The pinion and girth gears of two 9 mw ball mills exhibited severe scoring within five months of lubrication failure, torsional vibrations, alignment and gear. This article focuses on ball and rod mills excluding sag and ag mills. We firmly perform our quality policy, we hold iso9001. Every combiflex drive is equipped with its own auxiliary drive unit. A ball mill is a type of grinder used to grind, blend and sometimes for mixing of materials for use in mineral dressing processes, paints, pyrotechnics, ceramics and selective laser sintering. If the ball mill would be equipped with fixed speed motors, then they will have to be washed out, isolated and stopped. Girth gears gear wheels are large ring gears which are normally fitted to the outside of ball mills or rotary kilns to provide the primary rotational drive,which is required to be operated in a long time so, the quality requirements during the actual production for the big gear ring are very high girth gears are applied in the mining, cement, minerals industries used in various types of. Pitch circle diameter of girth gear mm 70 60 50 40 30 20 10 0 1. How to choose suitable ball mill girth gear and pinion. In dual arrangement, with one gear unit on either side of the mill, our maag lgdx gear unit covers grinding applications up to 14,000 kw. We are engaged in manufacturing and supplying girth gear, industrial girth gear, kiln girth gears. Cr4thread ball mill girth gear and pinion alignment.
As soon as the gear and pinion have been cleaned and coated with the proper lubricant, the gear guard should be assembled and set on its foundation. We can provide all elements of a mill drive system as a fully optimised solution to suit your process exactly, or individual mill drive gearboxes, girth gears, pinions and couplings as required. Mill and kiln gears method of mounting flange tangent plate or other max. Shell deformation measurement on rotary kilns or ball mills with laser distance sensors. Gear alignment is the most important technical procedure for optimum operation of two gears in mesh. Normally i would treat the mill as the datum and align everything back to the motor as the last adjustment. The girth gear of ball mill is the major component used in rotary kiln and ball grinding mill which is required to be operated in a long time. Common types of grinding mills include ball mills and rod mills. Girth gears with durable, heavyduty performance flsmidth. Jul 21, 2018 therefore, the ball mill girth gear and pinion materials are required to have sufficient strength, high wear resistance and good processing performance.
Chaeng arranges lineation process several times, in order to make ensure the machining accuracy and position accuracy of girth gear. A plate steel gear guard is furnished with the mill for safety in operation and to protect the gear and pinion from dirt or grit. It is attached to the girth gear and provides continuously the. Raw material mill, also called raw meal mill, is important grinding equipment in cement production process. The mill is driven by a girth gear bolted to the shell of. Get best price and read about company and get contact details and address. Phased array eddy current array testing provides 100% coverage of root and load face in one pass and ideally suited for mill and kiln girth gears testing with two probes able to cover most sizes. Cm1 girth gear report gear mechanical engineering free 30. For smaller gears a flexible probe like a piece of thick vinyl can conform to any gear shape required. Gear cutting of a split girth gear for a cement mill having an input power of 2200 hp 5. Flangemounted girth gears, the more common of the two, are most frequently utilized in cold processing equipment such as sag semi autogenous grinding mills and ball mills for use in the mining and cement industries. Department of machine design, kth, se100 44 stockholm. Mill and kiln gears installation maintenance gear screw scribd.
Girth gears can be supplied individually, or as part of a fully optimised mdx mill drive package which includes. The gear unit with its integral selfaligning drive pinions forms a single unit together with the girth gear, sliding shoe bearing assembly, slide ring and axial guide. Although their concepts are very similar, they are not discussed here. Denver ball mill tablas free download as pdf file pdf text file txt or read online for free be sure to list size and description of machines total length of the shell may colvist of several shell lengths flanged together to provide the desired mill length liners bearings gears and drives are similar to those standard on all. A ring gear may be fastened in one of several ways depending on the application, e. Girth gear is with super large diameter, the module is more than 10mm.
