Eaton Airflex® High Energy VC

© 2015 Eaton. All Rights Reserved..

 Hydraulic Solutions -
Broadest portfolio in the industry

Pumps Motors Valves Systems Mechatronics Hose & Fittings

generating executing directing/ meeting converting connecting,
flow commands, transmitting large-scale electric conveying,
work load pressure & application signals to filtering
flow needs hydraulic

© 2016 Eaton. All Rights Reserved. 2

Industrial Product Applications
Mining & Mineral Processing
Hydraulic
Airflex® Cylinder Power Units
Drives
Extraction
Bulk Handling
Material Handling
Mineral Processing

© 2014 Eaton. All Rights Reserved.. 3

Eaton Airflex® Summary
With over 60 years of experience, Eaton Airflex is a top tier, global supplier
of custom clutch and brake solutions specializing in the oilfield, marine, Value Prop
mining and process manufacturing industries.
Why choose Airflex…
• Wide range of heavy industrial clutches and brakes spanning many
industries and markets OEM
• Decades of experience on a broad range of applications guaranteeing
accurate product selection
• Customer-specific product and custom projects
• Capable of providing packaged systems and solutions by leveraging the Distributor
breadth of Eaton’s product reach
• Global manufacturing footprint allows for faster deliveries and
customer support worldwide
• Tenured Applications Engineering team work directly with customer to End User
ensure all requirements and needs are met

Primary Markets/Platforms/Applications
Markets Applications
Oil & Gas /
• Drawworks, Top Drives, Offshore Winch, Deck
Marine
Machinery, Top Drive Test Stand

Mining & • Grinding Mills, Draglines, Shovels, Conveyors,

Processing Bucket Wheel, Stacker/Reclaimer

Process • Press Brakes, Printing Machines, Shears,

Industries Stamping/Forming Presses, Woodworking,
Canmaking Machines
 Traditional Industries Served

Oilfield Mineral Processing Mining Marine

Clutches and brakes used
on thousands of oil rigs
around the world
First clutch ever used on Used on the largest
these applications to surface mining equipment
engage the motor to the in the world
mill Clutches as large as Primary parking &
76 inches in diameter emergency brakes for all
functions
Supplying clutches to
naval vessels since 1938
used to drive the main
propulsion systems
Brakes used on the most
strenuous winch
applications

Additional Industries: Dredging, Metalworking, Can Making, Paper Mills, Tire Building, Textiles, Cement Manufacturing

Eaton Airflex products are critical to powering the global energy industry. Our product
breath and depth far surpasses all competitors and our quality superiority differentiates us
in our markets.

©2016 Eaton Corporation. All rights reserved. 5

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Airflex Global Analysis
Manufacturing
Dedicated Sales
Engineering
Product Management

Eaton Airflex is a top tier, global supplier of custom clutch and brake solutions
specializing in the oilfield, marine, mining and process manufacturing industries.

© 2014 Eaton. All Rights Reserved.. 6

 Airflex Product Portfolio
Drum Product Disc Clutch Disc Brakes Torque Couplings Combination CL/BR Caliper

Oil & Gas

Drawworks
Mooring Systems
Top Drives

Mineral Processing
Ball Mill, SAG Mill

Mining
Electric Shovel
Dragline

Marine
Drives
Dredge
Winch System

Metal Processing
Metal Working
Paper

Can Making

Pneumatic Disc Water-Cooled 3rd Gen Torque Limiting

New Products High Energy VC
Clutch Floating Housing Brake Couplings
©2016 Eaton Corporation. All rights reserved. 7
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HEVC – Summary Overview
Product Description: Applications
The High Energy VC (HEVC) achieves 9000 ft-lb / • Mineral Processing
in2 energy capacity and capable of increasing • Ball Mills
• AG & SAG Mills
mill engagement slip times over 10 Seconds • Rod Mills
• Oil and Gas
• Marine Engines
Higher Energy provides Greater Flexibility
1. Increased energy provides a potential cost reduction
with ability to downsize the clutch
2. Increased energy allows longer mill startup times to
reduce peak energy usage while safeguarding driveline
components
3. Increased energy yields flexible designs, downgrading
from dual to single pinion systems
4. Increased energy enables high motor clutch
engagements, eliminating costly wrap around motors
5. Available in 6 sizes – Dual Wide Only

Highest Energy Capability of any Drum Clutch Available

© 2016 Eaton. All Rights Reserved.. 8
Product Comparison – VC vs HEVC

VC HEVC
Appearance Base line Same as VC
Performance
Dynamic torque Base line 28% Higher
Energy Base line 50% Higher
Power Base line 30% Higher
Slip time Base line Application Dependant
Specifications
Overall dimensions Base line Same as VC
Drum thickness Base line Higher
Drum width Base line Same as VC
Shaft Gap(X gap) Base line Higher
Friction Organic Sintered metallic
Weight & inertia(Overall) Base line Higher

© 2016 Eaton. All Rights Reserved.. 9

 Product Comparison – VC vs HEVC
• Shaft Gap(“X” Gap): HEVC “X” Gap Increases – adjustment of shaft
length may be needed when replacing VC with HEVC
• Note: The shaft overhang load will be increased by the amount of
increased HEVC drum weight.

