ThyssenKrupp Polysius

InfoLetter
Service: A helping hand - always

Edition 3 - October 2012

Keyfacts
POLDRIVE® is a service for checking drives, particu-
larly those of ball mills, but also other large drive units.
POLDRIVE® has the purpose of preventing damage
and increasing the service life of the drive.
POLDRIVE®, as a standard check-up, for example for
large drives comprises:
- a visual inspection,
- checking of the static and dynamic tooth patterns,
- measurement of the temperature distribution,
- detailed vibration measurement and analyses along the draw on many years of experience in the checking
entire drive train.
POLDRIVE® is available all around the world. Work at
the drive unit takes one day. The POLDRIVE® Team ex-
perts recommend regular checking once or twice a year.
- internal use only -
POLDRIVE®
Check-up for drives
Advantages for our customers:
1. Thanks to POLDRIVE®, damage will be detected at an
early stage and the availability of drive systems will be
improved significantly.
2. The POLDRIVE® Team is a competent partner and
consultant, that plant owners have permanently at
their side for all questions relating to drives – even
when machines from other manufacturers will be
involved.
During every check, the POLDRIVE® experts
3.
of large drive systems. During every analysis, the
POLDRIVE® Team makes full use of the extreme-
ly broad knowledge of plant and equipment that is
available at ThyssenKrupp Polysius.
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 ThyssenKrupp Polysius

InfoLetter
Service: A helping hand - always

Edition 3 - October 2012

Cause Identified - Problem Eliminated!

Report by Christian Speith and Jörg Kuster from POLBECK

A European cement plant owner asked ThyssenKrupp Polysius for assistance with
solving a vibration problem in a mill girth gear.

Background information: without Polysius involvement, the customer, a cement plant

owner in Southern Europe, had purchased a new girth gear for his cement mill.
After the customer‘s personnel had mounted the girth gear on their own, problems
occurred during recommissioning of the grinding system, leading to damage of
some of the tooth flanks of the girth gear. Right from the beginning, operation of the
mill was accompanied by severe vibrations. Investigations and actions carried out by
the plant owner did not achieve any significant improvement. Even with the aid of the
girth gear manufacturer and an external service provider for vibration analyses, the
cause of the vibrations could not be found. At his wit‘s end, the customer turned to Manual checking of the toothing
the plant engineer: ThyssenKrupp Polysius. involute with a tooth thickness
calliper gauge.

We, the POLDRIVE® Team, were then assigned the task of checking the drive. Our
vibration measurement at the pinion bearings confirmed the high levels reported by
the plant „owner. Analysis of
„ the dynamic contact pattern of the girth gear then re-
vealed a day-night effect , i.e. a poor load distribution over the tooth faces caused
by manufacturing faults. In addition, there was a faulty contact pattern over the
height of the girth gear toothing which results in an untypical pitch line apperiance.

The static contact pattern check confirmed the assumptions reached on the basis
of the dynamic contact pattern check. The contact pattern of the girth gear did not
extend over the full height of the toothing. In view of the short running time of the
girth gear and the appearance of the tooth contact pattern, we excluded wear as the
reason for this abnormality and suspected a discrepancy in the toothing involute.
Random checking of the involute with a tooth thickness calliper gauge supported this
assumption.
Jörg Kuster is the POLDRIVE®
In order to obtain conclusive proof that the involute of the girth gear toothing was product manager.
faulty, we joined-up with colleagues from the Polysius Quality Division to perform an
automatic involute measurement on-site using the involute measuring device deve-
loped by Polysius. This measurement produced the definitive data confirming that
the involute of the girth gear toothing was not correct.

After a number of consultations and discussions with the manufacturer, it turned out
that while manufacturing the girth gear there had indeed been problems with the
tooth cutting machine and that these were the cause of the involute deviation.
Finally the girth gear was send back to the manufacturer for recutting the involute.

This assignment demonstrates the knowhow of ThyssenKrupp Polysius, the good

interaction of different company disciplines and our unremitting determination to
help customers. This is what we call Polysius Service.

