Gearless mill drives for conveyors

7/30/2019 Gearless mill drives for conveyors

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Gearless Conveyor Drive (GCD)Conveyor Portfolio Meeting

BU Minerals PG Material Handling and Grinding


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ABB GroupSeptember 28, 2012 | Slide 2

New market demands on Overland Conveyors

Environmental friendly transport of material

Increased length e.g. concentrator plant on lower altitudes

Increased length reduce number of flights and transfer stations

Higher conveying capacity

Higher drive power required, it means:

Gear power for angular gears limited to approx. 3000 kW @ ~ 70 min-1

New drive concept with new equipment needed

Overland ConveyorChange in Market demand


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Pulley 1 (twin drive)

2 x 1045 kW, 1793 min-1, 4kVCouplingBrakeAngular GearboxPulley with antifriction bearings

Frequency Converter ACS1000

Angular gear box and brake in single or twin drive configuration

Pulley 2 (single drive)

1 x 1045 kW, 1793 min-1, 4kVCouplingBrake

Angular GearboxPulley with antifriction bearingsFrequency Converter ACS1000

Overland ConveyorConventional Drive Configuration


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Overland ConveyorChange to gear- & bearing-less drive solution

Helical gear box and brake in single or twin drive configuration


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Overland ConveyorLonger belts with higher capacity


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Conveyor Drive TechnologyMechanical Configuration

General arrangement of

head drive station (Takraf

GmbH) with Gearless

Drives (ABB) on one side

and disc brakes on the

opposite side

Gearless Drives


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Conventional Drive Configuration

Tail: 0 kW Head: 2 x 2500 kW

New Drive Configuration

Tail: 0 kW Head: 1 x 5000 kW

Conveyor Drive TechnologyLess Equipment with Gearless Conveyor Drives

New Drive Configuration allows a component reduction of 50%, means only one:

Driven Motor shaft per pulley

Motor, Frequency Converter, Transformer, MV-breaker in case of single drivesper pulley or smaller Multidrive system.

Max. belt tension might be higher (to be checked for each project)


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Conveyor Drive TechnologyLess Equipment with Gearless Conveyor Drives

Avoiding limiting Gears (max.3 MW), the new Gearless Drive Configuration allows:

Longer Overland Conveyors due to new Belt and

Reduction of number of Flights and Transfer-Stations

Tail: 1 x 2500 kW Head: 2 x 2500 kW

Overland Conveyor 1 Overland Conveyor 2Transfer Station

Tail : 1 x 2500 kW Head: 2 x 2500 kW

New Gearless Drive Configuration

Tail: 1 x 5000 kW Head: 2 x 5000 kW


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MaintenanceGear Reducer

Gear reducers:- limited to ~ 3 MW- intensive maintenance required

- life time ~ 10 years

The bearings of the gear reducer (failures on input bearings are mostcommon) have a life time of down to 3 - 4 years. The change of thebearings is linked to a major overhaul.

High focus on lubrication is required. Common issues:- Water contamination- Inadequate oil supply to individual bearings- Defective or unsuitable shaft seals

The life time of gear reducers of approx. 10 years are not matchingthe life time expectations of the conveyor and need to be replaced.


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Conveyor drive technologyWear & tear parts / MTBF of drive train

MTBF of drive train (excl. pulley & pulley bearing)

> 22 wear & tear partsMTBF < 3 4 Years(MTBF = Mean Time Between Failures)

Benefits:2 main wear & tear parts

MTBF > 30 Years(MTBF = Mean Time Between Failures)

High efficiency

Preferred solutionLoad

Motor 1

5 MW

Load

Motor 1 Motor 2

2.5 MW 2.5 MW

Motor 2

Disk Brake 2Disk Brake 1 Gearbox1

Coupling 1.1

Coupling 1.3 Load Coupling 2.3

Coupling 2.1Motor 1

Gearbox 2


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Low Speed & Bearing-less SolutionCooling forms & accessories

Cooling : typical IC37, IC666, IC86W, others on request

Protection class up to IP55

PT100s for winding

Space heater

Speed and position encoder

Sole plates, anchor bolts and shim

Make up filters are not accepted due to high dust content in

ambient air. Protection class at least IP55 (preferred IP65)


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Motor with or without bearings ?

Motor with bearings

limited life time of bearings

reduced reliability

additional supervision for bearing

higher Capex & Maintenance Costs

larger size and higher weight (transport, crane capacity) longer drive train (higher tendency to oscillations)

Motor without bearings

much higher reliability

almost maintenance free motor design, means:- excitation-, earthing-brushes & cooling device only

Air gap sensors to keep air gap in tolerance

Conveyor Drive TechnologyMechanics and Installation

no maintenance required on the heavy components


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Gearless Conveyor DriveDescription / Flange Connection up to ~ 4 MW

Connection between motor / rotor and drive pulley with rigid flange


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Gearless conveyor driveDescription / flange connection > ~ 4 MW

Connection between motor / rotor and drive pulley with rigid flange

M

otor

Pu

lley-F

lange

Supports for bearingless rotor


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Gearless Conveyor DrivesTransport & Installation of Motor


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Transportation

After test run motor is dismantled and stator and rotor aremounted on steel supports and enclosed with wooden boxes


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Transportation

Rotor inside transportation cage is uncrated and turned to verticalposition. Lifting ring is mounted around the rotor at factory.

2300

4600


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Rotor / Stator installation (bolted flanged rotor) Flange connection. Sleeve bearing on load side.


