presentación de powerpoint€¦ · cope drive concept for vertical roller mills sept 2014...

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

16-Sep-14 5

Loesche Worldwide 2014

America

• LOESCHE America,

Inc.

Pembroke Pinkes,

Florida, USA

LOESCHE Engergy

Systems

Horsham, UK

LOESCHE South

Africa (Pty.) Ltd.,

Johannesburg

South Africa

LOESCHE Middle East

Tehran Branch Office

Tehran, Iran

Europe Africa Asia

LOESCHE Latino-

americana S. A.

Madrid, Spain

LOESCHE GmbH

(Head Office) /

LOESCHE Automation

Düsseldorf, Germany

LOESCHE OOO

Moscow, Russia

LOESCHE Middle East

FZE

Dubai, UAE

LOESCHE India (Pvt.)

Ltd.

New Delhi, India

LOESCHE Mills Ltd.

Shanghai & Beijing, PRC

LOESCHE GmbH Vietnam

Branch

Ho Chi Minh City, Viet Nam

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

RENK Aktiengesellschaft Industrial Gears Sept. 2014 10

CO

PE

Power up!

RENK Aktiengesellschaft Industrial Gears March 2014 11

…better with the

requirements

COPE! For LOESCHE vertical roller mills (VRM)


KPBV 190

5400 kW

990/21,59 rpm

(AGMA > 2,5)

Ridgid support of

grinding forces

Maintenance free

sleeve bearing version

(SB) optional

Unique RENK RS

round pad axial bearing

Bullet-proof

hydrostatic design

Modul spares stocked

KPBV the best features shall be treassured


COPE 1

COPE 2

COPE 3

COPE 2

COPE 3


COPE System Overview

690 V –

6000 V

Drive System

Transformers (690 V only) Welding VSD

Cycle converters

(variable speed drives – VSD)

Outgoing Feeder

(constant speed drives only)

COPE 2stage Gear Water Cooled Asynchr. Motor

400 V

Oil Supply System

Sensors Cooling

Low Pressure Oil Heating

High Pressure Oil Filtration Coolin

g

Control System

SCS GEARcontrol Bus Comm.

MCC control Interlocking

Start sequences CMS VIBcontrol Pow

er

http://www.process-informatik.de/images/katalog/TrT-VPN.png


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


COPE - Mechanical Design

6 (LM70.5) to 8 (LM70.4)

off standard

6-pole ELIN 690 V to 6 kV

motors liquid cooled

KPBV dimensions

Oil volume in gear

housing,

Flooded 2*8 = 16

Round Pad Axial Bearing


COPE - Mechanical Design

final status for prototype December 2013

Drivers engageing

with Central wheel

Double cardanic

connect to output

stage Oil volume

Customary 6-planet

output stage, i=3,47

Mill radial bearg.

Mill axial bearg.

Torque recording

Qill shaft COPE III


COPE - Mechanical Design Motor, Drive Shaft Cartridge and Drive Shaft bearings

Motor with two

radial roller

bearings

However axial

force borne in

gear bearings

Both flanks of

central wheel

can be used

Motor hollow

shaft and quill

shaft driven

pinion


COPE - Mechanical Design Separation of Milling and Grinding Forces

milling

gear


COPE - Mechanical Design Motor handling


30 mm

Uncouple Drive Set

quickly without

disassembly

30 mm i.e. no

pinion/gear

engagement

COPE - Mechanical Design Drive Set disengagement


COPE Mechanical Analysis Multi Body Simulation Modell

MBS model consists of

• Masses

• Joints

• Force Elements


Torsional Eigenfrequences

1st : 7,2 Hz input – mill table f (coupling shaft)

2nd :7,9 Hz motor – central gear f (quillshaft)

3rd : 36,3 Hz central wheel – mill table f (central wheel)

No torsional eigenfrequency between 8 and 36 Hz

COPE Mechanical Analysis Multi Body Simulation Modell


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)

COPE – Electrical Drive e.g. ELIN water jacket cooled motors


Outer water jacket

Water flow

Terminal box

Water inlet and Water outlet

Inner water jacket

Separating bars

COPE – Electrical Drive e.g. ELIN water jacket cooled motors


4 to 28 ELIN Motors (110 kW to 380 kW) driving the cutter head via a gear drive

COPE – Electrical Drive References of similar motor use: Tunnel Boring


COPE Power Section Constant speed with MV Motors 6 kV (3-6,6 kV)

Welding operation

via one Motor -

LV VSDS

DOL starting



M M M M M M M M

Renk

Abgangs-felder mit LS

FU

Plant, 11 kV

Trafos11 kV / 690 V

LS LS

COPE Power Section Constant speed with LV Motors 690 V

Welding and

starting operation

via one Motor -

LV VSDS



COPE Power Section Variable speed with LV Motors 690 V

LV VSDS

on all motors



690 V / 50 Hz

FU 1 FU 2

COPE M M

M

M

M

M

M

M

Electrical energy

(system looses)

Electrical energy

Temporary DC coupling

COPE Load Testing With original motors

• Without complex

arrangements the COPE

drive system can be

load- tested in 1st stage

• The entire system

including the S7

GEARcontrol and the

Condition Monitoring

System is also tested

• For shorter comissioning



Feature Target Challenge Solved by COPE?

Load range up to

8 MW (CEM drive)

15 MW (EMPP)

Larger Mills no

concept change

output torque

through final gear

stage – COPE 4-250

2,5 MW – LM46 to

12 MW-LM75.4

Independent

drives

enable operation @

partial damage

Not possible for last

stage

YES

Higher Reliability,

no bevel gear

Increased

availability, low TCO

Contradiction to

independent drives

YES

(70% lower risk)

Accessibility

w/o gear removal

Maintenance

friendly, low TCO

Partial contradiction

to compactness

YES

(60% elements)

no necessity of

VSDS

Lower invest comp.

to other designs

Not every mill

requires var. speed

YES

(-25% for const.)

Efficiency Low TCO High motor

efficiency, no VSDS

YES

(+1% to 5%)

Do we reach the target?


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

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

presentación de powerpoint€¦ · cope drive concept for vertical roller mills sept 2014...

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