ValueTrue is a reliable, value-priced extension to Danaher Motion's family of Micron True planetary gearheads - with over 1000 size and ratio combinations.
Danaher Motion introduces Micron ValueTrue planetary gearheads. ValueTrue is a reliable, value-priced extension to Danaher Motion's family of Micron True planetary gearheads - with over 1000 size and ratio combinations, the largest selection of planetary gearheads worldwide. They offer simple drop-in replacement for most common helical gearheads at up to 30% less cost than comparable gearhead technology.
ValueTrue provides precise operation with just 4arc-min of backlash.
They are available in eight frame sizes from 60 to 200mm, with inline and right-angle configurations.
Additionally, they are RediMount compliant for mounting to any motor in three easy steps - simply align, mount and tighten.
ValueTrue gearheads are lubricated for life and require no maintenance and feature a stainless steel output housing that provides the durability required in harsh application environments.
Customised gearbox aids extraterrestrial search
Cone Drive enlisted the help of sister company David Brown to upgrade the shutter motion of the world's largest optical and infra-red telescope.
The second stage of an upgrade project has seen Cone Drive working with Dangel Robots and Machinery to provide another specialist solution for the world famous WM Keck Observatory at the summit of Hawaii's Mauna Kea. Cone Drive had already been involved in a successful project to replace exterior mounted worm boxes in 2004 and this time returned with additional expertise provided by its sister company David Brown to upgrade the shutter motion of the world's largest optical and infra-red telescope. The latest stage of the project involved installation of new drives for the two massive shutters on the dome that encloses the Keck I telescope.
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea.
Each telescope stands eight storeys tall and weighs 300 tonnes, yet operates with nanometre precision, probing the deepest regions of the universe.
The dome and shutters for the Keck II telescope were originally built using Cone gearboxes in 1995 and they are still performing today.
Cone Drive provided a 'drop in' solution to replace the reducers on the shutters for the Keck I telescope that was built in 1991.
The original reducers were undersized and causing maintenance problems.
Seal leaks were of special concern because of the low temperatures and dry air at such high altitude.
The observatory presents obvious maintenance problems and the aim was to find a replacement reducer that would require minimum modification at the summit, and which offered an increased service factor and improved seal arrangement.
For the final stage of the project four David Brown G14 gearboxes with a ratio of 41.6:1 were added to the 14 previously installed Cone custom 8.000in centre distance HP double enveloping worm reducer units with a special ratio of 9.75:1.
Modified shafting, housings, mounting flanges and keeper plates were provided to mount the gearboxes and connect them together.
The gearboxes incorporate taconite seal arrangements on both input and output shafts.
Oil expansion chambers were supplied to provide sealed units since the gearboxes change attitude as the shutters move up and down over the dome.
The second stage of an upgrade project has seen Cone Drive working with Dangel Robots and Machinery to provide another specialist solution for the world famous WM Keck Observatory at the summit of Hawaii's Mauna Kea. Cone Drive had already been involved in a successful project to replace exterior mounted worm boxes in 2004 and this time returned with additional expertise provided by its sister company David Brown to upgrade the shutter motion of the world's largest optical and infra-red telescope. The latest stage of the project involved installation of new drives for the two massive shutters on the dome that encloses the Keck I telescope.
The upper and lower shutters weigh around 47 and 23 tonnes, respectively.
Central drive motors were replaced with synchronised drives on each side of the shutters.
Cone Drive and David Brown - both Textron companies - worked together to provide custom gearbox input and output shafting to match the drive train requirement and simplify the installation which was an onerous task given the telescope's location at 4300m elevation and the requirement to complete the work during a scheduled shutdown.
It was critical to minimise the length of the shutdown required to perform this work in order to avoid losing valuable observing time.
Dangel Robots was engaged to assist with the drive train design and provide the motion control system and software.
The new motion control system incorporates a number of unique features not available previously.
The most significant operational improvements are the ability to use the shutters to track the vertical motion of the telescope to minimise the effect of wind buffeting, and faster shutter speed to close up quickly if the weather turns bad.
Other new capabilities are to move the shutters together with a minimum gap for daytime maintenance, to independently operate the left and right side drives for alignment, and to control shutter speed during portions of the move profile.
For the power transmission, Dangel Robots specified a David Brown G14 right angle bevel-helical gearbox to combine the functions of both the original mitre and helical reduction boxes.
A motor bracket was designed to mount both the motor and the G14 gearbox using some of the existing holes in the shutter frame to ensure the drive train output alignment.
The close working relationship between Cone Drive and David Brown provided custom gearbox input and output shafting to match up the drive train requirement.
This drop-in solution greatly simplified installation on the shutter.
Dangel Robots built a custom enclosure for the motion controller, 40hp inverter drives and drive components to fit inside the curvature of the dome.
Dangel Robots also created a twentieth-scale model of the shutters with 1hp motors to test the motion control electronic components and the software.
The mechanical model and motion control system were interfaced to the Keck telescope operating computer to test all of the motion control functions prior to installation on the actual dome.
Keck Observatory personnel installed the new drive train hardware and control system during a shutdown in the late summer of 2005.
Installation went smoothly and was completed on time.
Shutter motion is faster, smoother and quieter than it was with the old power transmission.
The Keck I telescope is one of two operated by the California Association for Research in Astronomy at the summit of Mauna Kea.
Each telescope stands eight storeys tall and weighs 300 tonnes, yet operates with nanometre precision, probing the deepest regions of the universe.
The dome and shutters for the Keck II telescope were originally built using Cone gearboxes in 1995 and they are still performing today.
Cone Drive provided a 'drop in' solution to replace the reducers on the shutters for the Keck I telescope that was built in 1991.
The original reducers were undersized and causing maintenance problems.
Seal leaks were of special concern because of the low temperatures and dry air at such high altitude.
The observatory presents obvious maintenance problems and the aim was to find a replacement reducer that would require minimum modification at the summit, and which offered an increased service factor and improved seal arrangement.
For the final stage of the project four David Brown G14 gearboxes with a ratio of 41.6:1 were added to the 14 previously installed Cone custom 8.000in centre distance HP double enveloping worm reducer units with a special ratio of 9.75:1.
Modified shafting, housings, mounting flanges and keeper plates were provided to mount the gearboxes and connect them together.
The gearboxes incorporate taconite seal arrangements on both input and output shafts.
Oil expansion chambers were supplied to provide sealed units since the gearboxes change attitude as the shutters move up and down over the dome.
Gearboxes drop in for speedy upgrade
Tarmac's Buxton Lime Quarry has replaced the gearboxes on its wash drums with the minimum of modification, thereby speeding up the installation and limiting production downtime.
A recent order for David Brown Series G units has enabled Tarmac's Buxton Lime Quarry to replace the gearboxes on its No 3 wash drums with the minimum of modification, thereby speeding up the installation and limiting production downtime. A combination of ready product availability and expert technical assistance from David Brown gave the quarry the confidence to undertake the important work with a minimum of disturbance. As a trusted supplier to the quarry over the years - more than 100 David Brown gearboxes are currently operating on the site - David Brown was approached to suggest possible replacements for existing gearboxes manufactured by a competitor and put forward its Series G as the best solution.
Aiming to get as close as possible to a 'drop-in' solution, David Brown's sales team liaised closely with the quarry, inspecting the installation and providing detailed drawings and advice necessary to enable the work to be carried out.
The standard gearboxes were customised to feature specially-shortened output shafts and needed only redrilling of the base plate and the use of packing plates to raise the shaft centres to the correct height.
The installation work took a total of 16 hours, and a further gearbox is being kept on site as a strategic spare.
The twin wash drums, motors and drives, which process a total of 2.5 million tonnes of material per annum, were supplied some years ago as a package and came already fitted with a competitor's gearboxes.
