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Page 1 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.

ppt

POLYCOM Design Overview

Dipl.- Ing.
Wolfgang Partsch
Page 2 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

General Overview
Page 3 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

POLYCOM material bed compression

Pressure curve

Max. Pressure Start of compression (nip line)


Compression zone

Grinding force End of compression

Cake
Page 4 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Fixed roller unit Feed hopper

Frame extension for


exchanging roller units Inspection platform

Torque support
system Piston accumulators

Cardan shaft with


safety coupling

Grease lubrication unit

Gear box

Floating roller unit


Motor
Inching drive Hydraulic
cylinder

Hydraulic tank
Page 5 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

General overview

Planetary gear Feed material


Motor
Floating grinding roller

Fixed grinding roller

Frame
Shaft
Bearing

Ground material

Piston accumulators Hydraulic system


Greasing system
Page 6 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Fully Assembled Polycom

Upper Beam Feed Hopper

Cardan Shaft

Floating Roller Unit

Gearbox
Gear oil water cooling floating roller
Page 7 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Frame Construction
Page 8 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Transverse Beams
POLYCOM Frame

Pressure Beams Upper Boom

Hydraulic cylinders

Slide plates

Base Frame with stiffening plates Feather Keys


Page 9 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Feed Hopper
Page 10 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

7 Feed hopper
5

1 1. Feed Hopper

2. Adjusting shaft

4 3. Grinding material guide

4. Inspection door
2
5. Hopper inlet
6
6. Hopper outlet
3
7. Load cell
Page 11 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Feed hopper
Short cut to GrundrahmenA.mpg.lnk

Hopper can be removed


with
I-Beam suspension
Page 12 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Feed hopper

Load cell

Manually adjustable
guide plates

Control of
de-aeration

Control of feed material


Page 13 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

The adjusting tongues

2.1 Side wall

2.2 Wear protection (side wall)

2.3 Inspection door

2.4 Spacer

2.5 Cover

2.6 Fixing traverse

2.7 Transport aid

2.10 Adjusting tongue

2.20 Position indicator

2.25 Isolating slide valve

2.32 Proximity switch

2.33 Seal for hydraulic cylinder


Page 14 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Feed Hopper wear protection

Upper part: - Eurodur 3600 (8 mm)

Vertical walls: - Compound steel plate (5+3 mm)

Inclined walls: - Compound steel plate (8+4 mm)

Adjustable Shaft: - Compound steel plate (6+4 mm)

Material guide plates and inner side of support:


- Compound steel plate (15+5 mm)

Adjustable guide plates:


- Compound steel plate (10+5 mm)

Hard metal mosaic


Page 15 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Cheek Plates
Page 16 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates


Page 17 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates


Page 18 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates


Page 19 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates


Page 20 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates

Cheek Plates in new and in worn out condition


Page 21 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates

New Cheek Plates design for CERROWAL with pasted Hard Metal plates
Page 22 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Replaceable Cheek Plates

Revised Cheek Plates design for CERROWAL with soldered Hard Metal plates

Additional Edge
Block protection
Page 23 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Hydraulic
Page 24 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Hydraulic

• Great reliability

• Simple functioning

• Few possible faults

• Little commissioning work

• No additional cooler for pressure


regulation and parallel gap control
Page 25 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

POLYCOM Hydraulic System

U Pressure Transmitter
P
U
Push back P
Slide Gate Solenoid Valve
Cylinders
Cylinders
Piston Accumulator

Hydraulic Cylinder

Main Cylinders

U
P

M Hydraulic
Pump
Page 26 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Hydro-pneumatic Spring System

Hydraulic Piston
Accumulator
Adjustable
Hydraulic Mechanical stoppers
Nitrogen Cylinders

Hydraulic Oil

Adjustable
throttle valve

Non-return
valve

Movable Roller Unit Fixed Roller Unit


Page 27 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Adjustable mechanical stoppers


Page 28 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Push back cylinder for floating roller


Page 29 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Lubrication System
Page 30 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Central lubrication unit with pneumatically driven barrel pump

Control unit 8.1 Barrel pump

8.2 Ball valve

8.3 Maintenance unit

8.4 Pressure switch

8.5 Throttle valve

8.6 Solenoid valve

8.7 Filter unit

8.8 Solenoid valve

Compressed-air station 8.9 Solenoid valve

8.10 Grease distributor


1 - 4 Lubrication points for roller bearing
8.11 Grease distributor
5 - 8 Lubrication points for guide rails
8.12 Pump bracket
Page 31 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Central lubrication compressed-air station

Compressed-air Compressed-air
from the mine to grease pump

3 1 5 13 4

Legend: 1 Maintenance unit with condensate trap and dust separator


3 Ball valve, 2/2-way
4 Solenoid valve, 3/2-way
5 Throttle valve, adjustable
13 Pressure switch 2-20 bar, set to 2 bar
Page 32 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Central lubrication control unit


Grease to guide rails
7 Floating Roller left
2

Grease to guide rails


Floating Roller left

Proximity switch
Grease from For rail lubrication
grease pump

Grease to bearings
Fixed Roller

Proximity switch
For bearing lubrication

3 4

Grease to bearings
Floating Roller
Legend: 2 Filter
3 Solenoid valves, 2/2-way, for Bearing and Guide Rail lubrication
4 Distributors for Bearing and Guide Rail lubrication
7 Pressure Gauge 0-250 bar
Page 33 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Central lubrication control unit

