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Large industrial drives

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A new generation of large industrial drives especially suited to demanding materials handling tasks is being introduced to Australasia by Bonfiglioli.

The new HDP parallel shaft and HDO bevel helical units in sizes of up to 72,000 Nm are the result of more than three years development to produce outstanding reliability and torque densities to record values.

The new HDP parallel shaft and HDO bevel helical units, which will be tailored to customer requirements through extensive assembly and service facilities in Australia and New Zealand, feature torque distribution across their entire ratio range, with gear ratios laid out in close progression and the drives having a rugged capacity to cope with the shock and impact of intermittent loads.

Outstanding research and development has gone into producing these drives, with finite element analysis and multi body simulations conducted, in order to identify the stress pattern on each of the main components and to optimize the design for:

System structural stiffness

Gear geometry

Shaft deflection

Extended gear and bearing lifetime

According to Bonfiglioli, boundary element method was used to reduce the noise emissions through the identification of all the direct and indirect vibration sources of the gear unit in actual operating conditions

Reliability was enhanced by a high radial load capacity, with 100 per cent heavy duty bearings, and by reduced vibration and noise levels achieved by gears that are entirely ground-finished. Units up to size of 120 (35,000 Nm) feature rigid monoblock housings, while larger units feature a horizontally split housing.

Input shafts are supported by robust taper roller bearings. They may be coplanar, sitting 90 degrees apart, for optional mounting positions, or allow both a main and pony drive to be fitted. Latest generation heavy duty roller bearings are used to withstand the forces generated internally and applied externally. Accurate proportioning of the shafts allows for lifetime balance of each axis.

Gears of optimized geometry and profile (entirely ground finished to quality class DIN 6) feature high load capacity, extended lifetime and reduced noise in operation. Output shafts are robustly fabricated from hardened and tempered alloy steel. Shafts may be requested as keyed hollow, solid or as hollow with shrink disc coupling for ease of mounting and dismantling. Large covers allow inspection of gears at any time.

The HDP parallel shaft and HDO bevel helical unit drives’ versatility in service is enhanced by numerous mounting options suitable to their typical applications, such as materials handling (inc belt, apron, bucket, screw and chain conveyors), manufacturing, mining, quarrying and minerals processing, rural and food product processing, paper, pumps, steel, sugar, timber, wrapping and stacking applications, and water and waste water treatment. The HDP parallel shaft and HDO bevel helical unit drives’ multi machined surfaces and symmetrical design allows them to be used in either left or right hand configuration.

Introduction of the HDP and HDO ranges follows the largest expansion ever of Bonfiglioli range and service facilities in Australasia, where it has more than doubled the size of its headquarters Down Under. The new ranges will be stocked at Bonfiglioli’s new $8 million facility located near the M7 Orbital in the Western Sydney.

In addition to the capital investment in its new Australasian headquarters, Bonfiglioli is spending a further $8 million on stock inventories in Australia and New Zealand to ensure the broad availability, and prompt deliveries of its drive technologies.

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