Reliable complete drive systems for the quarrying industry

When building a materials handling or processing machine for the quarrying or mining industries the first requirements that come to mind are "toughness' and "durability'. The machine's components must have the toughness to withstand the heavy and abrasive materials that are associated with these industries; as well as the durability to survive the shock loading, heavy workloads and harsh weather conditions they will be subjected to - especially in areas where maintenance access may be difficult.

For design engineers, finding companies whose products can be trusted for such difficult conditions can prove to be time consuming and frustrating. Fortunately Brevini Power Transmission, manufacturers of the PIV Posiplan hybrid gearbox, has shown that with the help of its sister company, Brevini Fluid Power, it is able to supply tough and reliable complete drive systems for moving and processing applications in the quarrying industry.

Brevini Power Transmission has been combining its technical competences and engineering abilities with Brevini Fluid Power for many years; the two companies providing high-strength and high-efficiency systems for OE quarrying equipment builders and maintenance providers across Europe and the rest of the world. Recently a system was designed and installed for material conveying and separating equipment built by Parnaby Cyclones, a UK manufacturer of equipment for the quarrying, coal mining and waste processing industries.

Dave Brown, Sales Manager for Brevini UK Ltd, comments: "Brevini is well known for designing gearboxes that run at high reduction ratios incredibly efficiently; this is ideal for the high-torque low-speed requirements that are often required in the quarrying and mining industries. The reduction ratios allow the drive systems to be powered by small hydraulic motors and small power packs, which keeps running costs to a minimum. By working with our sister company, we can offer complete drive packages in short lead times that integrate seamlessly."

The requirements from Parnaby Cyclones were for Brevini to provide a main drive to deliver a torque of 9000Nm and output speed of 4.0rpm as well as two chain drives and a spinner drive that were each required to deliver a torque of 3000Nm and output speeds of 4.0rpm for the separating process. A hydraulic power pack would also be required to feed pressure to individual hydraulic motors at each of the four gearboxes.

Brevini was able to supply four of their PIV Posiplan bevel planetary helical gear units, each with a Samhydraulik motor and an 11kW 250L hydraulic power pack that included proportional control valves for PLC control. The overall lifetime of the package was calculated to exceed 50,000 hours.

Delivery of torque and speed

The gearbox for the main drive was a 3-stage Posiplan BPH323 gearbox with an ISO6336 torque rating (T2ISO) of 15100Nm and a reduction ratio of 58.82:1. The gearboxes for the chain and spinner drives all used 3-stage Posiplan BPH313 gearboxes with torque ratings (T2ISO) of 3900Nm and reduction ratios of 45.68:1. Combined, respectively, with Samhydraulik BR200 and BR080 orbit motors, the drives comfortably delivered the torque and speed required by the application.

Brevini's PIV Posiplan gearbox is a power transmission system suitable for many of the material-handling applications found in quarrying and mining. The hybrid design combines the high-efficiency, high-reduction ratios and low-weight benefits of planetary gear stages with the strength, capacity and durability of bevel helical gears. A modular design incorporating the flexibility of the Brevini planetary gear range ensures versatility and the ability to engineer packages according to the application and customer demands, while product lead time and product costs remain competitive.

Brevini Fluid Power offers a range of axial piston and orbit motors from Samhydraulik as well as hydraulic pumps and proportional valves to complete the motor / gearbox package. Hydraulic drives are well suited for conveying and processing equipment as they offer the flexibility to deliver variable application demands and are conveniently packaged in compact independent power units for each driven stage of the process.

For further information about Brevini's tough and reliable complete drive systems, visit the website at www.brevini.co.uk.