Modern drive technology with hydrodynamic couplings in belt conveyor and AFC drives

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Modern drive technology with hydrodynamic couplings for Coal-Mine Applications

Klaus Maier

Head of Constant-fill Fluid Couplings

Voith Turbo GmbH & Co. KGProduct Group Startup ComponentsSouth African Colliery Engineers Association

Technical Symposium, April 2006

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Abstract

•Principle of Hydrdynamic Couplings•Research and Development•Conveying technology for belt conveyor drive•Taks of Conveying Technology for AFC drives•Tasks for Crusher drives•ATEX•Latest Development•Summary

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VoithPrinciple of Operating– Hydrodynamic Couplings

Hydro → waterDynamics → Theory of drive

and energy

Hydrodynamics=

Fluid ernergy

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Princip of Hydrodynamic Couplings

Pump WheelPump Wheel Turbine WheelTurbine Wheel ShellShell

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Princip of Hydrodynamic CouplingsThree variables which determine a fluid coupling’s rating:

1. Motor Speed

2. Runner D

iameter

3. Oil Fill Level

PumpWheel

TurbineWheel

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Princip of Hydrodynamic Couplings

2P

5PDT ω⋅⋅ρ⋅λ=

K

D

TT

ϕT

TP

ϕP

ΘP ΘT

Pump side Turbine sideVTC

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Research and DevelopmentOperating Fluids

Mineral Oil

Water

Phosphate Esther

Synthetic Oil

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Research and DevelopmentProfiles optimized for constant torque

0

0.5

1

1.5

2

2.5

3

020406080100 s / %

λ*103

0

0.5

1

1.5

2

2.5

3

020406080100 s / %

λ*103

0

0.5

1

1.5

2

2.5

3

020406080100 s / %

λ*103

Stepped Profile Stepped Profile with Plate Mixed Profile

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Conveying technology for belt conveyor driveRequirements to be met by the drives

• Unloaded motor start• Utilisation of economically priced, • low-maintenance squirrel-cage motors• Smooth build-up of starting torque up to

break-away of the belt conveyor • Limitation of maximum torque during

start-up • Adaptation of the start-up torque to the

prevailing load condition• Reduction of longitudinal oscillations of

the belt

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Conveying technology for belt conveyor driveRequirements to be met by the drive units

• Load adaptation with multi-motor drives• Staggered activation of the motors with

multi-motor drives, in order to avoid a summation of inrush currents

• Easy handling and compact design• Low-wear and low-maintenance operation• Possible use of water as operating

medium, especially for underground mining applications

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Conveying technology for belt conveyor drive•• Motor current greatlyMotor current greatlyreduced during accelerationreduced during acceleration

•• TorsionalTorsional vibration significantly reducedvibration significantly reducedvia hydrodynamic actionvia hydrodynamic action

•• Voith Couplings protects drive components Voith Couplings protects drive components by limiting max. torque transmitted duringby limiting max. torque transmitted during““JAMJAM”” conditioncondition

•• Voith Couplings limit peakVoith Couplings limit peakacceleration torque acceleration torque to 140 % or lower!to 140 % or lower!

•• Voith Couplings eliminate high stresses Voith Couplings eliminate high stresses by gently accelerating equipment with by gently accelerating equipment with controlled torque responsecontrolled torque response

•• Unloaded motor startUnloaded motor start

•• Effective load Effective load shringshringfor multiple motor drivesfor multiple motor drives

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TT

TVTV

TVVTVV TVVSTVVSMotor Motor torquetorquecurvecurve

Peak Torque = 140 %!!Peak Torque = 140 %!!

Conveying technology for belt conveyor drive

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Conveying technology for belt conveyor driveTVVS

0

250

500

750

1000

1250

1500

0 10 20 30 40 50 60Zeit [s]

torq

ue[N

m]

ou

tput

spee

d[1

/min

]

0

25

50

75

100

125

150

tem

pera

ture

[°C

]

load torque 800 Nm load torque 500 Nm load torque 300 Nm

output speed [1/min]

temperature [° C]

Coupling torque [Nm]

conveyor simulation with various load torques

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Conveying technology for belt conveyor driveFill Controlled Coupling

Figure 10

Tuned PID Tension Loop

TPKL

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Conveying technology for belt conveyor drive

Site: Lignite Mine, IndonesiaConveyor data:•length: 2060 m•capacity: 1600 t/h•belt speed: 3.8 m/s•drive configuration: 1 drive at head pulley•motor power: 1 x 500 kW at 1480 rpm•coupling type: 750 TVVS•commissioning: 1996

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Conveying technology for belt conveyor drive

Site: Coal Mine, New MexicoConveyor data:•length: 2100 - 3000 m•capacity: 6500 t/h•belt speed: 4.5 m/s•drive configuration: tripper drive, 3 drives at head pulleys, 3 drives at booster pulleys

•motor power:6 x 560 kW at 1780 rpm

•coupling type: 650 TPKL•commissioning: 2002

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• Regular asynchronous motors• Relieved run-up of the motor• Vibration-reducing• Vibration cutting function• Torque reduction• Protection of the drive and the equipment• Load compensation / sharing

Conveying technology for belt conveyor driveAdvantages

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Conveying technology for belt conveyor driveAdvantages - Load Sharing

