MAAGTM WPV three-stage gear

unit for vertical mills

Our quality policy

FLSmidth MAAG Gear is committed

to creating strong relationships with
customers, suppliers and employees that establish us as a trustworthy, reliable and professional partner.
This commitment includes providing
high quality and high value solutions,
products and services that create satisfied and loyal customers.
We are certified according to the ISO
9001:2008 standards. With our process management we endeavor to
meet and exceed international quality
standards and provide adequate resources to support the quality system.
Our quality policies are centered on
the importance of meeting our customers requirements.
The quality objectives are continuously established and reviewed by
our management. Our employees are

committed to the companys Management System and to the continual

improvement of the system and the
entire organization. Each employee
is aware of the vision and strategy of
FLSmidth MAAG Gear, and works in a
culture of opportunity.
With our suppliers and external partners we cultivate an open communication and work on performance-oriented results.

A pioneer of modern
gear technology
FLSmidth MAAG Gear has almost 100
years of experience in manufacturing
gear units. The company was founded
in 1913 and quickly expanded into an
international group. FLSmidth MAAG
Gear introduced the technology of
mill gear units for the cement and
minerals-industry with great success in
1966. Since then around 6000 MAAGTM gear units and 1000 girth gears
have been installed.
The company
At the FLSmidth MAAG Gear headquarters in Winterthur, Switzerland,
more than 100 employees work in
development, design, finance, project
management, sales, customer service and marketing. Production takes
place in two modern plants equipped
with high-performance machines.
In Elblag/Poland and Milano/Italy
more than 200 employees manufacture gear units, drive systems and
components which satisfy the most
demanding quality standards. The
company belongs to the successful
FLSmidth Group, a listed Danish firm.
Our strength
The combination of unique precision,
accuracy and modularized solutions
with compact design are leading to
high efficiency products and therefore
low maintenance cost for the customer. Experience, new technical solutions
and the latest manufacturing techniques are regularly incorporated into
the production process.
Intensive development and training of
our engineers assure best understanding of how to operate and lengthen
the lifecycle of a gear unit.

A constant willingness to innovate,

and close collaboration with our customers have helped to ensure that
MAAG gear units continue to operate
reliably throughout the world under
the toughest conditions.
Product range
Today, the product range includes
various gear units for mills, complete drive systems, gear solutions
for bucket wheel excavators and belt
conveyors, as well as maintenance
systems for all types of plant. In addition FLSmidth MAAG Gear manufactures components such as bevel
sets, girth gears and various spare
parts.
All MAAG gear units are available as
standard solutions or are customized
to the required needs.

The three-stage system

Introduction
Modern vertical roller mills are becoming increasingly larger with a
higher performance densities and
now require gear units that can transfer higher levels of torque. The grinding table speed that is needed for an
optimum grinding process is determined by the output drive speed of
the gear unit. Slower table rotating
speeds at the same gear unit input
speeds increase the total gear ratios
that are required. The new design of
the three-stage MAAGTM WPV gear
unit meets all of these requirements.
New design
The WPV three-stage bevel and planetary gear units, all of which are
equipped with slide bearings, have
reached an impressively compact design. This is made possible by torque
split in the planetary stages, new arrangement of axial trust pads and the
symmetrical, now cast housing. The
housing absorbs the mill forces and
the torque in an optimum way and
passes them through into the foundations. A high degree of standardisation has also been achieved in spite

of the varying requirements of different mills. Approximately 25% of the

torque is passed to the output flange
directly from the first planetary stage
in this two-stage planetary gear unit.
The second planetary stage, which
has only four smaller planet wheels
remaining, has to transfer the remaining 75% of the torque, enabling
a compact design. The new MAAG
WPV gear units fit under any existing vertical roller mill and cover the
whole range of power rates and existing grinding table diameters.
Bevel gear
The bevel pinion is adjustable from
outside, the bevel wheel through the
leveling wedge, which enables easy
adjustment of the tooth contact. The
bevel pinion can be removed fast
without removing the gear. On top its
easy to examine the bevel gear thanks
to the large dimensional manhole.
This ensures short maintenance stops
as the gear unit stays in place.

