SPINNING GEARS: BULK HANDLING DRIVES, SYSTEMS AND CONTROLS

bulk handling drives, systems and controlsSpinning gears

Old Kiepe E-Stop Cast iron switch, designed in 1984 – always in function in a power plant.

From E-Stop to E-Mobility to E-Stop – Kiepe Electric

Jay Venter

The robust Kiepe Electric industrial devices have been used in conveyor technology for more than 80 years. As emergency pull-rope switches, misalignment switches, limit switches and speed monitoring devices, the high-quality yellow devices with the Kiepe logo fulfill their function unobtrusively and are valued for their reliability and durability.

The cement industry, power plants, opencast mines, steel works and coking plants, recycling plants, transshipment points, fertilizer production, sugar, salt production and processing are just a few of the areas in which Kiepe devices are used around the world.

The special design of Kiepe E-StopSwitches allows for extremely long installation lengths in free environment exposure, which cuts costs significantly in long, straight overland conveyor belts.

In the cyclone-impacted region of North West Australia, Kiepe switches with 2x125m rip cord installation have been in use for more than 12 years and they are still working trouble free.

But Kiepe offers even more.

Since 1906, Kiepe has been successfully developing and producing e-mobility devices in the Kiepe group, such as pantographs, traction controls as well as motor management systems and small devices for local public transport such as bus and train vehicles. The high-power charging module developed by Kiepe in Switzerland and a Traction controller is now added to the portfolio.

KIEPE HIGH POWER CHARGING INFRASTRUCTURE v decentralized charging infrastructure powered by existing rail power supply; v mobile and containerized charging infrastructure for fast and flexible deployment; unlimited interface compatibility to all

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v electric bus manufacturers; seamless integration into all charging management software and SCADAsystems; and HPC: high power charging infra structure up to 800kW.

HIGH POWER CHARGING - ECOSYSTEM The High-Power Charging ecosystem includes a large number of applications. Different energy supply options, from catenary fed installations to local energy grid or alternative energy source supplied installations are possible. The charging infrastructure may be housed in a stationary or mobile outdoor container or in an indoor cabinet depending on power and application requirements. The infrastructure can contain batteries to buffer energy or to allow a balanced load pattern to the supply grid. For depot installations indoor cabinets or ceiling mounted equipment is available to supply energy from catenary to bus battery for overnight charging.

Kiepe Belt Misalignment switch with adjustable switching points in a bio-recycling plant – in use since 2010 without any problems.

High-power charging.

Crane and reeling cables are being produced to perform in extreme environmental conditions. They are specifically designed to carry power and control signals to wide variety of mobile, lifting and handling equipment. These cables are durable for high mechanical and torsional stress and tensile loads, which impacts their operational performance and lifetime.

It is vital these cables withstand multiple daily moving cycles; ensure reliable, longterm, trouble-free performance of the cranes; and comply with the crane’s components, such as the reel, festoon, and cable chain. During operations, the cables must be robust enough to withstand torsional and tensile stress, whilst being at risk of mechanical, abrasive, water, chemical damage, and current overload. Therefore, it is crucial that specified cables meet the demands of each specific application and are stored and installed correctly.

Cable sizes must factor in the installation environment and currentcarrying capacity by considering the thermal effects, electrical shock, overload and short-circuit currents, voltage drop and mechanical strength, and any other specific demands a unique application may have.

Üntel Kablo manufactures crane and reeling cables according to international standards and design principles that have been developed throughout years of manufacturing experience. Üntel’s cable range for ports, terminals, cranes, and heavy equipment builds on years of experience within the industry and by listening to its customer base, continuously investing in its R&D, and upholding international quality standards. Its reputation has ensured it is a recognized solution partner within the sector. Its technically trained team provides advice on types of cables for application and storing, handling, preparing, and installing the cables.

Üntel uses CCV (catenary continuous vulcanization) line technology for rubber cable production in its factory. This technology can extrude three layers of rubber in a single operation. The factory lines include instruments that control the entire cable production process, and the cables are made using high-quality cable compounds, ensuring they can withstand demanding industrial applications. Its end products are certified to international standards by certification and testing bodies, ensuring safety and quality are paramount throughout its entire product range. Üntel crane cables meet VDE standard and customer demands.

