These drives advance availability. High-performance FLENDER conveyor drives are made for extreme conditions. siemens.com/conveyorbeltdrives Answers for industry.
At home in the mine All over the world from Peru, China and Australia to Chile and Russia and on to Zambia, Brazil, India and the USA conveyor systems move billions of tons of freight for many miles, often under extreme environmental conditions and more often than not through nearly impassable terrain with no water, poor infrastructure and extreme temperatures. As the leading supplier of drive technology for primary production and material extraction, we are very familiar with all of the requirements for mine operation. For decades we have worked together with our customers to develop optimized and integrated solutions that meet the needs of extreme on-site tasks. To ensure permanent conveyor system availability over long routes, in restricted spaces and in hot mountainous terrain with little water, we have adapted our various solutions completely with regard to situational conditions. Output capacity and speed represent only the most obvious conditions that our customers request here. During project planning, our discussions often include flexibility, usually include cooling and always include conveyor availability. An idle conveyor way out in a peripheral region is every mine operator s nightmare. For this reason, downtime must be prevented no matter what. The goal we want to achieve for you is a constantly running conveyor. 2
Poor infrastructure and extreme temperatures the right application area for our drives. 3
24 hours a day, 365 days a year When the temperature requirement is the critical determining factor, the key issue is thermal capacity. This is the critical parameter for the operational availability of a gear unit and an important deciding factor when it comes to selecting the right supplier. It determines drive design. It could even happen that a smaller design size is chosen because the housing surface determines the degree of heat dissipation. In turn, this means a significant cost saving potential for our customers because, due to the outstanding thermal capacity of FLENDER gear units, selecting the next larger size may not be necessary. There are many determining factors that influence a drive s reliability. The most important are the quality of the drive components, the coordination of the entire system and the thermal conduction of the gear unit in continuous operation. Two central parameters are critical in determining the latter: the natural environmental conditions and the gear unit s own temperature progression, which in turn demonstrates its quality and development status. 4
Drive train on a swing base with coupling and gear unit from the standard product range. As an option, the drive train can be expanded: In the end, the best achievement in gear unit engineering is demonstrated in extreme power density, which cannot be attained without the most advanced production methods and the highest degree of precision in production. An operating temperature that is too high over long periods results in a reduction of the lubrication capacity of the oil, damage to the seals and increased wear. For this reason, an optimized gear unit temperature increases operational life, decreases life cycle costs and maximizes drive service life. For many conveyor system operators, cooling systems represent another potential risk. There is often absolutely no water supply available. With an optimized housing surface, up to a certain design size it is possible to cool the gear unit with ambient air. But a larger housing surface is just part of the solution. It is critical that the ambient air is successfully conducted directly over as much of the housing surface as possible. To ensure that the air of the boundary layer is in continuous motion, Siemens uses highly efficient fans. They conduct the air over the housing and ensure that the heat is dissipated. Siemens has invested a great deal of development work in related fluid technology. Specially designed air guide covers ensure that the air flows evenly over the entire surface. This effective and mature air guidance system is the only one of its kind in drive technology in the world. Gear unit with larger surface. Air guide cover with axial fan. Auxiliary drive and backstop. 5
The right solution for every conveyor With the FLENDER gear units, Siemens offers you the largest product range of advanced conveyor gear units in the world by far. With three types, a total of 46 sizes and an immense variety of standardized design constructions we have the right drive solution for any requirement. As an alternative for moderate temperature zones, the product range also includes a self-aligning system with gear units from the standard portfolio with added motor bell housings. Here the advantages of a self-aligning drive are combined with the advantages of the standard portfolio quality that is quickly available and inexpensive. 6