Planetary system
The planetary system is a proven concept and offers different advantages.
Due to the torque split, the second
stage has only 75% of the torque. An
optimised force-flow is achieved by
the self centring inner gear and sun
pinion. Smaller gear wheels can be
used through the use of the torque
split and 4 planets in the second
stage.
Design size
By careful consideration of the power ranges and the table diameters of
various vertical roller mills FLSmidth

MAAG Gear has managed to keep

to only eight different types of gear
units in the WPV new design. All of
them are able to fulfill the requirements of the various mill manufacturers. Within the design size and gear
unit type itself, a further splitting is
arranged. For the planetary stage,
wide or narrow options for the toothing width are available. For example
narrow toothing is used for specific
lower factors (calculation: P/n*). Planet wheels with narrow toothing are
lighter in weight and therefore result
in lower costs.

N2
75%

25%

1st stage

2nd stage

Torque split

Narrow toothing

N1

Wide toothing

Selection chart for a vertical mill gear unit

5000

4500

4510
4200

Diameter table (DT)

4000
3800

II

II
II

3500
3480
3000

3170
2650

2500

II

II

II

2440 I II
2000
1850
1500

50

100

150

200

250

P/n

300

350

400

450

500

I:
Narrow toothing
II:
Wide toothing
P/n*: Gear unit power in kW / Gear unit output speed

Slide bearings
Slide bearings stand out due to short
delivery time and an unlimited lifetime
which ensures high availability of the
plant. Higher damping compared to anti-friction bearings results in less vibration. In the unlikely case of a damage,
local emergency repair is possible. The
slide bearings are easy to install and
highly service friendly.

Lubrication system

Lubrication system
The gear unit is lubricated by a
closed circuit oil system. The oil tank
serves as a platform on which all the
assemblies and components such as
motor pumps (high and low pressure), switchable double oil filter, oil
cooler and instrument panel are installed. The design of the lubrication
system is standardised thus it is applicable for several gear unit types.
This ensures easy handling, optimal
insertion and low costs. Also the
components of the lubrication system like instrumentation, filter and

cooling/heating system are consistent. The lubrication system is monitored with digital indication on site.
Top priority is given to guarantee operational reliability.
Auxiliary drive/maintenance
drive
The maintenance drive is placed between the mill motor and the gear
unit, whereas the auxiliary drive is
located behind the mill motor. The
maintenance drive is a low budget drive for build-up welding on the
mill table, or for convenient replacing of the lining plates.
The auxiliary drive can be used when
the mill starting procedure requires
a start with its help. It is equipped
with a claw type overrunning clutch
and a fluid coupling. The fluid coupling provides a smooth start up
while the overrunning clutch disengages automatically when the mill
motor has started.

Customer benefits

Wide power range

Highly standardized
components
Proven and robust design
Torque split for compact
design
Lower weight for easy
handling
Cast parts and housing

Improved maintenance
through
- slide bearing application
- easy access to major
components
Bevel stage adjustable
without removing the
main motor
Gear unit with reduced
height fits to all mills

Quality
Production and all activities are monitored by the internal quality assurance
system in strict compliance with ISO
9001.

Troubleshooting
FLSmidth MAAG Gear field service
technicians are strategically located
around the world to minimize response time and reduce costs.

Customer service
Customer service staff is highly trained
and guarantees professional support in
routine and emergency services, gear
unit inspections, overhaul or assembly.

Service Hotline
24hrs/day 7days/week
+41 79 619 91 00
service@FLSmidthMaagGear.com

Installation
The compact design simplifies shipping and reduces erection time.
Training
FLSmidth MAAG Gear offers training programs for local maintenance
personnel to enable them to serve the
gear units in the best way.
Spare parts
Spare parts are available throughout
the life of the gear units.

Production
The latest machines and technical
aids are used in manufacturing.
Test running
Gear units are tested and logged in
detail on our test bed prior to delivery.
Delivery time
Thanks to continuous monitoring of
our production schedule, our clients
are provided with the up-to-date status of a project at any time.

FLSmidth MAAG Gear AG

Lagerhausstrasse 11 P.O. Box
8401 Winterthur Switzerland
Tel +41 52 260 35 00
Fax +41 52 260 35 35
info@FLSmidthMaagGear.com

www.FLSmidthMaagGear.com

C 07-11 500-4-ENG V1

Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth and MAAG are (registered) trademarks of FLSmidth A/S. This
brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure
are for general reference only and may change at any time.