siemens gearless drive

5/28/2018 Siemens Gearless Drive

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Answers for industr

SIMINE for conveyors

The information provided in this brochure contains merelygeneral descriptions or characteristics of performance whichin case of actual use do not always apply as described or whichmay change as a result of further development of the prod-ucts. An obligation to provide the respective characteristicsshall only exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product namesof Siemens AG or supplier companies whose use by thirdparties for their own purposes could violate the rights of theowners.

Subject to change without prior notice 09/12Order No.: E20001-A230-T195-X-7600DISPO 21662SCH26136 GD.LD.VM.MIMI.52.2.02GB 120265 WS 06122.0Printed in Germany Siemens AG 2012

Siemens AGIndustry SectorDrive TechnologiesMining TechnologiesSchuhstrae 6091052 ERLANGENGERMANY

More information:www.siemens.com/mining

Contact:[email protected]

For more information and technical descriptions,click on the Support navigation point on our Website.

siemens.com/mining


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SIMINE for conveyors g

High system availabil

Low operating

and energy costs

Low maintenance cos

Your challenge:Moving mountains reliably and efficiently

To meet worldwide demands for raw materials, under-ground mines and open pit mines are being established

in increasingly remote areas. Every year, billions of tonsof bulk materials such as ore, coal, copper ore, and min-ing waste have to be moved powerfully, reliably, andefficiently.

Comprehensive requirementsBelt conveyors operate under the harsh-est conditions, often far removed fromcenters that provide replacement andspare parts. To operate efficiently, it isessential that these conveyors remainfailure-free, a factor that in turn dependson high availability and reliability. Highavailability coupled with ease of main-tenance must ensure a long service life,

which is possible only if all the electro-technical components and mechanicalelements are perfectly coordinated.

More than just technologyBesides production-oriented concerns,mine operators must increasinglyconsider ecological aspects as well,including compliance with emissionsguidelines and maximum energy effi-ciency wherever possible. The appropri-ate fuel-efficient drives not only reduceenergy costs but also reduce the carbonfootprint.

Mines subsist on moving raw anbulk material. This makes conveysolutions business critical in termof performance and availability.


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Our solution:Comprehensive belt conveyor expertisefrom a single source

Where it all fits togetherModern belt conveyor systems placehigh demands on the equipment used.Seamless interaction between the indi-vidual components above all betweenelectrical and mechanical components is a basic requirement for the safe, opti-mal operation of a belt conveyor. Basedon our many years of experience in theseareas Siemens developed SIMINE as a

comprehensive concept for belt convey-ors. Combined with SIMINE, we coverthe entire life cycle of the belt conveyorand its components, offering a complete,broadly based range of belt conveyorproducts.

Customized solutionsSiemens specialists are available to assistyou from the planning phase, construc-tion, and commissioning to service andmaintenance.

On the following pages the most impor-tant products, systems, and solutionsfor belt conveyors will be presented. Ofcourse, this can be no more than a brief

introduction, but well naturally be gladto meet with you individually at any timeto discuss your own particular on-siterequirements.

Siemens provides belt conveyor solutions for the miningindustry from electrical drives to instrumentation. And

we are one of the few international companies withsufficient know-how to combine all the relevant compo-nents into a truly integrated over-all concept.

With its comprehensive portfolioSiemens covers the entire life cyof conveyors, thus ensuring prodtivity at all times.

SIMINE

Sensors,

measurementCommunication

Power distribution

Converter

technology

Motors

Automation/control

Mechanical drive

components and

systems

Service


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Drive systemsThe right power for every application

Each mine is different. The demands

on belt conveyors also differ depend-

ing on the material being conveyedand the particular landscape. Drives

must be sufficiently versatile. Siemens

offers both conventional constant-

speed drives and variable-speed

drives.

Conventional drives quickly up to

speedIn the case of conventional drive sys-tems, the belt conveyer is operated ata constant speed. Asychronous motorsexecuted as slip ring motors or squirrel-cage motor.

In connection with a gear unit, theydeliver the necessary speed and thenecessary torque to the b elt conveyor.

The slip ring motors s tart up behaviouris determined by the starting resistors,which are switched on in s tages untilthe motor and belt conveyor reach theirrated speeds, or with liquid starters.

