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Gear Drive Technology for Belt Conveyors: Easy Installation Combined with Low Installation Costs and Improved Reliability
Misalignment of connected rotating equipment is one the leading causes of drive system-related failures and downtime in heavy-duty belt conveyor applications. However, that problem may become a thing of the past with the introduction of our new Alignment Free Drive for belt conveyor applications. The Alignment Free Drive eliminates shaft misalignment as a cause of failure and downtime. Simple registered fits and bolt together construction assure quick and proper assembly for trouble-free operation. Heavy-duty belt conveyor systems provide an effective means of moving high volumes of bulk materials in mining, power generation, cement, bulk food processing and other applications. As in every step of the production process, companies are continually exploring ways to reduce the cost of material transportation. End users must do everything they can to understand the total costs of conveyor system operations, how that affects cost per ton hauled, and to develop solutions that improve efficiencies, productivity, reliability and reduce costs. Consequently, end users, system designers and component suppliers are working together to understand conveyor system total costs, and create ways to reduce haulage costs. It was with these goals in mind that the Alignment Free Drive was designed. Originally designed as part of customized application solutions, Falk Alignment Free Drives are now available as standard product offerings.
The gear drive output connection to the conveyor system can be either a flange- moment coupling or a hollow shaft with a shrink disk locking device. With the flange-moment coupling, the gear drive output shaft and the conveyor shaft are brought into alignment as the bolts on the register flanges are tightened. The entire drive assembly is supported by the conveyor pulley-shaft and torque arm reaction point. Two elements are key to the Alignment Free Drive gear drive configuration. First, the system must be properly designed and engineered. Such a system will generate a low bending moment on the conveyor pulley shaft under dynamic loading conditions by virtue of the reaction point location. Second, a non- binding torque arm design is important to avoid inducing shaft deflections.
Lower Total Lifetime Costs with the Alignment Free Drive System
A comparison of installed costs for a conventional bedplate-mounted drive versus the Alignment Free Drive system demonstrates lower costs for the latter. The comparison in Figure One indicates lower costs for a Falk Alignment Free Drive based on initial purchase and installation costs. In many applications, the Alignment Free Drive can result in start-up savings of up to 20 percent compared to a conventional configuration. The foundation and installation costs can be up to 90 percent less with an Alignment Free Drive system versus a conventional drive.
Conveyor Drive - Installed Cost Comparison 400 HP/298 KW, 1750 RPM, 75 RPM Output Heavy Duty, 16 Hours/Day
Drive Size & Type (Falk) Exact Ratio Mech. Rating Service Factor Thermal Rating Suggested Drive $ % Difference
Alignment-Free Drive 445ABRCM3 Conventional 445AB3C Alignment-Free Drive 22.83:1 Alignment-Free Drive 651 hp/486 kW Alignment-Free Drive 1.63 lignment-Free Drive 620 hp/463 kw Alignment-Free Drive $75,072 Alignment-Free Drive Base Conventional 22.83:1 Conventional 651 hp/486 kW Conventional 1.63 Conventional 620 hp/463 kW Conventional $74,658 Conventional -.5%
All selections include the basic drive, cooling fans, bedplate or motor flange, fluid coupling, output coupling, and high-speed backstop
Motor $ Motor Mounting $ Foundation Cost ** $ Installation Cost** $ Total $ % Difference Alignment-Free Drive $20,120 Alignment-Free Drive $360 Alignment-Free Drive $900 Alignment-Free Drive $750 Alignment-Free Drive $97,202 Alignment-Free Drive Base Conventional $17,063 Conventional $720 Conventional $11,000 Conventional $4,300 Conventional $107,731 Conventional +10.9%
AFD W/Scoop Trim Coupling and Control approx. 1.3 xBase Total AFD W/DC Motor and Control approx. 1.5 x Base Total ** Will vary by plant site Figure One The combination of lower start-up and lifetime operating costs favors the Alignment Free Drive in comparison to a conventional drive system. An Alignment Free Drive will yield the lowest cost over the life of the installation. The cost savings, coupled with improved operational reliability, ranks the Alignment Free Drive as a true advance in heavy-duty belt conveyor technology.