Std. VC HEVC Std. VC HEVC Std. VC HEVC Std. VC HEVC

Size
“X” Gap “X” Gap Drum dia Drum dia Male Drum Male Drum Female Drum Female Drum
Dual Wide
(inch) (inch) (inch) (inch) Weight (lb) Weight (lb) Weight (lb) Weight (lb)
28VC1000 12.75 13.55 28.00 28.19 295 557 282 554
51VC1600 20.00 20.75 51.00 51.56 890 2411 890 2394
60VC1600 20.38 21.13 60.00 60.56 1980 3675 1980 3647
66VC1600 22.00 22.75 66.00 66.56 1867 4487 1867 4292
76VC1600 20.38 21.13 76.00 76.56 2230 4780 2060 4566
76VC2000 24.37 25.12 76.00 76.56 2780 5615 2640 5401
Other parameters are same as VC

© 2016 Eaton. All Rights Reserved.. 10

High Energy VC Anatomy
Thicker Flange Drum

Sintered Linings

© 2016 Eaton. All Rights Reserved.. 11

HEVC Value Proposition
Energy Power
• 50% increased energy lb-ft/in² hp/in²
VC 6000 1.05
• 30% increased power HEVC 9000 1.35 HEVC
50% 30%
• Torque Increase Increase STD VC

• HEVC has 28% higher

Dynamic Torque
Size Std. VC HEVC % torque
• HEVC* downsizing is (Dual Wide) lb-in lb-in increase

possible in ~80% of the 28HEVC1000 592,000 758,000 28%

instances.
51HEVC1600 3,220,000 4,122,000 28%

60HEVC1600 4,366,000 5,588,000 28%

66HEVC1600 5,600,000 7,168,000 28%

*Based on 20 application studies ranging from
4.7kHP to 12.0kHP mills 76HEVC1600 7,300,000 9,344,000 28%

76HEVC2000 9,300,000 11,904,000 28%

© 2016 Eaton. All Rights Reserved.. *Static torque/Dynamic torque = 0.94 12

HEVC Value Proposition

• Mill Engagement Slip time

• Same size HEVC: ~1 – 1.5 sec additional slip time is possible
• Downsized HEVC*: ~5 – 7 sec slip time can be achieved with downsized HEVC
• Longer slip time >10 sec : Capable – Airflex Applications Engineering needs to evaluate case by case

Enquiry 2722 (BALL Mill) 2728 (SAG Mill)

HP 9045 11400
Clutch RPM 188 176
Mill RPM 12 10
Mill ID 24 35
Available
100 100
pressure
Inertia 148,906,000 314,000,000
Size (Dual
66VC1600 66HEVC1600 60HEVC1600 76VC2000 76HEVC2000 76HEVC1600
Wide)
Approx. Start
5.9s 7.8s 6.8s 7.4s 9.1s 8.2s
Time
Dynamic SF 2.2 2.8 2.2 2.67 3.5 2.7
Static SF 2.8 2.7 2.1 3.34 3.2 2.5
Approx. Cost Base +5% -12% Base +10 -8%

Slip time capacity and downsize possibility needs to be analyzed case by case
© 2016 Eaton. All Rights Reserved.. 13
 Airflex Available HEVC Conversion Kits

• HEVC Upgrade Kits are available to convert

existing VC Installations
• 28VC1000 – 28HEVC1000
• 51VC1600 – 51HEVC1600
• 60VC1600 – 60HEVC1600
• 66VC1600 – 66HEVC1600
• 76VC1600 – 76HEVC1600
• 76VC2000 – 76HEVC2000
• Upgrade Kit Contents
• Friction Shoe Assemblies for 1 Full Dual Wide Clutch
• Male & Female Register Internal Flange Drum
• Torque Bars & Springs

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VC to HEVC Upgrade & Conversion

• New HEVC element assemblies can be installed in place of

existing VC elements
• The HEVC Upgrade Kits can be used to upgrade, rebuild and
replace existing VC elements
• The existing internal flange drum must be replaced with the
HEVC drums
• Replaced standard drums can be used on other mills with the
same size clutch, not requiring HEVC

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When to Upgrade VC

• Mill main drive motor is continuously exceeding the full

nameplate motor horsepower / amperage
• Example
• 5000 HP motor is running at its maximum S.F. of 1.15 or 5800 HP

• Mill fill percentage is increased beyond the designed

ratio, causing struggles to start the mill
• Air pressure is increased, shortening the start time

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Why to Upgrade VC

• Increase the allowable start time, keep start time

consistent, to avoid harsh and damaging mill starts
• Boosts torque capacity on the same size clutch
• Reduce friction material wear
• Reduce drum wear and warping due to high heat
starts
• Reduce clutch fire potential

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How to Select HEVC

• HEVC requires same input parameters as current VC

• Service factors are same as VC
• Inertia and charge weight inputs are must
• Airflex Applications Engineering will conduct Grinding Mill
Simulation to determine feasibility

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Required Information for HEVC Selection

• Type of Mill:
• Main motor MW/kW/HP:
• Main motor RPM:
• Clutch RPM:
• Mill Inertia (empty @mill speed):
• Mill RPM:
• Inside diameter of liners:
• Total charge weight:
• Normal or current percent fill:
• Maximum Available air pressure:
• Clutch spider and element mounting: (forward on motor or reducer output shaft)
(reverse mount on pinion shaft):
• Bearings w/ hydraulic lifters: (yes/no):
• Cascade angle / if known:
• Send to Airflex AE@eaton.com

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FAQs

• Are Single Elements HEVC available?

 No. Will be handled through internal change control upon request.

• What is the maximum pressure for HEVC?

 120psi

• Can we replace existing VC’s with HEVC?

 Yes – through the use of the upgrade kit and feasibility confirmation by Airflex
Applications Engineering

 Upgrade kits are approximately 40% less than full application replacements

• Can we use existing slip detect controls with HEVC?

 Yes – with the support of Airflex Applications Engineering, slip detection controls can be
selected to enhance your system

© 2016 Eaton. All Rights Reserved.. 20

Questions?
© 2015 Eaton. All Rights Reserved.. 21
© 2015 Eaton. All Rights Reserved.. 22