Drive systems with a squirrel-cage motoruse modern hydraulic couplings. At s tartup, the motor is practically load-free and

achieves its rated speed very rapidly.As the coupling halves slowly fill, thebelt conveyor accelerates until it reachesits rated speed.

Modern drives flexible and efficient

Modern drive systems use variable-speed(speed-controlled) drives. Asynchronousmotors executed as squirrel-cage motorare combined with a gear unit.

For belt conveyors that require severalmegawatts of power, drive systemswithout gear units that are, directdrives with synchronous motors arealso used.

Both drive systems employ frequencyconverters that can adapt drive behav-iour to various operating conditions.Proven control options make it possibleto adjust the interaction between a drivesystem and belt conveyor precisely asneeded. Such control algorithms permit:

Simultaneous starts and stops of theentire conveying routes

Load sharing for multi motor and multipulley belt conveyors

Reduced slip between drive pulleys andbelt during starting and stopping

Smooth starts and stops to reduce wearand tear on mechanical components

Whether you are looking for constant or variable speed drives, Simens offers the right solutions.

Conventional drive systems,fixed speed

Modern drive systems,speed-controlled

Asynchronous motorResistance starter

Asynchronous motorHydraulic coupling

Asynchronous motorFrequency converter

Synchronous motorGearless drive

Brake

VFC

Transformer

Synch.

motor

Belt

drive

pulley

CouplingBrake

VFC

Transformer

Asynch.

motor

Coupling

Gear box

Belt

drive

pulley

Resistor

CouplingBrake

Starter

Asynch.

motor

SRM

Coupling

Gear box

Belt

drive

pulley

HydraulicCoupling

Brake

Starter

Asynch.

motor

Coupling

Gear box

Belt

drive

pulley

SRM

VFC

Slip Ring MotorVariable Frequency Converter


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MotorThe heart of your belt conveyor solutions

Thanks to our various type series, you

can select the right motor for each

operating mode required, whether

constant speed, variable, or direct

drive. Our robust, reliable motors are

the perfect basis for your customized

belt conveyor as well as for moderniz-

ing existing systems.

For maximum availability

In addition to tried-and-tested geareddrives, Siemens also produces gearless

synchronous motors, which, when inter-acting with a corresponding converter,generate the requisite speed and torqueand transfer it to the belt conveyorsdrive drum. Our direct drive systems areindividually configured for each applica-tion in terms of sp eed, torque, and otherrequirements.

Economically attractiveIn addition to providing a solution that isoptimally matched to individual require-ments, our direct drives also offer con-crete economic advantages. Eliminationof the gear unit means elimination of themajority of moving parts, thereby sig-nificantly reducing wear, extending theservice life, lowering maintenance costs,and increasing overall availability andproductivity.

We offer our customers all the com-

ponents needed for an efficient trans-

mission of power from the motor to

the drive shaft of the belt conveyor,

either as individual elements or as a

complete drive system.

Gear units

Proven FLENDER gear units are ideallysuited to the requirements of belt con-veyors and guarantee the reliable opera-tion of the drive system.

Drive unit for belt conveyor with gearboxB3SH26, with external oil cooler OLGE 09/V2,operation torque 439.220 Nm, power rating2052 kW, input speed 980 rpm, transmissionratio 22,4

The right gear unit is available for everydrive task. Thanks to extensive standard-ization, all the components are perfectlycoordinated, which not only increasesreliability but also improves efficiency with distinct cost advantages comparedto solutions that are not coordinated.

CouplingsCouplings form the link between motorsand gear units, and often between gearunits and drive drums as well. The con-nection permits a reliable transmissionof speed and torque, and can also forexample, by means of hydraulic cou-plings influence the start up behaviorof the entire drive system.

We supply high-quality FLENDER cou-plings and offer a wide range of flex-ible, highly flexible, torsionally rigid andhydrodynamic couplings in a numberof different sizes and versions. SomeFLENDER coupling series are mainte-nance-free, while others have longmaintenance intervals. Wearing partscan be easily replaced and are availableworldwide, thus reducing downtimes toa minimum.

Geared motorsGeared motors combine motors and gearunits in an extremely compact structure.

For power ranges up to 200 kW andtorques up to 20,000 Nm, versions areavailable with helical, flat, or bevel heli-cal gear units.