As these gearboxes approached the end of their working lives a quote was obtained for their substitution on a 'like-for-like' basis but by this stage the model had gone out of normal production and was prohibitively expensive, with a significant delay in availability, and an 'equivalent' product in the competitor's range would have required too much modification to be practical - hence the attraction of the David Brown solution.
The washing plant at Tarmac's Buxton Lime Plant produces hydrated limes used for a soda ash process in Cheshire and for flue gas desulphurisation at three power stations in the East Midlands.
Series G gearboxes are offered in seven sizes from 11 to 130kNm output torque, with a ratio coverage of 6:3:1 to 315:1.
Designed to meet the requirements of applications including bulk handling, mixing, water treatment, cooling towers and conveyor drives, Series G units can be specified in parallel shaft helical and right angle shaft bevel/helical units in double, triple and quadruple reduction gear stages.
Modular design and construction, a high degree of interchangeability of parts and subassemblies, and a universally machined, horizontally split casing has created a family of speed reducing gear units that can be quickly manufactured and is simple to maintain with significant delivery and cost benefits for customers.
The innovative modular construction of the inherently reliable Series G units minimises part count to maximise availability of product.
Fewer than 160 major components meet 10,000 drive solutions.
In many cases units can be ordered and delivered within days compared with a typical schedule of over 6 weeks for a comparable competitor unit.
This not only produces a radical reduction in potential down-time of vital plant, but also enables end-users to reduce stock levels.
Strength and efficiency are maximised, while noise and vibration are kept to a minimum by case hardened and ground helical gears, and hard finished spiral bevel gears.
For extended, efficient life, oil is kept where it belongs by the patented end cover, which improves bearing lubrication and allows a 30% improvement in thermal capacity.
A recent order for David Brown Series G units has enabled Tarmac's Buxton Lime Quarry to replace the gearboxes on its No 3 wash drums with the minimum of modification, thereby speeding up the installation and limiting production downtime. A combination of ready product availability and expert technical assistance from David Brown gave the quarry the confidence to undertake the important work with a minimum of disturbance. As a trusted supplier to the quarry over the years - more than 100 David Brown gearboxes are currently operating on the site - David Brown was approached to suggest possible replacements for existing gearboxes manufactured by a competitor and put forward its Series G as the best solution.
Aiming to get as close as possible to a 'drop-in' solution, David Brown's sales team liaised closely with the quarry, inspecting the installation and providing detailed drawings and advice necessary to enable the work to be carried out.
The standard gearboxes were customised to feature specially-shortened output shafts and needed only redrilling of the base plate and the use of packing plates to raise the shaft centres to the correct height.
The installation work took a total of 16 hours, and a further gearbox is being kept on site as a strategic spare.
The twin wash drums, motors and drives, which process a total of 2.5 million tonnes of material per annum, were supplied some years ago as a package and came already fitted with a competitor's gearboxes.
As these gearboxes approached the end of their working lives a quote was obtained for their substitution on a 'like-for-like' basis but by this stage the model had gone out of normal production and was prohibitively expensive, with a significant delay in availability, and an 'equivalent' product in the competitor's range would have required too much modification to be practical - hence the attraction of the David Brown solution.
The washing plant at Tarmac's Buxton Lime Plant produces hydrated limes used for a soda ash process in Cheshire and for flue gas desulphurisation at three power stations in the East Midlands.
Series G gearboxes are offered in seven sizes from 11 to 130kNm output torque, with a ratio coverage of 6:3:1 to 315:1.
Designed to meet the requirements of applications including bulk handling, mixing, water treatment, cooling towers and conveyor drives, Series G units can be specified in parallel shaft helical and right angle shaft bevel/helical units in double, triple and quadruple reduction gear stages.
Modular design and construction, a high degree of interchangeability of parts and subassemblies, and a universally machined, horizontally split casing has created a family of speed reducing gear units that can be quickly manufactured and is simple to maintain with significant delivery and cost benefits for customers.
The innovative modular construction of the inherently reliable Series G units minimises part count to maximise availability of product.
Fewer than 160 major components meet 10,000 drive solutions.
In many cases units can be ordered and delivered within days compared with a typical schedule of over 6 weeks for a comparable competitor unit.
This not only produces a radical reduction in potential down-time of vital plant, but also enables end-users to reduce stock levels.
Strength and efficiency are maximised, while noise and vibration are kept to a minimum by case hardened and ground helical gears, and hard finished spiral bevel gears.
For extended, efficient life, oil is kept where it belongs by the patented end cover, which improves bearing lubrication and allows a 30% improvement in thermal capacity.
Distributor takes clutches and couplings to Spain
Renold Clutches and Couplings has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK.
Renold Clutches and Couplings of Cardiff has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK. The Spanish distributor will stock Renold's range of interchangeable trapped roller and sprag clutch freewheels to provide an off-the-shelf service to engineers throughout Spain. Martin Slade, Renold Clutches and Couplings' Sales Director said: 'We are delighted with this new agreement with another distributorship within the Brammer group'.
'Spain is an important country for us and we know that USA Brammer will provide the best possible service for our customers there'.
Renold recently announced that its entire range of trapped roller and sprag clutch freewheels is interchangeable with those of other leading American and European manufacturers such as Formsprag, Stieber, Ringspann and Cross and Morse.
Renold Clutches and Couplings of Cardiff has gone into partnership with Spanish distributor USA Brammer, a sister company to BSL Brammer in the UK. The Spanish distributor will stock Renold's range of interchangeable trapped roller and sprag clutch freewheels to provide an off-the-shelf service to engineers throughout Spain. Martin Slade, Renold Clutches and Couplings' Sales Director said: 'We are delighted with this new agreement with another distributorship within the Brammer group'.
'Spain is an important country for us and we know that USA Brammer will provide the best possible service for our customers there'.
Renold recently announced that its entire range of trapped roller and sprag clutch freewheels is interchangeable with those of other leading American and European manufacturers such as Formsprag, Stieber, Ringspann and Cross and Morse.
Gearboxes drop in to upgrade mill capacity
David Brown Engineering has supplied five large gearboxes and pinions to JSW Steel in India in the first stage of a major upgrading of the company's hot strip mill facilities completed during April and May 2006. This initial project will increase capacity by 40% and other planned improvements are designed to progressively double throughput at the facilities. The plant near Bellary in the province of Karnataka has six finishing mills with 5000hp motors and these motors have been upgraded to 7000hp.
The replacement gearboxes and pinions from David Brown Engineering have the same footprint and critical dimensions as the existing ones, enabling a 'drop-in' solution.
This caused the minimum disruption to production when they were installed together with new motors as well as obviating the main obstacle to upgrading given that reorganisation of the mill equipment layout invariably involves monumental cost and long term disruption.
Close co-operation between JSW Steel and David Brown and all the partners in the project has been the hallmark of the operation and experts from the engineering company made a number of visits to the plant to discuss the project, offer technical advise, take measurements and work in conjunction with other major suppliers who were involved in motors and couplings and in overall consultancy.
In fact representatives of David Brown Engineering visited the plant to take measurements and plan for the project five times in conjunction with the other three partners in the project: main contractor VAI (UK), motor manufacturer Siemens, Germany and couplings producer Maina, Italy.
A good example of the spirit of co-operation that characterises the project was the fitting of couplings before dispatch of the gearboxes from Huddersfield.
In the original plan the Italian-built Maina couplings would have been fitted on site in India, but it was judged that critical installation time could be reduced on site by first shipping the couplings to the UK.
Furthermore David Brown Engineering supplied services of commissioning engineering, flying out to India to supervise the installation of the gearboxes, and in the run-up to the operation team meetings are being held at VAI offices in Sheffield.