• different motor curves

• installation of Turbocouplingreduces the difference

• increase torque of motorby slip reduction of coupling 1

• reducing torque of motorby slip increase of coupling 2

connected ridgedly

lead to big differences in torques

M

∆Mcoupling∆Mstiff

Mload

n2 with coupling

increasefilling F1

reducefilling F2

fillingF1 = F2

M1 M2

n synchronn1

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Tasks of Conveying Technology for AFC drivesRequirements to be met by the drives

• almost load-free start-up of the asynchronous motors• sequential start of the individual drive at multi-motor drives• automatic torque limitation on start-up,

no stalling of the motor over pull-out torque smooth, quick torque build-up on the chain

• torque build-up against blocked conveyor and holding of the motor pull-out torque

• repeated start-ups without thermal problems

• clockwise and counter-clockwise running of the conveyor to release blockages

• automatic load sharing• simple control

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Tasks of Conveying Technology for AFC drivesRequirements to be met by the drives

•very high thermal capacity•possibility of inspection run/creep speed

•chain tightening in connection with a locking brake

Additional requirements of the drive unit , particularly with AFCsof higher output:

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Type TVVFSType TVVFType TVF

Tasks of Conveying Technology for AFC drives

The Turbo Coupling type TVF is usually used with lower drive outputs. The Turbo Coupling type TVVF (with enlarged delay chamber) and TVVFS (with additional annular chamber) offer

• an even better relief of motor during startup• a higher thermal capacity

and are therefore particularly used with higher drive outputs.

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Tasks of Conveying Technology for AFC drives

Motor characteristic curve

at nominal voltage

Motor characteristic curve

at voltage drop

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Tasks of Conveying Technology for AFC drives

•closed loop for minimum water consumption

•optional with external cooler

•very high thermal capacity

•automatic load compensation

•creep speed•defined chain tensioning

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Tasks of Conveying Technology for AFC drives

Coal Mine, Poland

Driven Machine: •AFCMotor power: •200 kW at 1480 rpmCoupling type: •562 TWVVF

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Tasks of Conveying Technology for AFC drives

Coal mine, Yanzhou Group, China

Driven Machine:•AFC 1 head and 1 tail driveMotor power:•2 x 700 kW at 1490 rpmCoupling type:•562 DTPKWL2

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Advantages

1. Load free motor start-up

2. Optimum protection of squirrel cage motor

3. Full use of the pull-out torque of the motor

4. Starting the AFC-drive under voltage drop conditionsAdditional for fill-controlled couplings

5. Ramping of a AFC-start

6. Creep-speed.

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Tasks for Crusher drivesRequirements to be met by the drives

•Relieved motor run-up

•Star-Delta control

•Overload protection

•Vibration damping

•Shock absorption

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Tasks for Crusher drives TVS_X

15 % higher heat capacitythrough S-chamber

10 % better heat dissipationthrough larger surface

lower noise levelspec. sealing for high temperature

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Tasks for Crusher drives

Coal Mine, China

Driven Machine:•Stage Loader

Motor power:•400 kW at 1480 rpm

Coupling type:•650 TUWVF

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Advantages

1. Load free motor start-up

2. Overload protection

3. Shock absorption

4. Vibration damping

5. For heavy-duty environmental conditions

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ATEX

Zone 2

Zone 0

Zone 1Zone 0

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ATEXAreas subject to explosion hazards are divided into zonesdepending upon the degree of risk

Zone 2

Zone 0

Zone 1

Presence of hazardous explosive atmosphere

infrequently and for short periods

in normal operation

no active sources of ignition

continuously or for long periods

in normal operation and rareincidents of malfunctioning andin the event of two independentfaults

occasionally in normal operation and in the event of frequently occurring disturbances

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ATEXDifferent safety standards - different adaptations of couplings

Standard of safety„German“ „British“

Operating fluid water/emulsion water/emulsionsynthetic oil 1) synthetic oil 1)

Material Silumin (Al) cast iron (GGG)

1) Sometimes mines also use mineral oil

Voith Turbo Couplings are in particular adapted to operating fluid water.• Material and surface treatment to avoid corrosion• sealings, lubrication to ensure long service time with low maintance

requirements

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For many years Voith Turbo couplings are reliably used in explosion hazardous areasaccording to latest ATEX 100a regulations the product has been verified especially with regard to the new safety requirements for explosion protection of mechanical componentsVoith Turbo couplings are specially adapted for the use in different explosion hazardous areas and various drive applications

Latest DevelopmentATEX

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W ire le ss S en so r

S ta tio n ary A n ten n a

S ign a l P ro cess in g U n it

W ire le ss S en so r

S ta tio n ary A n ten n a

S ign a l P ro cess in g U n it

Latest DevelopmentBTM

Advantage

•Permanent Check

•Process SystemOptimization

•Less brake downs

•Heigh operatingtimes

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Latest DevelopmentTurboSyn - Functional principle of the World-wide Voith Patent

Advantages

• Lowering operating express

• Increase of speed

• Increase of output power 3 % - 10 %

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Latest DevelopmentTurboSIM

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Summary

• The Hydrodynamic Coupling is a MODERN and COST-advantage drive element

• It is robust• It ist easy handling equipment• It is easy forgiving• It reduce segnificant the downtime• It has World wide Service• The Hydrodynamic Coupling, it is a MUST

Nowadays it is no longer only important to offer good drivecomponents, it is to integrate them in the Task Drive!

Voith has the Know How

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