GEBR.

PFEIFFER AG

New drive design

for Pfeiffer MPS mills

Dr. Dirk Hoffmann

Progress is our tradition

 Subjects

1. Motivation

2. Potential of the solution

3. Design principle

4. Customer benefit

5. Risk evaluation

6. Development status / future prospects

TK-N/Hof 02/05

Subjects
GEBR. PFEIFFER AG
 1. Motivation

conventional bevel-planetary gears available up to approx. 6,000 kW

increase in mill size: power ratings > 5,000 kW and i > 50 require:

further development of conventional gear units

Flender: KMP => KMPS

Maag: development of a 3-stage

gear unit > 5,000 kW

Renk: KPAV => KPBV

new development of GP / Flender:

DMGV girth gear unit

TK-N/Hof 02/05

Motivation
GEBR. PFEIFFER AG
 Flender KMP

TP/ Ne- 08 / 04

Gearbox
Flender KMP GEBR. PFEIFFER AG
 Flender KMPS

TP/ Ne- 08 / 04

Gearbox
Flender KMPS GEBR. PFEIFFER AG
 Renk KBPV

TP/ Ne- 08 / 04

Gearbox
Renk KBPV GEBR. PFEIFFER AG
 2. Potential of the solution – history of DMGH

DMGH girth gear units successfully used on tube mills up to 11,000 kW

since 1989

approximately 290 DMGH units sold, 120 of these in the past 5 years

DMGH 30 DMGH 25,4 DMGH 22 DMGH 18

TK-N/Hof 02/05

Potential of the solution – history of DMGH

GEBR. PFEIFFER AG
 2. Potential of the solution – DMGV
Basic functions of a mill gear unit:

conversion of torque / speed

suspension of axial mill load

change of direction of rotation from horizontal to vertical

DMGV of modular design, 3 modules:

DMGV 22 : 3,000 kW

DMGV 25,4: 4,500 kW

DMGV 30 : 5,500 kW
covering the range from 3,000 to 11,000 kW either as single or twin drive.
Actually, this makes sense from > 5,000 kW.
TK-N/Hof 02/05

Potential of the solution – DMGV

GEBR. PFEIFFER AG
 2. Potential of the solution – allocation of model ranges

Allocation of MPS model ranges to DMGV model ranges:

today: for 6 MPS mills with grinding bowl diameters from 5,600 to
7,300 mm, 30 gear units are required, covering a range from 3,000
to 11,000 kW and an axial load range from 6,600 to 28,500 kN
(MPS-BC: 2 speeds each / MPS-B: 3 power modules each)

DMGV: 3 modules: DMGV 22 / DMGV 25,4 / DMGV 30:

3 gear units are required

gear rim and axial bearing are selected individually

TK-N/Hof 02/05

Potential of the solution –

allocation of model ranges GEBR. PFEIFFER AG
 3. Design principle – DMGV gear units

train of wheels supported on roller bearings and case hardened; AGMA
2.5 referred to Pinst

4 gear stages:
1. input stage comparable with conventional
bevel-planetary gears, however, with a
smaller bevel gear
2. spur gear stage
3. load distribution by means of a floating
intermediate shaft; mass balance by
means of helical gearing
4. output onto gear rim with two self-aligning
pinions

gear units with enclosed housings => not
comparable with the open, grease lubricated
girth gear units
TK-N/Hof 02/05

Design principle – DMGV gear units

GEBR. PFEIFFER AG
 3. Design principle – details of DMGH gear rim

floating
intermediate
shaft

self-aligning pinions

sketch showing principle of

wheel train in the main gear unit
TP/ Ne- 08 / 04

Design principle – details of DMGH

GEBR. PFEIFFER AG
 3. Design principle – gear rim and axial bearing
gear rim:

integral part of the gear unit => oil lubricated

cast steel / hob cut teeth

AGMA 2.5 referred to Pinst

axial bearing:

comparable with conventional
bevel-planetary gears

gear housing not exposed to

grinding forces

TK-N/Hof 02/05

Design principle – gear rim and axial bearing

GEBR. PFEIFFER AG
 4. Customer benefit: I. capital investment

single-mill concept: > 5,000 kW also possible => reduced investment

for mill

security of investment: increase of mill size / mill capacity with proven

components  290 DMGH gear units sold

standardization: in the range from 3,000 to 11,000 kW 3 modules rather

than 30 gear units => reduced investment for mill drive > 5,000 kW

TK-N/Hof 02/05

Customer benefit
I. capital investment GEBR. PFEIFFER AG
 4. Customer benefit: II. production

temporary operation with one drive assembly in the case of a twin drive
(60% grinding capacity) => no shutdown of production during maintenance
work on the gear

maximum reliability thanks to reduced time requirement for inspection

and rapid availability of spare parts

maximum reliability: gear rim => as compared with conventional gear

units, robust design including the option of emergency repair of individual
teeth by welding
TK-N/Hof 02/05

Customer benefit
II. production GEBR. PFEIFFER AG
 4. Customer benefit: III. maintenance

maximum reliability thanks to simplified spares inventory

standardization / 3 modules and gear sizes, respectively

gear unit not exposed to grinding forces => contact pattern remaining
unchanged => longer lifetime

ease of access: inspection and maintenance work on gear is

facilitated

visual inspection can be done on complete wheel train

during removal of the gear unit, the grinding bowl can remain on the
axial bearing and the electric motor can be left in operating position

TK-N/Hof 02/05

Customer benefit
III. maintenance GEBR. PFEIFFER AG
 5. Risk evaluation

lack of field experience with the DMGV gear on the roller mill

operating behavior of the roller mill is different from that of the tube mill

mechanical dynamics of the vertical distribution shaft => mass

balance provided

(electrical) dynamics with twin drive

tightness of housing is increased compared to the DMGH gear on a

tube mill, i.e. it is similar to that of conventional bevel-planetary gears

TK-N/ Hof 02/05

Risk evaluation
GEBR. PFEIFFER AG
 6. Development status / future prospects

DMGV 22 design completed

DMGV 25,4 and DMGV 30: conceiving stage completed

TK-N/Hof 02/05

Development status / future prospects

GEBR. PFEIFFER AG