Complete drive system

The individual components are combinedinto complete drive systems for belt con-veyors. Our complete solutions are con-figured to meet your exact requirementsfor the specific application. Thanks tothe high quality of our components, webuild reliable, efficient, economical drivesystems.

Conveyor Drive FLENDER Self Aligning SystemTMas integrated drive train with SIEMENS Motor,input coupling, gearbox and ouput flange

MechanicalcomponentsEverything for the efficient transmission of power

The heart of every conveyor is itsmotor. Siemens makes it beat

reliably.

With its comprehensive portfolioSiemens ensures the efficient potransmission.

Series Power Voltage Type Operating type

kW

N-CompactIEC

Standard

200 1,000 400 V 690 V asynchronousdrive squirrel-

cage rotor

for controlleddrive systems

H-Compact

IEC

200 3,000 690 V 11 kV asynchronousdrive squirrel-

cage rotor

for constantspeed as well asfor controlleddrive systems

Vario 315 1,900 400 V 11 kV asynchronousdrive slip ring

rotor

for constantspeed

Low speedsynchron

motor

2 ,0 00 1 0, 00 0 6 90 V 13 .2 kV s yn ch ro no usmotor

for speedcontrolled drivesystems


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Converter technologyConverters for variable drive systems

For variable-speed drives to oper-

ate at maximum efficiency, they

must have the right frequency con-

verter. Siemens SINAMICS familyoffers proven converter technology

for a variety of tasks. Depending onrequirements, services range from

the simple movement of a machine to

open- and closed-loop control of com-plex motion sequences.

Efficiency is always a question ofcontrol. SINAMICS is our answer.

Medium-voltage converters from the

world market leaderAs the undisputed number-one supplierof MV drives, Siemens sets worldwidestandards in terms of installed capacity,market share, and breadth and depth ofofferings. For belt conveyor solutions,we offer various voltage source convert-ers, load-commutated inverters, andcycloconverters. In addition to simple

air-cooled converters, also water-cooledmodels for the higher power ranges areavailable.

Low-voltage converters for maximum

flexibilityOur low-voltage converters are suitablefor all performance levels and featuremaximum flexibility, functionality, andengineering comfort. Converters in thisrange can operate in two- and four-quadrant mode.

Whether medium or low voltage Siemens delivers the converter tmeets your needs.

Converter LV Converter MV

Type Power Voltage Type Apparent power Voltage

kW V MVA kV

G130 75 800 380 690 GM150 0.8 21 2.3 4.16

G150 75 1,500 380 690 SM150 3.4 31.5 3.3 4.16

S120 1.6 4,500 380 690ROBICON Perfect

Harmony0.15 120 2.3 13.8

Dynavert T 2.2 6,600 230 690 SL150 3 25 1 4

Convert types and functional range (power, voltage) specialized for minin


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Power distributionOver 160 years of power know-how

Every belt conveyor needs power,

which includes the corresponding

infrastructure of medium- to low-volt-

age power distribution. As the worldsleading provider in the area of power

distribution and with over 160 years

of experience, we contribute to the

sustainable and responsible use ofelectrical energy. Our comprehensive

portfolio for medium- and low-voltage

power distribution makes it possible toimplement intelligent power networks

and thus lay the foundation for indus-

trial applications.

Reliable switchgear for every situationThis includes reliable connection onevery distribution level, for every per-formance range, for every type of appli-cation, and for every system type.

Siemens has developed product seriesthat are exactly in line with the specificrequirements. Our SIVACON models, forexample, have stood the test at the low-voltage level. With a switching capacityof up to 7,000 A, they offer sufficientreserves to guarantee a safe, flexible,and cost-effective power supply.

On the medium-voltage level, the SIV-ACON models are supplemented by ourNXPLUS C and 8DA10 switchgear.

Our unique transformer portfolioFor over 100 years and in more than100 countries, Siemens transformershave been synonymous with top quality.Our expertise as a technology leaderenables us to provide the right trans-former for every task, from large powertransformers to compact distributiontransformers. Above all, our GEAFOLcast-resin transformers have seen

decades of successful use wherever com-pact designs are required that also meetthe highest safety standards. GEAFOLhas none of the limitations of liquid-immersed transformers while retainingtheir operational reliability and long ser-vice life.

