01 Polycom Design-Overview

Page 1 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.
ppt
POLYCOM Design Overview
Dipl.- Ing.
Wolfgang Partsch
Page 2 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.ppt
General Overview
POLYCOM material bed compression
Pressure curve
Max. Pressure Start of compression (nip line)

Compression zone
Grinding force End of compression
Cake
Fixed roller unit Feed hopper
Frame extension for

exchanging roller units Inspection platform
Torque support
system Piston accumulators
Cardan shaft with

safety coupling
Grease lubrication unit
Gear box
Floating roller unit

Motor
Inching drive Hydraulic
cylinder
Hydraulic tank
General overview
Planetary gear Feed material

Motor
Floating grinding roller
Fixed grinding roller
Frame
Shaft
Bearing
Ground material
Piston accumulators Hydraulic system

Greasing system
Fully Assembled Polycom
Upper Beam Feed Hopper
Cardan Shaft
Floating Roller Unit
Gearbox
Gear oil water cooling floating roller
Frame Construction
Transverse Beams
POLYCOM Frame
Pressure Beams Upper Boom
Hydraulic cylinders
Slide plates
Base Frame with stiffening plates Feather Keys

Feed Hopper
7 Feed hopper
5
1 1. Feed Hopper
2. Adjusting shaft
4 3. Grinding material guide
4. Inspection door
2
5. Hopper inlet
6
6. Hopper outlet
3
7. Load cell
Feed hopper
Short cut to GrundrahmenA.mpg.lnk
Hopper can be removed

with
I-Beam suspension
Feed hopper
Load cell
Manually adjustable
guide plates
Control of
de-aeration
Control of feed material

The adjusting tongues
2.1 Side wall
2.2 Wear protection (side wall)
2.3 Inspection door
2.4 Spacer
2.5 Cover
2.6 Fixing traverse
2.7 Transport aid
2.10 Adjusting tongue
2.20 Position indicator
2.25 Isolating slide valve
2.32 Proximity switch
2.33 Seal for hydraulic cylinder

Feed Hopper wear protection
Upper part: - Eurodur 3600 (8 mm)
Vertical walls: - Compound steel plate (5+3 mm)
Inclined walls: - Compound steel plate (8+4 mm)
Adjustable Shaft: - Compound steel plate (6+4 mm)
Material guide plates and inner side of support:

- Compound steel plate (15+5 mm)
Adjustable guide plates:

- Compound steel plate (10+5 mm)
Hard metal mosaic

Cheek Plates
Replaceable Cheek Plates




Cheek Plates in new and in worn out condition

New Cheek Plates design for CERROWAL with pasted Hard Metal plates
Revised Cheek Plates design for CERROWAL with soldered Hard Metal plates
Additional Edge
Block protection
Polycom Hydraulic
Polycom Hydraulic
• Great reliability
• Simple functioning
• Few possible faults
• Little commissioning work
• No additional cooler for pressure

regulation and parallel gap control
POLYCOM Hydraulic System
U Pressure Transmitter
P
U
Push back P
Slide Gate Solenoid Valve
Cylinders
Cylinders
Piston Accumulator
Hydraulic Cylinder
Main Cylinders
U
P
M Hydraulic
Pump
Hydro-pneumatic Spring System
Hydraulic Piston
Accumulator
Adjustable
Hydraulic Mechanical stoppers
Nitrogen Cylinders
Hydraulic Oil
Adjustable
throttle valve
Non-return
valve
Movable Roller Unit Fixed Roller Unit

Adjustable mechanical stoppers

Push back cylinder for floating roller

Lubrication System
Central lubrication unit with pneumatically driven barrel pump
Control unit 8.1 Barrel pump
8.2 Ball valve
8.3 Maintenance unit
8.4 Pressure switch
8.5 Throttle valve
8.6 Solenoid valve
8.7 Filter unit
8.8 Solenoid valve
Compressed-air station 8.9 Solenoid valve
8.10 Grease distributor

