High Torque Planetary Gears PBLZ

for Ball Mill Central Drives

 Large Horizontal Drives

Your Ball Mill, our Central Drive

Endurance – Efficiency – Excellence

Spur gearing with 2

power-transmission
paths
Spur gearing with 3
tons power transmission
paths
180 to Well proven epicyclic gear technology
2 stages
165 to
2 planetary stages,
149 to 1 parallel stage RENK epicyclic gears are used e.g. in central ball mill drives
2 planetary stages, since 1974 when RENK has supplied the first epicyclic gear for
1 parallel stage, a 2,5 MW ball mill featuring 2 planetary stages each with three
109 to hydrodynamic bearings
planets. The epicyclic gear technology has been the step to take
as the powers of the mill systems increased steadily. With
75 to
new materials, manufacturing technologies, improved lube oils
and last but not least condition monitoring technologies, the
RENK central drives were improved to their third generation on
the market named PBLZ type.

Development of the drive technology for ball mill central drives

within 50 years: 4 MW drive for a 15.6 rpm mill. At the same time
increasing the AGMA service factor from 2 to 2.5. The weight is
the system weight including couplings.

2
3

The Drive System Design

Complete package of equipment

1
1 Auxilliary Gear for positioning an balancing of mill body with: 3
3 Main Gear / Coupling: 14 - 18 rpm
Motor, Hydrodynamic Clutch-Retarder, Back stop Brake System, 4
4 Cement Mill
Reducer, semi automatic Claw Clutch Ratio: > 8000 5
5 Oil System, optional with SCS Controller
2
2 Main Motor: 3000 - 10000 kW; 750 - 1500 rpm

2 3
 Large Horizontal Drives

RENK Auxilliary Drive System

Mill Stop
The mill swings to stop after a motor stop.
This requires backward rotation.

Stop signal or black out 30 to 60 sec.

Nominal speed 1

2
forward speed

3
Aux drive speed
time
4
backward speed

Start Max. Max.

operation kinetic Energy potential Energy

Auxilliary Drive System

Features

1 Claw Clutch:
1
engaged until overruning
takes place; manual disan-
gagement only after
balancing
2 Auxilliary Gear:
2
reducer
3 Drum Brake:
3
opening electically only with
interlock to oil pressure
4 Hydraulic Clutch:
4
clutch works as a dynamic
brake for balancing the mill
in controlled manner
5 Auxilliary Motor:
5
equiped with back stop –
can not turn reversly

4 5
 Large Horizontal Drives

Safety and Dependability 1

Are on Top of the List 2

3
5 4
RENK will provide all components of the drive system! The
condition of all elements is continuously monitored by sensors
and switches.

A logic diagram provided to configure a Programmable Logic Con-

troller (PLC) or a readily programmed Sub Control System (reporting
In any case the operation is save and interlocked against faulty
to the main PLC) is available. The RENK programmed and tested SCS
operation.
shortens the commissioning time and reduces the risk of site work
mistakes.
The Oil System features a hot standby pump, a double switch fil-
ter system with remote clogging indicator and a temperature control
Central Control System (CCS) valve to provide constant operation conditions also at changing cool- 6
Power Supply
ing media. The oil quantity born in the tank is rated generously to al-
Power
Customer cable low an extended running time without oil change. The oil is continu-
Power Profibus
ously fine filtered to minimise the impact on the gear elements by 7
cable cable
abrasives which cannot be prevented to penetrate the oil circuit in
the cement plant environment.
SCS
Control Control
Terminal box Sub Control System (SCS)
cable RENK PLC with
local screen
cable In addition to all those elements an emergency oil tank is provided
to make sure the shaft system can coast down safely in case of
Oil supply Starterbox frequent black outs or a delay in stopping the main motor in case
Gear unit lube oil pumps and
unit immersion heater
with local operation of a major failure of the system. Two minutes of operation are
possible without power source.
The Oil System
Features
The backstop on the auxiliary drive motor turns the hydraulic clutch
into a retarder for controlled ballancing – brake is opened electrically
1
1 Local Instruments:
and is interlocked with oil pressure for gear.
optional SCC
2
2 Water Cooler:
maintenance maintenance
Nominal speed / torque optional air
3
3 Stand by Pump:
forward speed

no stop for pump failure

4
4 Main Line Filter:
40 um cleaneable,
stainless steel
5 Pypass Filter:
5
Aux drive speed
10 μm non cleaneable, fleace
time
5 6 Tank:
6
approx 5 times pump cap
backward speed