Üntel is a member of the Port Equipment Manufacturers Association (PEMA). PEMA represents the interests of equipment and technology suppliers on a worldwide basis, providing a platform to inform, educate and promote best practice, both within the industries it serves and externally with port and terminal operators and other key stakeholders.

Today as a global player in cable business and with products that have been used in Turkey and all around the world, Üntel puts its signature to major and prestigious projects in crane and reeling projects that are used in ports, factories and constructions.

Üntel Kablo exports cables to over 80 countries on six continents, with 60% of its manufacturing dedicated to these markets, boasting over 250 international certificates for its 15,000 strong cable product range.

ENGINEERING & EQUIPMENT Ideal for high force requirements in demanding environments

RINEER HEAVY-DUTY VANE MOTORS FROM BOSCH REXROTH The RINEER vane motor series from Bosch Rexroth, which was previously used primarily in North America, is now available worldwide. The series offers the highest power density with maximum torque as well as the robustness even under the most adverse climatic conditions and high dirt loads. The vane motor makes only low demands on oil cleanliness. In the US, the motors have primarily been used in maritime and offshore applications, but are also used in oil and gas production and numerous other heavy-duty applications.

RINEER motors are particularly robust and provide continuously high starting and stalling torques right from the start. Working vanes in the rotor create uninterrupted output torque regardless of angular position, while sealing vanes in the stator create an effective seal between the high- and low-pressure sections. This allows users to utilize maximum torque even at very low rotations. At the same time, the motor enables maximum speeds and full torque on a continuous basis. Frequent and fast start/stop sequences as well as direction changes are possible at any time without mechanical wear. As a result, the RINEER vane motor from Bosch Rexroth offers a long service life with maximum availability.

The motor family comprises four series consisting of more than 70 displacement variants and covers a torque range from 248Nm to 18.718Nm. Due to their design, the economic motors achieve an optimum power-to-weight ratio with very high power density and lower noise emissions. The compact direct drive can replace otherwise necessary gearboxes due to the wide torque and speed range and requires fewer components than conventional solutions. A variety of optional features, including bearing options to handle application loads, make Bosch Rexroth's RINEER one of the most versatile hydraulic motors available.

Many years of application experience in North America demonstrate the extreme robustness of RINEER motors, even under the most adverse climatic conditions and high dirt loads. They are frequently used in the maritime sector, for example for winches, as well as in the offshore industry in jack-up and drilling applications. The vane motor is insensitive to oil contamination. Optionally, air, water or drilling fluid can even be fed through a hollow shaft in the motor without contaminating the fluid.

Bosch Rexroth ensures efficient, powerful and safe movement in machines and systems of any size. The company bundles global application experience in the market segments of mobile applications, machinery applications and engineering, and factory automation. With its intelligent components, customized system solutions and services, Bosch Rexroth is creating the necessary environment for fully connected applications. Bosch Rexroth offers its customers hydraulics, electric drive and control technology, gear technology and linear motion and assembly technology, including software and interfaces to the Internet of Things. With locations in over 80 countries, more than 31,000 associates generated sales revenue of around €6.2 billion in 2021.

RINEER motors are particularly robust and provide continuously high starting and stalling torques right from the start.

DER ANTRIEB

Reliable Versatile Global

HOIST SOLUTION The new MAXXDRIVE® XD

Robust Modular From a single source

A torque sensor is helping analyse recipes’ mixing properties in a project that could slash development costs in the food and plastics industry and help nanotechnology advances in the pharmaceuticals world.

The research and development is being carried out at the University of Bradford by Professor Hadj Benkreira and Dr Raj Patel in collaboration with Dr Martin Gale, formerly of RAPRA Technology (Shawbury) now Visiting Professor. They have been developing a miniature mixer (5-25 grams batch) that incorporates a set of integral instruments to monitor the properties of materials as they are being mixed. The instruments work in real time during the mixing process and their output is captured to a PC for subsequent analysis. Software is being written so that the analysis can be performed simultaneously with the mixing and perhaps even used to interactively control the mixer itself.

One of the key parameters to be measured is the torque of the mixing element, as this will become constant once mixing is complete. This is measured by a TorqSense non-contact sensor that offers the development team the great advantage of not requiring complex and delicate slip rings, making the mixer easier to build (and rebuild between trials) and far more robust in operation.

The Mini Mixer development and validation is the result of a three year EPSRC sponsored programme of research. The results of this research are expected to have a major impact on formulation of viscous mixes and scale-up of extruders.

