The BMG team works closely with sugar mill engineers in the industry’s off-crop period each year, to refurbish and replace worn components in preparation for high productivity in the upcoming season.
Dorstener gearboxes have been used on diffuser drives, mill drives and feeder tables for many years and three of these planet carriers recently needed to be replaced, due to excessive bearing journal wear and cracking. “In spite of tight time restrictions before the seasonal start-up of the mill, BMG designed, fabricated and installed new carriers, reducing the normal 24-week delivery period to only four weeks, with cost savings of about 7,5 times,” explains Mike Cooper, general manager, engineering, BMG. “Carriers are normally manufactured by Dorstener from cast iron, which is extremely difficult to repair. In this case, there was the additional problem of bores positioned close together, with virtually no wall thickness between the bearing journals, which was where the cracking had occurred. Because of the harsh operating conditions of the mill and the high torque load, we decided replacement was the preferred option over refurbishment.”
The planet carriers were reengineered and fabricated out of 355WA steel plate, which is not only stronger than the original cast iron units, but crucially allowed manufacture in only three weeks.
The team was on a tight deadline to have drawings and designs approved to ensure highly accurate dimensions for a perfect fit and clearances and to accommodate the gear mesh.
Welding challenges, to maintain structural rigidity of the system, were overcome by machining interlocking tabs in the top and bottom main plates, as well as in the webs and side rings, to ensure a more precise assembly for welding, with less distortion. The webs and side plates were welded to the bottom ring and the entire assembly was then fitted onto the top ring, for welding into place. Slots were later filled with weld, so that the webs form an integral part of the structure.
BMG’s specialist services to the sugar sector also include bearing and gearbox inspection, bearing and chain refurbishment, large size bearing assembly and alignment and balancing, as well as customised product design.
New precision planetary gearboxes
Motion Control & Drives
Teknic offers precision planetary gearboxes with a wide selection of frame sizes, gear ratios, output flanges and body configurations to accommodate a range of motion control requirements.
Read more...MEPS rules create opportunity but smart moves are critical
Motion Control & Drives
SEW-EURODRIVE says that South African regulations on premium efficiency IE3 motors open a door of opportunity for geared motor users, but forward planning and the considered advice of established and trusted experts is vital.
Read more...Open-source humanoid robot redefining human-machine interaction
Motion Control & Drives
Pollen Robotics is working on an ambitious mission: to imagine and advance useful robotics for humans. Their flagship creation, Reachy combines accessibility, innovation and open-source collaboration.
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.
printer friendly version