2.1 Three-Phase Low-Voltage Motors

Three-phase low-voltage motors are internationally standardized drives that are built
with power ratings of up to 500 kW. They are connected to the low-voltage power supply
(400 V, 500 V or 690 V) and may operate in one or both directions of rotation.
The main dimensions, design and power levels of the motor meet the requirements of the Standard
IEC standard. These motors are surface-cooled, completely enclosed and splash-proof
(IP44 or IP54 type of protection).
The most commonly used motor design is the three-phase squirrel-cage motor. Fig. Squirrel-CageMotor
2.1-1 shows an example of a motor of this type. Three-phase squirrel-cage motors are
characterized, in particular, by the following features:
surface-cooling by self-ventilation
low-maintenance
low wear
low procurement costs
If smooth, low-impact starting of the working machine is particularly important then a SlipringMotor
low-voltage slipring motor is used (Fig. 2.1-2). Instead of the short-circuited squirrel-
cage winding in a three-phase squirrel-cage motor, a winding is provided where the three
conductor ends are taken to an adjustable resistor starter via sliprings attached to the
rotor and carbon brushes located on the stator. The starting current and therefore the
starting torque can be limited by changing the resistance of this resistor.
Features of the Slipring Motor:
low-impact or impact-free starting of the machine
limitation of network loading
successful control of difficult start-up conditions (high starting torque, high electrical
inertia)
higher maintenance costs for servicing of carbon brushes
slipring wear

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 2 Basics of Electric Drives

Figure 2.1-1: Three-Phase Squirrel-Cage Motor .

Y W Z U X V stator winding terminals

stator windings

rotor windings

sliprings on the rotor shaft

brushes

u v w rotor winding terminals

Figure 2.1-2: Three-Phase Slipring Motor .

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 2.2 Three-Phase High-Voltage Motors

resistor starter maintenance

greater circuit and control system complexity
Fig. 2.1-3 shows the rotational speeds and torques of a drive in the start-up and operating
ranges.
M 300 %

R=R
MN

R=

2
R

2R
=
R

3R

2
=
200 %

R
R

2
=
=

R2
R

5
7

R
=
9 R2

2
R2

100 %

n
0%
n
25 % 50 % 75 % 100 % N 3
Figure 2.1-3: Characteristic Speed/Torque Curves at Different Levels of Resistance in the Rotor Circuit
.

The torque curve is plotted against rotational speed, based in each case on rated values. At
the rated speed (i.e. nnN = 100%), the torque falls to zero. The figure shows a group of
curves produced by changing the external resistance R. In this instance R2 is the resistance
of the rotor winding. When the external resistance is increased the maximum achievable
torque (breakdown torque) shifts in the direction of lower rotational speed. For example,
at R = R2 (i.e. the external resistance is equal to the resistance of the rotor winding) the
maximum torque occurs at more than 75 % of the rated speed. If the external resistance is
doubled to R = 2R2, the maximum torque occurs at less than 75% of the rated speed.

2.2 Three-Phase High-Voltage Motors

The selection of motor voltage for high-voltage motors depends on the structure of the
power network in the cement works. Voltages of 6 kV and 10 kV are normal. Voltages of
2.4 kV, 3 kV and 5 kV may also be found in older plants. Advantages of the use of high-
voltage motors include:
low motor losses
low network costs (lower transformer power)
lower network losses
lower cable costs.
However, the higher investment costs of high-voltage motors also have to be taken into
account.
High-voltage motors are used in the following drives in particular: Use
 crusher systems
 cement or raw meal grinding systems
 large fans
 large compressors
Three-phase motors (Fig. 2.2-1) are largely used to control the required start-up conditions,
such as torque, impact loading and starting current. If the network conditions and machin-

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 2 Basics of Electric Drives

ery allow the drive motor to be started up directly, a three-phase squirrel-cage motor may
also be used in a power range from 200 kW to 800 kW.

Figure 2.2-1: High-Voltage Motor .

