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The mill’s gearbox. MAAG Gear: A pioneer of modern gear technology. MAAG Gear on the move. 1913Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland 1927Start of internationalisation (MAAG Italy, MAAG France, etc.) 1989Foundation of MAAG Gear AG, Switzerland 1997Acquired by FLSmidth - PowerPoint PPT Presentation
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MAAG Gear AG
August 09
The mill’s gearbox
MAAG Gear: A pioneer of modern gear technology
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 2
1913 Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland
1927 Start of internationalisation (MAAG Italy, MAAG France, etc.)
1989 Foundation of MAAG Gear AG, Switzerland
1997 Acquired by FLSmidth
2000 Acquisition of factory in Elblag/ Poland
2003 Move to Winterthur, Switzerland
2007 Sales of marine and turbo business
2009 Move into City of Winterthur
MAAG Gear on the move
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 3
MAAG Gear is a leading global player and belongs to FLSmidth since 1997
Engineering, sales, marketing and project management in Winterthur
Production in Poland and Winterthur Quality ISO 9001 certified More than 90 years of grown expertise
Facts
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 4
Figures 2008
Turnover: 115 mio CHF Production capacity 80 –100 gear units Employees: 280
Engineers: 105 Technicians: 78 Service: 30 Administrative: 45 External Assistance: 14 Trainees: 8
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 5
Engineering experts Gearing technology - parallel gears Gearing technology - bevel gears Metallurgy FEA Antifriction bearings Journal bearings Toothed couplings Acoustics/vibration analysis CAD/PDM Integrated Logistic Support (ILS) /
Reliability Availability Maintenance (RAM)
Supporting tools CAD / Solid Works PDM-Systems / Team Center Ansys for FE-Analysis Various tools for material analysis MAAG Gear-developed program systems
representing the unique experience of generations of gear exports
Collaboration with our customer Cooperation with universities and research
centers
Know-how in engineering and technology
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 6
MAAG Gear, a member of FLS since 1997
FLSmidth & Co.
MAAG Gear
FLSmidth Project Division
Cement
FLSmidth
FLSmidth Customer Services
FLSmidth Airtech
Pfister
Ventomatic
Dansk Eternit Holding
Minerals
FLSmidth Minerals
FLSmidth Minerals Division
FLSmidth Dorr-Oliver EIMCO
FLSmidth Krebs
FLSmidth Buffalo
FLSmidth Koch / MVT
FLSmidth Möller
Excel Foundry & Machine
FLSmidth RACHO
FLSmidth ABON
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 7
Driving equipment for the cement industry
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 8
CPU/CPV/LGDCemet mill
Cement processes driven by MAAG Gear
WPU/WPVRaw mill
PPURoller Press
WPUCoal mill
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 9
Driving equipment for the cement industry
Ball mills lateral drive
LGD
Ball mills central drive
CPU/CPV
Roller mills vertical drive
WPU
Roller mills vertical drive
WPV
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 10
Benefits to customer High operational reliability Efficiency exceeds 96.5% Customers-specific design of gear units Very high efficiency Planetary stage and thrust
bearing for grinding table with very long service life
Low-cost maintenance
Technical overview Fully developed compact two-stage design
(bevel gear / planetary gear stage) Case hardened or hardened and quenched tooth Bevel gear stage with its own casing Thrust bearing mill table hydro static and hydro
dynamic lubricated Power: 250 to 6,000 kW
Roller mills drive, 2-stage (Type WPU)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 11
Roller mills drive, 3-stage (Type WPV)
Benefits to customer Torque split for compact design Flex pin solution for optimized load distribution Efficiency exceeds approx. 95 % Slide bearing application in bevel and planetary
gear stage Simple mechanism for assembly and adjustment
of bevel gear stage without remove the gear unit
Technical overview 1st stage 3 planets, 2nd stage 5 planets Toothing case hardened or quenched and
tempered Thrust bearing mill table hydro static and hydro
dynamic lubricated Power: 2,500 to 9,000 kW
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 12
24/7 Hotline Tel +41 79 619 91 00Troubleshooting
Experienced and skilled service engineers Timely managed
Installation and commissioning
Preventive Monitoring / short reports Assessments Service plan agreementOverhaul Planning and project management Execution and support
Maintenance
Installation / Maintenance
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 13
Better performance for longer periods Guaranteed productivity and profitability Continued customer satisfaction Enhanced reliability
Vibration and operating readings Material analysis and monitoring Advisory opinion
Expert reports
During installation and commissioning In house / in MAAG Gear workshop Tailor-made On-site
Customer training
Support
Service packages
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 14
Mill thrust bearing
Thrust pads Thrust bearings lined with babbitt metal