What is the ball mill gear material crusher mills, cone. It transfers the torque and speed from the mill motor to rotate the ball mill. Standard girth gear castings confirming to specified levels of mechanical properties covering hardness, tensile, yield and elongation is given in the table below. Ball mill pinion alignment pdf alianzcanineitaliait cr4 thread ball mill girth gear and pinion alignment re ball mill girth gear and pinion alignment 08272011 207 am pinion alighnment is done by coating the pinion with a lead based grease after rot. The pinion shaft failures usually occur as a result of a fatigue fracture, which originates from the corner of the keyway in the pinion shaft. After temporary alignment of the teeth of pinion and girth gear with the mill empty, fig. A ball mill consists of a hollow cylindrical shell rotati. This includes all rotating mills with heavy grinding media loads. Lateral drive alignment ball mill crusher mills, cone. Besides particle size reduction, ball mills are also widely used for mixing. Cement mill girth gear pinion alignment procedure pdf.
Make rotary kiln girth gear in the basically correct position, turn the kiln body, use dial indicator to measure the radial and endon jerk value. Lewicki nasa ames research center summary in this paper, the authors show a detailed analysis of the vibration signal from the destructive testing of a spiral bevel gear and pinion pair containing seeded faults. The girth gear cracking usually initiates from a defect in the gear. Elastic mill sag by weight of mill balls and materia. A complete range of gear and pinion sets, inspections, design, installation and alignment services to drive your mill s performance. Ball mill girth gear and pinion alignment cr4 discussion. This girth gear is widely demanded in different industries to be installed in different machines such as rotary kilns, rotary dryers and ball mills, girth gear for ball mill, girth gear for cement mill, girth gear for raw mill, girth gear for rod mill, gear for ball mill, gear for rod mill, gear. With a variety of options for cast, fabricated steel or sg iron and multisegmented gears, david brown santasalo is your one stop shop for girth gears for ag, sag, ball mill, kiln and dryer applications. Open gear drives are very common in the raw materials industry. Maintenance and replacement of rotary kiln girth gear. The kiln girth gears are available mainly in bipart, four parts, 8 parts or multi segments as per the requirement and suitability with the application of gear. Chaeng ball mill girth gear in the grinding process of metal mines, ball mill plays an important and irreplaceable role, and the girth gear is rotating device of ball mill, playing a big role in long term stable operation of ball mill. By current standards, girth gears can be as large as 14 meters 46 feet in diameter, 1. You can expect the same quality supported by decades of gearing and oem expertise.
New girth gears and drive pinions for two ball mills. Industrial gear units, segmented girth gear seweurodrive. Moving the pinion to achieve alignment to the gearbox will disturb the pinion to girth gear alignment. We bring forth a highly advanced ball mill, specifically engineered for both wet as well as dry cement grinding applications. Symetro gear unit the ideal central drive solution for your ball mills around the world more than 1 000 gear units are in operation some of them since more the eighty years spare parts for all gear units supplied since 1926 are still available based on our comprehensive documentation files the symetro gear. A typical application consists of a motordriven primary singlestage reducer that, through a flexible coupling, drives a large open pinion which in turn, meshes with a large ball mill ring girth gear that is attached directly to the ball mill. This type is suitable for rotary kiln and ball mills as transmission gear. This manual needs to be available for use during installation of the girth gearing supplied. Singlepinion and dualpinion fixedspeed gear drives offer. We can provide all elements of a mill drive system as a fully optimised solution to suit your process exactly, or individual components as required. Senior design engineer maag gear ag rocco amato head of mill gear engineering maag gear ag. The rotation is through the ball mill motor driven pinion gear shift operation, the material in the feed gradually into the hollow. So, the quality requirements during the actual production for the big gear ring are very high. Hi we have replaced the girth gear of a ball mill used for coke grinding, and we have completed gear alignment.
The shim may span several bolts in sectors where the required thickness is substantially constant. Kumera active drive girth gear ensures optimal load distribution on girth gear teeth throughout the years of operation without a need for high accuracy alignment. The girth gear is the major component used in rotary kiln and ball grinding mill which is required to be operated in a long time so, the quality requirements during the actual production for the big gear ring are very high. The flexible concept from seweurodrive has simplified manufacturing, transport and assembly. Re ball mill girth gear and pinion alignment 08272011 2 07 am pinion alighnment is done by coating the pinion with a lead based grease. Ball mill gear guard a plate steel gear guard is furnished with the mill for safety in operation and to protect the gear and pinion from dirt or grit. Optimize girth gear based on the operation characteristics of the rotary kiln and ball mill, to ensure the stability of the girth gear during the long time operation and extend its service life. Its normally fixed in the outer sphere of the metal shell. Ball mill close circuits ball mill and open circuits ball mill. Girth gears mill pinion gear s the results of detailed investigations have indicated that fatigue failures have occurred in the majo rity of cases. Idmdrivers runtime engine from national instruments file name. Damage to mill cylinder, neck or stub endanger girth gear and pinion.