1
4
7 Heating:
7
Close brake Open brake 2
3 21 kW

6
7
6 7
 Large Horizontal Drives

Our Gear Lifetime

Makes Your Money
• 3-stage design for compactness and safety.
• Moderate bearing loads to provide safety margin.
• Hydrodynamic sleeve bearings are selected for
ultimate lifetimes.

The lifetime of sleeve bearings is mainly subject to propper

lubrication! In case white metal bearings are wiped out repair
is possible.

PBLZ Ball mill drives feature all over hydrodynamic sleeve bearings.
The bearings of the two planetary stages feature brass surfaces to
be most resistant against any adverse operation condition. The brass
bearing metal provides a higher strength than usual white metal
spindles.
Gears are case hardened (except annulus) and precision machined.
The casing is cast from cold climate enabled globular cast iron. Fine
filtration minimizes wear of gears and bearings.

Before we supply our gears we carefully assemble them by skilled

hands and test the complete system on our test bed.

8 9
 Large Horizontal Drives

Condition Monitoring and Service The RENK PBLZ Central Drive at a Glance
Completes the Package
Long life time is the result of good equipment and proper mainte- Such assistance includes the judgement of the outputs from the Questions to ask before you decide
nance. The RENK Service group is not only present for installation condition monitoring system which is supplied with the equipment. The following has been found to be advantages of RENK central drives:
and troubleshooting but can assist on a regular basis in the frame With such results preventive maintenance can be planned well
of a maintenance contract. aimed.

Feature – RENK has it! Why do you need this?

High torque Parallel shaft gears and to deflect under torque affecting the
Planetary design (low speed stages)
load pattern and are ultimately heavy
Designs ready for use
L 3-stage design with compact dimensions
Compact parts means to save parts cost. Ratio can go up to
100 with no problem – i.e. 4-pole standard motors can be used
L Cleanliness for increased lifetime of the components especially in
Best quality materials and QA made in Germany abrasive atmospheres; hot LP pump for uncompromising availability;
oil viscosity optimization for oil pump power saving.
n:n: speed
speed
a a a a
T: T: temperature
temperature Hot stand by pump, bypass cleaning, ISO4406 20/17/14 cleanliness increases lifetime; hot LP pump for
s p: pressure temperature control valve uncompromised availability; oil viscosity optimization
s a:p: acceleration
pressure (vibration)
T T s:a: position
acceleration (vibration) All sleeve bearing design;
T T s: position High margin and no restricted lifetime elements
AGMA Sf > 2.5; ISO6336 Ka > 1.6 & Sf > 1.6 & Sint > 2.0;
T T T
Temperature, Vibration and Mill Axial Position Condition monitoring for preventive maintenance and proactive maintenance
T T T T p Lube Oil Inlet
Ø
p p
T p Lube Oil Inlet
a CD Main Maintenance
Filter Filter
p p

T
aT CD Main Maintenance
Filter Filter

T T
Center Distance (CD)

Weight of gear unit

typical mill speed
PBLZ rating table

Maximum power
Maximum Torque
AGMA SF=2.5

Ø of Casing
Length L

Gear size kNm rpm kW mm mm mm tons

160 1,750 16.5 3,000 2,750 2,120 560 32
180 2,400 16.0 4,000 3,050 2,320 592 43
200 3,200 14.8 5,000 3,300 2,620 710 56
225 4,500 14.8 7,000 3,560 2,970 830 76
250 6,500 14.5 10,000 4,030 3,330 1,000 102

10 11
RENK GmbH

Augsburg Plant
Goegginger Str. 73
86159 Augsburg
Germany
Phone: +49 821 5700-0
Fax: +49 821 5700-460
Email: info.augsburg@renk.biz

www.renk-group.com

Edition: 09.2016