January 2010 BOGIFLEX® KGD - FICEM– Bogiflex is not sensitive to thermal expansion conditions THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING • Optimised meshing and

BOGIFLEX® KGD

January 2010

http://www.cmdgears.com539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX® KGDSelf Aligning and Floating

Kiln Gear Drive

BOGIFLEX® KGD

January 2010


Cement Kiln operation – Influence parameters on Gear Meshing

Meshing of the kiln girth gear depends on the thermal condition of the kilnThe kiln has variable thermal expansion due to condition and type of its refractory and coating

Change in center distance between pinion and kiln axis

Wobbling of girth gear

The sustainability of the meshing of the kiln girth gear is major concern

BOGIFLEX® KGD

January 2010


Cement Kiln – Influence parameters on Gear Meshing

• Occurs due to variation in kiln operation - uneven coating formation

leading to shell temperature differences and thermal cranks

=> Proper meshing of the teeth no longer assured – contact area is

reduced and changing from one side to the other

Wobbling of Girth Gear

Center distance change

Lack of tip to root clearance

Overloading

due to wobbling

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD is solving these issues

BOGIFLEX® KGD

January 2010


BOGIFLEX – Concept

Floating drive + Self aligning principle applied for Gear Meshing

= BOGIFLEX

Spherical

plain

bearings

Pillow block

Self aligning is achieved because the pinion can move freely

onto the wheel

The rotation shaft of the pinion is free from the rotation shaft of

the wheel

⇒ The 2 contacting surfaces or gear meshing between pinion

and girth gear will permanently adapt to each other

BOGIFLEX® KGD

January 2010


BOGIFLEX – Contact pattern and Advantages

Floating drive + Self aligning principle applied for Gear Meshing

= BOGIFLEX

The 2 contacting surfaces or gear meshing between pinion and girth gear will permanently adapt to each

other

⇒ The Hertz contact pressure will be uniformized and, therefore, be minimized allong the complete tooth

of gear meshing.

⇒ No more stress concentration

⇒ Increased life of gear

⇒ Coefficient used for Wear and Breakage calculation according in applicable norms (DIN; ISO)

are effectively applied

Safety factor results are corresponding to effective condition of meshing

BOGIFLEX meshing CONVENTIONAL meshing

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD – General Principle

General Design:

cardan

KGD

Spring platesKILN SHELL

Girth gear

ERmaster

1 gearbox ERmaster standard

1 cardan with fixed length

1 BOGIFLEX drive KGD with main pinion 23 teeth

1 Girth gear - in two halves – cast steel

1 Set of tangential plates Y shape with shoes

BOGIFLEX® KGD

January 2010



General Design:

Ømax

Ømin

Length of spring plates are adjusted to enable

the mounting onto each kind of shell diameter

considered with the drive range

BOGIFLEX® KGD

January 2010



Pinion rollers:• Roll on Girth gear

– Adjust permanently the center

distance ; Keep the tip to root

clearance constant

– Meshing adjustment not performed

in plant: Workshop machining

Kiln backlash always adjusted

No post adjustment required

between pinion and girth gear

– Contact teeth meshing calculated

coefficient always right

• Floating on pinion

– Relative rotation with pinion

Low speed

– Floating fitting

• Oil lubrication

– Injection and bath lubrication

BOGIFLEX® KGD

January 2010



Inner rollers:

• To keep BOGI-Pinion

in position at kiln stop

• To enable driving during kiln

backward

• Roll on inner track

of the girth gear

• Made up with Glicodur

bearings

(standard calculation)

• Global clearance with the girth gear

Are not in contact with girth gear at

normal kiln driving

• Grease lubrication for complete life

BOGIFLEX® KGD

January 2010



Main Bearings:

• Over designed

– Dimension from pinion

dimension, not from loads

– Standard calculation L10h

gives 100’000 hrs minimum

• Oil lubrication

– Oil injection + splash

– Higher life time

• Securities on lubricated

equipment (flow, pressure)

• Thermal monitoring

of the bearings

BOGIFLEX® KGD

January 2010



Reaction Bar

Movement possibilities:

• Reaction bar with one shaft on top side

and one spherical plain bearing at bottom

side

• Allowing axial and radial displacement of

the BOGI-pinion by allowing rotation

movements

• BOGI-pinion casing independent from girth

gear casing for self alignment and

permanently good positioning onto girth

gear

BOGIFLEX® KGD

January 2010

FR b/w

FN w/p

RN b/w

FP b/w

Pushing effect



Reaction Bar

Load distribution:

• Reaction arm positioning gives

Pushing load effect

• Pinion always right positioned onto the

Girth gear

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD – Range guide line

General definition of KGD range:

Gear drive depends on

kiln torque value and

shell diameter.