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Gearless Conveyor DrivesSystem Comparison

Efficiency comparison

Price comparison drives (without mechanical part)


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Efficiency (typical)System HSS/LSS 2 x 2500 kW / LSS 1 x 5000 kW

Efficiency vs Motor Load (IEC)

86

88

90

92

94

96

98

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

Motor Load [T/Tn]

Efficiency

[%

]

Operation at nom. conveying capacityapprox. 75% of nominal motor loadSM Eff iciency (5 MW):

+ 4.3% higher than SCIM+ 4.3% higher than WRIM

No load operation example @ 35%of nominal motor loadSM Efficiency (5 MW):

+ 6.2% higher than SCIM+ 5.8% higher than WRIM

Eff. design point for equipment:Over sizing factor: 125 135%of nominal motor load

2 x 2500kW to 1 x 5000 kW Motor @ 100% speed

SM 1 x 5000 kW

SM 2 x 2500 kW VSD with Squirrel Cage(SCIM) + Gear

Slip Ring Motor (WRIM) +

Gear

VSD with SynchronousMotor (SM)

VSD with SynchronousMotor (SM)


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Lifecycle CostsCAPEX (2 x 2.5 MW, 1 x 5.0 MW, 20 years)

Inve

stmen

tCo

sts

100 %

40%

80 %

20 %

140 %

120 %

180 %

200 %

60 %

160 %

0 %

2 x 2.5 MW 2 x 2.5 MW2 x 2.5 MW2 x 2.5 MW

ACS

Motor

Trafo

ACS

Motor

Trafo

Investment costs (3-stage gear box, 1 add. Coupling)Investment costs (drive system), Price adder for high efficiency EUR 50000 / 2500 kW MotorExcluding mechanics, foundations & control (not available yet)

High SpeedGeared Drive

VSD HSS 2x12-p. VSD HSS 24-p.

10

0%

(142%)

11

4%

(158%)

14

6%

13

3%

ACS

Motor

Gear

Trafo

Gear

repl.

after

10 y.

Gear overhaul or replacement after approx. 10 years operation required

ACS

Motor

Gear

Trafo

Gear

repl.

after

10 y.

1 x 5.0 MW

ACS

Motor

Trafo

9

6%

Gearless VariableLow Speed Drive 24-p.

VSD LSS Bearing VSD LSS Bearingless

Lif l C E


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Lifecycle Costs EuropeCAPEX & OPEX (2 x 2.5 MW, 1 x 5.0 MW, 20 years)

Lifecyc

leCo

sts

50 %

20%

40 %

10 %

70 %

60 %

90 %

100 %

30 %

80 %

0 %

Investment costs (3-stage gear box, 1 add. Coupling)Investment costs (drive system)

Maintenance & Service Costs

Operation, Energy Costs (EUR 0.065 / kWh)

(Gearless 2500 kW drive: Energy savings 2.3% at 85% drive load)

2 x 2.5 MW2 x 2.5 MW2 x 2.5 MW

High SpeedGeared Drive

VSD HSS 2x12-p. VSD HSS 24-p.

9.

8%

2

%

Trafo, ACS, Motor

5.8

%

6

%

Trafo, ACS, Motor, Gear

6.6

%6%


8.0

%

2

%

Trafo, ACS, Motor

+ LESS DOWN TIME

with Gearless andBearingless Drives

5.6

%

1.8%


2 x 2.5 MW

Gearless VariableLow Speed Drive 24-p.

VSD LSS Bearing VSD LSS Bearingless

1 x 5.0 MW

> 7.0%

88

.2%

100%

88

.2%

85

.9%

85

.9%

85

.7%

1

01%

100%

1

00%

95

.9%

97

.7%

93

.1%


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Gearless Conveyor DrivesReferences

ABB D i S l ti


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Same drive technology used for mine hoist drive

Power demand up to 8000 kW @ 50 min-1

Drive System consisting of:- Synchronous Motor- Frequency Converter ACS6000- Converter Transformer

- Control System- etc.

No. of worldwide installations in operation:

ACS6000 Single- & Multi-Drive (several applications) ~ 1000 systems Low Speed Synchronous Motors (several applications) ~ 1000 pcs

ABB Drive SolutionsReferences

ABB D i S l ti


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Mine Hoist drive installations: ~ 100 systems

Operation conditions harder compared to conveyor applications:- High number of start / stop cycles- Change from motoric to regenerative operation

Number of overland conveyor with ACS6000 drive installations

high speed solution with gear box: 9 drives- 3 ACS6000 Multi-Drive uphill 3 x 2 x 2000 kW

- 1 ACS6000 Multi-Drive downhill Active Front End 3 x 2000 kW

- 1 ACS6000 Single-Drive uphill 1 x 2000 kW

Other conveyor installations:

- 32 projects since the year 2000 with approx. 120 LV- & MV-Drives

ABB Drive SolutionsReferences

Actual Projects


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1 Project: Order expected in October 2012

Gearless Conveyors with several 12 x 2500 kW Drives

Engineering Order for Development Project in Progress Gearless Conveyor with 3 x 7000 kW, Design study with several

solutions

Several Projects in Discussion (Feasibility Study)

Power range 2000 kW . 7000 kW

Actual ProjectsGear- & Bearing-less Conveyor Drive

Summary


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Benefits of Gear- & Bearing-less Synchronous Motors

Compact and simple design less space

High efficiency, better than induction motor (no slip losses)

No gearbox losses

Less components less interfaces, engineering, projectmanagement and spare parts

Drive train free of oscillation Almost maintenance free drive system

No gearbox cooling, monitoring, supervision, oil coolers / heaters

No back lash during oscillations and at load reversals

Less installation and commissioning

Higher availability & reliability

SummaryGear- & Bearing-less Conveyor Drive


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Gearless mill drives for conveyors

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