2.3 Variable Speed Drives

One of the requirements of an optimal, energy-saving and automated process is that some
of the drives should have variable speeds. Variable-speed drives are now designed as
converter drives. The table below (Fig. 2.3-1) gives an overview of the different drive
systems used in cement works. A distinction is made between two groups:
1 Group I: converter DC drives
2 Group II: converter three-phase drives
DCDrive For a long time the DC drive was the standard solution for variable speeds. However, it
has been largely replaced by drives in group II, as the low-maintenance and cost-effective
three-phase squirrel-cage motor is now used instead. DC motors have the following
drawbacks compared to the squirrel-cage motor:
maintenance costs for commutator servicing
carbon brush wear
higher investment costs
high repair costs in the event of winding damage
A three-phase slipring motor with subsynchronous converter cascade (no. 3 in Fig. 2.3-
1) can be used for large drive power ratings (> 1,000 kW) and relatively small control
ranges. In this circuit the slip power is not lost as heat in the starting resistors, but is
fed back to the power supply network by a converter circuit. The starter, which is still
required for the start-up process, is switched off during cascade operation. Mechanical
control gears (PIV gears) are also still used in older plants for drives with power ratings
of up to approximately 100 kW.
Fields of Application The fields of application for variable-feed drives include:
 feed belts for crusher plants

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 converter drive systems

no. converter motor excitation system name

converter -
DC drive

1 for one direction of rotation

controllable DC drives

DC

- with 2 anti-parallel thyristor bridges

1a for four-quadrant drive
DC

converter -
three-phase drive

2 3-phase - synchronous motor with direct converter

5
3-phase - slipring motor with subsynchronous
controllable three-phase drives

converter cascade

4 3-phase - squirrel-cage motor with voltage-source converter

and uncontrolled rectifier for
one direction of rotation

4a 3-phase - squirrel-cage motor with

2 anti-parallel-controlled bridges
for four-quadrant drive

5 - cage motor with current-source

, converter
3-phase
for one-four-quadrant drive

Figure 2.3-1: Converter Drive Systems .

 fans
 classifiers
 metering equipment
 high-pressure roller mills
 grate coolers
 rotary kilns

3 Fields of Application of Electric Drives

Most of the motors used to drive working machinery are three-phase motors with a
surface-cooled, completely enclosed and splashproof design (protection type IP 44 or IP
54).
 The total power for all motors in a cement works with a daily production of approx. Electric Drives in a
3,500 t is approx. 30,000 kW. About 900 drives are installed for this purpose. Works

 The largest single drive is a mill motor with a power rating of approx. 3,500 kW.
 In larger plants single drives with a power up to 6,000 kW are used.
 The majority (approx. 98 %) are low-voltage motors with individual power ratings of
up to approx. 200 kW.

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 3 Fields of Application of Electric Drives

 High-voltage motors are used for preferance for drives over 200 kW (approx. 2
%). This power boundary may rise to 500 kW depending on the design of the cement
works power network.
An overview with regard to the different engine types is given in Fig. 3.0-1.

Figure 3.0-1: Different Kinds of Motors in a Cement Plant . (Source: Siemens AG (Editing by VDZ))

3.1 Tube Mill Drive

The following drive variants are generally used:
 three-phase squirrel-cage motors up to approx. 300 kW
 three-phase slipring motors
Three-phase squirrel cage motors cannot be used at higher power levels because the
starting current and torque impact on the mechanical transmission elements, such as the
coupling and gear unit, are too high. They are therefore only suitable for small mills, such
as coal grinding plants.
The three-phase slipring motor is most commonly used since the starting current and
the starting torque can be adapted to the operating conditions by starting resistors in the
rotor circuit of the motor. This applies to both single drives and double drives. The initial
breakaway torque of the drive is lower than the nominal torque of the mill so high-inertia
starting is not possible. Fig. 3.1-1 shows the start-up characteristics of a mill motor with
three starting steps.
Curve 3 shows the start-up process at maximum rotor resistance, for curve 2 a third of
the rotor resistance is disconnected, while curve 1 shows the torque curve when the rotor
resistors are short-circuited. However, a normal starter has 9 to 12 steps, is motor-driven
and has a starting time of 30 to 50 seconds. Liquid starters, in which the change in
resistance is achieved by the adjustment of immersion electrodes in an electrolyte, have
the following features:
 smooth resistance change

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 3.1 Tube Mill Drive

M 240 start-up characteristics

M N 220 of a slipring rotor
3 2 1 curves 1-3
200
torque-speed curve
180 for a slipring motor at
160 different rotor
resistances
140
120 curve 4
100 A counter-torque
the mill
of
80
4 A
60
operating point
40 of the motor
20
0
10 20 30 40 50 60 70 80 90 100 % synchronous speed

Figure 3.1-1: Start-Up Characteristics of a Mill Drive .

 simple adjustment of the resistance to the drive by changing the electrolyte concentra-
tion
 low wear
7
 maintenance-free
6 kV 50 Hz

A A
3

m1 5 m1

6
7
M

1 disconnecting switch
2 power switch
3 current transformer for current measurement
4 current transformer for bimetallic relay
5 mill motor
6 starter
7 adjusting motor for the starter

Figure 3.1-2: Dual Mill Drive with Two Separate Starters .