1 - 4 Lubrication points for roller bearing
8.11 Grease distributor
5 - 8 Lubrication points for guide rails
8.12 Pump bracket
Central lubrication compressed-air station
Compressed-air Compressed-air
from the mine to grease pump
3 1 5 13 4
Legend: 1 Maintenance unit with condensate trap and dust separator

3 Ball valve, 2/2-way
4 Solenoid valve, 3/2-way
5 Throttle valve, adjustable
13 Pressure switch 2-20 bar, set to 2 bar
Central lubrication control unit

Grease to guide rails
7 Floating Roller left
2
Grease to guide rails

Floating Roller left
Proximity switch
Grease from For rail lubrication
grease pump
Grease to bearings
Fixed Roller
Proximity switch
For bearing lubrication
3 4
Grease to bearings
Floating Roller
Legend: 2 Filter
3 Solenoid valves, 2/2-way, for Bearing and Guide Rail lubrication
4 Distributors for Bearing and Guide Rail lubrication
7 Pressure Gauge 0-250 bar
Central lubrication control unit
Pressure Gauge
Filter
Grease from grease pump
Solenoid for guide rail lubrication

Solenoid for bearing lubrication
Distributor for bearing lubrication
Distributor for guide rail lubrication

Polycom Roller Units

Polycom Roller Unit

102 tons on the hook
at just one Roller Unit
Cerro Verde site
Polysius workshop
POLYCOM - Roller unit components

Shaft
Bearing
Tyre
Roller
Bearing Block
POLYCOM - Roller unit components
Roller
Self aligning Bearing

Polycom - Roller unit components
Studs
Edge Blocks
Shaft
Tyre
Side face protection segment,
plug-welded
Polycom - Roller unit components
Bearing Block
Bearing
Polycom Bearings
Polycom bearings
Polycom bearings
Self Aligning Roller Bearings

with seal arrangement:
+ grease lubricated
+ minimum no of parts
+ easy assembly/disassembly
+ large inside diameter allows bolting of
reducer to shaft
- relatively large diameter

(requires rolls with small L/D ration)
Self-aligning roller bearings
+ Uniform distribution of the load onto both rows of rollers
+ No edge compression pressure if the grinding rolls are not parallel or if the
shaft bends
+ Easy to guide the roll in the frame. No special mechanics necessary for tilting
the bearing blocks
+ No separate axial bearing is required
+ Higher safety factors are possible for the shafts, due to larger bearing diameter
+ Larger bore diameter allows for flanged shaft connection.

Bearing seals
Bearing seals
Self Aligning Roller Bearings

with seal arrangement
Grease inlet
Grease direction
Grease outlet
Bearing seals
Grease inlet
Grease direction
Grease outlet
Bearing seals
Grease direction
Grease outlet
Polycom Cooling
Polycom Bearing Block Cooling
Legend: 3 Slanted sear sleeve valves

5 Dirt traps, filtration grade 0.25 mm Cooling water in- and outlet points
Polycom Shaft Cooling
process heat
+ Cooling of the shaft at the bearing blocks
+ no weakening of the shrink fit between tyre and shaft to ensure

maximum safety during transition phases in the grinding process
Polycom Gear Oil Cooling

Water - Oil Cooler
with Double Filter

Air - Oil Cooler with double filter

Polycom Drive
Polycom with drive unit

Drive unit
9.1 Motor
9.2 Cardan shaft
9.3 Universal joint shaft flange
9.4 Safety coupling
9.5 Gear unit
9.6 Oil cooler
9.7 Torque stay arm
9.10 Coupling bar
9.12 Lever
9.14 Connection to the rolls
9.15 Auxiliary drive
9.16 Auxiliary motor
9.18 Protection of Cardan shaft
9.19 Gear unit protection

Drive unit
9.1 Motor
9.2 Cardan shaft
9.3 Hub to the motor for chain drive
9.4 Safety coupling
9.5 Gear unit
9.15 Auxiliary gear unit
9.16 Auxiliary motor
9.17 Chain
9.18 Cardan shaft guard
9.23 Bracket
9.24 Limit switch for cardan shaft guard

