Modular industrial gearboxes for heavy-duty tasks
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NORD has changed from Transmissionmanufacturer to the value chain partner for complete solutions Drive Technology developed. The product portfolio also includes the industrial gear Maxxdrive series for maximum output torques of 282.000 Nm for applications in heavy-duty industries. The example of one Bascule bridge shows how individual drive solutions can be created with short delivery times.
Contents
- The team: industrial gear units, motors, frequency converters
- Tons of weight are gently gripped electromechanically
- The industrial gear unit Maxxdrive
- Condition monitoring avoids unplanned downtime
The team: industrial gear units, motors, frequency converters
Industrial gearboxes from the modular construction kit Maxxdrive are used in combination with the engines and frequency converters from Nord Drivesystems to a high-performance and intelligent drive system. The Maxxdrive transmissions offer a wide range of options and industry-specific drive solutions with almost endless customization options.
A good example of the performance of the drive portfolio from industrial gear units to electronic drive technology is one electromechanically operatede bascule bridge. Opening and closing the bascule bridge, which weighs many tons, requires high torques. The bridge moves very slowly. Shortly before the end positions, the movement must be precisely dosed to avoid damage to the structure and mechanics.
Tons of weight are gently gripped electromechanically
The powerful one is suitable for driving bascule bridges Hydraulic System. However, if you look at system costs, energy requirements and maintenance effort, there is a strong, efficient electric motor In conjunction with robust industrial gears, which are controlled by an intelligent frequency converter, they are often cheaper, more reliable and more space-saving than other products.
Reading tip: Planetary gearboxes for numerous applications
In the present application, the drive experts have one electromechanical drive designed from two Maxxdrive industrial gear units and two motor-mounted frequency converters. These drive a pinion that meshes with a toothed ring. This moves a lever mechanism that turns the bridge around the support point. The two frequency converters regulate the speed of the drives. The process control synchronizes the speed of the two drives using a torque adjustment.
With engineering to a complete solution
Such a drive concept cannot be automatically derived from the Construction kit put together. Here, know-how in the form of application engineering from several areas is required. The engineers support the client in developing their individual plug-and-play drive.
So which were they Requirements for the bridge drive? It should be low-maintenance and offer the longest possible service life. It has to open and close reliably several times a day - regardless of the weather. If a component fails, emergency operation must step in and the spare part quickly replaced. In the end positions, especially when the bridge is open, the drive system must be locked.
Design of industrial gears
To Fine regulation of the drive behavior the right electric motor as well as industrial gear units and frequency converters are selected based on the physical parameters of drive power, torque and speed.
A separate one is also required Brake for safe holding in any position, even with the engine dismantled, as well as an auxiliary gear for very slow crawl speed, emergency operation and maintenance operation. The auxiliary gear must also be able to be operated manually in an emergency.
All components get one Corrosion Protection according to the environmental conditions. The components are transported on a common frame for easy transport and assembly. The drive specialist has developed its own programs for calculating and selecting suitable drive systems. Once the optimal size of the gear unit has been determined, the modular Maxxdrive kit contains a large variety of combinations. The experienced engineers select the best possible variant from the options.
The industrial gear unit Maxxdrive
The maximum output torque is 282.000 Nm. This makes the Maxxdrive industrial gearbox very suitable for heavy-duty applications. In addition to the bascule bridge, these are z. B. mixers, agitators, drums, belt drives, mills or crushers.
The one-piece Block housing are particularly torsion-resistant and thus achieve a longer bearing life than parting joint gears. The industrial gearboxes also ensure efficient power conversion and high tolerance to impacts and load peaks. Large, low-friction rolling bearings ensure extremely high radial and axial load capacity as well as a long service life.
IE5 + synchronous motor for variant reduction and TCO reduction
The industrial gear unit runs thanks to the high axis accuracy noise. The gearboxes are available as Spur gears or bevel-helical gearboxes. They offer ratios from 5,60:1 to 400:1, with pre-gearing up to 30.000:1. For optimal integration into the system, the design offers mounting surfaces on all six gearbox sides. This allows the industrial gearboxes to be optimally integrated into the system. Flexible shaft arrangements and universal installation positions are possible.
Additional options expand individual design
Eleven sizes of Maxxdrive industrial gear units are available as three or four-stage Bevel and two or three-stage spur gear units. For applications that require low gear ratios in combination with high power, Nord has also designed the 2-stage bevel helical gear unit series XT.
The Maxxdrive XT Series includes seven sizes. In the standard version, this industrial gearbox is equipped with a heavily ribbed block housing and an integrated axial fan. The enlarged surface and the air duct hoods optimize the air cooling flow and ensure a very high thermal limit performance. This means that additional cooling options can often be dispensed with. Size Rolling and center distances increase the resilience and service life of the components.
Projected on the basis of the modular construction kit Nord Drive Systems Complete, customer-specific drive systems for heavy-duty operations – short delivery times included. The diverse offering includes Inverter, engines, transmissions and add-on components such as Couplings, Brakes, Cooling options, swing frame and numerous other options. These can have a wide variety of designs for input and output shafts, fastenings, backstops, seals, auxiliary drives, cooling equipment and sensors to monitor the operating status.
Condition monitoring avoids unplanned downtime
Drive systems for Heavy duty applications In addition to industrial gear units, electric motors and converters, they also need a fourth part: condition monitoring. Such industrial gear units are mostly used in sensitive applications in which failure can cause severe damage.
A pair of Condition monitoring The system ensures condition-based maintenance (predictive maintenance): On the basis of intelligent algorithms and software in an Industrial Internet of Things (IIoT) environment, networked drives collect their status data in the converter's own PLC and process it together with the data from connected sensors or actuators. The results of the preprocessing or the complete data are optionally transmitted to an edge device. This manages the data of all subsystems and evaluates them.
The gearboxes are then pre-selected and prepared Smart data available for further use and clear visualization. In this way, unplanned downtimes can be significantly reduced. Condition-based maintenance replaces the more complex, time-based maintenance. Users benefit from reduced maintenance requirements, can plan their maintenance, optimize energy consumption and increase the availability of the systems. The bascule bridge already benefits from it.
Predictive maintenance with the Nord cloud solution
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Dirk Boysen, Electronic Drivesystems is Head of Business Development at the Nord Drivesystems Group in Bargteheide.