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NORD industrial gear units succeed in massive construction project

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In the context of the “Linthal 2015” project, the underground central chamber for a new pumped storage power station has been built at an altitude of about 1,700 m – 600 m deep into the Swiss Alps. With an extreme incline of 45 degrees and a height difference of approximately 180 m, conveyor systems transported 500 t of excavated material per hour, around the clock. The conveyor belts were driven by NORD industrial gear units.

The underground central chamber is the core of the gigantic extension project. It consists of a 150 m long, 30 m wide machinery chamber with a maximum height of 53 m, as well as a separate transformer vault which is about 130 m long, 20 m wide and 25 m high. The excavation work for the two chambers was carried out continuously, i.e. 24/7 in 3-shift operation. Every day about 800 m³ of rock were removed from the mountain and in total almost 2,445,000 m³ were excavated from both chambers.

NORD industrial gear units were used in the conveyor systems which are located in the central area of the “Linthal 2015” construction project. Two “S-conveyors” conveyed 500 t of material per hour over a distance of about 260 metres. The excavated material was then conveyed down to a crushing plant. This conveyor belt was driven by a NORD industrial gear unit with brake control, which simultaneously generated electricity. On the second conveyor belt, the crushed material was conveyed up to the gravel plant, where it was stored until it was needed for further processing.

The manager of the plant construction company is extremely satisfied with NORD products and services . The high delivery availability was particularly praised: It only took ten weeks from ordering to delivery. The excellent price-performance ratio, the optimum advice as well as the high quality of the NORD products were also commented on positively.

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

Gearbox

Dişsan DKP Series Planetary Gear Units for Mixers

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Planetary gear units enable high power capacities in compact sizes. DKP series planetary gear units are specially designed for twin shaft concrete mixers. They are available in sizes suitable for 1 m3, 2 m3, 3 m3 and 5 m3 mixers.

DKP series gear units have a special input flange that enables to connect the gearbox with belt pulley as well as to connect two gearboxes with cardan shaft. 

Thanks to their rigid structure, they are suitable to operate safely even in harshest conditions. Housing material is GGG40 cast iron. Gears are produced from high quality, case hardened steel. Heat treatment process is applied to obtain 58-60 HRC surface hardness. The gears are precision ground to ensure a quiet and low vibration operation. Special oil seal options are available.

Input Options: 

  • With flange
  • Solid input shaft

Output Options: 

  • Hollow output shaft
  • Solid output shaft

Applications: Concrete, asphalt and other mixing applications 

Industries: Construction, Concrete and Asphalt Plants, Mining, Chemical 

Specifications:                                    Advantages:

Ratios: 5/1 – 28/1 Robust housing

High quality gears

Easy mounting

Long life bearings

High quality oil seals

Power: 11 – 75 kW
Optional:  Output coupling

Output shaft

Adapter and cardan shaft

 

Gearbox Size DKP2-360 DKP2-400 DKP2-420 DKP2-450
Nominal Torque (N.m.) 28,000 36,000 52,000

DKPK – Planetary Gear Unit with Reinforced Output

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Gearbox

Main causes of gearboxes failures

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In a world of optimization and digitization where factories are trying to reduce costs and downtime, the identification of basic gearbox failures can help you to save money and precious time so let the repair shop and service team become a key part of your optimization process.

With almost 50 years of years in the design, development, production and servicing of gearboxes and power transmission solutions, I-MAK’s experience has produced over a million possible configuration of its products implemented in thousands of applications. As a result, and while closely communicating with customers and end users we identified 3 main reasons for gearboxes failures.

1. Alignment of the gearbox on the application

This first cause of gearbox failure is purely mechanical, gears being designed to work in a certain configuration and backlash settings for each gear tooth, that when misaligned can cause a concentration of loads on a part of the gear, housing, bearings or other weaker part of the gearbox and induce premature failure. The identification of misalignment can be done during the maintenance period throughout the lifetime of the gearbox. Before failure, the healthier way to process is to ensure the right mounting of the gearbox during the installation in a new application or after the servicing of some of the machine’s components. We also advice a regular control of the gearbox alignment, our service team is controls this alignment during our regular visits with end users that signed an I-MAK Service plus agreement, securing an early identification or future failures.