Christian Speith is a member of

the POLDRIVE® Team speciali-
sing in vibration measurement
and diagnosis.
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- internal use only - 2
 ThyssenKrupp Polysius

InfoLetter
Service: A helping hand - always

Edition 3 - October 2012

Our POLDRIVE® Experts

POLBECK POLBECK
Jörg Kuster Christian Speith
Product Manager POLDRIVE® Product Manager POLDRIVE®
+ 49 2525 99-2586 + 49 2525 99-3048
joerg.kuster@thyssenkrupp.com christian.speith@thyssenkrupp.com

POLDRID
POLAT

POLMAS

POLPERU

POLBRAS POLJOB
POLAUS

to be installed until 2012/13

Which other measurements can ThyssenKrupp Polysius provide?

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- internal use only - 3
 ThyssenKrupp Polysius
InfoLetter
Service: A helping hand - always
Edition 3 - October 2012
What else?
Service-Flyer:   





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

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


 

 
POLDRIVE® – preventive checkup for large tooth gearing - Kilns







(Cement + Minerals)
 

 


 
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 

 



Z-105 _ 09/11
POLDRIVE® – preventive checkup for large tooth gearing - Mills
CEMENT



 
(Cement + Minerals)   












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POLDRIVE . The check-up for your drive
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M -303 _ 09/11
Minerals
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 
SERVICE
by ThyssenKrupp Polysius
Jörg Kuster
Member of our POLDRIVE Team
POLDRIVE. The check-up for your drive.
To make sure that your mill drive has a long and reliable working life, you should regularly check the health
of its teeth. For this purpose, we developed POLDRIVE, our regular check-up service specially conceived for
newer and older ball mill drives.
Your benefit: the Service experts keep an eye on your drive and offer you competent help before damage occurs.
This check-up includes not only the standard measures such as visual inspection, vibration measurement,
checking of the dynamic and static tooth bearing patterns and measurement of the temperature distribution,
but also a comprehensive service that will certainly convince you that a gram of prevention is worth a kilogram
of cure. In order to give a holistic overview, we incorporate the maintenance history of the machine in every
check-up. Naturally we provide you with a comprehensive report and personal recommendations. POLDRIVE
thus offers custom-tailored service, as individual as a health check.
SERVICE by ThyssenKrupp Polysius – the difference
www.polysius.com/service
tk Polysius AG
Graf-Galen-Str. 17 · 59269 Beckum · Germany tk Polysius
Tel.: +49-2525-99-0 · Fax: +49-2525-99-2100
Service 03-2011, GBA4.indd 1 01.08.11 15:44
Presentation
Possible damage pattern on large toothing 
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Pictures
The assortment of picture is optimized
for emailing and usage in powerpoint
presentations. If you need one of the
pictures in printing quality please contact
Daniela Wessel (+49 2525 99-2620,
daniela.wessel@thyssenkrupp.com)
http://sharepoint.kp.thyssenkrupp.com/sites/PGS/OurForum/InfoLetter/Poldrive/Bilder
- internal use only -
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  
   
    
 
 
    

   
 

   
Z-303 _ 09/11
   
 
CEMENT


  
 

  













 

 







 

 


 

 

 
 
 
  


   
  
    
 

   
M -104 _ 09/11
   
 
Minerals


  
 
Checklist
 
 
 
 



 


 
 


 

 
 

 
 
 
 
 
 

 
 
 

 
 
 

 
 
 

Address: ThyssenKrupp Polysius AG, Graf-Galen-Strasse 17, 59269 Beckum-Neubeckum, Germany
Phone: +49 2525 99-0 Telefax: +49 2525 99-2100 E-Mail: polysius@thyssenkrupp.com
Internet: www.polysius.com
Chairman of Supervisory Board: Dr. Niclas Müller
Executive Board: Dr.-Ing. Detlev Rose, Chairman, Dr. Friedrich-Wilhelm Dierkes,
Dr.-Ing. Detlev Kupper, Dipl.-Ing. Norbert Patzelt
Trade Register: Amtsgericht Münster HRB-Nr. 7717 Registered Office: Beckum-Neubeckum
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