Designed and produced for critical thermal conditions the Siemens Self Aligning System. If environmental conditions allow, it makes sense to put a drive together inexpensively, using elements in the standard portfolio. The FLENDER gear units in the standard portfolio are compact, feature high power density and are available in 25 sizes. Here the standard building blocks, which include a large selection of gear units, motors, bell housings, swing bases and add-on parts, leave nothing to be desired. For special temperature requirements, FLENDER gear units with optimized housing surfaces, axial fans and air guide covers are used for the drive. They guarantee outstanding heat balance and are available in 13 sizes. Not every mine has enough space for performing elaborate measuring, alignment and installation work. In addition, some operators find the necessity of using specialized personnel with the required expertise for assembly work challenging. In this case, the patented Self Aligning System is the perfect overall drive solution for capacity ranges up to 550 kw. It is available in 8 sizes and ensures optimum heat dissipation with its axial fan, air guide cover and the patented Clever Cooling System for intelligent air flow guidance. It offers flexibility during commissioning, whether in regard to spatial circumstances, location or assembly. For conversions or removal, no special skills are required because the drive unit does not need to be aligned. The flange provides a fixed connection between the motor and gear unit. High production quality guarantees the necessary connection precision at the bell housing. The elimination of measuring and alignment errors during initial assembly ensures undisturbed operation. The Self Aligning System can be used as a right-hand or left-hand version without any conversion necessary. This means that side selection on the conveyor belt is left to the assemblers on-site. These are features that especially operators of underground mines appreciate. The drive has a very compact design, is delivered as a fixed unit and is simply installed on-site, where it ensures maximum availability for your conveyor system. The design advantages of the FLENDER gear units: Largest selection due to numerous sizes with few component variants Dependability and operational reliability at the greatest power density Absolutely dust-proof due to labyrinth seals that are, for the most part, free of contact and wear Flange output shafts for easier gear unit assembly with low space requirement High degree of efficiency and outstanding noise behavior due to ground bevel gears, noise-absorbing housings and exceptionally large contact ratios 7
Integrated Drive Systems The more effective a drive, the lower the operational costs. Coordinating and controlling the entire system plays a critical role here. Siemens has always been convinced that the drive train must be seen and understood as a whole. We are the only provider in the world that offers complete industrial drive systems. In the context of the Integrated Drive System concept (IDS), complete drive solutions have proven successful in many industries and have become standards upon which today s industrial drives are based. Drive train components SINAMICS frequency converter SIMOTICS motors FLENDER couplings FLENDER gear units FLENDER oil supply system Our gear units have been used in conveyor technology for many years as integrated components in thousands of complete solutions. These drive systems make our customers planning easier, remove the burden of interface risk and reduce the number of contact persons to just one all crucial factors. The drive train as a whole is a rigorous, goal-oriented development to meet the requirements of our customers. For this reason, Siemens provides not only the entire range of drive train components of the highest quality, but also the perfect integration and adaptation from the initial concept to the functioning conveyor system. Siemens Integrated Drive Systems concept makes simple drive components into real systems. Drive technology based on IDS guarantees maximum productivity, energy efficiency and reliability in every area of automation and over the entire life cycle. 8
The advantages of integrated drive systems 1 Horizontal integration Integrated drive portfolio: all frequency converters, motors, couplings and gear units available from a single source. Perfectly integrated, perfectly interacting. For all power and performance classes. As standard solutions or combined to provide an individual solution. 2 Greater plant availability Vertical integration Integrated into automation: from the field level via the controller level up to MES thanks to Totally Integrated Automation (TIA). Whatever the application. Faster engineering By request, we offer not only the main gear unit, motors and couplings, but also the following from a single source: Transformers Frequency converters Motors Auxiliary and maintenance drives Bell housings Add-on components (backstop, swing base, auxiliary drive) Oil supply systems Oil cooling systems Sensor technology Condition monitoring Drive and process control (CEMAT) Financing 3 Life cycle integration Integrated software and services throughout the entire life cycle. For better performance and maximum investment protection. Those who enter a system partnership with Siemens profit in every way from a functioning drive system supported by proven control technology. We ensure that the right drive components are selected and constructed, coordinate them with each other and optimize them for you in the field. Lower maintenance costs For more information on integrated drive systems, visit: siemens.com/ids 9