Two separate starters are used in dual drives, as shown in Fig. 3.1-2. They are mechanically
and electrically linked for simultaneous stepping of the starting resistors. Liquid starters
are connected by pipelines so that the concentration of the electrolyte remains the same
in both starters. This avoids different starting currents and therefore also different starting
torques.

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 3 Fields of Application of Electric Drives

3.2 Vertical Roller Mill Drive

The same types of motor as for tube mills, p. 6 are used to drive vertical roller mills
(Fig. 3.2-1). Depending on the system, vertical roller mills are connected to the motor via
angular gear units.

Figure 3.2-1: Drive of a Vertical Roller Mill .

An innovative drive concept, especially for larger mills, is the so-called MultiDrive. The
Mul-tiDrive (s. Fig. 3.2-2) consists of two to six identical drive modules which turn the
grinding table via a gear ring. The gear ring is located below the grinding table.

Figure 3.2-2: Siemens/Flender MultiDrive concept for the grinding table. (Source: Siemens AG)

As shown by the torque curve (Fig. 3.2-3), the breakaway torque of the vertical roller mill
lies below the nominal torque. However, the load torque increases during start-up (with
uneven material distribution on the grinding table) to up to 150 % of the nominal torque.
The starter is designed accordingly.
Start-Up The bed of material is smoothed using an auxiliary drive that has a rotational speed of

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 3.3 High-Pressure Roller Mill Drive

torque curve of a vertical roller mill MA1breakaway torque

M 240 MK MA starting torque
M N 220 MK breakdown torque
1
200 ML load torque
180 MN nominal torque
MA n motor rotational speed
160
140 ns synchronous speed
ML
120 2
M N 100
80
M A1 60 3

40
20
0 n
10 20 30 40 50 60 70 80 90 100 % n
s
1 curve of a short-circuited rotor
2 the size of the load torque is dependent on the settings of the roller hydraulics

Figure 3.2-3: Torque Curve of a Vertical Roller Mill .

approx. 10 % of the main drive so that the vertical roller mill can be started up with
9
the grinding table completely covered. This auxiliary drive drives the other projecting
end of the main motor shaft through an auxiliary gear unit. The grinding table is then
driven through the angular gear unit. An overrunning clutch between the auxiliary gear
unit and the main motor as well as an electric interlocking system prevent the danger of
the auxiliary drive being driven by the main motor.
Large fluctuations in current and therefore power (curve 3 in Fig. 3.2-3), caused by the
composition of the bed of material, occur during normal grinding operation.

3.3 High-Pressure Roller Mill Drive

High-pressure roller mills are normally started up with an empty feed shaft. Therefore
only the rollers, couplings and gear units have to be accelerated in the start-up process.
The following drive variants are used:
 three-phase squirrel-cage motors
 three-phase slipring motors
 variable speed drives (Fig. 3.3-1)
Three-phase slipring motors are only used if the network conditions do not permit the high
starting currents of squirrel-cage motors.
If the feed shaft is empty the high-pressure roller mill drives can be started up either to-
gether or separately one after the other.
Variable speed drives are used if grinding is to be carried out with different feed materials
or at different feed rates. This requires the rotational velocity of the rollers to be matched.

3.4 Rotary Kiln Drive

The physical properties of the raw meal feed change as it passes through the rotary kiln. TorqueFluctuations
As a result of the fluctuations in mass flow through the kiln caused by these changes, it
is not possible to make an accurate specification of the kiln drive torque required for the
rotation and conveying.
Furthermore, the material may back up as a result of the formation of coating or rings or
else the raw meal may flush through. These will increase the torque required to drive

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 3 Fields of Application of Electric Drives

10

Figure 3.3-1: High-Pressure Roller Mill Drive .

