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MAAG GEAR - Techinal and Commercial Considerations Related To The Cement Mill Production
MAAG GEAR - Techinal and Commercial Considerations Related To The Cement Mill Production
MAAG Gear: A
pioneer of modern
gear technology
August 09
MAAG Gear on the move
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Facts
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Figures 2008
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Know-how in engineering and technology
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MAAG Gear, a member of FLS since 1997
Cement Minerals
FLSmidth FLSmidth Minerals
FLSmidth ABON
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Driving equipment for the cement industry
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Cement processes driven by MAAG Gear
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Driving equipment for the cement industry
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Roller mills drive, 2-stage (Type WPU)
Benefits to customer
High operational reliability
Efficiency exceeds 96.5%
Customers-specific design of gear units
Very high efficiency Planetary stage and thrust
bearing for grinding table with very long service
life
Low-cost maintenance
Technical overview
Fully developed compact two-stage design
(bevel gear / planetary gear stage)
Case hardened or hardened and quenched tooth
Bevel gear stage with its own casing
Thrust bearing mill table hydro static and hydro
dynamic lubricated
Power: 250 to 6,000 kW
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Roller mills drive, 3-stage (Type WPV)
Benefits to customer
Torque split for compact design
Flex pin solution for optimized load distribution
Efficiency exceeds approx. 95 %
Slide bearing application in bevel and planetary
gear stage
Simple mechanism for assembly and adjustment
of bevel gear stage without remove the gear unit
Technical overview
1st stage 3 planets, 2nd stage 5 planets
Toothing case hardened or quenched and
tempered
Thrust bearing mill table hydro static and hydro
dynamic lubricated
Power: 2,500 to 9,000 kW
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Installation / Maintenance
Maintenance Preventive
Monitoring / short reports
Assessments
Service plan agreement
Overhaul
Planning and project management
Execution and support
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Support
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WPU: The Gear Drive System
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The WPU Gear System
Roller Mill
Mill thrusts
Annulus
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Schematical Design Concept
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Set of instrumentation for trend analysis
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Set of instrumentation continue
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Selection chart for vertical mill gearbox
350
320
298
300
275
WPU WPV 254
250 233
212
200
Maximum 191
P/nt
P/nt
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
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WPV - Concept
Main advantages:
Torque split 30% to 70%,
=> 2nd stage with smaller dimension
5 Planets on the 2nd PV-Stage,
=> smaller dimension of the stage
Planets on the 2nd Stage with flex pin,
=> much better load distribution
No housing integrated Planetary stage
=> standard components possible
=> casing optimised to the axial load
Only slide bearings used
=> unlimited lifetime of bearings
Adjustment of bevel gear
=> No need of gearbox disassembly
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Slide bearings in the bevel gear stage
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Easy adjustment of bevel gear
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WPV 360 Bevel Gear Stage
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Summary
First Test run results and assembly show very encouraging results
High potential for optimisation of investment cost
Improvement on maintenance and service friendliness increasing
the gearbox availability
Lower transport weight and consequently easier erection and
reduced transport costs
The independent gearbox modules allow a more flexible and faster
production
Lower delivery time for spares due to the smaller gear parts
The gearbox is build up with long term approved technologies
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Maintenance philosophy
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Daily checks
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Routine 1000 h checks
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Regular 6000 h check
- Check all important bolt connections (reducer, lube oil supply unit,
coupling, etc.)
- Check and if necessary re-tighten gearbox anchoring
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Regular 12000 h check
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Special checks - Overhaul
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Customer Service Products
32
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Customer Service Products
33
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MAAG Gear AG
Gearbox Damage
How to handle
material availability
August 09
Source of information and procedures
Emergency situation:
a) Customer contacts Field Service Dept: Emergency
description, detailed information
b) Customer contacts Sales: availability of spare parts, delivery
schedules
Service report at customer
Sales travel report at MAAG Gear
Customer / Agency request once procedure defined
Monitoring system
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Material planning for repair (1)
1. Emergency case:
Damage assessment and evaluation
Material selection (parts, spares)
Availability at customer site
2. Service report:
History of the gearbox
Detect background of failure
Recommendations for repair
3. Sales travel report:
Spare parts already delivered
Identification of spares required
Contact persons
Express delivery
Quotes
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Material planning for repair (2)
5. Monitoring system
Data exchange
Analysis
Recommendations
Follow up after repair
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Information flow
Customer address
Service
Contact name; e-mail; phone No.
Report Basic Info
Plant code name
Gearbox type & ex. Order No.
Parts description
Drawing No.
SAP No. (If available)
Material Info
Quantity
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Repair options (1)
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Repair options (2)
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MAAG Gear locations and service centers
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MAAG Gears vision
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