Archive | May, 2010

Integrated pinion stand beam mill drive

Friday, May 21, 2010

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Galbiati Group reconditions gear drives for all heavy industrial applications.

Individual components are inspected to determine wear and deformation. Non-destructive tests, are conducted by skilled and experienced technicians, using high-precision instruments and a ZEISS MMZ-G 30 60 25 three dimension measuring machine.

Once completed, a full-speed running test is performed. Temperatures, noise levels, and vibrations are continuously detected and properly recorded.

A “Certification File” is issued for each drive, which contains the materials and inspection certificates as well as all intermediate and final inspection drive report.

Beam mill pinion stands before revamping operationsBeam mill pinion stands after revamping operations

Hydroelectric power plant gear increaser (vertical axis)

Friday, May 21, 2010

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Vertical axis gear increaser installed between Kaplan turbine and 1.000 kW generator. Sized  for 24/7 continuous operation,  more than 8.300 hours/year. Full-load > 98.5% efficiency.

Equipped with temperature probes for oil and bearing temperature detection, and vibration probes with relevant analysis and control equipment.

Vertical axis RPM multiplier installed between Kaplan turbine

Pinion Shafts for Edger drive

Friday, May 21, 2010

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Pinion Shafts  for Edger drives hot mill.

Technical Data: NiCrMo alloy steel; single helical carburized (58 – 62 HRc) and ISO-DIN 6 quality ground finished.

Shaft pinions for Edger drives - hot sheet lamination

Rubber mixer drive 2500 kW at 77 rpm

Friday, May 21, 2010

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270 l rubber mixer drive for tire manufacturing.

2.500 kW at 77 rpm (37.000 kg mixer drive weight).

Rubber mill drive 2500 kW at 77 rpm

Rubber mill drive 2500 kW at 77 rpm

Steel Pipe Drawer Drive

Friday, May 21, 2010

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Steel pipe drawer drive including chain driving pinion, 220 kW – 2 rpm – 150 ton thrust (weight 63.000 kg).

Tube extruder drive including chain drive starwheel, 220 kW – 2

Screw Down drives

Friday, May 21, 2010

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Worm screw gear set  for screw down drive; 970 mm center distance, ratio 29.5. 87 tons total assembly weight,  including support frame, auxiliary equipment, breaks, auxiliary gear motors, etc.

Screw drivesScrew drives

Hot strip mill main drive

Friday, May 21, 2010

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Hot strip mill main drive.

2.000 kW  Power – 20 rpm

Hot sheet mill drive

Crop Shear Drive

Friday, May 21, 2010

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Galbiati Group designed and manufactured large crop shear drives.

The figure shows a 1.600 kW at 27 rpm crop shear drive, max 6.000 kNm torque. Total unit weight exceeds 160 ton.

NiCrMo Output gear wheel, double helical ISO-DIN quality 6 finish, 600 + 600 mm width, m 32, more than 3 m outer diameter, total weight 40.000 kg approx .

Crop Shear Drive

Crop Shear Drive

Crop Shear Drive

Tilting converter drives/Steel Industry

Friday, May 21, 2010

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350 ton tilting converter drive unit, four motor driven , 2.500.000 Nm (peak torque).max. transmitted torque.

NiCrMo steel ring bull gear, welded under controlled pre-heating and cooling procedure on electrowelded carbon steel frame; spur teeth 3.900 mm, module 20, induction hardened, 50 – 55 HBn surface hardness .

Tilting converter drives/Steel Industry

Integrated pinion stand mill drive for special alloys

Friday, May 21, 2010

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Galbiati Group design and manufactured a complete integrated pinion stand mill drive for special alloys milling (silica, tungsten, vanadium, etc.) for an Austrian customer. The plant consists of a reversible mill stand driven by an integrated pinion stand mill drive, equipped with two pinions meshing together on a center distance just less than 1 m, running at 50 rpm. The input shaft is connected by a toothed coupling to two motors in series, with a total power of 2.400 kW at 195 rpm. This provides a transmissible torque of approximately 460.000 Nm with a suitable service factor, or a nominal torque that greatly exceeds 1.000.000 Nm.

Integrated gear reducer-pinion stand unit for special alloysIntegrated gear reducer-pinion stand unit for special alloys

Integrated pinion stand mill drive for special alloys

Assembly of the integrated pinion stand mill drive for special alloys.

The basic engineering and the detailed design, such as the nominal torque and minimal center distance between pinions (960 mm) as consequence of the maximum inclination of the spindles between the gear drive and the mill stand rolls, were technical challenges resolved positively thanks to many years experience in high-power mechanical transmission design, modern instruments for structural analysis and, above all, thanks to FEM (Finite Element Method) analysis.

The mill drive consists of reducer high speed pinion – gears set and a double helical carburized and ground output pinion set. The low speed gear wheel, about 2.600 mm approx. diameter, was built using two toothed wheels fitted to the intermediate pinion, each with single helical wheel slightly less than 600 mm facewidth . The intermediate pinion is unique as it reaches a total length of slightly more than 5 meters, with different diameters in the various sections, with a maximum diameter of about 1.000 mm. Manufacturing of the intermediate pinion, requires all of our most modern technology and largest equipment. We even needed to modify the only existing largest carburizing furnace in Italy in order to house, restrain and support such a long part.

Furthermore, due to the high length/diameter ratio, and therefore the consequent bending due to the radial loads, a third hyper-static shaft support was required. This caused the need for very high precision machining of the 2+1 holes to allow the three bearings centers to be on same line.

Once again Galbiati Group solved the problem by machining the entire housing on its high precision CNC boring machine, equipped with a rotating table for loads up to 120 ton. The result is an integrated pinion stand mill drive with an overall weight of more than 170 ton: electrowelded, high rigidity, steel housing; carburized and high-quality ground gears and pinions; radial and thrust bearings, primary brands; forced feed lubrication system piping and fittings mounted on drive.

At the end of July 2008 the drive was successfully tested at Galbiati Group workshop in the presence of the customer and the end-user, both of who were fully satisfied. Equipment like the drive described above has made Galbiati Group the benchmark supplier on the European and World markets for the design and manufacture of cutting-edge metallurgical and mechanical engineering products. In a stagnant period for industrial investments, such as we are now experiencing, Galbiati Group pays as much attention as possible to innovation and high-tech production which have become the only solution for global competition.

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Galbiati Group - Engineering & Machining

23848 Oggiono (Lc) Via Cà Bianca Pascolo, 26 Italy | Fax +39 341.2633300 | s.origgi@galbiatigroup.it
P.Iva: 03301540963 | Capitale sociale: 500.000 euro | REA: MI-1665349
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