These drives advance

availability.
High-performance FLENDER conveyor drives are
made for extreme conditions.

siemens.com/conveyorbeltdrives

Answers for industry.

At home in the mine
All over the world – from Peru, China
and Australia to Chile and Russia and
on to Zambia, Brazil, India and the
USA – conveyor systems move billions
of tons of freight for many miles, often
under extreme environmental condi-
tions and more often than not through
nearly impassable terrain with no
water, poor infrastructure and extreme
temperatures.
As the leading supplier of drive technol-
ogy for primary production and material
extraction, we are very familiar with all of
the requirements for mine operation. For
decades we have worked together with
our customers to develop optimized and
integrated solutions that meet the needs
of extreme on-site tasks.
The goal we want to achieve for you
is a constantly running conveyor.
2
To ensure permanent conveyor system
availability over long routes, in restricted
spaces and in hot mountainous terrain
with little water, we have adapted our
various solutions completely with regard
to situational conditions.
Output capacity and speed represent only
the most obvious conditions that our cus-
tomers request here. During project plan-
ning, our discussions often include flexi-
bility, usually include cooling and always
include conveyor availability. An idle con-
veyor way out in a peripheral region is
every mine operator’s nightmare. For this
reason, downtime must be prevented no
matter what.
Poor infrastruc-
ture and extreme
temperatures –
the right appli-
cation area for
our drives.

3
24 hours a day,
365 days a year
When the temperature requirement is
the critical determining factor, the key
issue is thermal capacity. This is the
critical parameter for the operational
availability of a gear unit and an im-
portant deciding factor when it comes
to selecting the right supplier. It deter-
mines drive design.
4
It could even happen that a smaller
design size is chosen because the hous-
ing surface determines the degree of
heat dissipation. In turn, this means a
significant cost saving potential for our
customers because, due to the outstand-
ing thermal capacity of FLENDER® gear
units, selecting the next larger size may
not be necessary.
There are many determining factors that
influence a drive’s reliability. The most
important are the quality of the drive
components, the coordination of the
entire system and the thermal conduc-
tion of the gear unit in continuous opera-
tion. Two central parameters are critical
in determining the latter: the natural
environmental conditions and the gear
unit’s own temperature progression,
which in turn demonstrates its quality
and development status.

In the end, the best achievement in gear
unit engineering is demonstrated in
extreme power density, which cannot be
attained without the most advanced pro-
duction methods and the highest degree
of precision in production. An operating
temperature that is too high over long
periods results in a reduction of the lubri-
cation capacity of the oil, damage to the
seals and increased wear. For this reason,
an optimized gear unit temperature
increases operational life, decreases life
cycle costs and maximizes drive service
life.
For many conveyor system operators,
cooling systems represent another poten-
tial risk. There is often absolutely no
water supply available. With an optimized
housing surface, up to a certain design
size it is possible to cool the gear unit
with ambient air. But a larger housing
Drive train on a swing base
with coupling and gear unit
from the standard product
range.
As an option, the drive train
can be expanded:
surface is just part of the solution. It is
critical that the ambient air is successfully Gear unit with larger
conducted directly over as much of the surface.
housing surface as possible. To ensure
that the air of the boundary layer is in
continuous motion, Siemens uses highly
efficient fans. They conduct the air over
the housing and ensure that the heat is
dissipated. Siemens has invested a great
deal of development work in related fluid
technology. Specially designed air guide
covers ensure that the air flows evenly
over the entire surface. This effective and Air guide cover with
mature air guidance system is the only axial fan.
one of its kind in drive technology in the
world.
Auxiliary drive and
backstop.
5
 The right solution
for every conveyor
With the FLENDER gear units, Siemens offers you the largest product range of
advanced conveyor gear units in the world – by far. With three types, a total of 46
sizes and an immense variety of standardized design constructions we have the
right drive solution for any requirement.

As an alternative for moderate tem-

perature zones, the product range
also includes a self-aligning system
with gear units from the standard
portfolio with added motor bell
housings. Here the advantages of a
self-aligning drive are combined
with the advantages of the standard
portfolio – quality that is quickly
available and inexpensive.