the kiln. If there is one-sided build-up then these situations can cause periodic changes in
torque superimposed on the constant load torque.
The fluctuations in torque that are to be expected are taken into consideration in the drive
design by allowing for a reserve capacity of 35 to 50 % of the power requirement. The
speed adjustment range of the rotary kiln is 10 to 100 % of the nominal speed. The low
range is required in particular for the heating and start-up processes.
DriveSystems Only the following variable speed drive systems are used:
 DC motors
 frequency converter drives
 hydraulic drives
PowerTransmission The drive power can be transmitted from the motor to the rotary kiln in the following ways:
 single motor gear unit pinion girth gear
 two motors two gear units two pinions girth gear
 direct drive of support rollers (Fig. 3.4-1)
Auxiliary Drive The rotary kiln is equipped with an auxiliary drive that permits slow rotation of the kiln
for emergency operation in case of power failure and for repair purposes. This drive is
flange-mounted to the main gear unit and is supplied by an emergency power supply.
Continuous slow rotation makes it possible to avoid any bending of the kiln tube during
power failure.
The hydraulic drive is described in the section on Rotary Kiln Drives, p. 14 .

3.5 Drive Motors for Fans

Low-voltage or high-voltage motors are used for fans to suit the power requirements.
The following motors are used for fixed speeds:
 three-phase squirrel-cage motors
 three-phase slipring motors
The following are used for variable speeds:

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 3.6 Crusher Drives

Figure 3.4-1: Support Roller Direct Drive for a Rotary Kiln .

 DC motors (Fig. 3.5-1)

 frequency converter drives
 subsynchronous converter cascades
11
Variable-speed drives are being used increasingly instead of dampers to change the vol- VariableSpeed Drives
ume flow of gases in order to improve the energy efficiency of a system. This does not
only apply to large fans, but also to fans in the small to medium power range.

Figure 3.5-1: Preheater Fan with DC Motor .

3.6 Crusher Drives

Low-power crusher systems are equipped with three-phase squirrel-cage motors. Three-
phase slipring motors that are supplied from the high-voltage network are used in large,
high-power systems (Fig. 3.6-1) to ensure that it is possible to start up the heavy rotating
masses involved. These rotating masses are necessary to keep the effects of load fluctua-
tions on the drive and power supply network within tolerable limits. As a further measure,
the motor is provided with an additional resistor in the rotor circuit that increases the slip

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 4 Special Drive Designs

of the rotor and so utilizes the energy stored in the rotating mass. This does, however, have
a detrimental effect on the overall efficiency of the drive.

12

Figure 3.6-1: Crusher Drive .

4 Special Drive Designs

Geared Motors Motors with flange-mounted gear units are robust, easy-care and low-maintenance drive
elements for driving working machinery at low input speeds. They are used, for example,
in the following forms:
 three-phase squirrel-cage motor
 DC motor
 frequency-controlled
 with brakes
 with rollback lock
 pulley motor
Heavy Starting The following special measures are necessary for drives with heavy starting start-up con-
ditions:
 star-delta circuit
 hydraulic starting coupling
 slipring motor with starter
 three-phase squirrel-cage motor with electronic smooth starting device
Star-Delta Circuit The star-delta circuit switches on the drive in two timed stages with a starting torque
reduced to 30 %. The continuous slip in hydraulic starting couplings has a negative
effect and causes a power loss of approximately 3 %. The electronic smooth starting
device is provided with a microprocessor control system that makes it possible to adapt
the drive to the working machinery. After the drive has started up the device is bypassed
so that additional energy loss can be avoided.
Unbalanced-Weight Unbalanced-weight drives are used to drive trough conveyors and screens as well as the
Drives discharge aids in containers, hoppers and chutes. These are three-phase squirrel-cage mo-

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tors that are used to drive unbalanced masses mounted on both protruding shaft ends. The
stroke can be altered by adjusting the unbalanced mass or by changing the speed.
The iron cores of electromagnets operate against spring assemblies. The stroke and there- Electromagnets
fore the flow rate can be altered in a range from 50 to 100 % by adjusting the voltage using
an electronic actuator.

5 Electro-Hydraulic Drives
Hydraulic systems are used when high power density and good thermal dissipation or very
strong forces are needed.

Electro-hydraulic systems (Fig. 5.0-1) are formed of hydraulic and electric compo-
nents; energy is transmitted between the power section and the hydraulic drive by a
liquid under high pressure.

Hydraulic cylinders, for example, can be used as drives.

13

K1
24V
directional
control
valve
y1

power section
M

K1

control section
OV

Figure 5.0-1: Electro-Hydraulic Circuit .