Polycom Gear box connection
Shrink
Key Disc
Keys
Location for dismantling

Gear box connection

Gear box connection
View from motor side
Shrink Disc
View from Polycom side

Gear box connection
Shaft with central key Intermediate flange with 2 keys

Gear box connection
Shaft with
groove
Shrink fitted
into gear box
Load fluctuation
10.000 Reducer
Torque [kNm]
1.000
100
1E-06 0,00001 0,0001 0,001 0,01 0,1 1 10 100
time [h]
Load fluctuation (design) Load capacity Load fluctuation (measured)
Life time calculation
Load fluctuation against time

90% operating time with 1.0 x rated motor torque
10% operating time with 2.0 x rated motor torque
1 load per hour with 4.0 x rated motor torque
Reducer
Gear box calculation according to DIN ISO 3990

kA = 2.3 application factor related to installed
motor power
sH  1.0 safety against pittings
sF  1.4 safety of teeth
Operating factors
SHB = kA · sH2  2.3 operating factor tooth flank
SFB = kA · sF  3.22 operating factor tooth root
Results: Bearings  50,000 h Reducer: no fatigue limit

Polycom planetary gearbox

Cylindrical
gear stage, adjustable
Torque
transmission
Shrink disc Planetary Planetary

stage 2 Stage 1
Polycom Cardan Shaft

with
Safety Clutch
Polycom cardan shaft with safety clutch
Safety Clutch
Polycom safety clutch
84
69.6
Safety Coupling - Torque Limiting



POLYCOM Design Overview
Questions?
Dipl.- Ing.
Wolfgang Partsch

01 Polycom Design-Overview

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Page 1 PartschW 16 Nov 2007 I:\Daten\PartschW \Training\POLYCOM\Presentation\1 Polycom Design-Overview.

POLYCOM Design Overview

POLYCOM material bed compression

Max. Pressure Start of compression (nip line)

Grinding force End of compression

Fixed roller unit Feed hopper

Frame extension for

Cardan shaft with

Grease lubrication unit

Floating roller unit

Planetary gear Feed material

Fixed grinding roller

Piston accumulators Hydraulic system

Fully Assembled Polycom

Upper Beam Feed Hopper

Floating Roller Unit

Pressure Beams Upper Boom

Base Frame with stiffening plates Feather Keys

4 3. Grinding material guide

Hopper can be removed

Control of feed material

The adjusting tongues

2.1 Side wall

2.2 Wear protection (side wall)

2.3 Inspection door

2.6 Fixing traverse

2.7 Transport aid

2.10 Adjusting tongue

2.20 Position indicator

2.25 Isolating slide valve

2.32 Proximity switch

2.33 Seal for hydraulic cylinder

Feed Hopper wear protection

Upper part: - Eurodur 3600 (8 mm)

Vertical walls: - Compound steel plate (5+3 mm)

Inclined walls: - Compound steel plate (8+4 mm)

Adjustable Shaft: - Compound steel plate (6+4 mm)

Material guide plates and inner side of support:

Adjustable guide plates:

Hard metal mosaic

Replaceable Cheek Plates

Replaceable Cheek Plates

Replaceable Cheek Plates

Replaceable Cheek Plates

Replaceable Cheek Plates

Cheek Plates in new and in worn out condition

Replaceable Cheek Plates

Replaceable Cheek Plates

• Few possible faults

• Little commissioning work

• No additional cooler for pressure

POLYCOM Hydraulic System

Hydro-pneumatic Spring System

Movable Roller Unit Fixed Roller Unit

Adjustable mechanical stoppers

Push back cylinder for floating roller

Central lubrication unit with pneumatically driven barrel pump

Control unit 8.1 Barrel pump

8.2 Ball valve

8.3 Maintenance unit

8.4 Pressure switch

8.5 Throttle valve

8.6 Solenoid valve

8.7 Filter unit