BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD Self Aligning and Floating

Kiln Gear Drive

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

Cement Kiln operation – Influence parameters on Gear Meshing

Meshing of the kiln girth gear depends on the thermal condition of the kiln
The kiln has variable thermal expansion due to condition and type of its refractory and coating
Change in center distance between pinion and kiln axis
Wobbling of girth gear

The sustainability of the meshing of the kiln girth gear is major concern

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

Cement Kiln – Influence parameters on Gear Meshing

Wobbling of Girth Gear
• Occurs due to variation in kiln operation - uneven coating formation
leading to shell temperature differences and thermal cranks
=> Proper meshing of the teeth no longer assured – contact area is
reduced and changing from one side to the other
Overloading Center distance change
due to wobbling Lack of tip to root clearance

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD is solving these issues

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX – Concept
Floating drive + Self aligning principle applied for Gear Meshing
= BOGIFLEX
Self aligning is achieved because the pinion can move freely
onto the wheel
The rotation shaft of the pinion is free from the rotation shaft of
the wheel

Spherical
⇒ The 2 contacting surfaces or gear meshing between pinion plain
and girth gear will permanently adapt to each other bearings

Pillow block

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX – Contact pattern and Advantages

Floating drive + Self aligning principle applied for Gear Meshing
= BOGIFLEX
The 2 contacting surfaces or gear meshing between pinion and girth gear will permanently adapt to each
other

⇒ The Hertz contact pressure will be uniformized and, therefore, be minimized allong the complete tooth
of gear meshing.
⇒ No more stress concentration
⇒ Increased life of gear
⇒ Coefficient used for Wear and Breakage calculation according in applicable norms (DIN; ISO)
are effectively applied
Safety factor results are corresponding to effective condition of meshing

BOGIFLEX meshing CONVENTIONAL meshing

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

General Design:
KGD
cardan

ERmaster

1 gearbox ERmaster standard

1 cardan with fixed length
1 BOGIFLEX drive KGD with main pinion 23 teeth
1 Girth gear - in two halves – cast steel Girth gear
1 Set of tangential plates Y shape with shoes

KILN SHELL Spring plates

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

General Design:

Length of spring plates are adjusted to enable

the mounting onto each kind of shell diameter
considered with the drive range

Ømin

Ømax

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Pinion rollers:
• Roll on Girth gear
– Adjust permanently the center
distance ; Keep the tip to root
clearance constant
– Meshing adjustment not performed
in plant: Workshop machining
Kiln backlash always adjusted

 No post adjustment required

between pinion and girth gear

– Contact teeth meshing calculated

coefficient always right

• Floating on pinion
– Relative rotation with pinion
Low speed
– Floating fitting

• Oil lubrication
– Injection and bath lubrication
http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Inner rollers:
• To keep BOGI-Pinion
in position at kiln stop

• To enable driving during kiln

backward

• Roll on inner track

of the girth gear

• Made up with Glicodur

bearings
(standard calculation)

• Global clearance with the girth gear

Are not in contact with girth gear at
normal kiln driving

• Grease lubrication for complete life

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Main Bearings:

• Over designed
– Dimension from pinion
dimension, not from loads
– Standard calculation L10h
gives 100’000 hrs minimum

• Oil lubrication
– Oil injection + splash
– Higher life time

• Securities on lubricated
equipment (flow, pressure)

• Thermal monitoring
of the bearings

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Reaction Bar
Movement possibilities:
• Reaction bar with one shaft on top side
and one spherical plain bearing at bottom
side

• Allowing axial and radial displacement of

the BOGI-pinion by allowing rotation
movements

• BOGI-pinion casing independent from girth

gear casing for self alignment and
permanently good positioning onto girth
gear

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Reaction Bar
Load distribution:
• Reaction arm positioning gives
Pushing load effect FN w/p

• Pinion always right positioned onto the

Girth gear

RN b/w
FR b/w

FP b/w
Pushing effect

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – Range guide line

General definition of KGD range:
Gear drive depends on
Power transmitted vs diameter on HOLCIM kilns
kiln torque value and
shell diameter. 13,00

