MULTI MIS-ALIGNMENT ROPE COUPLING (MMRC)

THE PRINCIPLE OF OPERATION

The Multi mis-alignment coupling is a revolutionary concept for transmitting torques from gear to
mill top. It replaces the square coupling and tail bars. Like all other couplings, the Rope
Coupling consists of a driving half and a driven half. The coupling directly connects the final
speed reducer of the Mill Drive to the Top Roller of the Mill. The driving half mounts on the final
speed reducer output shaft square end and the driven half mounts on the square end of the mill
top roller. Torque is transmitted from the driving half to the driven half by means of Polyester
Slings hence the name ‘ROPE COUPLING’. Because of the Polyester Slings the design is
completely flexible and absorbs large mis-alignments of the top roller with respect to the output
shaft of the driving gear. These flexible elements forms balanced couples in a plane normal to
the coupling axis. This eliminates in a single coupling the large bending moments and thrust
generation that normally results from the axial and radial mis-alignments between gear and top
roller.

ADVANTAGES OF MULTI MIS-ALIGNMENT COUPLINGS

 Improves extraction performance of the Mill. The conventional Tail Bar obstructs free
floating of the Mill Top Roller. The Multi Mis-alignment coupling does not impose any
constraining thrust on the Top Roller. With free floating of Top Roller, the Mill operates at
the designed setting and optimum hydraulic pressure and consequently performs more
efficiently.
 If installed on the last Mill, final Baggasse Moisture will be lower.
 Mis-alignment between square end of the Gear shaft and the Top Roller either due to
tilting of the Top Roller or initial alignment error in installations fully absorbed by the Rope
Coupling. As a result no significant lateral thrust or bending moment is transmitted to the
final gear.
 Reduced Torque and Power consumption of Mill.
 Breakage of crown pinion and top roller is completely eliminated.
 Negligible maintenance.
COMPARISON OF MILL TAIL BAR COUPLING AND ROPE COUPLING
S. No Description
Misalignment capability
1 end float more than Tail bar
2 Ratio of (Bending
moment) /(Drive torque)
3 Amplitude of the cyclic
bending stress
4 Bearing at gear side &
Mill side
5 Vibration on the driving
gear Plummer block
6 Gear teeth Surface
7 Extraction performance
8 Bagasse Moisture
9 Torque and Power
consumption
10 Misalignment between
Gear shaft & Mill shaft
11 Mill stoppages
12 Space requirement
13 Initial installation cost
14 Payback period
Tail Bar coupling Rope coupling
Marginal Can take axial displacement,
angular misalignment along with
coupling and can handle all
simultaneously without breaking
100 % < 5%
105Mpa <5 Mpa
Wear out faster due to end No thrust & No wear
thrust
Vibrations are moderate to Vibrations are eliminated
heavy
Due to thrust loads gear No uneven wear patterns on
teeth surfaces show signs gear. Normally improves after
wearing out fast installations
Obstruct the free floating of Does not impose any
the top roller hence constraining thrust on the top
extraction is less roller shaft. Hence free floating
of top roller & improved juice
extraction performance
Since top roller floating is Due to floating of top roller final
restricted moisture in bagasse moisture will be lower
Bagasse is higher side
Tail bar & coupling cause Since it removes the constraint
loss of Torque and Power on free floating of top roller the
mill is able to operate with
reduced friction losses and hence
saving in the operating torque
requirement of the mill & hence
reduction in power consumption
Causes damages to top Misalignment fully absorbed by
roller, crown pinion & drive rope coupling.
system. Abnormal wear & Abnormal wear & tear to final
tear of the final gear gear is eliminated
Chokes caused by tail bar No chokes due to this coupling
coupling restraints since top roller floating freely
Space between gear shaft & Can be accommodated in
Mill shaft required more minimum space between Mill
and gear shaft
Less Higher
- Less than 2 seasons
PAYBACK PERIOD
S.No Description With Rope Without Rope Remarks
coupling Coupling
1 Plant Capacity TCH 273
2 Fiber % 15
3 Season Days 250
4 Mill Size 40’ x 80’ 4nos
5 Input power to at Kw/hr 1100
shaft
6 Overall efficiency % 0.85 0.77
7 Consumed Power Kw/hr 1294 1429
8 Saving Power Kw/hr 135
9 Total power saving Kw 810,000
per season
10 Total cost saving $ 81000 @$0.1/Kw
11 Rope coupling cost $ 100,000 4nos
12 Pay Back period Yrs 1.25