Traditionally recipes for formulating say specific coloured plastics for consumer products are developed in 25 to 50kg batches, mixed in an industrial scale twin screw compounder. Several batches may be required before the recipe is finalized, so the cost and time involved can be considerable.

Clearly the development of a smaller mixer is advantageous, but the laboratory device must be able to duplicate mixing in the larger scale and guide design and operation of large machines and that is what the research programme has achieved. That fact that the technology will transfer to the plastic industry and other soft solid sectors means it is likely to rapidly recoup development costs.

Dr Raj Patel explains why he selected TorqSense in preference to a conventional strain gauge based transducer. “In a development project like this you are constantly dismantling and rebuilding the equipment. TorqSense torque sensors saves us considerable time and effort (and therefore cost and frustration) because it is so simple to set up.”

“It will be used in the final commercial design of the mixer too, where its simplicity of use will be much appreciated by busy scientists, engineers and technologists.”

Range extension for innovative wireless torque sensor.

Modular, intelligent and communicative: The new NORDAC PRO SK 500P

Getriebebau NORD’s new NORDAC PRO SK 500P frequency inverters for all drive applications provide concentrated functionality in a very small space. With a power range from 0.25 to 22kW and five sizes, the inverter family is suitable for a wide range of applications.

With its integrated PLC, the NORDAC PRO SK 500P frequency inverter optimally fits into modular system designs. The inverter does not only guarantee smooth and intelligent communication of all system components. It also has a multi-protocol Ethernet interface and a USB interface and is therefore perfect for condition monitoring and predictive maintenance applications. The NORDAC PRO SK 500P can be expanded at any time and thus easily adapted to changed process conditions. The inverters are conveniently operated via a mobile device in combination with the NORDAC ACCESS BT Bluetooth stick and the NORDCON APP.

Dana introduces new Brevini EvoMax™ helical and bevel-helical gearbox range for marine, offshore applications

Dana Incorporated, based in Maumee, Ohio, USA, on 31 August 2022, announced the launch of the Brevini EvoMax™ series of helical and bevel-helical gearboxes for marine and offshore applications. The gearbox range introduces five completely new sizes and includes 14 redesigned gearboxes to provide higher torque, greater efficiency, and longer service.

In the field of bulk material handling, where the conveyor drives are running continuously, demanding high power and often with no external cooling solutions, the new Brevini EvoMax™ has an answer to these key issues and offers a host of benefits, including integrated cooling and superior durability.

The modular series is designed to provide greater product flexibility, higher efficiency, and increased sustainability while helping to minimize total operating costs.

“The demand for global shipping continues to rise, and our customers require robust solutions that can be adapted to their specific on-shore port or off-shore marine applications,” said Jeroen Decleer, senior vice president of Dana OffHighway Drive and Motion Technologies. “Dana continues to supply new equipment, upgrades, and modernizations for the marine industry through our broad range of solutions for this critically important sector.”

Leveraging decades of product application knowledge and customer feedback, Dana's new series of gearboxes provides a highly engineered solution with a comprehensive suite of features, including: v a new housing design to reduce weight, increase structural strength, and optimize internal oil flow for better thermal management; v custom gearing for smooth operation, low noise levels, and high efficiency; v updated housing materials and seals to enable low temperature operation; v best-in-class torque density; and v increased product range to provide a more targeted solution for customer applications.

In addition to helical and bevel-helical gearboxes, Dana offers Brevini® -brand axial piston motors, axial piston pumps, slewing drives, proportional directional valves, winches, winch drives, wheel drives, and other motion products for the marine and offshore industry.

ABOUT DANA INCORPORATED Dana is designs and manufactures highly efficient propulsion and energymanagement solutions that power vehicles and machines in all mobility markets across the globe.

The company is shaping sustainable progress through its conventional and clean-energy solutions that support nearly every vehicle manufacturer with drive and motion systems; electrodynamic technologies, including software and controls; and thermal, sealing, and digital solutions.

For bulk material handling, steel and cement works, running continuously and with a high power demand, conveyor drives will benefit from the Brevini EvoMax’s improved thermal capacity, an integrated cooling fan, reduced weight for easy installation and compact design.

EvoMax™ STS Hoist Drive

EvoMax™ E4B28

EvoMax™ E3B42