Measurement tools for the cement industry mechanical condition monitoring on rotary kilns 15. Grinding ball mill girth gear root clearance cr4 discussion thread. Your heavyduty processes need components that are up to the task and our maag gear girth gears deliver highperformance for your mill or kiln. Our factory advantages manual gear pumps of ball mill pdf. One side drive provides a power range up to approximately 8,000 kw when engaged with the girth gear of your ball mill.
Metso is proud to announce the launch of our new rebranded offer. Detailed vibration analysis of pinion gear with timefrequency methods marianne mosher, anna h. It is only natural that this kind of force subjects the gear wheels to very high stresses. Highly resilient girth gears and pinions were used to modernize two ball mills. The femethod is utilized for deformation and stress calculation of a whole girth gear including the strength calculation of the fixing structure.
Such gears are usually designed as spur or helical gears with. The girth gear and pinions manufactured as our standard offering are governed by the specification under agma 60146114a06, published in 2006 this is. Mill drive gearbox girth gear pinions barring drive auxiliary equipment including couplings, brakes, pedestal bearings and clutches whichever option you chose, be assured that your girth gear will be. As a guideline for the alignment of large girth gear drives, the. Repairs entail extra work for girth gear dismantling. Damage to mill cylinder cannot endanger gear teeth.
Open gear drives of kilns and ball mills are often exposed to harsh operating conditions. In order to maintain alignment of the girth gear and mill pinion, standard practice in the industry is to measure the temperature difference across the face width of the girth gear. Generally use gear root as alignment reference, and weld girth gear with spring plate through electric welding. Girth ring gears if you need large diameter girth gears in your process machinery, then you need a product you can rely on.
Maag gear symetro gear unit spare parts and accessories. The girth gear driving pinion ends up getting aligned to the reducer, causing a misalignment issue between the girth gear teeth and the driving pinion teeth fig. These large coal crushing drive systems are usually rotated by motordriven gearing. Pinion pittings in open girth gear pinion pittings in open girth gear rkarthik mechanical. Shramdeep engineering offering ball mill girth gear. Gears and pinion for ball mill crusher mills, cone. Girth gear applications girth gears fall into two basic categories. In progress part three rotating girth gear using alignment fixtures duration. The david brown standard is a maximum temperature difference deltat of 6 degrees celsius across the face width of the girth gear.
Mwl, department of vehicle engineering, kth, se100 44 stockholm. Flange mounted gears rely, in large part, on the mill structure to provide the stiffness and geometric stability. Girth gears more than just metal and teeth gear technology. Industrial gear units girth gear series girth gears are used to drive large, rotating systems such as dryers, rotary kilns or horizontal mills. What are the insandouts of quality inspection of girth gears, from both a. Pcm specialist in vibr, laser, gear alignment, condition based maintenance on mills.
Unfortunately, to get what is required, this information needs translation into something that the gear. Girth gear testing using advanced ndt phased array eddy. High vibrations on a ball mill amp maintenance forums. The raw meal is grinded into fine powder by the motion and squeezing of steel balls.
Gear unit that perfectly fits your ball mill flsmidth. Our symetro gear is a split torque central drive unit for ball mills. Classified depending on the circuit design, bearing, grinding type and drive, the selection is made on the basis of the product fineness, quality, and nature of raw material, site conditions and specific requirements. Great wall steel casting has large production capability in steel castings, so we can provide girth gear with short cast period and large amount. Ball mill girth gear and pinion alignment 08272011 2. This compact solution utilizes the full load capacity of the valuable girth ring while providing maximum usability and. Drive pinions and segmented girth gears made from robust adi keep. Ball mill girth gear and pinion alignment cr4 discussion thread. Cm1 girth gear report free download as excel spreadsheet. Great wall castings big gears are applied in rotary kiln and ball mill of 5000 tpd cement production line in domestic famous cement enterprises, such as xinjiang tianshan building material group, henan mengdian group, etc. This can be an internal or and external surface defect. The girth gear drives that are used in tube mills, coolers, washing drums, kilns, calciners and other machines have to transmit enormous torques i.
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