High power density is one of the main features of hydraulics. This refers to the ratio
of power output from a motor to its weight or size.
PowerDensity
Electric motors, for example, have a considerably lower power density. An electric motor
that has the same power out as a hydraulic motor is many times heavier and larger.
However, signal input and signal processing are carried out using electrical and electronic Advantage:
components. Electric signals can be transmitted reliably and over large distances using SignalTransmission

cables. Mechanical signal transmission (rods, cable pulls) or hydraulic signal transmission
(tubes, pipes) is considerably more complex and more susceptible to failure. For this
reason electro-hydraulic systems are also, for example, being used increasingly in aircraft
or motor vehicles. In automation technology all the signal processing is usually carried
out electrically. Electro-hydraulic systems are therefore better suited for use in automatic
production systems, e.g. cement production plants.
The interface between electric/electronic and hydraulic systems is the electromagnetically Valve Interface
actuated valve. The electromagnet (Fig. 5.0-2) is the core element of the valve. The
action of the electromagnet is based on the fact that a magnetic field is produced by a

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 5 Electro-Hydraulic Drives

iron magnet

coil core
14
Figure 5.0-2: Electromagnet .

conductor winding (coil) through which current flows. This exerts a force on an iron
rod (core) immersed in this magnetic field. The arrangement of the coil and core can be
designed in such a way that the core can be moved into different positions. This movement
makes it possible to carry out control processes. It is, for example, possible to operate a
directional control valve.

The force of the electromagnet on the core is proportional to the strength of the
current flowing through the coil and the number of windings in the coil.

5.1 Rotary Kiln Drives

The electro-hydraulic rotary kiln drive station (Fig. 5.1-1) is designed so that the kiln,
driven by a friction drive through hydraulic motors, is supported on two support rollers
on the supporting structure. The word friction comes from Latin and in engineering it
describes the transmission of forces and torques by rubbing, which ensures the frictional
connection between two wheels.
The hydraulic motors used are radial piston motors with a fixed housing and a rotating
shaft. They are connected in parallel so that the torques at the support rollers are identical.
The pump station is formed of three units that are linked together hydraulically. There
are generally two main pump units for normal operation, each of which consists of two
electrically driven main pumps, a serviced oil tank and an oil treatment unit.
A further unit is used for turning the kiln or for operation with emergency power. The
process control system controls the hydraulic system and monitors the requisite operating
parameters, such as pressure and temperatures. The kiln speed can be continuously varied
with a hydraulic system design of this type.
The four hydraulic motors (Fig. 5.1-2) are mounted on the support roller journals in such
a way that torque can be transferred to the support roller shafts, generally via a double
torque arm. This design ensures that only torsion is transferred to the support roller shafts.

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 5.1 Rotary Kiln Drives

rotary kiln

cooler

tank

Figure 5.1-1: Electro-Hydraulic Rotary Kiln Drive .

A spring-loaded, hydraulically operated disc brake is mounted on each hydraulic motor. 15

The disc brake is normally locked by spring loading; the brake can be released by hydraulic
pressure.

1. cam disc
2. cam roller
3. piston
4. shaft coupling
5. radial cylinder/hollow shaft
6. guide plate
7. roller bearing on cam roller
7a. roller bearings for radial
cylinders
8. terminal block
9. valve disc
10. front housing
11. rear housing
R = "R" inlet or outlet
L = "R" inlet or outlet
D1, D2, D3 and (D4)* = leak ports

*D4 = MB 1150 - MB 4000

Figure 5.1-2: Hydraulic Motor .

As previously mentioned, the pump module for the kiln drive station consists of three
modules. Two of these are main modules, each consisting of two electrically driven main
pumps. The hydraulic pumps are axial piston pumps with variable displacement. This
adjustment is controlled individually by a proportional valve.
The third module consists of a small electrically driven pump with its own filters. This
pump is used with emergency power for normal rotation of the kiln, but this small pump
can also generate higher pressure than the four main pumps. It is used during start-up.
Maximum speeds of 0.2 revolutions per minute can generally be achieved with this pump.

