A drive train package, launched by ABB at Hillhead 2014, demonstrates the benefits of using a single source supplier for all components from electric motors, variable-speed drives, gearboxes, bearings and couplings.
If required, a single service contract can be purchased for the entire drive train. However, components such as gearboxes, couplings and bearings are designed for easy and rapid removal and installation, offering major time saving for in-house maintenance teams. Specific features, such as the sealing techniques used in bearings, aim to extend the life cycle of the components. All the benefits are designed to reduce downtime, lower operating costs, improve reliability while increasing productivity levels.
Bearings
Highlights of the bearings on show include an adapter sleeve system used on the ISN spherical, ISN hydraulic assisted mounting and GripTight bearings which makes removal and installation quicker. An internal bearing puller removes the inner ring from the adapter and then pushes the adapter in the opposite direction out from under the bearing. Utilising the internal puller eliminates the need for special external tools, and allows the bearing to be installed or removed quickly.
The sealing system for these bearings plus the Setscrew ball bearing features flingers that protect the bearing by keeping lubricants in and contaminants out, thereby extending the life of the bearings, increasing up-time by up to 50 percent, minimising maintenance costs and lowering overall installation costs.
The ISN range is a complete unit that is delivered ready out-of-the-box.
Gearboxes
The ABB Dodge Quantis line features three global industry-leading gear motors and reducer solutions: In-Line Helical (ILH), Motorised Shaft Mount (MSM) and Right Angle Helical-Bevel (RHB). Designed to achieve greater output torque and power ratings and expanded ratio range, the Quantis range can allow the customer to downsize from existing units, resulting in a reduced product cost.
The range features an optional XT harsh duty output seal for wet and abrasive environments. This seal has a quadra lip design, rubber coated inner and outer seals and a protected seal running surface. ABB Dodge® speed reducers, come with sealing options that keep dirt and debris out giving a minimum operating life of 25,000 hours in harsh high load conditions such as those found in aggregates applications.
Modular assembly and motor/ reducer packaged combinations provide flexibility and ensure fast delivery. Options including integral motors (for limited space), clamp-collar construction or three piece coupled construction for increased flexibility. The clamp collar design allows the use of a standard ABB, IEC motor with B5 flange. There is no need to remove pulleys/ sprockets from the drive shaft when the motor goes down. Simply undo the motor flange bolts and clamp collar to replace with a new motor.
Couplings
Among the many couplings available, ABB Dodge® is displaying its Para-Flex, D-Flex and Grid-Lign range. The Para-Flex flexible coupling offers extra bore capacity that allows smaller coupling selections. No lubrication and no need for visual inspection helps save time. Torque is transmitted through a composite element system that is reinforced with torque carrying tension cords and split end reinforcement.
The D-Flex flexible coupling offers reduced vibration. The flange outside diameter is concentric to bore for ease in alignment.
The Grid-Lign rigid coupling is interchangeable with other industry standard tapered grid couplings.
The flexible couplings have misalignment capabilities and are able to accommodate torsional, angular and parallel misalignment while the rigid coupling offers high torque capability with output speed connections for both a motor or speed reducer.
Electric motors
The new, innovative synchronous reluctance motor (SynRM) range is available as: IE4 SynRM, cast iron frame sizes 160 to 315 (11 to 315 kW), High output (HO) SynRM, aluminium frame sizes 90 to 132 (1.1 to 37 kW), and cast iron frame sizes 160 to 315 kW (17 to 350 kW)
ABB’s new, energy-efficient SynRM motor is an innovative motor design that has no rotor windings (no squirrel cage), unlike traditional asynchronous designs. The rotor, therefore, suffers virtually no power losses and its temperature remains lower than in conventional rotors. This helps achieve better power density and higher energy efficiency. In addition, lower temperatures mean longer bearing life and longer re-greasing intervals which extends the maintenance periods. Compared to permanent magnet motors SynRM is lighter, less expensive and easier to repair, yet gives the same performance levels.
The SynRM has a high output (HO) variant that produces the same power as traditional asynchronous AC motors but in mechanical motor frames which are two sizes smaller. This HO variant boasts IE3 efficiency figures.
The second super premium high efficiency variant has the same physical dimensions as a standard synchronous AC motor, but is able to achieve IE4 efficiency levels, which is ideal for minimising energy usage in fan and pump applications.
The SynRM motors bring many advantages over traditional motors including reduced lifetime costs, quieter running, longer greasing intervals and less heat in the control room.
The SynRM requires an ABB variable-speed drive to control the speed of the shaft. There are currently three matched packages. One includes the high performance machinery drive (ACS850), one includes the industry specific water drive (ACQ810) and one includes an ABB industrial drive, ACS880, matched to either an IE4 or HO motor.
Variable-speed drives
The ABB industrial drive, ACS880, is an all-compatible variable-speed drive, designed for every eventuality. Featuring 4th generation motor control DTC core, the drive is compatible with any motor. Energy saving functions include redundant speed controlled cooling fans, energy optimizer and reporting of kWh, MWh, CO2 emissions and cost, as standard. New innovations include built-in machinery safety functionality. Rated from 0.55 to 5,600 kW, the ACS880 is available as wall mounted up to 200kW. Modules for cabinets installation and mutlidrives for full process lines are also available. ABB’s next generation of industrial drives are suitable for applications including cranes, winders, hoists and extruders as well as heavy conveyors common in aggregates production.
Hillhead 2014 takes place on the 24th to the 26th June at Lafarge Tarmac’s Hillhead Quarry, near Buxton, Derbyshire.
