RENK Loesche America COPE Drive Concept for Vertical Roller Mills - PowerPoint PPT Presentation

RENK Loesche America COPE Drive Concept for Vertical Roller Mills Sept 2014 Introduction: Guillermo Benjumea COPE Drive: Peter Boiger

LOESCHE INNOVATIVE ENGINEERING

Loesche History & Milestones 1906 - Foundation in Berlin: The exclusive European sales rights of the brand new Kent Mill

Loesche Worldwide 2014 America Europe Africa Asia •  LOESCHE Engergy LOESCHE America,  LOESCHE South  LOESCHE Middle East Inc . Systems Africa (Pty.) Ltd., Tehran Branch Office Pembroke Pinkes, Horsham, UK Johannesburg Tehran, Iran Florida, USA South Africa  LOESCHE Latino-  LOESCHE India (Pvt.) americana S. A. Ltd. Madrid, Spain New Delhi, India  LOESCHE Middle East  LOESCHE GmbH FZE (Head Office) / Dubai, UAE  LOESCHE Mills Ltd. LOESCHE Automation Shanghai & Beijing, PRC Düsseldorf, Germany  LOESCHE GmbH Vietnam  LOESCHE OOO Branch Moscow, Russia Ho Chi Minh City, Viet Nam 16-Sep-14 5

Evolution in Power Transmission The VRM has qualified to be a universal tool for grinding in the cement industry. The maximum mill powers doubled from 2500 kW in the mid-seventies to 5000 kW two decades later. It duplicated again in the past 20 years and achieved 10 MW. The gear technology, developed with the mill power. The current state of the art three stage bevel planetary gear is the third generation of VRM drives. New fourth generation gear concepts were proposed and tested to cope with the increasing torques – always with the target to further improve the key performance features.

The Innovation COPE is a synthesis of the various advantages of those concepts and will establish the fourth generation in VRM drives of RENK. In tight cooperation with LOESCHE, COPE has been offered worldwide and a first order has been acquired. The presentation will explain the design and highlight the various new features which greatly improve availability and maintainability of VRM drives with the result of lower TCO compared to conventional drives or to two half size systems of the mid-nineties state of the art.

COPE Drive System for VRM Peter Boiger Head of Sales and Applications Industrial Gear Branch RENK, AG AUGSBURG

COPE (CO mpact P lanetary E lectric Drive) under LOESCHE - VRM

Power up! COPE RENK Aktiengesellschaft Industrial Gears Sept. 2014 10

COPE! For LOESCHE vertical roller mills (VRM) … better with the requirements RENK Aktiengesellschaft Industrial Gears March 2014 11

KPBV the best features shall be treassured KPBV 190  Ridgid support of 5400 kW grinding forces 990/21,59 rpm  Maintenance free (AGMA > 2,5) sleeve bearing version (SB) optional  Unique RENK RS round pad axial bearing  Bullet-proof hydrostatic design  Modul spares stocked RENK Aktiengesellschaft Industrial Gears March 2014 12

COPE 1 COPE 2 COPE 3 COPE 2 COPE 3 RENK Aktiengesellschaft Industrial Gears March 2014 13

COPE System Overview 690 V – 6000 V Drive System 400 V Transformers (690 V only) Welding VSD Cycle converters Outgoing Feeder (variable speed drives – VSD) (constant speed drives only) COPE 2stage Gear Water Cooled Asynchr. Motor Control System Oil Supply System Cooling SCS GEAR control Bus Comm. Sensors Cooling Power MCC control Interlocking Low Pressure Oil Heating Start sequences CMS VIB control High Pressure Oil Filtration RENK Aktiengesellschaft Industrial Gears March 2014 14

COPE - Features  Up to 12 MW  2-stage design  Driven by 6 to 8 cage induction motors  System with motors and controller  Without or with VSD  Low or medium voltage cage induction motors  No bevel gear!!!  Maintenable when installed under the mill RENK Aktiengesellschaft Industrial Gears March 2014 15

COPE - Mechanical Design KPBV dimensions Flooded 2*8 = 16 Round Pad Axial Bearing 6 (LM70.5) to 8 (LM70.4) off standard 6-pole ELIN 690 V to 6 kV motors liquid cooled Oil volume in gear housing, RENK Aktiengesellschaft Industrial Gears March 2014 16

COPE - Mechanical Design final status for prototype December 2013 Mill axial bearg. Mill radial bearg. Customary 6-planet output stage, i=3,47 Torque recording Double cardanic connect to output stage Oil volume Drivers engageing with Central wheel Qill shaft COPE III RENK Aktiengesellschaft Industrial Gears March 2014 18

COPE - Mechanical Design Motor, Drive Shaft Cartridge and Drive Shaft bearings Both flanks of central wheel can be used Motor with two radial roller bearings However axial force borne in gear bearings Motor hollow shaft and quill shaft driven pinion RENK Aktiengesellschaft Industrial Gears March 2014 19

