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

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

• f 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

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COPE Power up!

RENK Aktiengesellschaft Industrial Gears March 2014 11

…better with the requirements

COPE!

For LOESCHE vertical roller mills (VRM)

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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

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COPE 1 COPE 2 COPE 3 COPE 2 COPE 3

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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

Cooling

Control System SCS GEARcontrol Bus Comm. MCC control Interlocking Start sequences CMS VIBcontrol

Power

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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

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COPE - Mechanical Design

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

• ff 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

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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

• utput stage, i=3,47

Mill radial bearg. Mill axial bearg. Torque recording Qill shaft COPE III

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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

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COPE - Mechanical Design

Separation of Milling and Grinding Forces

milling gear

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COPE - Mechanical Design

Motor handling

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30 mm

Uncouple Drive Set quickly without disassembly 30 mm i.e. no pinion/gear engagement

COPE - Mechanical Design

Drive Set disengagement

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COPE Mechanical Analysis

Multi Body Simulation Modell

MBS model consists of

• Masses
• Joints
• Force Elements

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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

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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

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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

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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

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COPE Power Section

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

Welding operation via one Motor - LV VSDS DOL starting

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M M M M M M M M

Renk

Abgangs- felder mit LS

FU

Plant, 11 kV Trafos 11 kV / 690 V

LS LS

COPE Power Section

Constant speed with LV Motors 690 V

Welding and starting operation via one Motor - LV VSDS

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COPE Power Section

Variable speed with LV Motors 690 V

LV VSDS

• n all motors

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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

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Feature Target Challenge Solved by COPE? Load range up to 8 MW (CEM drive) 15 MW (EMPP) Larger Mills no concept change

• utput 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?

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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