Bonfiglioli alignment-free drives have been deployed by ThyssenKrupp in the conveyor systems at a major gold mine expansion project in Papua New Guinea.
Bonfiglioli was contracted by ThyssenKrupp Materials Handling to supply drives for the discharge and spillage conveyors in the two jaw crushing lines operating in parallel at the mine. The discharge conveyors have a design throughput of 1200 tph, while the spillage conveyors receive a small fraction of that throughput in finer ores from spillage.
Mr Malcolm Lewis, Managing Director, Bonfiglioli Transmission (Aust) explained that the alignment-free drives needed to meet the 24/7/365 operational requirements of the application. The discharge conveyors were specified with right angle bevel helical drives incorporating rigid flange couplings, backstops and fluid couplings while the spillage conveyors were specified to be shaft mounted gear motors with torque arm, with bearing L-10 life to be greater than 60,000 hours and gear life to be 100,000 hours.
Bonfiglioli supplied drives of its Alignment Free Drive (AFD) configuration, which has extended the versatility of its HD series of advanced heavy duty drives and cost-effectively integrates motor and gearbox. Produced by Bonfiglioli’s recently expanded Drives Service Centre, the Alignment Free input design negates the need for a costly baseplate.
The AFD input is basically a large bell housing that contains the fluid coupling and fan, and provides a standard IEC interface for the flange mounted motor. This type of input also saves time and labour during commissioning of the drive as the alignment of the transmission components has already been done.
Key features of Bonfiglioli alignment-free drives:
- Offers an alternative to laser-aligned baseplate types, allowing the use of close coupled IEC B5 flange mounted motors up to a G315 frame size
- Reduced initial costs compared to traditional baseplate designs
- Capacities up to 1,115 kW and 79,150 Nm (4 pole) complement Bonfiglioli’s Hi Torque drives
- Quick, trouble-free assembly and maintenance of high speed components including fans, fluid couplings and brakes
- No need to laser align the motor and gearbox shafts, saving time and money
- Applications include conveyor drives, shuttle drives, bucket elevators, inching drives and other materials handling equipment
- Enhances serviceability by permitting high speed components to be removed and replaced without re-alignment
- Vents in the bell housing allow air from the fan to be forced along a path to provide optimum cooling for the gearbox, increasing reliability
- Bell housing provides a collection point for fluid lost by the fluid coupling in a blowout