12,00 LARGE
11,00

10,00

9,00

8,00
3 areas defined
paramètres

SMALL 7,00

MEDIUM 6,00
MEDIUM
LARGE 5,00 SMALL
Similar design for each size 4,00

3,00

Number of teeth and 2,00

modules are different 1,00

gamme de fours HOLCIM

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – Range guide line

General definition of KGD range:
• Technical data for predefined KGD sizes
– Kiln shell from 3,8 to 4,6 m – KGD Small
• Admissible torque value of 1’000’000 Nm corresponding to 470 KW@4.5 rpm
– Kiln shell from 4,6 to 5,2 m – KGD Medium
• Admissible torque value of 2’200’000 Nm corresponding to 1050kW@4,5 rpm
– Kiln shell from 5,3 to 5,3 m _ KGD Large
• Admissible torque value of 4’500’000 Nm corresponding to 2’120 kW@4,5 rpm

• Service factor acc. ISO 6336 Pitting KB > 1.51 ; Breakage KB > 1.75
• Kiln axial and radial displacements usually recorded
– Kiln Axial +/- 40 mm
– Kiln Radial displacement + thermal expansion +/- 30 mm

• BOGIFLEX KGD capacited in displacements

– KGD admissible axial +/- 80 mm
– KGD admissible radial +/- 40 mm

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – Complements

Lubrication system:
Separate Lubrication ERmaster
1) Girth Gear / pinion + Main pinion To Ermaster
bearings
To HD gear set
- Forced lubrication of Girth gear &
pinion with adequate lubrication unit

- Choice of oil lubricant viscosity Low viscosity

depends on teeth working temperature Unit
- Oil viscosity should be higher than 300 Oil 460 Cst
Tank 600 L
Cst at effective working temperature of
teeth meshing Tank 200 L
pump
2) HD gear set + Ermaster
High viscosity unit
- Injection lubrication of intermediate pump
gear set & primary gearbox
Oil 3000 Cst
- Usual lubricant viscosity grade: ISO
VG 460
filter 40 µm Motor filter 80 µm
3) All gear stages have a safety splash
lubrication with foreseen reservoir
http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – Complements Natural frequencies:

Y FORM – KGD Standard BASIC FORM

9.6 Bending 9.9

Hz Mode Hz

68.3 Torsion 63.6

Hz Mode Hz

70.3 Bending 78.1

Hz Mode Hz

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – Complements

Main Components:

• Spring plates

• Girth gear

• Bogi-pinion KGD

• Reaction arm

• Cardan shaft

• Primary gearbox

• Baring unit / Inching drive

• Lubrication unit

• Housing & Sealing

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD – General Principle

Conclusion:
• No need of post adjusting of the pinion in front of the girth gear
– Bogiflex is not sensitive to thermal expansion conditions
THE GEAR MESHING IS INDEPENDENT FROM THE KILN PROCESSING

• Optimised meshing and lubrication conditions and High safety factors:

– Components designed for expected life time
– Criticality has been studied ; Criticality reduced by monitoring
RELIABILITY INCREASED

• Optimized Maintenance:
– Maximum number of elements are standard ones
– KGD studied in standard range in view of having available a set of pool spare parts in addition
to plant spare parts
– Design of KGD has been studied for each part to take care of time required to change it as
short as possible: To shorten shut down time of kiln for maintenance has been taken into
consideration when design

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE
BOGIFLEX® KGD

January 2010

BOGIFLEX® KGD successful commissioning

Venezuela San Sebastian Plant

Ecuador Holcim Guayaquil
Mexico Apasco Macuspana*
USA Holcim Devil Slide*

Argentina Holcim Capdeville*

Slovaquia Holcim Rohoznik
Azerbaijan Holcim Garadagh

http://www.cmdgears.com
539, avenue du Cateau - 59400 Cambrai - FRANCE