MAAG TM PPU gear unit for roller presses, horizontal mills and kilns

MAAG TM PPU gear unit for roller presses, horizontal mills and kilns

2 Our quality policy FLSmidth MAAG Gear is committed to creating long lasting relationships that establish us as a trustworthy, reliable and professional partner for customers, suppliers and employees. This commitment includes providing high-quality and high-value solutions, products and services that result in satisfied customers. Certified to ISO 9001 standards With a clear focus on process management, we endeavour not only to meet but exceed international quality standards while providing appropriate resources to support and develop our purpose-designed quality system. Our quality policies reflect the importance of meeting our customers requirements. Our management regularly defines and reviews quality goals. Our employees are committed to the company s management system and to continuously improving not only the system but our entire organisation. Also, each employee is aware of the company vision and strategy and works to maintain a culture of opportunities. We are committed to providing a safe working environment for our employees and for those who use our products and systems. With our suppliers and external partners, we cultivate open communication and focus on performance-based results.

3 A pioneer of modern gear technology FLSmidth MAAG Gear has almost 100 years of experience in manufacturing gear units. The company was founded in 1913 and quickly expanded into an international group. FLSmidth MAAG Gear introduced the technology of mill gear units for the cement industry with great success in 1966. Since then over 700 MAAG TM gear units were sold in this sector. The company At the FLSmidth MAAG Gear headquarters in Winterthur, Switzerland, more than 100 employees work in development, design, finance, project management, sales, customer service and marketing. Production and assembly takes place in three modern plants equipped with high-performance machines. In Elblag/Poland, Milano/Italy and Bawal/India more than 200 employees manufacture gear units, drive systems and components which satisfy the most demanding quality standards. The company belongs to the successful FLSmidth Group, a listed Danish firm. A constant willingness to innovate, and close collaboration with our customers have helped to ensure that MAAG gear units continue to operate reliably throughout the world under the toughest conditions. Product range Today, the product range includes various gear units for mills, complete drive systems, gear solutions for bucket wheel excavators and belt conveyors, as well as maintenance systems for all types of plant. In addition FLSmidth MAAG Gear manufactures components such as bevel sets, girth gears and various replacement parts. All MAAG gear units are available as standard solutions or are customized to the required needs. Our strength The combination of unique precision, accuracy and modularized solutions with compact design are leading to high efficiency products and therefore low maintenance cost for the customer. Experience, new technical solutions and the latest manufacturing techniques are regularly incorporated into the production process. Intensive development and training of our engineers assure best understanding of how to operate a gear unit and lengthen its life cycle.

4 Proven technology geared up Design concept 1987 The PPU concept of 1987 is established in the cement and minerals market. Redesign 2013 With the objective of improving already proven technologies, MAAG has taken a critical look at the existing design and potential areas of use of the MAAG PPU, taking into consideration technological advances made in recent years. The results speak for themselves: Weight reduction of 25%, 15% smaller outer diameter, diversity of parts reduced by 20% all of which lead to lowered cost. Originally developed to drive roller presses, the field of application has been expanded during the redesign: The PPU drive train is now an attractive option to drive small ball mills. The drive train consists of main motor, gearbox with foot, high and low speed coupling, oil unit, auxiliary drive and optional water injection. Features Three-stage gear unit with input stage reduction (e.g. spur gear or bevel stage) and two planetary stages Power range up to 4000 kw Ratio 45 140 Input speed: 980 1800 rpm Integrated oil tank Bearing lifetime L 10hm > 100,000 Left and right gear units are interchangeable (for roller presses) Applications Roller presses, horizontal mills, kilns and others Industries: Cement production, minerals, mining and food Design criteria ANSI/AGMA 2101-C95 ISO 6336 and ISO 1328 Typical roller press application 1. Input stage (sample: spur gear) 2. 1 st planetary stage 3. 2 nd planetary stage 4. Cardan shaft 5. Torque limiting safety coupling 6. Balanced torque arm system (sample: FLS design) 7. Shrink disc 1 2 3 7 5 4 6

5 Scope of supply MAAG PPU The gearbox consists of two standardized planetary stages and a spur type pre-stage to adjust the speed. The oil tank is integrated into the gearbox and the toothing is splash lubricated and partially force lubricated. This also minimizes the complexity of the oil supply unit. Thanks to the highly standardised and modular concept, ratio adjustments have no impact on delivery times. Input stage The MAAG PPU is delivered with a spur gear input stage. Ratio requirements can easily be fulfilled simply by changing the wheels of the input stage, thereby providing the highest possible flexibility. Lubrication unit An oil supply unit with low-pressure pump, double oil filter and oil cooler are part of the scope of supply. For roller press drives, we offer a cost-effective solution with a single oil unit lubricating both gear units. The gear unit casing also serves as oil circulation tank. Torque arm system MAAG provides customised torque arm solutions such as balanced torque arm system (self-regulating system without foundation connection) or a single torque arm with torsion shaft for torque absorption into the foundation. Auxiliary gear drive The auxiliary gear drive has a high speed shaft with a sprocket wheel. Auxiliary drive and gear unit are connected via roller chains. Standard instrumentation Allmetra, ABB or equivalent Shrink discs Tollok, Stüwe or equivalent Torque limiting safety coupling Voith, Malmedi or equivalent Cardan shaft Voith, GKN or equivalent Couplings for ball mill application Low speed couplings of type MAAG ZCF are being used. Apart from the high power density which the toothed couplings provides, it allows some misalignment between mill and gearbox. Thermal growth of the drive train can also be compensated. To connect motor and gearbox, rubber type high speed couplings are being used. Torsionally flexible couplings are beneficial due to damping possible resonance conditions and transient dynamic overloads. Optional condition monitoring system Excluded from our scope of supply is the condition monitoring system which helps to save money by enabling condition-based maintenance. We offer solutions of Prüftechnik or Dalog. Spur gear input reduction Bevel stage input reduction Possible torque arm system for roller presses

