Alignment-free Drive System Thyssenkrupp uses Alignment-Free Drives for Belt Conveyor Systems
Thyssenkrupp is deploying Bonfiglioli alignment-free drive systems at a major gold mine expanding production in Papua New Guinea. The drives are used for discharge and spillage conveyors involved in the mine’s process plant expansion.
The application consists of two jaw crushing lines operating in parallel. Each line has two conveyors; one for discharging and one for spillage. The discharge conveyors have a design throughput of 1200 t/h, while the spillage conveyors receive a small fraction of that throughput in finer ores from spillage.
The general needs of the application were for operation 24 hours a day, 7 days a week, 52 weeks per year. Discharge conveyors were specified with right angle bevel helical drives incorporating rigid flange couplings, backstops and fluid couplings. Spillage conveyors were specified to be shaft mounted gear motors with torque arm, with bearing L-10 life to be greater than 60 000 h and gear life to be 100 000 h.
Bonfiglioli responded with drives of its Alignment Free Drive (AFD) configuration, which has extended the versatility of its HD series of heavy duty drives and which cost-effectively integrates motor and gearbox. The Alignment Free input design for the project – produced by Bonfiglioli’s recently expanded Drives Service Centre – negates the need for a costly baseplate.
The AFD input is basically a large bell housing that contains the fluid coupling, fan and provides a standard IEC interface for the flange mounted motor. This type of input also saves time and labour during commissioning of the drive as the alignment of the transmission components has already been done.
According Bonfiglioli, reliability of the drives is enhanced by vents in the drives’ bell housing, which allow air from the fan to be forced along a path to provide optimum cooling for the gearbox. The bell housing also has a additional benefit as it provides a collection point for fluid lost by the fluid coupling in case of a blowout.