VRM Gearbox

Gear Unit
© FLSmidth Private Limited 2017, all Rights Reserved 1
WPU – 2 Stages Gearbox for VRM
2
1
WPU Gearbox Range
350
320
298
300
275
P Mill Power [kW] 254
250 = 233
n Mill Speed [rpm] 212
200 191
P/n
170
155
150 140
125
110
97
100 84
72
61
51
50 42
35
28
22
0
26 35 43 54 64 78 92 107 125 142 161 182 200 222 242 274 302 332 360 390 420
Gearbox Type
3
WPU. VERTICAL DRIVE FOR ROLLER MILL
 Customer specific design

 High efficiency
 High operational
reliability
 Compact design
 Optimal distribution of
static and dynamic
grinding forces
 Gearing and journal
bearings with very long
life
 Short installation time
 Low-cost maintenance
2
WPU. VERTICAL DRIVE FOR ROLLER MILL
 The grinding pressure

including grinding table weight
is transmitted straight to the
foundation via the tilting-pad
thrust bearing and the casing
wall
 Input shaft has no contact with
the casing in order to avoid
deformations in the bevel gear
shaft. In case of overload, no
deformation of the roller
bearings
WPU - 2 Stages Gearbox
Output
flange
Thrust
bearing
Planetary
stage
Main
housing
Bevel stage
3
Bevel Stage
Axial bearings Main

pinion housing
Radial bearings
pinion
Radial bearings
bevel wheel
Bevel wheel Bevel wheel
shaft
Gearing Design Criteria
 Bevel stage according DIN 3991

Application Factor KA = 2.0
Safety Factor for Durability SH = 1.5
Safety Factor for Bending SF = 2.0
 Planetary stage according ISO 6336

Application Factor KA = 2.0
Safety Factor for Pitting SH = 1.2
Safety Factor for Tooth Breakage
external gearing SF = 1.6
internal gearing (ring gear) SF = 1.4
 Planetary stage according AGMA 421

Service Factors KSF,CSF = 2.5
9
4
Gearing Bevel Stage
 Case hardened and hard cut
 Longitudinal and profile modification
 Toothing quality Q=6 according ISO
10
Gearing Planetary stage
 Sun pinions and planets case hardened and

ground
 Sun pinions with longitudinal and profile
modification
 Planets with profile modification
 Toothing quality for sun pinions and planets
Q=4 according ISO
 Ring gears quenched and tempered
 Milled and ground or shaped
 Toothing quality for ring gears Q=5 according
ISO
11
5
ATOX Mill
The axial thrust bearing supporting the grinding table and the grinding
force has reliable hydrodynamic/semi-hydrostatic bearing of segmented
design. (Only hydrodynamic for small mills). All the thrust pads are
immersed in an oil bath.
Slide Bearings
 Nearly infinite life time
 Surface scraped
 Excellent dry-running characteristic
 Less sensitive against contamination
 Casted bearing can be temporarily

repaired
13
6
Other Design Criteria
 High speed coupling

Depending on the application approx. S=3
 Roller bearings (only WPU)

Life time Lh10 80000 hours
 Other components
Slide bearing, shafts and housings are designed according our
internal rules and limits.
14
High speed coupling
Rubber
elements
Spacer
Coupling
hubs
15
7
Bevel Stage
Sun
pinion
Tooth
coupling
Bearing
sleeve
Bevel Bevel stage

pinion housing
16
Planetary Stage
Ring gear Radial bearings
Planet Sun pinion Planet Planet