WPU: The Gear Drive System
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 15
Roller Mill
Mill thrusts
Annulus
WPU gear reducer
The WPU Gear System
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 16
Schematical Design Concept
Spiral bevel gear set
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 17
Set of instrumentation for trend analysis
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 18
Set of instrumentation continue
Process signals – directly wired to CS51.1: T1 – Bearing temperature (self-aligning roller bearing bevel pinion, coupling
side)
51.2: T2 – Bearing tempersature (axial self-aligning roller bearing bevel pinion, gearing side)
51.3: T3 – Bearing temperature (self-aligning roller bearing bevel pinion, gearing side)
51.4: T4 – Bearing temperature (roller bearing bevel wheel, below wheel)
51.5: T5 – Bearing temperature (roller bearing bevel wheel, above wheel)
50.1: T11 – Bearing temperature – Segment of axial thrust bearing
46: T12 – Oil temperature at gearbox outlet
Vibration Sensors – directly wired to CS86.1: VS1 – Ring Gear (Annulus) of the planetary stage
86.2: VS2 – Ring Gear (Annulus) of the planetary stage (perpendicular to 86.1)
Note: Wiring between gearbox and centre control room shall be done by the customer
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 19
WPV sectional drawing
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 20
22 28 3542
5161
7284
97110
125140
155170
191
212
233
254
275
298
320
0
50
100
150
200
250
300
350
26 35 43 54 64 78 92 107 125 142 161 182 200 222 242 274 302 332 360 390 420
Gearbox type
P/n
t
WPU WPV
MaximumP/nt
Selection chart for vertical mill gearbox
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 21
Main advantages:
Torque split 30% to 70%, => 2nd stage with smaller dimension
5 Planets on the 2nd PV-Stage, => smaller dimension of the stage
Planets on the 2nd Stage with flex pin, => much better load distribution
No housing integrated Planetary stage => standard components possible => casing optimised to the axial load
Only slide bearings used => unlimited lifetime of bearings
Adjustment of bevel gear=> No need of gearbox disassembly
WPV - Concept
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 22
Advantages of the slide bearings:
Short delivery time
Unlimited lifetime => high availability of plant
Higher damping compared to anti- friction bearings => less vibration
easy installation and highly service friendly
high know-how basis at MAAG Gear through an enormous amount of deliveries for the Cement, Turbo, and Marine applications
Slide bearings in the bevel gear stage
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 23
Advantages of the improved adjustment method:
Tooth contact easy to adjust
Bevel pinion is adjustable from outside
Bevel gear wheel is adjustable through conic shoe
Fast removal of bevel pinion, without need to remove gear
Service friendly through large dimensioned man hole => short maintenance stops=> no pull out of the gearbox
Easy adjustment of bevel gear
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 24
WPV 360 – Bevel Gear Stage
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 25
Summary
MAAG new developed WPV gearbox show several importantadvantages in investment and operation:
First Test run results and assembly show very encouraging results High potential for optimisation of investment cost Improvement on maintenance and service friendliness increasing
the gearbox availability Lower transport weight and consequently easier erection and
reduced transport costs The independent gearbox modules allow a more flexible and faster
production Lower delivery time for spares due to the smaller gear parts The gearbox is build up with long term approved technologies
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 26
Maintenance philosophy
- Permanent surveillance, daily checks (by site personnel)
- Checks after every 1‘000 h of operation (by site personnel)
- Checks after every 6‘000 h – and 12’000 h of operation (annually)(under supervision of MAAG Service personnel)
- Special checks after approx. 80‘000h of operation, or 12 years (under supervision of MAAG personnel)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 27
Daily checks
Permanent surveillance/daily checks (by site personnel)
- Quick check of the whole drive group
- Checking and recording of operating data
- Checking of drive group and accessories for eventual leaks (reducer, couplings, lube oil supply unit, etc.)
- Checking of oil level in lube oil reservoir
- Check p of lube oil filter (if not monitored)
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 28
Routine 1’000 h checks
Checks every 1‘000h of operation (by site personnel), (additionally to the aforementioned daily checks)
- Record and check operating data (complete checklist 1 of the instruction manual)
- Check lube oil filter and filter/breather for contamination, cleaning or replacing at need
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 29
Regular 6’000 h check
Checks every 6‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned routine checks)
- Check all important bolt connections (reducer, lube oil supply unit, coupling, etc.)