2. Lubrication of the gearbox

Most of I-MAK’s gearboxes are supplied with high quality lubricant oil adapted to the type of application, environment and mounting configuration. As the manufacturer, IMAK calculates the right quantity and defines the right type of oil to ensure an ideal lubrication for both gears and bearings. The bath and splash lubrication configurations allow the right spread of oil in the gearbox, allowing the oil to create a thin film on the gears. This thin layer of oil prevents a metal to metal contact between the gears during their engagement. During the gearbox lifetime the oil quantity and quality can change depending on the applications and regular service intervals. Sealed and protected from external pollutants, that can affect the oil quality is a good method to ensure the health of the gearbox, a yearly oil change is recomended to allow for optimal lubrication. During the oil drain a quick analyse of the oil quantity, colour, presence of external elements, can give key indicator of the gearbox health and conditions. Gearboxes working in harsh condition can lose significant quantity of oil during their lifetime, causing a lack of lubrication of the primary gears and irreversible damages. 

3. Overload and operating mistakes 

Often exposed to harsh working condition, the gearboxes also suffer from overload and operating mistakes. Gearboxes are initially supplied with the right configuration and service factor to offer optimal working and enhanced performance. Yet the working conditions at the end user facility can differ from day to day and sometimes grow to extreme for the gearboxes, in facilities like; water treatment plants, bulk material producer and recycling companies.  These applications are often the ones imposing the hardest working conditions to the gearboxes. Exposed to external conditions these operators are regularly forced to stop their operation in emergency due to rain, electrical outages, feeder overloads etc.  During these emergency stop events, heavy loads are applied to the output shafts, torque arms and backstop devices. Fully loaded a conveyor, mixer or shredder is demanding an extra effort to the geared motors until it gets to the requested operating speed. Soft start devices and adapted automation can reduce the overload and mitigate the efforts made by the gearboxes. Unfortunately, it is hard to identity a damaged gearbox in such noisy environment, at the same time the gearbox rarely shows noise or vibration difference until it is too late. At this stage the operating temperature of the gearbox remain a good factor to identify potential failures that sometimes take years to appear. 

Although gearbox failures cause are not limited to these 3 causes, applying these basic advice could help you to save thousands of dollars and precious hours. We also invite you to consult our I-MAK Online service team, a unique online support service available in 5 different languages 24h/7.  

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Gearbox

Industrial type heavy duty gearboxes by Dişsan

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DA series helical and DK series bevel-helical gearboxes are suitable for heavy duty industrial applications. They are designed to transmit high output torques in optimized dimensions. They enable wide range of ratios with single to quadruple reduction options.

Thanks to their rigid structure, they are suitable to operate safely even in harshest conditions. Housing material is GGG40 cast iron. Gears are produced from high quality, case hardened steel. Heat treatment process is applied to obtain 58-60 HRC surface hardness. The gears are precision ground to ensure a quiet and low vibration operation. 

The gearboxes are available with hollow shaft or solid shaft. According to operating conditions, they are offered with optional accessories such as cooling systems, forced lubrication systems or oil expansion tanks. Back-stops, shrink discs and IEC B5 motor flanges are also available as optional accessorries. Special oil seal options are applied for dusty operation conditions.

Dişsan also offers complete solutions with motor, input coupling, gearbox and output coupling set on a steel base frame. 

For extruder applications, special extruder type right or left output options are available.

Input Options: 

  • Motor adapter for standard IEC B5 motors
  • Solid input shaft, without motor (right input, left input or double input shafts)

Output Options: 

  • Hollow output shaft
  • Solid output shaft (single or double)
  • Output flange

Applications:

Conveyors, Elevators, Mills, Cranes, Washing Units, Mixing Units, Extruders

Industries:

Mining, Construction, Metal Processing, Cement, Concrete Plants, Sand and Gravel Plants, Ceramics and Glass, Plastics

Industrial Gear Unit Types

DA – Helical Gear Units

DK – Bevel – Helical Gear Units

DAE – Extruder Gearboxes

Gearboxes with Auxiliary Drive

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