The installation took place in one planned 5 week shutdown with the actual installation performed by JSW Steel.
VAI and Siemens were also present to oversee the installation of the motors.
The existing plant was purchased in its entirety from the United States a decade ago and the gearboxes were reaching the end of their natural life.
The plant, in the remote province of Karnataka in southern India, is part of the JSW Group, in turn part of India's fourth largest business conglomerate, the Jindal Organisation with interests in mining, carbon steel, stainless steel, power and oxygen and currently valued at US $4 billion.
The group was founded in 1964 by OP Jindal who from humble beginnings, rose to become one of India's leading industrialists and founded a steel making dynasty of world importance.
This particular step in investment and expansion is seen as a major opportunity for the group against the current backdrop of a world steel shortage.
The replacement gearboxes and pinions from David Brown Engineering have the same footprint and critical dimensions as the existing ones, enabling a 'drop-in' solution.
This caused the minimum disruption to production when they were installed together with new motors as well as obviating the main obstacle to upgrading given that reorganisation of the mill equipment layout invariably involves monumental cost and long term disruption.
Close co-operation between JSW Steel and David Brown and all the partners in the project has been the hallmark of the operation and experts from the engineering company made a number of visits to the plant to discuss the project, offer technical advise, take measurements and work in conjunction with other major suppliers who were involved in motors and couplings and in overall consultancy.
In fact representatives of David Brown Engineering visited the plant to take measurements and plan for the project five times in conjunction with the other three partners in the project: main contractor VAI (UK), motor manufacturer Siemens, Germany and couplings producer Maina, Italy.
A good example of the spirit of co-operation that characterises the project was the fitting of couplings before dispatch of the gearboxes from Huddersfield.
In the original plan the Italian-built Maina couplings would have been fitted on site in India, but it was judged that critical installation time could be reduced on site by first shipping the couplings to the UK.
Furthermore David Brown Engineering supplied services of commissioning engineering, flying out to India to supervise the installation of the gearboxes, and in the run-up to the operation team meetings are being held at VAI offices in Sheffield.
The installation took place in one planned 5 week shutdown with the actual installation performed by JSW Steel.
VAI and Siemens were also present to oversee the installation of the motors.
The existing plant was purchased in its entirety from the United States a decade ago and the gearboxes were reaching the end of their natural life.
The plant, in the remote province of Karnataka in southern India, is part of the JSW Group, in turn part of India's fourth largest business conglomerate, the Jindal Organisation with interests in mining, carbon steel, stainless steel, power and oxygen and currently valued at US $4 billion.
The group was founded in 1964 by OP Jindal who from humble beginnings, rose to become one of India's leading industrialists and founded a steel making dynasty of world importance.
This particular step in investment and expansion is seen as a major opportunity for the group against the current backdrop of a world steel shortage.
On-site services solve tricky problems
Manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team.Overcoming extremely limited clearances while manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team. In this case a special cradle was constructed under David Brown's guidance and the gear was transferred into place on rails. The cement mill gearbox operated by Australia's major cement producer had suffered a bearing failure and the resulting debris caused significant damage to the slow speed dual drive double helical pinions and gear teeth.
Engineers from David Brown attended the site to make repairs and allow continued production, at a reduced rate of 75% of full capacity, while the replacement gear and pinions could be manufactured by David Brown Australia.
In the interim there was close liaison with the client to plan the gear set replacement method and keep downtime to a minimum.
Production resumed at 100% following installation of the new gear set in 2004.
An inspection carried out in 2005, following 12 months of full production, showed exceptional tooth contact patterns and an absence of tooth wear, giving the overall refurbishment project a double 'thumbs up'.
The contract underlines the scope of David Brown's on-site services in a market which is increasingly driven by service as well as product excellence.
The team that worked on the project is just part of David Brown's fully qualified field service engineer resource which is available in most key geographies to provide a number of key services from performance testing, fault diagnostics through to installation/commissioning, alignment checks and emergency repairs.
Recognising the importance of preventative maintenance, the company also boasts a range of applications knowledge, gained through close long-term customer partnerships in many heavy process industries, to offer performance improvements to transmissions and other rotating equipment.
Using appropriate condition monitoring and analysis techniques, David Brown is able to pin point critical process issues and recommend courses of action to substantially reduce the associated risks.
David Brown's deep knowledge of transmissions and other rotating equipment, combined with its close geographic proximity, means it is well positioned to respond rapidly to its customers' needs, seeking to identify and predict issues, and offering solutions to improve their process performance.
Service engineers are also available to install and inspect transmissions and other rotating equipment throughout the world and David Brown provides installation services and alignment checks that cover everything from a simple equipment installation to a complete drive system installation.
To ensure a proper startup of the equipment, David Brown service engineers can also provide its customers with inspection services and advice on project managing installations.
Finally, experienced service engineers, using modern equipment and leading technology, provide repair services at the site to restore or enhance performance of transmissions or other rotating equipment.
The services range from emergency repairs, as in Australia, to repairs of equipment during planned shutdowns.
Repair services cover all transmissions used in a variety of heavy process industries, from metals processing through to mining and cement manufacture.
Engineers from David Brown attended the site to make repairs and allow continued production, at a reduced rate of 75% of full capacity, while the replacement gear and pinions could be manufactured by David Brown Australia.
In the interim there was close liaison with the client to plan the gear set replacement method and keep downtime to a minimum.
Production resumed at 100% following installation of the new gear set in 2004.
An inspection carried out in 2005, following 12 months of full production, showed exceptional tooth contact patterns and an absence of tooth wear, giving the overall refurbishment project a double 'thumbs up'.
The contract underlines the scope of David Brown's on-site services in a market which is increasingly driven by service as well as product excellence.
The team that worked on the project is just part of David Brown's fully qualified field service engineer resource which is available in most key geographies to provide a number of key services from performance testing, fault diagnostics through to installation/commissioning, alignment checks and emergency repairs.
Recognising the importance of preventative maintenance, the company also boasts a range of applications knowledge, gained through close long-term customer partnerships in many heavy process industries, to offer performance improvements to transmissions and other rotating equipment.
Using appropriate condition monitoring and analysis techniques, David Brown is able to pin point critical process issues and recommend courses of action to substantially reduce the associated risks.
David Brown's deep knowledge of transmissions and other rotating equipment, combined with its close geographic proximity, means it is well positioned to respond rapidly to its customers' needs, seeking to identify and predict issues, and offering solutions to improve their process performance.
Service engineers are also available to install and inspect transmissions and other rotating equipment throughout the world and David Brown provides installation services and alignment checks that cover everything from a simple equipment installation to a complete drive system installation.
To ensure a proper startup of the equipment, David Brown service engineers can also provide its customers with inspection services and advice on project managing installations.
Finally, experienced service engineers, using modern equipment and leading technology, provide repair services at the site to restore or enhance performance of transmissions or other rotating equipment.
The services range from emergency repairs, as in Australia, to repairs of equipment during planned shutdowns.
Repair services cover all transmissions used in a variety of heavy process industries, from metals processing through to mining and cement manufacture.
Universal joints need no tools for maintenance
Abssac continues to expand its rotary product portfolio by teaming up with Curtis Universal of the USA and its unique range of Curtis TakeApart universal joints. Universal joint applications by design normally require two shafts not in line with each other limited freedom of movement in any direction while transmitting rotary motion. Where Curtis excels is in the design and assistance developing a universal joint application to achieve a cost effective transmission solution, applying more than 75 years of universal joint experience.
The company can incorporate different types of end attachment as well as allowing telescopic action during rotation into the design.
The universal joints are machined, not cast, which enables high tensile strength and outstanding reliability but also lends itself perfectly for unique transmission designs.
As standard all universal joints are available in alloy steel, stainless steel, however many applications have been developed using nonstandard materials such as titanium and Monel alloys.