- Check and if necessary re-tighten gearbox anchoring
- Check lube oil for water content/contamination, Analysis of lube oil by the supplier (replacement according to recommendation)
- Visual check of lube oil-sample from axial bearing casing
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 30
Regular 12’000 h check
Checks every 12‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned regular checks)
- Checking of alignment to driving- and driven machine
- Inspection of central bearing no. 1 (input shaft)
- Check of instruments and interlocks, record setting points (complete checklist no. 2)
- Inspect and clean lube oil cooler (if required)
- Partial disassembly and inspection of in- and output coupling, replacing of lubricants and seals
- Functional and alignment check of auxiliary drive
- Inspection of spare parts (if available), special tools
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 31
Special checks - Overhaul
Special checks, overhaul after approx. 80‘000 h of operation, or 12 years (under supervision of MAAG personnel)
- Disassembly of the entire reducer, inspection of all parts. Ultrasonic bonding test of all bearings. (replacement of parts if required)
- Maintenance of components (motors, instruments, etc.) (according to the individual supplier)
Estimated shutdown time 2 weeks, depending upon accessibility, availability of facilities as well as findings and results of the inspection.
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 3232
Customer Service Products
Overview Customer Service Products
Service & Spare Parts Contracts Easy – Training Concept Performance – Gear Box upgrade Prevention – Security thanks obviating Speed – Security thanks fast information flow
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 33
Customer Service Products
Easy – Training Concept
- training of customers service personnel
Challenge – Gear Box upgrade
- exchange of an existing gear box, incl. gear boxes from
competitors
Prevention – Security thanks obviating
- checks via vibration measuring, incl. gear boxes from competitors
Speed – Security thanks fast information flow
- 24 h/day vibration measurement thanks direct access of
customers data’s via internet.
33
MAAG Gear AG
August 09
Gearbox Damage
How to handle material availability
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 35
Source of information and procedures
Emergency situation: a) Customer contacts Field Service Dept: Emergency
description, detailed information b) Customer contacts Sales: availability of spare parts,
delivery schedules Service report at customer Sales travel report at MAAG Gear Customer / Agency request once procedure defined Monitoring system
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 36
Material planning for repair (1)
1. Emergency case: Damage assessment and evaluation Material selection (parts, spares) Availability at customer site
2. Service report: History of the gearbox Detect background of failure Recommendations for repair
3. Sales travel report: Spare parts already delivered Identification of spares required Contact persons Express delivery Quotes
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 37
Material planning for repair (2)
4. Customer / Agency request: Contact Field Service Dept. for details / history Proceed standard spare parts quotation
5. Monitoring system Data exchange Analysis Recommendations Follow up after repair
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 38
Information flow
Customer address
Contact name; e-mail; phone No.
Plant code name
Gearbox type & ex. Order No.
Parts description
Drawing No.
SAP No. (If available)
Quantity
Reason for material request
Time frame
ServiceReport Basic Info
Material Info
Gen. Info
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 39
Repair options (1)
1. On site repair by MAAG Gear Field Service Engineers Field Service Dept. to contact customer & make proposal for
service intervention (material inspection on site) If damage material is already specified, then standard part
quotation is issued If defective material is already inspected, then procedure
according to inspection report recommendations
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 40
Repair options (2)
2. In house repair at MAAG Gear production site Delivery of damaged parts Quote for damage assessment and inspection Quote for repair
3. Repair by 3rd. Party Cooperation under customer responsability
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 41
MAAG Gear locations for development, production and sales Winterthur, Switzerland / Elblag, Poland Bethlehem, North America / sales office Beijing, China / sales office
Service Centers including agents and FLS partner offices world wide(MAAG Gear service centers in USA, Mexico, Poland and Denmark)
MAAG Gear locations and service centers
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 42
MAAG Gears in operation around the world
Algeria Angola Argentina Austria Bangladesh Belgium Bolivia Brazil Bulgaria Canada China Colombia Costa Rica Croatia Denmark Ecuador Egypt El Salvador France Germany Greece Honduras
India Indonesia Iran Ireland Israel Italia Japan Jordan South Korea Kuwait Lebanon Malaysia Mexico Nigeria Pakistan Peru Philippines Poland Russia Saudi Arabia Senegal South Africa
Spain Sudan Sweden Switzerland Syria Taiwan Thailand Togo Turkey UAE Ukraine Uruguay USA Vietnam Yemen
MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 43
Core Elements of our Corporate Strategy Sustainable sales growth Dynamic, relevant innovation pipeline Operational excellence Winning organization Ensure we have the right people and the right
working environment to deliver our vision Constant willingness to innovate and close
collaboration with our customer
MAAG Gear‘s vision