6
Designed and produced for critical
thermal conditions – the Siemens Self
Aligning System.
If environmental conditions allow, it
makes sense to put a drive together inex-
pensively, using elements in the standard
portfolio. The FLENDER gear units in the
standard portfolio are compact, feature
high power density and are available in
25 sizes. Here the standard building
blocks, which include a large selection of
gear units, motors, bell housings, swing
bases and add-on parts, leave nothing to
be desired.
For special temperature requirements,
FLENDER gear units with optimized hous-
ing surfaces, axial fans and air guide cov-
ers are used for the drive. They guarantee
outstanding heat balance and are avail-
able in 13 sizes.
Not every mine has enough space for
performing elaborate measuring, align-
ment and installation work. In addition,
some operators find the necessity of
using specialized personnel with the
required expertise for assembly work
challenging.
In this case, the patented Self Aligning
System is the perfect overall drive solu-
tion for capacity ranges up to 550 kW.
It is available in 8 sizes and ensures opti- The design advantages of
mum heat dissipation with its axial fan, the FLENDER gear units:
air guide cover and the patented Clever
◾◾ Largest selection due to
Cooling System for intelligent air flow
numerous sizes with few
guidance. It offers flexibility during com-
component variants
missioning, whether in regard to spatial
circumstances, location or assembly. For ◾◾ Dependability and opera-
conversions or removal, no special skills tional reliability at the
are required because the drive unit does greatest power density
not need to be aligned. The flange pro-
◾◾ Absolutely dust-proof due
vides a fixed connection between the
to labyrinth seals that are,
motor and gear unit. High production
for the most part, free of
quality guarantees the necessary connec-
contact and wear
tion precision at the bell housing. The
elimination of measuring and alignment ◾◾ Flange output shafts for
errors during initial assembly ensures easier gear unit assembly
undisturbed operation. with low space requirement
The Self Aligning System can be used as ◾◾ High degree of efficiency
a right-hand or left-hand version without and outstanding noise
any conversion necessary. This means behavior due to ground
that side selection on the conveyor belt bevel gears, noise-absorb-
is left to the assemblers on-site. These ing housings and exception-
are features that especially operators of ally large contact ratios
underground mines appreciate.
The drive has a very compact design, is
delivered as a fixed unit and is simply
installed on-site, where it ensures maxi-
mum availability for your conveyor
system.
7
Integrated Drive Systems
The more effective a drive, the lower the operational costs. Coordinating and
controlling the entire system plays a critical role here. Siemens has always been
convinced that the drive train must be seen and understood as a whole. We are
the only provider in the world that offers complete industrial drive systems. In
the context of the Integrated Drive System concept (IDS), complete drive solu-
tions have proven successful in many industries and have become standards
upon which today’s industrial drives are based.

Drive train components

SINAMICS® SIMOTICS® FLENDER FLENDER FLENDER

frequency converter motors couplings gear units oil supply system

Our gear units have been used in con-
veyor technology for many years as
integrated components in thousands of
complete solutions. These drive systems
make our customers’ planning easier,
remove the burden of interface risk and
reduce the number of contact persons
to just one – all crucial factors. The drive
train as a whole is a rigorous, goal-ori-
ented development to meet the require-
ments of our customers.
For this reason, Siemens provides not
only the entire range of drive train com-
ponents of the highest quality, but also
the perfect integration and adaptation
from the initial concept to the function-
ing conveyor system.
Siemens’ Integrated Drive Systems con-
cept makes simple drive components into
real systems. Drive technology based on
IDS guarantees maximum productivity,
energy efficiency and reliability in every
area of automation and over the entire
life cycle.

8
The advantages of integrated drive systems

1 Horizontal integration

Integrated drive portfolio: Perfectly integrated, perfectly

all frequency converters, interacting. For all power and
motors, couplings and gear performance classes. As stan-
units available from a single dard solutions or combined to
source. provide an individual solution.

▶ Greater plant availability

By request, we offer not only the main
gear unit, motors and couplings, but
also the following from a single source:
◾◾ Transformers
2 Vertical integration ◾◾ Frequency converters
◾◾ Motors
Integrated into automation: from the ◾◾ Auxiliary and maintenance drives
field level via the controller level
up to MES thanks to Totally ◾◾ Bell housings
Integrated Automation ◾◾ Add-on components
(TIA).
Whatever the
(backstop, swing base, auxiliary drive)
application. ◾◾ Oil supply systems
◾◾ Oil cooling systems
◾◾ Sensor technology
◾◾ Condition monitoring
◾◾ Drive and process control
▶ Faster engineering (CEMAT)
◾◾ Financing

3 Life cycle integration

Integrated software and services

Those who enter a system partnership
throughout the entire life cycle.
For better performance and with Siemens profit in every way from a
maximum investment functioning drive system supported by
protection.
proven control technology. We ensure
that the right drive components are
selected and constructed, coordinate
them with each other and optimize them
for you in the field.