Pressure Gauge

Filter
Grease from grease pump

Solenoid for guide rail lubrication


Solenoid for bearing lubrication

Distributor for bearing lubrication

Distributor for guide rail lubrication


Page 34 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Roller Units


Page 35 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Roller Unit


102 tons on the hook
at just one Roller Unit

Cerro Verde site

Polysius workshop
Page 36 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

POLYCOM - Roller unit components


Shaft

Bearing

Tyre

Roller

Bearing Block
Page 37 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

POLYCOM - Roller unit components

Roller

Self aligning Bearing


Page 38 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom - Roller unit components

Studs

Edge Blocks
Shaft

Tyre
Side face protection segment,
plug-welded
Page 39 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom - Roller unit components

Bearing Block
Bearing
Page 40 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Bearings
Page 41 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom bearings
Page 42 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom bearings

Self Aligning Roller Bearings


with seal arrangement:

+ grease lubricated
+ minimum no of parts
+ easy assembly/disassembly
+ large inside diameter allows bolting of
reducer to shaft

- relatively large diameter


(requires rolls with small L/D ration)
Page 43 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Self-aligning roller bearings

+ Uniform distribution of the load onto both rows of rollers

+ No edge compression pressure if the grinding rolls are not parallel or if the
shaft bends

+ Easy to guide the roll in the frame. No special mechanics necessary for tilting
the bearing blocks

+ No separate axial bearing is required

+ Higher safety factors are possible for the shafts, due to larger bearing diameter

+ Larger bore diameter allows for flanged shaft connection.


Page 44 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Bearing seals
Page 45 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Bearing seals

Self Aligning Roller Bearings


with seal arrangement

Grease inlet
Grease direction

Grease outlet
Page 46 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Bearing seals

Grease inlet
Grease direction

Grease outlet
Page 47 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Bearing seals

Grease direction

Grease outlet
Page 48 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Cooling
Page 49 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Bearing Block Cooling

Legend: 3 Slanted sear sleeve valves


5 Dirt traps, filtration grade 0.25 mm Cooling water in- and outlet points
Page 50 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Shaft Cooling

process heat

+ Cooling of the shaft at the bearing blocks

+ no weakening of the shrink fit between tyre and shaft to ensure


maximum safety during transition phases in the grinding process
Page 51 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Gear Oil Cooling


Page 52 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Gear Oil Cooling

Water - Oil Cooler

with Double Filter


Page 53 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Gear Oil Cooling

Air - Oil Cooler with double filter


Page 54 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Drive
Page 55 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom with drive unit


Page 56 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Drive unit

9.1 Motor

9.2 Cardan shaft

9.3 Universal joint shaft flange

9.4 Safety coupling

9.5 Gear unit

9.6 Oil cooler

9.7 Torque stay arm

9.10 Coupling bar

9.12 Lever

9.14 Connection to the rolls

9.15 Auxiliary drive

9.16 Auxiliary motor

9.18 Protection of Cardan shaft

9.19 Gear unit protection


Page 57 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Drive unit

9.1 Motor

9.2 Cardan shaft

9.3 Hub to the motor for chain drive

9.4 Safety coupling

9.5 Gear unit

9.15 Auxiliary gear unit

9.16 Auxiliary motor

9.17 Chain

9.18 Cardan shaft guard

9.23 Bracket

9.24 Limit switch for cardan shaft guard


Page 58 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Gear box connection

Shrink
Key Disc

Keys

Location for dismantling


Page 59 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Gear box connection


Page 61 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Gear box connection

View from motor side

Shrink Disc

View from Polycom side


Page 62 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Gear box connection

Shaft with central key Intermediate flange with 2 keys


Page 63 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Gear box connection

Shaft with
groove

Shrink fitted
into gear box
Page 64 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Load fluctuation

10.000 Reducer
Torque [kNm]

1.000

100
1E-06 0,00001 0,0001 0,001 0,01 0,1 1 10 100
time [h]
Load fluctuation (design) Load capacity Load fluctuation (measured)
Page 65 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Life time calculation

Load fluctuation against time


90% operating time with 1.0 x rated motor torque
10% operating time with 2.0 x rated motor torque
1 load per hour with 4.0 x rated motor torque
Reducer

Gear box calculation according to DIN ISO 3990


kA = 2.3 application factor related to installed
motor power
sH  1.0 safety against pittings
sF  1.4 safety of teeth
Operating factors
SHB = kA · sH2  2.3 operating factor tooth flank
SFB = kA · sF  3.22 operating factor tooth root

Results: Bearings  50,000 h Reducer: no fatigue limit


Page 66 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom planetary gearbox


Cylindrical
gear stage, adjustable

Torque
transmission

Shrink disc Planetary Planetary


stage 2 Stage 1
Page 67 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom Cardan Shaft


with
Safety Clutch
Page 68 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom cardan shaft with safety clutch

Safety Clutch
Page 69 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom safety clutch

84

69.6
Page 70 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom safety clutch

Safety Coupling - Torque Limiting


Page 71 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom safety clutch

Safety Coupling - Torque Limiting


Page 72 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

Polycom safety clutch

Safety Coupling - Torque Limiting


Page 73 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt

POLYCOM Design Overview

Questions?

Dipl.- Ing.
Wolfgang Partsch