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 5 Electro-Hydraulic Drives

5.2 Reciprocating Grate Drive of Clinker Coolers

Grate Drive
Modern reciprocating and pendulum grates in clinker coolers are driven by one or more
hydraulic cylinders (Fig. 5.2-1). The cylinders are generally protected by pressure limiting
valves to counteract pressure surges that may occur on, for example, emergency shutdown
. These valves are adjustable and limit the maximum pressure to approx. 200 to 350 bar.
In addition, proportional valves for controlling the movement of the cylinder are also
located on the cylinder. These proportional valves consist of the following modules:
 valve electronics
 P-valve for controlling the main valve
 magnetic position measuring system that detects the position of the main valve piston
 main valve with piston
 pressure control valve
 2-way flow control valve
16
Cylinder Position Control
The proportional valve operates in a closed control circuit. Its position measuring system
detects all the current positions of the main valve piston, and the position is compared with
the predetermined setpoint in the valve electronics.

Figure 5.2-1: Reciprocating Grate Drive .

If the position is different to the intended position, the magnets of the pilot valve are
activated by the valve electronics, which changes the amount of control oil passing to the
main valve. Its piston position is changed so that correspondingly more or less oil under
pressure enters the piston end or the fixed end of the cylinder.
The valve electronics are integrated into a subordinate control circuit. The stroke time is
generally set by the control room and reaches the controller module via the programmable
control. The card calculates the corresponding speed profile, which is supplied to the
valve electronics as a setpoint. Position data is fed back to the controller module by a
displacement transducer integrated into the cylinder.

Pressure Control
Once the hydraulic system has been started, the maximum value is generally initially set
as the control pressure setpoint and is then reduced or adjusted in steps with each stroke.

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The cylinder is equipped with two pressure transducers that, together with a manometer
for displaying the control pressure, are mounted externally in the vicinity of the cylin-
der. One of the pressure transducers measures the pressure on the piston side whilst the
other measures the pressure on the rod side. These pressures are read continuously by
the programmable control. At the end of the stroke the lower value is compared with the
predetermined threshold value. The higher the control pressure should be, the more the
pressure control valve is closed.

17

Figure 5.2-2: Pressure Control System .

6 Health and Safety Practices

The following particular risks are encountered when working on drives:
 mechanical danger of pinching, striking, shearing, being pulled in
 risk of fire and explosion in grinding plants and transport systems for fuels
 risk posed by hot meal at the preheater of the rotary kiln
 risk posed by electric current
 risk posed by noise and vibration
The following instructions and measures must be observed to avoid accidents and injury:
 inform production supervisors and managers before any work is carried out
 disconnect drive at all poles before work is carried out and secure against reconnection
 disconnect conveying equipment at all poles before work is carried out and secure
against reconnection
 use personal protective equipment
 follow operating instructions
 report back to production supervisors and managers once work has been completed
Work may only be carried out on electric drives and systems when the power supply has
been switched off. The following five safety rules must therefore be followed:
1 isolate SafetyRules
2 secure against reconnection
3 check that the system is safely isolated from power supply
4 earth and short circuit
5 cover or shield any adjacent live parts

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 9 Maintenance and Inspection

7 Operation and Quality

DriveBreakdown Operationally reliable drives are essential for a trouble-free production process. The indi-
vidual production steps in the cement production process are interconnected so the failure
of a drive could have severe consequences for the entire process.
Common Causes of Drive Failure:
 overloading
 overheating
 blockages
 electrical malfunctions
 bearing damage
 interruption of the power supply
Possible Consequences of Plant Downtime Following Drive Breakdown:
 production losses
 blockages and overloading in transport routes
18  reduction in the service life of refractory linings
 increase in dust emissions
 damage caused by overheating in gas ducts
Quality Uniform, uninterrupted production operation is essential for high product quality. Drive
failures lead to additional start-up and shutdown procedures, which has a detrimental effect
on the quality of the product.

8 Environmental Protection
Energy Consumption Operating unnecessary equipment, such as compressors, or running empty conveying
equipment such as bucket elevators or the like has a negative effect on specific power
consumption. Inadequate maintenance and servicing of production systems also leads to
higher energy consumption.
Noise The emissions from drives are largely limited to noise. This is produced in particular
when operating large motors and frequency-controlled drives. Noise can be prevented
or reduced by design measures. Pumps and compressors are enclosed to reduce noise
emissions. Special noise protection measures must be taken at the air intake and discharge
openings that are needed to cool the drives.
Discharge of Oil The environmentally harmful discharge of hydraulic and lubricant oils and their pene-
tration into the ground is prevented by using catchment basins or by structural measures
such as oil-tight sumps.