6 PPU selection diagram Product range MAAG PPU for roller presses 3200 kw 1600 kw PPU-56 PPU-52 PPU-48 PPU-44 Installed motor power [kw] 800 kw 400 kw 200 kw PPU-40 PPU-37 PPU-34 PPU-32 PPU-30 PPU-27 PPU-25 PPU-22 PPU-20 PPU-18 100 kw PPU-16 Application factor If the MAAG PPU is used for roller presses, we calculate on the appropriate application factor K A = 2 (ISO). 50 kw 10 rpm 12 rpm 14 rpm 16 rpm 18 rpm 20 rpm 22 rpm 24 rpm 26 rpm 28 rpm 30 rpm Roller speed [rpm] PPU Type Nominal Torque [KA = 1] 25 27 30 32 34 37 40 44 48 52 56 472 knm 590 knm 756 knm 940 knm 1110 knm 1400 knm 1740 knm 2260 knm 2800 knm 3500 knm 4200 knm n Bolts Ø B d [mm] Ø 330 Ø 360 Ø 400 Ø 450 Ø 460 Ø 480 Ø 530 Ø 600 Ø 640 Ø 700 Ø 760 e [mm] Ø 1110 Ø 1200 Ø 1250 Ø 1385 Ø 1480 Ø 1540 Ø 1685 Ø 1820 Ø 2020 Ø 2080 Ø 2270 f [mm] Ø 1007h8 Ø 1092h8 Ø 1128h8 Ø 1255h8 Ø 1350h8 Ø 1424h8 Ø 1555h8 Ø 1701h8 Ø 1892h8 Ø 1945h8 Ø 2147h8 Ø f Ø d Ø e Ø D 0 B [mm] Ø 39 Ø 39 Ø 45 Ø 45 Ø 45 Ø 52 Ø 52 Ø 62 Ø 62 Ø 70 Ø 70 n [mm] 17 17 17 17 18 17 19 17 19 17 19 L t Ø s L [mm] 1851 2001 2072 2162 2265 2370 2505 2732 2819 3060 3209 D [mm] Ø 1007 Ø 1092 Ø 1128 Ø 1255 Ø 1350 Ø 1424 Ø 1555 Ø 1701 Ø 1892 Ø 1945 Ø 2147 O [mm] 262 305 316 336 361 382 410 450 482 502 522 s [mm] Ø 110m6 Ø 110m6 Ø 120m6 Ø 120m6 Ø 130m6 Ø 140m6 Ø 140m6 Ø 160m6 Ø 160m6 Ø 160m6 Ø 180m6 t [mm] 198 198 220 220 234 243 243 320 320 320 282 mass [t] 3.4 4.7 5.3 6.7 7.8 9.3 12.3 15.8 20.3 25.4 31.6 Data for PPU Types 16 (120 knm), 18 (190 knm); 20 (260 knm) and 22 (358 knm) on request

7 Features/benefits Reduced to the max: smaller, lighter and more compact design Input stage exchangeable Both senses of rotation possible Flexibility with modular and standardised design Only five different types of bearings implemented Ring gear is part of the casing Cast and welded parts long operating life Design The design of the PPU gear unit is optimised to suit the power required, the motor/mill speed and local circumstances. It is easily adaptable to different applications thanks to the flexible input stage concept. Quality Production and all activities are monitored by the internal quality assurance system in strict compliance with ISO 9001. Production The latest machines and technical equipment are used in manufacturing. Delivery time Thanks to continuous monitoring of our production schedule, our clients are provided with the real time status of a project at any time. Installation The compact design simplifies transport and reduces assembly time. Test running Gear units are tested and logged in detail on our test bed prior to delivery. Spare parts Spare parts are available throughout the life of the gear units. Thanks to standardisation, fewer different spare parts are necessary. Customer service Customer care by trained and skilled personnel guarantees professional after sales support. Maintenance High service comfort. Easy accessibility of gear units due to removable input stage. Monitoring system Gear units are equipped with temperature monitoring sensors. Option Customised condition monitoring system VIBROWEB XP ask us for more information about this compact solution. PPU in assembly Installation of PPU Drive train PPU for ball mills

Copyright 2015 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth and MAAG are (registered) trademarks of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidthmaaggear.com CM 10-15 500-21-ENG V2 FLSmidth MAAG Gear AG Lagerhausstrasse 11 P.O. Box 8401 Winterthur Switzerland Tel +41 52 260 35 00 Fax +41 52 260 35 35 info@flsmidthmaaggear.com