The switchgear and transformersolutions from Siemens meet theneeds of mine operators at anypoint.

When it comes to power distribu-tion there is hardly any competitorwith a comparable track record like

Siemens.

Siemens medium voltage switchgear NXPLUS CGEAFOL transformers


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SIMINE Automation is the result ofSiemens unique experience in bothautomation technology and conveyorexpertise. Its reliability and efficiencyhas been proven in numerous installa-tions around the world.

Minerals Automation StandardThe Minerals Automation Standard pro-vides a comprehensive library focusedon mining-specific requirements and ishighly scalable from single equipmentlike conveyors up to automation of com-plete mine operations. With its modernarchitecture based on SIMATIC PCS 7the Minerals Automation Standard is theideal basis for future-proof and economi-cal solutions for the mining industry.Open communication standards such asethernet and industrial WLAN are thebasis for easy communication to the cen-tral control level.

Sensors and communications

A wide range of instrumentation, sensorsand communication solutions includehigh precision belt scales, flow meters,level instruments, industrial s witches,and WLAN products that meet the indus-trial requirements to operate in harshmining conditions.

Maintenance and diagnosticOur standardized solutions offerenhanced diagnostic features to reduceunplanned shut down times to a mini-mum. Siemens devices are availablewith intelligent diagnostics and condi-tion monitoring. The valuable informa-tion is available for local diagnosticsand Plant Asset Management via remoteconnection.

Industrial automation

Siemens offers a complete range of auto-mation products for the mining industrystarting with the world market leadingPLC SIMATIC S7, a comprehensive solu-

tion for a plant wide DCS with SIMATICPCS7 and the library Minerals Automa-tion Standard, Industrial PC, and SIMATICIT the MES solution from Siemens.

Belt weighing

With Milltronics, Siemens offers systemsfor belt weighing, which feature simplemounting and low maintenance require-ments isolated from lateral forces, withminimal hysteresis and maximum linear-ity. Together with our high-resolutionspeed sensors you can achieve a highmeasuring accuracy and repeatability.

Siemens Automation for conveyors:

A complete field instrumentation andautomation portfolio for mining

Automation for vendor packages inclu-ding seamless integration into

the automation of a complete mine Advanced control packages for speed

and volume control from single convey-ors to complex conveyor systems

Advanced stockyard management sys-tems from precise material tracking to3D stockpile management including au-tonomous operation solutions

Siemens Automation products and

solutions for conveyors are designed

to increase through-put and productquality,

to minimize maintenance and wear

and tear, to protect man and conveyor during

continuous operation,

for operation under harsh environmen-tal conditions,

to comply with environmental regulati-ons, and

to control and minimize energyconsumption.

AutomationBrings intelligence and connectivity

to your conveyor

SIMINE Automation products andsolutions for conveyors help you to

engineer, operate, and maintainyour conveyor efficiently and

reduce the project risk due to stan-dardized and out of the box

solutions.


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InstrumentationKnow whats happening

Technology-based servicesFor a greater competitive edge

Optimal conveyance of bulk materi-

als depends on having the very latest

information. A comprehensive net-

work of measuring points and sensors

is required to ensure the necessary

information density and quantity.

Siemens offers a comprehensive port-

folio of Process Instrumentation. Our

solutions cover the most diverse appli-

cations and requirements.

With a track record for consistent performance inharsh environments, Milltronics conveyor beltscales combine simple, drop-in installation, lowmaintenance and repeatable accuracy for pro-ductive operations.

Belt weighingSiemens offers systems for belt weigh-ing, which feature simple mounting andlow maintenance requirements iso-lated from lateral forces, with minimalhysteresis and maximum linearity.Together with a high-resolution speedsensor high accuracy and repeatability

are achieved. The belt scale data can becollected in a stand-alone integrator orseamlessly integrated in SIMATIC S7 witha SIWAREX weighing module.

Point level measurement for all

applicationsSiemens level switches are built to resistthe most demanding conditions in themining industry. Various technologies,such as non-contacting ultrasonics,vibrating forks, paddle switches, tiltswitches and capacitance technol-ogy allow the best solution for everyapplication.