9 Maintenance and Inspection

A high level of availability of the drives is essential to achieve substantially trouble-free
production. This can be ensured by preventive maintenance and inspection measures
carried out at regular intervals.
These measures should be supported, where possible, by an EDP-based system: a system
of this type contains information, such as the scope of the measures to be carried out, the
intervals at which they are to be carried out, parts to be replaced, etc. However, regular
visual inspections of the drive systems are also carried out during normal operation. Where
possible the repairs and maintenance work are carried out during planned plant downtime.

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However, in the case of serious malfunctions, short-term plant downtime may also be
necessary in order to carry out repairs.
 inspection of the bearings MaintenanceMeasures
 checking of the winding temperature
 functional testing of the protective relay and interlock devices
 functional testing of bearing temperature monitoring system
 inspection and cleaning of the cooling systems
 inspection and maintenance of the carbon brushes
 inspection and maintenance of slipring elements and collectors
 functional testing and maintenance of oil circuits
 functional testing and maintenance of cooling water circuits
 functional testing of safety switch devices
 In addition, special attention must be paid to the operating instructions for the drive in
question.
The following points have a significant effect on the operability and service life of drives: Wear and Corrosion
 protection against dust and radiant heat 19
 protection against vibration
 uninterrupted supply and removal of cooling air
 effective overload protection

10 Questions on Course LB 6.5 Drive Technology

You can test your knowledge by answering the following questions.

Question 10.0 A:
1.: Which type of motor is most commonly used?
2.: For which drives is a slipring motor used?
3.: How are electric motors cooled?
4.: Name some factors that contribute to the cost-effectiveness of high-voltage motors.
5.: Which are the drives and power levels for which high-voltage motors are used for
prefence?
6.: Which drive types are suitable for variable-speed drives?
7.: Name the fields of application for variable-speed drives in a cement works.
8.: Why are three-phase slipring motors used to drive tube mills?
9.: What are the advantages of a liquid starter?
10.: What causes strong fluctuations in torque of a vertical roller mill during normal
mill operation?
11.: Why must a roller mill always be started up with an auxiliary drive?
12.: Why is the drive of a high-pressure roller mill equipped with a variable-speed main
drive system?
13.: Why are rotary kiln drives always provided with variable-speed drives?
14.: Why is it necessary to allow for a power reserve capacity of 35 to 50 % of the
nominal power in rotary kiln drives?
15.: What is the purpose of the auxiliary drive of a rotary kiln?
16.: How is the volume flow of a fan adapted to the process requirements?
17.: Name some special drive motor designs.
18.: Name the drive types used for heavy starting.
19.: What are the advantages of the electronic smooth starting device?

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 10 Questions on Course LB 6.5 Drive Technology

20.: When are hydraulic drives used for preference?

21.: Name the main features of hydraulic drives.
22.: What safety rules must be followed when working on electric machinery and sys-
tems?
23.: What negative effects does drive failure have on production?
24.: What circumstances that affect the drive can have a negative influence on wear?
25.: Name some measures to be taken in relation to maintenance and servicing of
drives.
Solution see p.21

20

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Research Institute of the Cement Industry
Solutions
Solutions to 10.0 A:
1.: Three-phase squirrel-cage motor
2.: For drives that require low-impact starting
3.: Surface-cooling by self-ventilation
4.:  low motor losses
 low network costs
 low network losses
 low cable costs
5.:  Crusher systems
 Raw meal systems
 Fans
 Compressors
 Cement grinding plants
from approximately 200 kW drive power, depending on the cement works power 21
network

6.: Converter DC drives

7.: Feed belts in crusher systems
 Fans
 Classifiers
 Metering equipment
 High-pressure roller mills
 Grate coolers
 Rotary kilns
8.: It is possible to limit the starting current and so avoid torque impact on the me-
chanical transmission elements
9.:  Smooth resistance change
 Simple adaptation of the resistance to the drive by changing the electrolyte
concentration
 Low wear
 Maintenance-free
10.: The composition of the bed of material
11.: To smooth the bed of material
12.: To be able to grind different feed materials or at different feed rates
13.: Because the raw meal changes physically as it passes through the kiln so it is
necessary to cope with fluctuating mass flows
14.: Because of the expected fluctuations in torque; formation of coating and rings
increase the torque required
15.: Slow rotation of the kiln tube during power failure and for repair purposes
16.: By a variable-speed drive
17.:  Geared motor
 Motor with rollback lock
 Motor with brakes
 Pulley motor
18.:  star-delta circuit
 hydraulic starting coupling
 slipring motor with starter
 three-phase squirrel-cage motor with electronic smooth starting device