▶ Lower maintenance costs

For more information on integrated drive systems,

visit: siemens.com/ids

9
Multiple drives prevent
total breakdowns.
The large spectrum of gear units
offers a suitable solution for ev-
ery requirement.
10
For a mine operator, the availability of Inexpensive add-on parts
the conveyor system is of supreme
To prevent the belt from continuing to
value. For this reason, particularly for
run if a stop is desired, our drives can be
large conveyor systems with several
equipped with small, inexpensive brakes
megawatts of power input, everything
on the drive shafts, and for a smooth
possible is done to ensure continuously
start, they can be furnished with our tried
smooth operation. In the contest to
and tested FLUDEX® fluid couplings. Our
win the favor of system operators,
backstops are also dimensioned such that
drive solutions with gear units do have
they are small and cost-optimized and
minimal disadvantages with regard to
are installed on the drive shafts. Inciden-
effectiveness, but in terms of service
tally, in regenerative operation, our asyn-
life and costs they come out ahead in
chronous motors are outstanding for use
every instance.
as generators for producing electricity.
The only sure solution Low overall costs
The fact is that in a large system only a In addition, our solutions do not require
multiple drive can ensure maximum sys- comprehensive monitoring by specialized
tem availability because only such a personnel. For the most part, the gear
drive, with its redundant drive trains, can units are maintenance-free; only low-cost
offer reliable protection against total oil maintenance is required.
breakdown. In very rare cases when ser-
For this reason, the low investment costs
vice is needed, the affected partial drive
and minimal maintenance costs for drives
can be disconnected from the drive sys-
and system design do not result in any
tem, which can continue to operate at
pressure to amortize in a time window in
lower capacity. Operation is only briefly
which it is not clear if the mine will still
interrupted in this case. Spare parts are
be in existence.
also redundant, are available quickly and,
moreover, are easy and inexpensive to In this way, the redundant FLENDER
stock. multiple drives can be seen as the only
meaningful drive technology that can
guarantee the availability of large con-
Highest degree of flexibility
veyor systems. Our drives give you maxi-
Conveyors are always moving. Our drive mum flexibility for your daily operation.
solutions are not sensitive to their ubiqui-
tous vibrations. They do not have any
special requirements with regard to foun-
dation, structure and system construc-
tion. They do not need to be installed on
the ground or floor. In addition, the head
end station can be moved without any
great effort.
Greater reliability
with early diagnos-
tics.
Benefit from
◾◾ our drive train expertise that is unique
in the world,
◾◾ the perfect design for the drives due to
our decades of experience,
◾◾ optimum drive solutions for every
requirement,
◾◾ the largest product portfolio that
covers the entire range of conveyor
technology,
◾◾ highly advanced drive components
manufactured with the newest and
most precise production technologies
and processes,
◾◾ reliability due to the outstanding
quality of all of the components,
◾◾ an industry standard tested in accor-
dance with the highest demands and
proven over and over again,
◾◾ our global production concept with a
high degree of production and assem-
bly capacity at many locations all over
the world,
◾◾ speed regulation with a perfectly
customized frequency converter and
outstanding system control,
◾◾ a comprehensive, international net-
work of certified service centers and
◾◾ early error detection with our SIPLUS®
Condition Monitoring System.
Condition monitoring
Availability, efficiency, reliability. A pio-
neer in the area of condition monitoring,
Siemens has offered online condition
monitoring systems (CMS) for the raw
materials industries as an extension of
gear unit service for more than 15 years.
With SIPLUS CMS, Siemens demonstrates
the highest level of reliability with the
early recognition, diagnosis and localiza-
tion of irregularities and determining
their causes. The diagnostic expertise of
a gear unit specialist combined with
Siemens automation technology signifi-
cantly expands the possibilities of early
error detection. The measuring system
based on SIPLUS CMS components fits
seamlessly into the Siemens automation
landscape, but also has interfaces to
other standardized bus systems. The ben-
efits are obvious: machines that are cost-
intensive and run under full loads are
monitored perfectly and the undisturbed,
optimal running of complex systems is
ensured.
This makes SIPLUS CMS an important tool
for increasing and ensuring system ser-
vice life and optimizing production pro-
cesses.
A Siemens product, SIPLUS CMS fits
seamlessly into the components of
the drive train.
11
Further information about drives:
www.siemens.com/flenderapplications
www.siemens.com/gearunits

Further information about couplings:

www.siemens.com/flendercouplings
www.siemens.com/hydrodynamiccouplings

Siemens partners near you:

www.siemens.com/automation/partner

Siemens AG Subject to change without prior notice 04/13 The information provided in this brochure contains merely
Industry Sector Order-No.: E20001-A390-P900-X-7600 general descriptions or characteristics of performance which
in case of actual use do not always apply as described or
Mechanical Drives DISPO 27904
which may change as a result of further development of the
Alfred-Flender-Straße 77 GD.MD.AP.XXXX.52.3.02 WS 04131.0 products. An obligation to provide the respective character-
46395 BOCHOLT Printed in Germany istics shall only exist if expressly agreed in the terms of con-
GERMANY © Siemens AG 2013 tract.

All product designations may be trademarks or product

names of Siemens AG or supplier companies whose use by
third parties for their own purposes could violate the rights
of the owners.