We are also familiar with dealing with different heat and surface treatments to achieve a desired hardness or corrosion resistance.
The basic universal joint uses a single joint configuration which can accept up to 35 degrees of angular misalignment.
Where more angular flexibility is required, the double joint design can accept up to 70 degrees of shaft misalignment.
For applications such as marine, which require unusually high noncorrosion standards, Curtis can supply universal joints in stainless steel, bronze, naval brass, aluminium-bronze, nickel-aluminium-bronze and Monel alloy.
Uniquely, the standard ranges can incorporate the Curtis TakeApart design, which allows the disassembly and reassembly of the universal joint without the use of special tools and replacement of component parts.
This feature enables the end user to machine the hubs to fit the mating shaft if a standard bore does not.
In addition to this, easier access to other components in a drive line can be achieved by being able to quickly and easily disassemble the joint after it has been installed in the application.
The company can incorporate different types of end attachment as well as allowing telescopic action during rotation into the design.
The universal joints are machined, not cast, which enables high tensile strength and outstanding reliability but also lends itself perfectly for unique transmission designs.
As standard all universal joints are available in alloy steel, stainless steel, however many applications have been developed using nonstandard materials such as titanium and Monel alloys.
We are also familiar with dealing with different heat and surface treatments to achieve a desired hardness or corrosion resistance.
The basic universal joint uses a single joint configuration which can accept up to 35 degrees of angular misalignment.
Where more angular flexibility is required, the double joint design can accept up to 70 degrees of shaft misalignment.
For applications such as marine, which require unusually high noncorrosion standards, Curtis can supply universal joints in stainless steel, bronze, naval brass, aluminium-bronze, nickel-aluminium-bronze and Monel alloy.
Uniquely, the standard ranges can incorporate the Curtis TakeApart design, which allows the disassembly and reassembly of the universal joint without the use of special tools and replacement of component parts.
This feature enables the end user to machine the hubs to fit the mating shaft if a standard bore does not.
In addition to this, easier access to other components in a drive line can be achieved by being able to quickly and easily disassemble the joint after it has been installed in the application.
Gear motors offer cost-effective alternative
The Watt Drive Company situated close to Vienna in Austria has been producing a quality range of gear motors for nearly 30 years.
The Watt Drive Company situated close to Vienna in Austria has been producing a quality range of gear motors for nearly 30 years. The products include a very robust range of helical worm motor gearbox product up to 7.5kW and then increasing in size using the bevel helical and Inline gearboxes suitable for motor power up to 90kW. The Watt Drive product is fully complemented by the Watt Drive multivoltage energy-efficient EUSAS motor and is suitable for operation with a range of electronic soft start and inverter controls.
All units can be fitted with brakes, backstops, forced cooling, encoders and many other options.
Available in the UK from Drummotors and More, the Watt Drive product range is complete, the quality second to none and the service first class.
The company reckons the Watt Drive product is a genuine cost effective alternative to other quality gearboxes on the market.
The Watt Drive Company situated close to Vienna in Austria has been producing a quality range of gear motors for nearly 30 years. The products include a very robust range of helical worm motor gearbox product up to 7.5kW and then increasing in size using the bevel helical and Inline gearboxes suitable for motor power up to 90kW. The Watt Drive product is fully complemented by the Watt Drive multivoltage energy-efficient EUSAS motor and is suitable for operation with a range of electronic soft start and inverter controls.
All units can be fitted with brakes, backstops, forced cooling, encoders and many other options.
Available in the UK from Drummotors and More, the Watt Drive product range is complete, the quality second to none and the service first class.
The company reckons the Watt Drive product is a genuine cost effective alternative to other quality gearboxes on the market.
Support is key in gear supply
Reliance reckons it is not just another catalogue supplier of gears and associated components.
For 50 years Reliance has been well known for supplying precision fine pitch gears for instrumentation and light actuation, but the company reckons it is not just another catalogue supplier of gears and associated components. Reliance consists of Reliance Precision (formerly Reliance Gear Company ) and its sister company Reliance Precision Mechatronics. Formed in 2005 to distribute Reliance's standard product range, Reliance Precision Mechatronics offers small quantities at stock prices for cost effective prototype development.
To complete the customer service package the company can also: predict the performance of its standard components in a customer's application; specify associated components for a customer's design; modify standard components to suit a customer's requirements; and offer unique solutions from proven concepts.
A team of dedicated mechatronic design engineers is on hand to support customer design requirements and develop turnkey mechatronic solutions.
Reliance Precision offers in-house design, manufacture, assembly and test all under one roof.
With dedicated manufacturing facilities the company can supply production quantities of customised components and, in many cases, provide full assembly support to its customers including: design for manufacture; weight critical design and analysis; safety critical design and analysis; prototype manufacture; life validation testing; and repair service and obsolescence management.
Quality assured to BS EN ISO9001:2000 and the aerospace standard AS 9100 Revision B, Reliance is committed to providing the highest quality in terms of both manufacture and service.
Reliance is certified to the environmental management standard BS EN ISO14001:2004
For 50 years Reliance has been well known for supplying precision fine pitch gears for instrumentation and light actuation, but the company reckons it is not just another catalogue supplier of gears and associated components. Reliance consists of Reliance Precision (formerly Reliance Gear Company ) and its sister company Reliance Precision Mechatronics. Formed in 2005 to distribute Reliance's standard product range, Reliance Precision Mechatronics offers small quantities at stock prices for cost effective prototype development.
To complete the customer service package the company can also: predict the performance of its standard components in a customer's application; specify associated components for a customer's design; modify standard components to suit a customer's requirements; and offer unique solutions from proven concepts.
A team of dedicated mechatronic design engineers is on hand to support customer design requirements and develop turnkey mechatronic solutions.
Reliance Precision offers in-house design, manufacture, assembly and test all under one roof.
With dedicated manufacturing facilities the company can supply production quantities of customised components and, in many cases, provide full assembly support to its customers including: design for manufacture; weight critical design and analysis; safety critical design and analysis; prototype manufacture; life validation testing; and repair service and obsolescence management.
Quality assured to BS EN ISO9001:2000 and the aerospace standard AS 9100 Revision B, Reliance is committed to providing the highest quality in terms of both manufacture and service.
Reliance is certified to the environmental management standard BS EN ISO14001:2004
Bore reducers come in brass and aluminium
Brass and aluminium bore reducers are designed to fit into couplings where smaller bores are required quickly and easily.
Ondrives offers a range of brass and aluminium bore reducers designed to fit into couplings where smaller bores are required quickly and easily.
They start from 5mm O/D and go up to 28mm O/D, the smallest bore available being 2mm in brass and the largest 25.4mm in aluminium.
It should be noted that both concentricity and traction may be affected when using a bore reducer, so customers are advised to check their application carefully before use.
Ondrives offers a range of brass and aluminium bore reducers designed to fit into couplings where smaller bores are required quickly and easily.
They start from 5mm O/D and go up to 28mm O/D, the smallest bore available being 2mm in brass and the largest 25.4mm in aluminium.
It should be noted that both concentricity and traction may be affected when using a bore reducer, so customers are advised to check their application carefully before use.
Bevel gearboxes offer many options
A miniature instrument bevel tee gearbox is available in a 1:1 ratio and comes with either steel or plastic gears as standard.
A wide variety of in-house UK produced gearboxes are offered by Ondrives of Chesterfield. One of the most popular ranges are the bevel gearboxes as they are available in many different configurations. One of the types is the miniature instrument bevel tee version which is available in a 1:1 ratio and comes with either steel or plastic gears as standard.
It is called miniature because it is only 30.5mm x 30.5mm wide.