3 areas defined

SMALL

MEDIUM

LARGE

Similar design for each size

Number of teeth and

modules are different

Power transmitted vs diameter on HOLCIM kilns

-

1,00

2,00

3,00

4,00

5,00

6,00

7,00

8,00

9,00

10,00

11,00

12,00

13,00

gamme de fours HOLCIM

para

mètr

es

SMALL

MEDIUM

LARGE

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD – Range guide line

General definition of KGD range:

• Technical data for predefined KGD sizes

– Kiln shell from 3,8 to 4,6 m – KGD Small

• Admissible torque value of 1’000’000 Nm corresponding to 470 [email protected] rpm

– Kiln shell from 4,6 to 5,2 m – KGD Medium

• Admissible torque value of 2’200’000 Nm corresponding to 1050kW@4,5 rpm

– Kiln shell from 5,3 to 5,3 m _ KGD Large

• Admissible torque value of 4’500’000 Nm corresponding to 2’120 kW@4,5 rpm

• Service factor acc. ISO 6336 Pitting KB > 1.51 ; Breakage KB > 1.75

• Kiln axial and radial displacements usually recorded

– Kiln Axial +/- 40 mm

– Kiln Radial displacement + thermal expansion +/- 30 mm

• BOGIFLEX KGD capacited in displacements– KGD admissible axial +/- 80 mm– KGD admissible radial +/- 40 mm

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD – Complements

Lubrication system:

Separate Lubrication

1) Girth Gear / pinion + Main pinion

bearings

- Forced lubrication of Girth gear &

pinion with adequate lubrication unit

- Choice of oil lubricant viscosity

depends on teeth working temperature

- Oil viscosity should be higher than 300

Cst at effective working temperature of

teeth meshing

2) HD gear set + Ermaster

- Injection lubrication of intermediate

gear set & primary gearbox

- Usual lubricant viscosity grade: ISO

VG 460

3) All gear stages have a safety splash

lubrication with foreseen reservoir

pump

High viscosity unit

Tank 600 L

Tank 200 L

Oil 3000 Cst

Motor filter 80 µm

ERmaster

Low viscosity

Unit

Oil 460 Cst

filter 40 µm

pump

To HD gear set

To Ermaster

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD – Complements Natural frequencies:

BASIC FORM

9.6

Hz

Bending

Mode

9.9

Hz

68.3

Hz

Torsion

Mode

63.6

Hz

70.3

Hz

Bending

Mode

78.1

Hz

Y FORM – KGD Standard

BOGIFLEX® KGD

January 2010

• Spring plates

• Girth gear

• Bogi-pinion KGD

• Reaction arm

• Cardan shaft

• Primary gearbox

• Baring unit / Inching drive

• Lubrication unit

• Housing & Sealing


BOGIFLEX® KGD – Complements

Main Components:

BOGIFLEX® KGD

January 2010



Conclusion:• No need of post adjusting of the pinion in front of the girth gear

– Bogiflex is not sensitive to thermal expansion conditions

THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING

• Optimised meshing and lubrication conditions and High safety factors:– Components designed for expected life time

– Criticality has been studied ; Criticality reduced by monitoring

RELIABILITY INCREASED

• Optimized Maintenance:

– Maximum number of elements are standard ones

– KGD studied in standard range in view of having available a set of pool spare parts in addition

to plant spare parts

– Design of KGD has been studied for each part to take care of time required to change it as

short as possible: To shorten shut down time of kiln for maintenance has been taken into

consideration when design

BOGIFLEX® KGD

January 2010


BOGIFLEX® KGD successful commissioning

Venezuela San Sebastian Plant

Ecuador Holcim Guayaquil

Mexico Apasco Macuspana*

USA Holcim Devil Slide*

Argentina Holcim Capdeville*

Slovaquia Holcim Rohoznik

Azerbaijan Holcim Garadagh

Documents

January 2010 BOGIFLEX® KGD - FICEM– Bogiflex is not sensitive to thermal expansion conditions THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING • Optimised meshing and