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 10 Questions on Course LB 6.5 Drive Technology

19.: The electronic smooth starting device is provided with a microprocessor control
system that makes it possible to adapt the drive to the working machinery. After
the drive has started up the device is bypassed so that additional energy loss can be
avoided.
20.: When high power density and good heat dissipation or very high forces are re-
quired
21.: High power density, electro-hydraulic system
22.:  Isolate
 Secure against reconnection
 Check that the system is safely isolated from power supply
 Earth and short circuit
 Cover or shield any adjacent live parts
23.: Production losses, blockages and overloading of transport routes, reduction in the
service life of refractory linings, increase in dust emissions, damage caused by
overheating in gas ducts
24.: Overloading, overheating, blockages, electrical malfunctions, bearing damage, in-
22
terruption of the power supply
25.: Inspection of the bearings, checking of the winding temperature, functional test-
ing of the bearing temperature monitoring system, inspection and cleaning of the
cooling systems, inspection and maintenance of the carbon brushes, etc.
Question see p. 19

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Research Institute of the Cement Industry
Glossary
DC motor
Electric motor operated with direct current.
electromagnet
A magnetic field is produced by a conductor winding (coil) through which current flows; this magnetic field
exerts a force on an iron core immersed in it
high-voltage motor
Electric motor that is operated at a higher voltage; the voltage is normally 6 kV or 10 kV, in older plants it may
also, for example, be 2.4 kV, 3 kV or 5 kV
hydraulic motor
Drive motor that converts the kinetic energy of a liquid into a rotational movement
IEC (International Electrotechnical Commission)
International Electrotechnical Commission; international standardization committee in the field of electrical en-
gineering and electronics (similar to ISO)
IP44
IP protection class 44 = protection against foreign bodies > 1mm in diameter (first 4) AND protected against
spray water (second 4) 23
IP54
IP protection class 54 = complete shock-hazard protection, protection against damaging internal dust deposits
(first number 5) AND protected against spray water (second number 4)
kW
short for kilowatt (= 1,000 watts); measure of electric power; W = current amperage (A) voltage (V); 1 W = 1
joule per second
liquid starter
Starter in which the resistance is formed by a liquid (salt solution)
low-voltage motor
Electric motor that is operated using a low-voltage power supply network (e.g. 400 V or 500 V)
power density
Ratio of power output from a motor to its weight or size
proportional
mathematical term for consistent change (e.g. doubling, tripling) of a variable
resistor starter
Starter with incrementally adjustable fixed resistors
rotor winding
Winding on the moving part (= the rotor) of an electric motor
slipring
The sliprings connect the rotor windings of the slipring motor to a starting resistor; the sliprings make it possible
for the current to flow from a stationary part (e.g. starting resistor) to the rotating part (rotor)
slipring motor
Three-phase motor in which the rotor winding is connected to an external starting resistor by sliprings
squirrel-cage motor
Three-phase motor in which the rotor winding is formed by short-circuit bars (cage)
star-delta circuit
A system for switching the three windings of a three-phase machine between star circuit and delta circuit.
In the star circuit the line-to-line voltage (voltage between 2 phase conductors) is 1.73 times as high as the phase
voltage (voltage between the phase conductor and the neutral conductor); the conductor current is equal to the
phase current.
In the delta circuit the conductor current is 1.73 times as high as the phase current; the conductor voltage is the
same as the phase voltage
starting current
Current drawn by an electric motor when switched on (i.e. in the start-up phase)
starting torque
Torque of an electric motor when switched on (i.e. in the start-up phase)

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 Glossary

stator
Stationary part of an electric motor;
three-phase motor
Electric motor that is operated using a three-phase power network (= three-phase network); a distinction is made
between the level of operating voltage (three-phase low-voltage motor or three-phase high-voltage motor) and
the type of rotor winding (three-phase squirrel-cage motor or three-phase slipring motor)

24

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Research Institute of the Cement Industry
Index

D
DC motor 4, 10, 11

E
electromagnet 13

H
high-voltage motor 6
hydraulic motor 10, 13

I
IEC 1
IP44 1
IP54 1

K 25
kW 5

L
liquid starter 6
low-voltage motor 5

P
power density 13
proportional 14

R
resistor starter 1
rotor winding 1

S
slipring 1
slipring motor 4, 6, 10
squirrel-cage motor 4, 6, 10
star-delta circuit 12
starting current 1
starting torque 1
stator 1

T
three-phase motor 5

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