Continuous level measurementContinuous level measurement monitorsdynamic processes. These measurementsare transmitted as an analogue signal or

digital value. For this purpose, Siemensis a world leader in solids level measure-ment and offers numerous solutionsbased on ultrasonic, radar, capacitance,gravimetric, and hydrostatic technolo-gies.

SITRANS LR560 2-wire, 78 GHz FMCW radar leveltransmitter for continuous monitoring of solids insilos to a range of 100 m (328 ft.)

Robust motion sensorsMonitoring moving equipment in amine is essential for safe operation ofthe process. Siemens motion sensorsare developed for the most demandingconditions and can monitor over-speed,under-speed or zero-speed of all kindsof conveyors. With a sensing distanceof 100 mm, they can be installed in themost challenging installations.

Intelligent mine operation needsinformation. Siemens provides the

necessary measuring equipment.

Minimum downtime and the optimumuse of staff and resources are key tosustainable success in industry. Siemensprovides the basis for greater productiv-ity, flexibility, and efficiency with tech-nology-based services throughout thelife cycle of an industrial plant reliably,globally, and around the clock. In-depthtechnology and product knowledge aswell as industry expertise within Sie-mens global network of experts ensure aconsiderable competitive edge.

Siemens offers far more than just prod-ucts and systems: A comprehensive

range of services is available for the min-ing industry worldwide.

From the start-up, to the mine operationacross the entire lifecycle for productsand systems, Siemens provides industryservices tailored to the mining needs.

Engineering support and technical con-sulting from Siemens assist customerswith specialist expertise right from thebeginning. In the start up phase of amine operation, Siemens provides ser-vices and solutions, such as online andtechnical support.

For mining operations, the availableoperational support and maintenanceservices can be enhanced, e.g. by repairand spare parts services as well as fieldservices. Furthermore, Siemens supportsmine operators to face new challengesand changing conditions with the

necessary know-how and experienceproviding mine-specific technologies formodernization and optimization require-ments as well as energy and environ-mental features.


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2010/2011 26 belt conveyorsfor llolar Lignite Open Pit Mine, Turkey

Conveyor characteristics

Total length: 26 conveyors, 17.4 km

C ap ac it y: 6 ,9 00 t /h a nd 9, 35 0 t /h

Belt width: 1,800 mm

Solution

Total installed power: 46,300 kW

Installation of drive systems consisting of

Siemens motors, Fludex turbo couplingsand Siemens-Flender gear boxes

1985 Belt conveyor with gear

Solution Prosper Haniel Coal Min


Length: 3.8 km

Capacity: 2,800 t/h

Belt speed: 5.5 m/s

Lifting height: 800 m

Solution

2 x 3,100 kW gearless drive systeconsisting of a low-speed synchromotor with cycloconverter

Gearless tandem drive located at

2010 Coal conveyor

Lignite Open Cast Mine Reichwald


Length: 13.5 km

Capacity: 6,000 t/h

Solution

6 single belt conveyors consisting

x 1,250 kW drive units and 9 x 90units

Conveyor speed adjustable accorrequirements

1998 Coarse ore conveyor sysMinera Los Pelambres, Chile


Length: 12.7 km

Capacity: 8,700 t/h

Solution

3 single belt conveyors consisting2,500 kW drive units, each compsquirrel-cage motor fed by 1 SIMOvoltage source converter 3,3 kV

Downhill conveyor, permanent g

Our referencesMeasure us by what we do

2007 14 km conveyor linefor Neyveli Lignite Corporation, India


Tota l length: 8 conveyors, 14 km

Belt width: 2,000 mm

Belt speed: 5.4 m/s

Solution

The conveyor system consists of 4 x 630 kWdrive units

Conveyors with slip ring motors withresistance starters

Asynchronous motorResistance starter

Asynchronous motorFrequency converter

Synchronous motorGearless drive

Asynchronous motorHydraulic coupling

Brake

VFC

Transformer

Synch.

motor

Belt

drive

pulley

CouplingBrake

VFC

Transformer

Asynch.

motor

Coupling

Gear box

Belt

drive

pulley

Resistor

CouplingBrake

Starter

Asynch.

motor

SRM

Coupling

Gear box

Beltdrive

pulley

Hydrauliccoupling

Brake

Starter

Asynch.

motor

Coupling

Gear box

Belt

drive

pulley

siemens gearless drive

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