Other gearboxes in the bevel collection range from right angled drive types, hardened teeth or hardened bevel versions, bore input or bore output only, bore input and output, heavy duty, counter rotating output, high bevel reduction and spiral bevel value boxes.
Ratios range from 1:1 to 24:1 dependant on the type of gearbox chosen.
Specials can be made according to customer's specifications and all are drawn out using the latest 3D CAD technology systems.
CAD drawings can be downloaded from the Ondrives website for all standard bevel boxes.
A wide variety of in-house UK produced gearboxes are offered by Ondrives of Chesterfield. One of the most popular ranges are the bevel gearboxes as they are available in many different configurations. One of the types is the miniature instrument bevel tee version which is available in a 1:1 ratio and comes with either steel or plastic gears as standard.
It is called miniature because it is only 30.5mm x 30.5mm wide.
Other gearboxes in the bevel collection range from right angled drive types, hardened teeth or hardened bevel versions, bore input or bore output only, bore input and output, heavy duty, counter rotating output, high bevel reduction and spiral bevel value boxes.
Ratios range from 1:1 to 24:1 dependant on the type of gearbox chosen.
Specials can be made according to customer's specifications and all are drawn out using the latest 3D CAD technology systems.
CAD drawings can be downloaded from the Ondrives website for all standard bevel boxes.
Clamps and collars can be made to order
Ondrives offer a wide variety of clamps and collars from its couplings range of mechanical drive components.
Ondrives offers a wide variety of clamps and collars from its couplings range of mechanical drive components. There are hub clamps in a single or double split type as well as set screw shaft collars in mild steel or stainless (dependant on size required), shaft clamps with keyways, integral clamp collars with clamp fixings in either aluminium or stainless and most finished bore sizes are to H7 tolerances. Specials are available to customer specifications.
Ondrives can read most formats including jpeg, DXF, 2D and 3D CAD, dwg, and the company uses the latest 3D CAD software to generate standards and specials alike.
Most Ondrives clamps and collars are produced in-house, so it is easy to modify bore sizes and add keyways or tapped holes quickly and affordably.
Ondrives offers a wide variety of clamps and collars from its couplings range of mechanical drive components. There are hub clamps in a single or double split type as well as set screw shaft collars in mild steel or stainless (dependant on size required), shaft clamps with keyways, integral clamp collars with clamp fixings in either aluminium or stainless and most finished bore sizes are to H7 tolerances. Specials are available to customer specifications.
Ondrives can read most formats including jpeg, DXF, 2D and 3D CAD, dwg, and the company uses the latest 3D CAD software to generate standards and specials alike.
Most Ondrives clamps and collars are produced in-house, so it is easy to modify bore sizes and add keyways or tapped holes quickly and affordably.
Couplings are approved for hazardous areas
Flender Power Transmission's extensive range of gear couplings now includes ATEX-compliant models for hazardous areas. Flender ATEX-approved couplings include N-Eupex flexible jaw couplings, Arpex steel torsionally rigid couplings and Fludex mechanical soft start couplings. N-Eupex couplings compensate for shaft misalignment, are used in general mechanical engineering, and as high and low-speed couplings for pump drives and conveyors, with torque ranges from 19 to 6200Nm and 23 sizes.
In cases of wear to flexible components, N-Eupex couplings will turn freely without metal-to-metal contact, of particular benefit in hazardous areas.
Arpex all-steel couplings allow for radial, angular and axial shaft misalignments, are maintenance-free and have torque ranges from 5Nm up to 10MNm.
They are widely used in the paper and cement industries and in cooling towers.
They have a reduced backlash feature and offer lifetime operation when correctly aligned.
Fludex soft start couplings are ideal for accelerating large masses smoothly, with excellent shock damping properties and a power range up to 2500kW.
Suitable for medium and high torque applications in conveyors, mixers, drum drives and cement plants, Fludex couplings provide torque limitation during start and overload and have excellent vibration separation and shock damping characteristics.
These are just three ATEX-compliant options from Flender's extensive series of couplings.
In cases of wear to flexible components, N-Eupex couplings will turn freely without metal-to-metal contact, of particular benefit in hazardous areas.
Arpex all-steel couplings allow for radial, angular and axial shaft misalignments, are maintenance-free and have torque ranges from 5Nm up to 10MNm.
They are widely used in the paper and cement industries and in cooling towers.
They have a reduced backlash feature and offer lifetime operation when correctly aligned.
Fludex soft start couplings are ideal for accelerating large masses smoothly, with excellent shock damping properties and a power range up to 2500kW.
Suitable for medium and high torque applications in conveyors, mixers, drum drives and cement plants, Fludex couplings provide torque limitation during start and overload and have excellent vibration separation and shock damping characteristics.
These are just three ATEX-compliant options from Flender's extensive series of couplings.
Jaw couplings operate with zero backlash
An innovative braking solution for positioning applications using linear motion guide bearings is available from Motion Drives and Controls, the Warwick based brake and clutch specialist. Nexen's RB series spring-engaged/air-released rail brake is designed to match the rail profile of linear motion guides from a wide range of from manufacturers including THK, NSK, SKF, INA, Hiwin and Schneeberger. The rugged and compact brake has similar dimensions to the corresponding bearing carriage and is simply mounted on the existing rail to provide a convenient means for fast response, emergency stop and power-off braking.
The Nexen RB series profile rail brake is particularly suited to z-axis' vertically loaded positioning systems and the spring based brake will provide full braking even under power failure conditions.
The brake may also be used on leadscrew, ballscrew and belt driven positioning systems in place of rotary motor mounted brakes for a more compact solution with improved drive-train backlash and elasticity characteristics.
Rail brakes can also be used for linear motor positioners and actuators to prevent machine movement under power-off conditions and to improve stiffness during heavy machining.
The Nexen RB range includes a unique facing gap adjustment feature that ensures maximum braking contact throughout application life.
This feature also provides a convenient manual release mechanism to aid assembly and to simplify machine maintenance.
The spring-engaged brakes require a clean air supply of 5.5bar for release and are capable of infrequent and noncyclic dynamic braking such as emergency stops.
The brake facings only contact the nonbearing rail surfaces and the design provides an equal pressure on both sides of the rail to minimise unwanted forces.
With a life of over 1 million cycles and with no lubrication or periodic maintenance in most applications, the RB series is available in a wide range of models to provide a holding force from 400 to 2600N.
Ordering and specifying is easy - customers simply specify the linear motion guide manufacturers' model and part number and their braking force requirements.
The Nexen RB series profile rail brake is particularly suited to z-axis' vertically loaded positioning systems and the spring based brake will provide full braking even under power failure conditions.
The brake may also be used on leadscrew, ballscrew and belt driven positioning systems in place of rotary motor mounted brakes for a more compact solution with improved drive-train backlash and elasticity characteristics.
Rail brakes can also be used for linear motor positioners and actuators to prevent machine movement under power-off conditions and to improve stiffness during heavy machining.
The Nexen RB range includes a unique facing gap adjustment feature that ensures maximum braking contact throughout application life.
This feature also provides a convenient manual release mechanism to aid assembly and to simplify machine maintenance.
The spring-engaged brakes require a clean air supply of 5.5bar for release and are capable of infrequent and noncyclic dynamic braking such as emergency stops.
The brake facings only contact the nonbearing rail surfaces and the design provides an equal pressure on both sides of the rail to minimise unwanted forces.
With a life of over 1 million cycles and with no lubrication or periodic maintenance in most applications, the RB series is available in a wide range of models to provide a holding force from 400 to 2600N.
Ordering and specifying is easy - customers simply specify the linear motion guide manufacturers' model and part number and their braking force requirements.
Gearboxes extend to heavy duty applications
Shaft mounted helical gearboxes extend to heavy duty applications, matching the largest equivalent units from Fenner, Benzler Sala and Dodge.