Multiple drives prevent total breakdowns. For a mine operator, the availability of the conveyor system is of supreme value. For this reason, particularly for large conveyor systems with several megawatts of power input, everything possible is done to ensure continuously smooth operation. In the contest to win the favor of system operators, drive solutions with gear units do have minimal disadvantages with regard to effectiveness, but in terms of service life and costs they come out ahead in every instance. Inexpensive add-on parts To prevent the belt from continuing to run if a stop is desired, our drives can be equipped with small, inexpensive brakes on the drive shafts, and for a smooth start, they can be furnished with our tried and tested FLUDEX fluid couplings. Our backstops are also dimensioned such that they are small and cost-optimized and are installed on the drive shafts. Incidentally, in regenerative operation, our asynchronous motors are outstanding for use as generators for producing electricity. The large spectrum of gear units offers a suitable solution for every requirement. The only sure solution The fact is that in a large system only a multiple drive can ensure maximum system availability because only such a drive, with its redundant drive trains, can offer reliable protection against total breakdown. In very rare cases when service is needed, the affected partial drive can be disconnected from the drive system, which can continue to operate at lower capacity. Operation is only briefly interrupted in this case. Spare parts are also redundant, are available quickly and, moreover, are easy and inexpensive to stock. Highest degree of flexibility Conveyors are always moving. Our drive solutions are not sensitive to their ubiquitous vibrations. They do not have any special requirements with regard to foundation, structure and system construction. They do not need to be installed on the ground or floor. In addition, the head end station can be moved without any great effort. Low overall costs In addition, our solutions do not require comprehensive monitoring by specialized personnel. For the most part, the gear units are maintenance-free; only low-cost oil maintenance is required. For this reason, the low investment costs and minimal maintenance costs for drives and system design do not result in any pressure to amortize in a time window in which it is not clear if the mine will still be in existence. In this way, the redundant FLENDER multiple drives can be seen as the only meaningful drive technology that can guarantee the availability of large conveyor systems. Our drives give you maximum flexibility for your daily operation. 10
Greater reliability with early diagnostics. Benefit from our drive train expertise that is unique in the world, the perfect design for the drives due to our decades of experience, optimum drive solutions for every requirement, the largest product portfolio that covers the entire range of conveyor technology, highly advanced drive components manufactured with the newest and most precise production technologies and processes, reliability due to the outstanding quality of all of the components, an industry standard tested in accordance with the highest demands and proven over and over again, our global production concept with a high degree of production and assembly capacity at many locations all over the world, speed regulation with a perfectly customized frequency converter and outstanding system control, a comprehensive, international network of certified service centers and early error detection with our SIPLUS Condition Monitoring System. Condition monitoring Availability, efficiency, reliability. A pioneer in the area of condition monitoring, Siemens has offered online condition monitoring systems (CMS) for the raw materials industries as an extension of gear unit service for more than 15 years. With SIPLUS CMS, Siemens demonstrates the highest level of reliability with the early recognition, diagnosis and localization of irregularities and determining their causes. The diagnostic expertise of a gear unit specialist combined with Siemens automation technology significantly expands the possibilities of early error detection. The measuring system based on SIPLUS CMS components fits seamlessly into the Siemens automation landscape, but also has interfaces to other standardized bus systems. The benefits are obvious: machines that are costintensive and run under full loads are monitored perfectly and the undisturbed, optimal running of complex systems is ensured. This makes SIPLUS CMS an important tool for increasing and ensuring system service life and optimizing production processes. A Siemens product, SIPLUS CMS fits seamlessly into the components of the drive train. 11
Further information about drives: www.siemens.com/flenderapplications www.siemens.com/gearunits Further information about couplings: www.siemens.com/flendercouplings www.siemens.com/hydrodynamiccouplings Siemens partners near you: www.siemens.com/automation/partner Siemens AG Industry Sector Mechanical Drives Alfred-Flender-Straße 77 46395 BOCHOLT GERMANY Subject to change without prior notice 04/13 Order-No.: E20001-A390-P900-X-7600 DISPO 27904 GD.MD.AP.XXXX.52.3.02 WS 04131.0 Printed in Germany Siemens AG 2013 The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.