COPE - Mechanical Design Separation of Milling and Grinding Forces milling gear RENK Aktiengesellschaft Industrial Gears March 2014 20

COPE - Mechanical Design Motor handling RENK Aktiengesellschaft Industrial Gears Sept. 2014 21

COPE - Mechanical Design Drive Set disengagement Uncouple Drive Set quickly without disassembly 30 mm i.e. no 30 mm pinion/gear engagement RENK Aktiengesellschaft Industrial Gears March 2014 22

COPE Mechanical Analysis Multi Body Simulation Modell MBS model consists of • Masses • Joints • Force Elements RENK Aktiengesellschaft Industrial Gears March 2014 23

COPE Mechanical Analysis Multi Body Simulation Modell Torsional Eigenfrequences 1 st : 7,2 Hz input – mill table f (coupling shaft)   2 nd :7,9 Hz motor – central gear f (quillshaft)  3 rd : 36,3 Hz central wheel – mill table f (central wheel) No torsional eigenfrequency between 8 and 36 Hz RENK Aktiengesellschaft Industrial Gears March 2014 24

COPE – Electrical Drive e.g. ELIN water jacket cooled motors Vertical axis, flange mounted Water Jacket Stator Cooling System, Insulation class H used to B/F UN = 690V / 6kV DOL / Converter P = 560 – 1500 kW Ah = 355, 450, 500 2p = 6, (8) f= 50Hz, (60 Hz) nsy = 1000rpm (900 rpm) RENK Aktiengesellschaft Industrial Gears March 2014 25

COPE – Electrical Drive e.g. ELIN water jacket cooled motors Water inlet and Water outlet Terminal box Water flow Inner water jacket Outer water jacket Separating bars RENK Aktiengesellschaft Industrial Gears March 2014 26

COPE – Electrical Drive References of similar motor use: Tunnel Boring 4 to 28 ELIN Motors (110 kW to 380 kW) driving the cutter head via a gear drive RENK Aktiengesellschaft Industrial Gears March 2014 27

COPE Power Section Constant speed with MV Motors 6 kV (3-6,6 kV) Welding operation via one Motor - LV VSDS DOL starting RENK Aktiengesellschaft Industrial Gears Sept. 2014 28

COPE Power Section Constant speed with LV Motors 690 V Plant, 11 kV LS LS Trafos 11 kV / 690 V Abgangs- felder mit LS Renk FU M M M M M M M M Welding and starting operation via one Motor - LV VSDS RENK Aktiengesellschaft Industrial Gears Sept. 2014 29

COPE Power Section Variable speed with LV Motors 690 V LV VSDS on all motors RENK Aktiengesellschaft Industrial Gears Sept. 2014 30

COPE Load Testing With original motors 690 V / 50 Hz • Without complex Electrical energy (system looses) arrangements the COPE drive system can be load- tested in 1 st stage Temporary DC coupling FU 1 FU 2 • The entire system Electrical energy including the S7 GEARcontrol and the Condition Monitoring System is also tested M M M • For shorter comissioning COPE M M M M M RENK Aktiengesellschaft Industrial Gears March 2014 31

Do we reach the target? Feature Target Challenge Solved by COPE? 2,5 MW – LM46 to Load range up to Larger Mills no output torque concept change 12 MW-LM75.4 8 MW (CEM drive) through final gear stage – COPE 4-250 15 MW (EMPP) Independent enable operation @ Not possible for last YES partial damage drives stage Higher Reliability, Increased Contradiction to YES no bevel gear availability, low TCO independent drives (70% lower risk) Accessibility Maintenance Partial contradiction YES w/o gear removal friendly, low TCO to compactness (60% elements) no necessity of Lower invest comp. Not every mill YES VSDS to other designs requires var. speed (-25% for const.) Efficiency Low TCO High motor YES efficiency, no VSDS (+1% to 5%) RENK Aktiengesellschaft Industrial Gears March 2014 32

Selling points – Elevator Pitch  More availability by redundancy  Shorter Comissioning by included, tested SCS  Shorter Maintenance outage without removal from mill  No Motor Maintenance by absence of slip ring  All gears have a second live by inverse mounting  VSDS not required (for fix speed applications)  Fix speed med. voltage integral welding speed function  1% (mechanical) to 5% (mechanical+electrical) better efficiency than other drives RENK Aktiengesellschaft Industrial Gears Sept. 2014 33

First COPE & largest compact VRM-drive acquired by LOESCHE: COPE 3-225 • LM70.4+4 • 8800 kW • 20,3 rpm • 4 Mio Nm • 170 to • Presentation to public August 2015

Thank you for your attention! RENK drives for Cement, & Raw materials