Renold Gears has extended its SMXtra range of shaft mounted helical gearboxes, for heavy duty applications, to include sizes 11 and 12 that match the largest equivalent units from Fenner, Benzler Sala and Dodge. The ATEX approved range is now available in 12 sizes up to 235kW capacity with a choice of single or double reduction units with ratios of up to 25:1 and output speeds from 10 to 400rev/min. The SMXtra gearbox range is manufactured with hardened, profile ground single helical gears with high capacity bearings to ensure maximum power transmission, maximum load carrying capacity and longer life.
The units mount directly onto the shaft of the driven machine completely eliminating alignment problems as there is no need for couplings, base plates, slide rails or support structures.
They are ideally suited to heavy-duty applications in hostile environments and provide the ideal drive for many types of machinery.
Depending on requirements the SMXtra range can be fitted with advanced seals to optimise protection from dust and moisture.
Additionally, by reversing one element of the standard design, the seal can provide additional security to prevent the egress of oil into sensitive environments such as in food manufacturing.
Renold Gears has produced a new catalogue for all the gearboxes in its SMXtra range, including the new sizes 11 and 12, with details of the power ratings for each unit.
Renold Gears has extended its SMXtra range of shaft mounted helical gearboxes, for heavy duty applications, to include sizes 11 and 12 that match the largest equivalent units from Fenner, Benzler Sala and Dodge. The ATEX approved range is now available in 12 sizes up to 235kW capacity with a choice of single or double reduction units with ratios of up to 25:1 and output speeds from 10 to 400rev/min. The SMXtra gearbox range is manufactured with hardened, profile ground single helical gears with high capacity bearings to ensure maximum power transmission, maximum load carrying capacity and longer life.
The units mount directly onto the shaft of the driven machine completely eliminating alignment problems as there is no need for couplings, base plates, slide rails or support structures.
They are ideally suited to heavy-duty applications in hostile environments and provide the ideal drive for many types of machinery.
Depending on requirements the SMXtra range can be fitted with advanced seals to optimise protection from dust and moisture.
Additionally, by reversing one element of the standard design, the seal can provide additional security to prevent the egress of oil into sensitive environments such as in food manufacturing.
Renold Gears has produced a new catalogue for all the gearboxes in its SMXtra range, including the new sizes 11 and 12, with details of the power ratings for each unit.
Gearboxes deliver more torque
Cost-effective planetary/spur gearboxes deliver a massive 10Nm of flexible torque.
Rotalink, a world-leader in the design and manufacture of miniature transmission products, has launched two highly cost-effective planetary/spur gearboxes. Fabricated from advanced materials, dedicated gear profiles enable these unique compact units to deliver a massive 10Nm of flexible torque at a highly competitive cost, significantly enhancing market opportunities for original equipment manufacturers. Key to the massive torque available in the planetary output stage is Rotalink's unique gear tooth design, which also minimises noise and backlash.
Power transfer to the stainless steel output shaft is maximised by the wide choice of ratios available in the spur input stage - up to 12800:1 - coupled with low friction standard front ball race and nylon or steel ball race rear bearings.
The zinc-plated pressed steel case's standard four-point fixing gives OEMs solid but flexible fixing options.
The gearboxes are the Type 230, delivering up to 5Nm through input ratios from 25:1 to 1000:1, and the 260 delivering up to 10Nm through input ratios from 50:1 to 2000:1, both with alternative input ratios available up to 12800:1.The units are rated at 80C at the gear case and are available with AC, stepper or DC motors, single or dual line encoders are optional across the range.
With the introduction of these miniature gearboxes, Rotalink has successfully used its state-of-the-art design capability and strategic manufacturing and sourcing to deliver the compact, cost-effective product essential to 21st century motion control, automation and system integration OEMs.
Typical applications include peristaltic pumps, dispensing equipment, vending machines and similar dosing/metering systems where air and/or liquid valve control is required; analytical instrumentation, semiconductor manufacturing plant and other applications where low cost and maximum performance are required.
Rotalink, a world-leader in the design and manufacture of miniature transmission products, has launched two highly cost-effective planetary/spur gearboxes. Fabricated from advanced materials, dedicated gear profiles enable these unique compact units to deliver a massive 10Nm of flexible torque at a highly competitive cost, significantly enhancing market opportunities for original equipment manufacturers. Key to the massive torque available in the planetary output stage is Rotalink's unique gear tooth design, which also minimises noise and backlash.
Power transfer to the stainless steel output shaft is maximised by the wide choice of ratios available in the spur input stage - up to 12800:1 - coupled with low friction standard front ball race and nylon or steel ball race rear bearings.
The zinc-plated pressed steel case's standard four-point fixing gives OEMs solid but flexible fixing options.
The gearboxes are the Type 230, delivering up to 5Nm through input ratios from 25:1 to 1000:1, and the 260 delivering up to 10Nm through input ratios from 50:1 to 2000:1, both with alternative input ratios available up to 12800:1.The units are rated at 80C at the gear case and are available with AC, stepper or DC motors, single or dual line encoders are optional across the range.
With the introduction of these miniature gearboxes, Rotalink has successfully used its state-of-the-art design capability and strategic manufacturing and sourcing to deliver the compact, cost-effective product essential to 21st century motion control, automation and system integration OEMs.
Typical applications include peristaltic pumps, dispensing equipment, vending machines and similar dosing/metering systems where air and/or liquid valve control is required; analytical instrumentation, semiconductor manufacturing plant and other applications where low cost and maximum performance are required.
Conveyor upgrade is ahead of schedule
David Brown is ahead of time with its management contract to overhaul and upgrade the massive conveying system at Australia's Yallourn power station in Victoria.
David Brown is ahead of time with its management contract to overhaul and upgrade the massive conveying system at Australia's Yallourn power station in Victoria - in turn part of a huge scheme that involves diverting the Morwell River and upgrading and modernising Yallourn mine. With the two year contract for Yallourn Energy (now called TRUenergy Yallourn) stipulating completion of 15 conveyor drive assemblies by September 2006, the company has already completed that number as well as two gearbox spares in a clear demonstration of its asset management capabilities as well as its widely recognised technical prowess. Extra work was also required following a serious fire in December 2005 that necessitated the urgent refurbishment and relocation of a number of drive conveyors in order to keep Yallourn operating.
Concurrent with this urgent work was the refurbishment of critical drive gearboxes on a large overburden dredger which was undergoing upgrade at the same time - David Brown once again pulled out all of the stops to assist Yallourn Energy at this difficult time.
Each of the 25 year old conveyor drive assemblies comprise a 370 or 610kW electric motor, gearbox, brake and fluid coupling, to absorb shock loading of the conveyors, all mounted on a base plate.
Whereas the gearboxes, of various origins, were transported from Melbourne and overhauled at David Brown's own facilities at Bulli, New South Wales, the work on motors and couplings was subcontracted.
The smooth running of the project therefore demonstrates the project management skills and QA knowledge of David Brown's management team and workforce.
Yallourn Energy had initially approached David Brown early in 2004 when the process of site visits and tendering was initiated.
On signature of the contract in the following December the real work began which required fortnightly meetings on-site to ensure the smooth running of the project.
The principal's requirements of stringent QA documentation, refurbishment to EOM standard or better, full load testing off site plus incorporation of condition monitoring devices on all refurbished equipment were challenges met by David Brown.
David Brown has also undertaken additional refurbishment works on the Yallourn overburden dredger drives, all based on the main contract terms and conditions.
'The Yallourn contract has been a very steep learning curve for us', commented David Brown Project Manager Geoff Kinniburgh.
'We were confident that we had all of the necessary experience and expertise but quite frankly we had never handled a project of this scale and importance before'.