Planet axis carrier
17
8
Axial Thrust Bearing
Thrust
pad
Hydrostatic Hydrodynamic
lubrication lubrication
19
9
Housing and Grinding Load
Grinding
load
Output
flange
Thrust
bearing
Ring gear
Main
housing
20
Lubrication Unit
LP pump
with motor
Inlet to the HP pump

gearbox with motor
Oil tank
Outlet from
the gearbox
21
10
Lubrication Unit
Instrumentation Oil cooler

panel
HP pipes
Double
oil filter
Water valve
Heating element
22
Plant Arrangement
Gearbox
Lubrication unit
Inlet pipe Outlet pipe HP pipe Level

difference
23
11
Standard Instrumentation WPU
Added Value:
n Basic concept
n Minimum protection of
machinery
n Basis information through
monitoring of key
measurements
Temperature Sensor
Vibration Sensor
24
Interlocking and Monitoring Table
25
12
26
WPU – 3 Stages Gearbox for VRM
27
13
Sun-pinion Konical wheel Mounting of
with coupling with coupling planetary
halfe halfe wheels
Built-inn planetary Planetary shaft Sun-pinion in

wheel with white metal engagement with
bearing planetary wheels
14
Differences between WPU and WPV
 WPU  WPV
- 2 Stages - 3 Stages
- Bevel stage with roller - Bevel stage with slide
bearing bearing
- Separate bevel stage - Bevel stage integrated
housing into main housing
- Ring gear part of the main - Planetary stages into main
housing housing
- One planetary stage with - Two planetary stages with
3 planets 3 and 4 planets
30
Summary
 Over 350 WPU sold
 Almost 100 years of experience
 High efficiency of the reducer
 High reliability
 Huge experience with slide bearings
 Compact design
 Remove high speed shaft from outside
 WPV access through manhole to the bevel stage
 WPV bevel wheel adjustable without removing the reducer
 Radial slide bearings can be temporarily repaired
 Slide bearings have extreme long life time
 Slide bearings are not delicate
 Power transmission above 8000 kW
 Ratio up to 60
 Equipped with standard instrumentation
 Hydrostatic and hydrodynamic lubrication of the axial bearing
31
15
WPV Gearbox Range
5000
4500 4510 4510
4200 4200
4000
3800 3800
Output Flange Size
3500 3480 3480
3170 3170
3000
2650 2650
2500
2440 2440
2000
1850 1850
1500
0 50 100 150 200 250 300 350 400 450 500
P/nt
32
WPV – 3 Stage Gearbox for VRM
Output
flange
Thrust bearing
housing
Planetary
stages
Main housing
Bevel stage
33
16
Bevel Stage
Tooth
coupling
Radial bearing
Thrust bearing wheel
Bevel pinion
pinion
Radial bearing
pinion
Main Thrust bearing

housing pinion
34
17

VRM Gearbox

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VRM Gearbox

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Gear Unit

© FLSmidth Private Limited 2017, all Rights Reserved 1

WPU – 2 Stages Gearbox for VRM

WPU. VERTICAL DRIVE FOR ROLLER MILL

 Customer specific design

© FLSmidth Private Limited 2017, all Rights Reserved 4

 The grinding pressure

© FLSmidth Private Limited 2017, all Rights Reserved 5

WPU - 2 Stages Gearbox

© FLSmidth Private Limited 2017, all Rights Reserved 7

Axial bearings Main

© FLSmidth Private Limited 2017, all Rights Reserved 8

Gearing Design Criteria

 Bevel stage according DIN 3991

 Planetary stage according ISO 6336

 Planetary stage according AGMA 421

 Case hardened and hard cut

 Longitudinal and profile modification

 Toothing quality Q=6 according ISO

Gearing Planetary stage

 Sun pinions and planets case hardened and

© FLSmidth Private Limited 2017, all Rights Reserved 12

 Nearly infinite life time

 Excellent dry-running characteristic

 Less sensitive against contamination

 Casted bearing can be temporarily

 High speed coupling

 Roller bearings (only WPU)

High speed coupling

Bevel Bevel stage

Ring gear Radial bearings

Planet Sun pinion Planet Planet

Axial Thrust Bearing

Inlet to the HP pump

Instrumentation Oil cooler

Inlet pipe Outlet pipe HP pipe Level

Interlocking and Monitoring Table

WPU – 3 Stages Gearbox for VRM

© FLSmidth Private Limited 2017, all Rights Reserved 28

Built-inn planetary Planetary shaft Sun-pinion in

© FLSmidth Private Limited 2017, all Rights Reserved 29

4500 4510 4510

3500 3480 3480

WPV – 3 Stage Gearbox for VRM

Main Thrust bearing

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