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All geared-up for a demanding industry

02 August 2012

When building a materials handling or processing machine for a quarrying or mining operation, the first requirements that come to mind are 'toughness' and 'durability'.

The machine's components must be able to withstand the heavy and abrasive materials that are associated with these industries, and have the durability to survive the shock loading, heavy workloads and harsh weather conditions they will be subjected to – especially in areas where maintenance access may be difficult.

Machine designers, on the whole, prefer their suppliers to provide modular assemblies rather than individual components; after all, the supplier is the expert when it comes to integration – that’s why you chose him. Finding companies that can offer this capability, however, is not always so easy.

Fortunately, if you are in the market for heavy-duty drives packages, Brevini Power Transmission, manufacturer of the PIV Posiplan hybrid gearbox, is one company that can definitely step up to the plate. With the help of its sister company, Brevini Fluid Power, it is able to supply tough and reliable complete drive systems for those really heavy-duty moving and processing applications characteristic of mining and quarrying operations.

These companies have been combining their technical expertise and engineering capabilities for many years now, providing durable efficient power transmission systems for quarrying original equipment builders and maintenance providers across Europe and, indeed, the rest of the world.

A specialist UK manufacturer of machines for this industry, Parnaby Cyclones, recently approached Brevini for help with the design and installation of drive systems for a material conveying and separating unit that it was contracted to build for a client. The requirement was for a main drive to deliver a torque of 9,000Nm and output speed of 4.0rpm, as well as two chain drives and a spinner drive that were each required to deliver a torque of 3,000Nm and output speeds of 4.0rpm for the separating process. A hydraulic power pack was also required to feed pressure to individual hydraulic motors at each of the four gearboxes. Brevini sales manager, Dave Brown takes up the story:

"we’re well known for designing gearboxes that run at high reduction ratios incredibly efficiently, and this is ideal for the high-torque low-speed requirements that are often required in the quarrying and mining industries. The reduction ratios allow the drive systems to be powered by small hydraulic motors and small power packs, which keeps running costs to a minimum. By working with our sister company, we can offer complete drive packages on short lead times that integrate seamlessly."

Brevini supplied four of its PIV Posiplan bevel planetary helical gear units, each with a Samhydraulik motor and 11kW hydraulic power pack that included proportional control valves for PLC control. The overall lifetime of the package was calculated to exceed 50,000 hours.

The gearbox for the main drive was a three-stage Posiplan BPH323 gearbox with an ISO6336 torque rating (T2ISO) of 15,100Nm and a reduction ratio of 58.82:1. The gearboxes for the chain and spinner drives all used three-stage Posiplan BPH313 gearboxes with torque ratings (T2ISO) of 3,900Nm and reduction ratios of 45.68:1. Combined respectively with Samhydraulik BR200 and BR080 orbit motors, the drives comfortably delivered the required torque and speed.

The PIV Posiplan gearbox is a hybrid design combining the high efficiency, high reduction ratios and low weight benefits of planetary gear stages with the strength, capacity and durability of bevel helical gears. The modularity of this series, moreover, ensures a closer match of product to application; this keeps the customer happy while reducing his lead times and development costs.

Brevini Fluid Power offers a range of axial piston and orbit motors from Samhydraulik as well as hydraulic pumps and proportional valves to complete the motor/gearbox package. Hydraulic drives are an excellent choice for powering heavy-duty mining and quarrying process equipment; they offer a flexible response whatever the load demand, and can be conveniently packaged in compact independent power units for each driven stage of the process.

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