'In completing the project successfully and ahead of time, I believe we have built a real reputation for ourselves in the field of asset management that will stand us in good stead for the future'.
In fact, as the two-year project approaches completion, David Brown is confident that it will be able to negotiate a possible extra 6-year renewal having demonstrated a much greater degree of ownership of Yallourn problems and challenges than previous asset management companies.
Yallourn W power station, located 160km east of Melbourne, provides 24% of Victoria's power and 8% of the national requirement, and the adjacent open cut brown coal mine is the second largest in Australia with available reserves sufficient to meet the projected needs of the power station until 2032.
To allow unimpeded access to the coal field a project was begun five years ago to divert the Morwell River and was recently completed on time.
The 3.5km diversion is an impressive feat of modern engineering in itself and cost Au $122 million (over GBP 50 million).
The mine upgrade and modernisation programme was also undertaken in the five year period and involved works to fixed conveyor plant and infrastructure that totalled an additional Au $50 million (GBP 20 million).
David Brown is ahead of time with its management contract to overhaul and upgrade the massive conveying system at Australia's Yallourn power station in Victoria - in turn part of a huge scheme that involves diverting the Morwell River and upgrading and modernising Yallourn mine. With the two year contract for Yallourn Energy (now called TRUenergy Yallourn) stipulating completion of 15 conveyor drive assemblies by September 2006, the company has already completed that number as well as two gearbox spares in a clear demonstration of its asset management capabilities as well as its widely recognised technical prowess. Extra work was also required following a serious fire in December 2005 that necessitated the urgent refurbishment and relocation of a number of drive conveyors in order to keep Yallourn operating.
Concurrent with this urgent work was the refurbishment of critical drive gearboxes on a large overburden dredger which was undergoing upgrade at the same time - David Brown once again pulled out all of the stops to assist Yallourn Energy at this difficult time.
Each of the 25 year old conveyor drive assemblies comprise a 370 or 610kW electric motor, gearbox, brake and fluid coupling, to absorb shock loading of the conveyors, all mounted on a base plate.
Whereas the gearboxes, of various origins, were transported from Melbourne and overhauled at David Brown's own facilities at Bulli, New South Wales, the work on motors and couplings was subcontracted.
The smooth running of the project therefore demonstrates the project management skills and QA knowledge of David Brown's management team and workforce.
Yallourn Energy had initially approached David Brown early in 2004 when the process of site visits and tendering was initiated.
On signature of the contract in the following December the real work began which required fortnightly meetings on-site to ensure the smooth running of the project.
The principal's requirements of stringent QA documentation, refurbishment to EOM standard or better, full load testing off site plus incorporation of condition monitoring devices on all refurbished equipment were challenges met by David Brown.
David Brown has also undertaken additional refurbishment works on the Yallourn overburden dredger drives, all based on the main contract terms and conditions.
'The Yallourn contract has been a very steep learning curve for us', commented David Brown Project Manager Geoff Kinniburgh.
'We were confident that we had all of the necessary experience and expertise but quite frankly we had never handled a project of this scale and importance before'.
'In completing the project successfully and ahead of time, I believe we have built a real reputation for ourselves in the field of asset management that will stand us in good stead for the future'.
In fact, as the two-year project approaches completion, David Brown is confident that it will be able to negotiate a possible extra 6-year renewal having demonstrated a much greater degree of ownership of Yallourn problems and challenges than previous asset management companies.
Yallourn W power station, located 160km east of Melbourne, provides 24% of Victoria's power and 8% of the national requirement, and the adjacent open cut brown coal mine is the second largest in Australia with available reserves sufficient to meet the projected needs of the power station until 2032.
To allow unimpeded access to the coal field a project was begun five years ago to divert the Morwell River and was recently completed on time.
The 3.5km diversion is an impressive feat of modern engineering in itself and cost Au $122 million (over GBP 50 million).
The mine upgrade and modernisation programme was also undertaken in the five year period and involved works to fixed conveyor plant and infrastructure that totalled an additional Au $50 million (GBP 20 million).
Gears and actuators set for airshow outing
Harmonic Drive will be using the Farnborough International Airshow to promote its range of motion control solutions specifically designed for a wide range of aircraft applications.
Harmonic Drive will be using the Farnborough International Airshow as a platform to promote its range of motion control solutions that have been specifically designed and developed for a wide range of aircraft applications where high precision and reliability are critical. Just as importantly, the latest Harmonic Drive precision gears and actuators offer high levels of accuracy, high torque, high power density and a long operating life, all in lightweight and compact dimensions. Harmonic Drive precision gears have been designed to achieve a mean time between failures (MTBF) in aircraft applications of more than 500,000 hours, with an extremely low failure probability.
Furthermore, Harmonic Drive gears and actuators provide positional accuracy of less than one minute of arc and a repeatability of just a few seconds of arc, making them suitable for use in aircraft applications requiring exceptionally high positional and tracking accuracy.
Harmonic Drive technology is used in a wide range of aircraft applications including military fighter jets for active pilot inceptors providing force-feedback to the operator, and commercial aircraft such as the Airbus A380.
On show will be Harmonic Drive's range of HFUC component sets, which offer a unique combination of low weight, compact dimensions, high torque capacity, exceptional repeatability and positioning accuracy, and can be used in a wide range of operating temperatures, making them ideal for use in various aircraft applications including cargo handing and in-flight systems.
The new HFUC component sets incorporate a shortened Flexspline, resulting in a significant reduction of the axial length.
Furthermore, the new component sets feature high performance IH tooth profiles to provide increased torque capacity in comparison to standard gears that incorporate traditional involute gear tooth profiles.
The HFUC range is available in fifteen gear sizes from 8 to 100, with a choice of gear reduction ratios, from 30:1 up to 160:1.
In addition, the HFUC component sets feature the optimised design of Flexspline, circular spline teeth and wave generator bearing, to eliminate completely the effects of backlash, provide high torsional stiffness and offer a range of output torque capacities from just 0.9 to 3550Nm.
Harmonic Drive will also be demonstrating its FHA series miniature hollow-shaft servo actuators, which are believed to be the world's smallest servo actuators.
Measuring just 50mm3 in size and weighing only 0.4kg, these ultracompact actuators are capable of delivering 1.8Nm of torque from an integrated AC motor, gearbox and encoder, while featuring a choice of gear reduction ratios, including a 30:1 gear ration - the first of its kind to be achieved with hollow shaft servo actuators.
Specially developed for use in demanding aircraft applications where highly accurate motion control and high torque capacity are key, or where operating space or weight are restricted, the innovative FHA series features advanced Harmonic Drive technology to eliminate the effects of backlash.
Additionally, the integrated AC servo motor provides exceptionally smooth torque curves, with output speeds between 60 and 200rev/min.
By integrating a motor, gearbox, output bearing and encoder into a single, compact and lightweight unit, the FHA actuators allow aircraft design and manufacturing engineers to reduce dramatically both the time and cost associated with system design, specification and construction.
Perhaps as importantly, the new servo actuators allow considerable improvements to be made in system performance, precision and reliability, while minimising overall size and weight.
Harmonic Drive will be using the Farnborough International Airshow as a platform to promote its range of motion control solutions that have been specifically designed and developed for a wide range of aircraft applications where high precision and reliability are critical. Just as importantly, the latest Harmonic Drive precision gears and actuators offer high levels of accuracy, high torque, high power density and a long operating life, all in lightweight and compact dimensions. Harmonic Drive precision gears have been designed to achieve a mean time between failures (MTBF) in aircraft applications of more than 500,000 hours, with an extremely low failure probability.
Furthermore, Harmonic Drive gears and actuators provide positional accuracy of less than one minute of arc and a repeatability of just a few seconds of arc, making them suitable for use in aircraft applications requiring exceptionally high positional and tracking accuracy.
