BOGIFLEX KGD

January 2010

BOGIFLEX KGD

Self Aligning and Floating

Kiln Gear Drive

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

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 kiln
The 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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

Cement Kiln Influence parameters on Gear Meshing

Wobbling of Girth Gear
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
Overloading due to wobbling Center distance change Lack of tip to root clearance

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD is solving these issues

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX Concept
Floating drive + Self aligning principle applied for Gear Meshing = BOGIFLEX
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

Spherical plain bearings

Pillow block

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

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
http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

CONVENTIONAL meshing

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

General Design:
KGD
cardan

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

Girth gear

KILN SHELL

Spring plates

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

General Design:
Length of spring plates are adjusted to enable the mounting onto each kind of shell diameter considered with the drive range

min

max

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

Main Bearings:
Over designed Dimension from pinion dimension, not from loads Standard calculation L10h gives 100000 hrs minimum
Oil lubrication Oil injection + splash Higher life time Securities on lubricated equipment (flow, pressure) Thermal monitoring of the bearings

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

Reaction Bar Load distribution:
Reaction arm positioning gives Pushing load effect Pinion always right positioned onto the Girth gear

FN w/p

FR b/w

RN b/w

FP b/w Pushing effect

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD Range guide line

General definition of KGD range:
Gear drive depends on kiln torque value and shell diameter.
Power transmitted vs diameter on HOLCIM kilns
13,00

12,00

LARGE

11,00

10,00

9,00

3 areas defined SMALL MEDIUM LARGE Similar design for each size

8,00

paramtres

7,00

6,00

MEDIUM
SMALL

5,00

4,00

3,00

Number of teeth and modules are different

2,00

1,00

gamme de fours HOLCIM

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

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 1000000 Nm corresponding to 470 KW@4.5 rpm

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

Admissible torque value of 2200000 Nm corresponding to 1050kW@4,5 rpm

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

Admissible torque value of 4500000 Nm corresponding to 2120 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 KGD admissible radial +/- 80 mm +/- 40 mm

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD Complements

Lubrication system:
Separate Lubrication

ERmaster
To Ermaster To HD gear set

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
http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

Low viscosity
Unit Oil 460 Cst Tank 200 L pump High viscosity unit pump Oil 3000 Cst Tank 600 L

filter 40 m

Motor filter 80 m

BOGIFLEX KGD
January 2010

BOGIFLEX KGD Complements

Y FORM KGD Standard

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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD Complements

Main Components:
Spring plates

Girth gear
Bogi-pinion KGD Reaction arm

Cardan shaft
Primary gearbox Baring unit / Inching drive Lubrication unit Housing & Sealing

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD General Principle

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

http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

BOGIFLEX KGD
January 2010

BOGIFLEX KGD successful commissioning

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http://www.cmdgears.com 539, avenue du Cateau - 59400 Cambrai - FRANCE

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