Harmonic Drive technology is used in a wide range of aircraft applications including military fighter jets for active pilot inceptors providing force-feedback to the operator, and commercial aircraft such as the Airbus A380.
On show will be Harmonic Drive's range of HFUC component sets, which offer a unique combination of low weight, compact dimensions, high torque capacity, exceptional repeatability and positioning accuracy, and can be used in a wide range of operating temperatures, making them ideal for use in various aircraft applications including cargo handing and in-flight systems.
The new HFUC component sets incorporate a shortened Flexspline, resulting in a significant reduction of the axial length.
Furthermore, the new component sets feature high performance IH tooth profiles to provide increased torque capacity in comparison to standard gears that incorporate traditional involute gear tooth profiles.
The HFUC range is available in fifteen gear sizes from 8 to 100, with a choice of gear reduction ratios, from 30:1 up to 160:1.
In addition, the HFUC component sets feature the optimised design of Flexspline, circular spline teeth and wave generator bearing, to eliminate completely the effects of backlash, provide high torsional stiffness and offer a range of output torque capacities from just 0.9 to 3550Nm.
Harmonic Drive will also be demonstrating its FHA series miniature hollow-shaft servo actuators, which are believed to be the world's smallest servo actuators.
Measuring just 50mm3 in size and weighing only 0.4kg, these ultracompact actuators are capable of delivering 1.8Nm of torque from an integrated AC motor, gearbox and encoder, while featuring a choice of gear reduction ratios, including a 30:1 gear ration - the first of its kind to be achieved with hollow shaft servo actuators.
Specially developed for use in demanding aircraft applications where highly accurate motion control and high torque capacity are key, or where operating space or weight are restricted, the innovative FHA series features advanced Harmonic Drive technology to eliminate the effects of backlash.
Additionally, the integrated AC servo motor provides exceptionally smooth torque curves, with output speeds between 60 and 200rev/min.
By integrating a motor, gearbox, output bearing and encoder into a single, compact and lightweight unit, the FHA actuators allow aircraft design and manufacturing engineers to reduce dramatically both the time and cost associated with system design, specification and construction.
Perhaps as importantly, the new servo actuators allow considerable improvements to be made in system performance, precision and reliability, while minimising overall size and weight.
Clutches cut down on downtime
Emerson Power Transmission has added three new products to the Browning torque overload device family.
Emerson Power Transmission has added three new products to the Browning torque overload device family: the Browning Torq/Pro X and Browning Torq/Pro Z torque overload devices, and the Browning Axial Gard linear overload device. In addition, the Browning Torq/Pro product line has been extended to include six new models. The products are all included in the new catalogue, MC-06, featuring the complete line of Browning and Morse mechanical clutches and torque overload devices.
The new catalogue provides general clutch and torque overload device information in order to help users select the proper device for their application.
The Browning and Morse product offerings provide the industry's broadest line of conveyor backstopping, overrunning and indexing clutches.
Both these product lines are designed to help increase production by reducing downtime.
The new Browning Torq/Pro X features a patent pending, innovative ball and pocket mechanism that nearly eliminates backlash.
The Torq/Pro X is an automatic reset torque overload device that has a bore range of 7-70mm, torque range of 1.7-784Nm and trip torque precision of +/-3%.
The Browning Torq/Pro Z is an overload device that allows the input side to continue to revolve freely after tripping.
The Torq/Pro Z is a manual reset torque overload device that has a bore range of 8-50mm, torque range of 2.4-450Nm and trip torque precision of +/-10%.
With the line expansion of the Browning Torq/Pro line, the bore range is 5-130mm, torque range of 3.5-7145Nm and trip torque precision of +/-10%.
The Browning Axial Gard linear overload device trips immediately an overload occurs, cutting off the axial load to the application.
The trip load setting range is 147-3430N, and trip torque precision is +/-15%.
Emerson Power Transmission has added three new products to the Browning torque overload device family: the Browning Torq/Pro X and Browning Torq/Pro Z torque overload devices, and the Browning Axial Gard linear overload device. In addition, the Browning Torq/Pro product line has been extended to include six new models. The products are all included in the new catalogue, MC-06, featuring the complete line of Browning and Morse mechanical clutches and torque overload devices.
The new catalogue provides general clutch and torque overload device information in order to help users select the proper device for their application.
The Browning and Morse product offerings provide the industry's broadest line of conveyor backstopping, overrunning and indexing clutches.
Both these product lines are designed to help increase production by reducing downtime.
The new Browning Torq/Pro X features a patent pending, innovative ball and pocket mechanism that nearly eliminates backlash.
The Torq/Pro X is an automatic reset torque overload device that has a bore range of 7-70mm, torque range of 1.7-784Nm and trip torque precision of +/-3%.
The Browning Torq/Pro Z is an overload device that allows the input side to continue to revolve freely after tripping.
The Torq/Pro Z is a manual reset torque overload device that has a bore range of 8-50mm, torque range of 2.4-450Nm and trip torque precision of +/-10%.
With the line expansion of the Browning Torq/Pro line, the bore range is 5-130mm, torque range of 3.5-7145Nm and trip torque precision of +/-10%.
The Browning Axial Gard linear overload device trips immediately an overload occurs, cutting off the axial load to the application.
The trip load setting range is 147-3430N, and trip torque precision is +/-15%.
Guideways with 30% more load capacity and rigidity
WMH Transmissions now offers Hiwin Linear Guides and Rails up to size 65, designed for load capacity and rigidity over 30% higher than other similar products
WMH Transmissions now offers Hiwin linear guides and Rails up to size 65. The HG series guideways are designed for load capacity and rigidity over 30% higher than other similar products with circular- arc groove and structure. The HG four row super heavy load range have a basic static load rating up to 457kN.
The full HG range of rails is stocked at their UK manufacturing and storage facility in Tamworth.
There is also a free of charge, in-house service to cut rails to any length on same day despatch.
Also at a very competitive price the rail ends can be ground to facilitate butt joints for continuous mounting, these are available for despatch on 24/48 hours lead-time.
WMH also offers from Hiwin the new EG four row low profile range, perfect for high speed automation equipment and other applications where space constraint is a concern.
These are available in sizes 15 to 30 with a basic static load rating up to 47.46kN.
To complement these products and services, WMH also offers the Hiwin range, stainless steel miniature guides and rails and ballscrews up to 80mm diameter with industry standard nuts.
Utilising its in-house machine shop, WMH also offers a machining service for ballscrews and leadscrews to suit its ex-stock Duki-Tec ballscrew support units, these screws can be machined to either standard recommended dimensions or customer specification.
WMH Transmissions now offers Hiwin linear guides and Rails up to size 65. The HG series guideways are designed for load capacity and rigidity over 30% higher than other similar products with circular- arc groove and structure. The HG four row super heavy load range have a basic static load rating up to 457kN.
The full HG range of rails is stocked at their UK manufacturing and storage facility in Tamworth.
There is also a free of charge, in-house service to cut rails to any length on same day despatch.
Also at a very competitive price the rail ends can be ground to facilitate butt joints for continuous mounting, these are available for despatch on 24/48 hours lead-time.
WMH also offers from Hiwin the new EG four row low profile range, perfect for high speed automation equipment and other applications where space constraint is a concern.
These are available in sizes 15 to 30 with a basic static load rating up to 47.46kN.
To complement these products and services, WMH also offers the Hiwin range, stainless steel miniature guides and rails and ballscrews up to 80mm diameter with industry standard nuts.
Utilising its in-house machine shop, WMH also offers a machining service for ballscrews and leadscrews to suit its ex-stock Duki-Tec ballscrew support units, these screws can be machined to either standard recommended dimensions or customer specification.
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