Introduction to the Bogiflex drive:

Kiln Gear Drive 20

HGRS/MER
 General information about the Bogiflex
Holcim has developed a project together with CMD to
make the Bogiflex kiln drive reliable
The Bogiflex should solve the current following issues:
Low kiln speed (new max speed 4,5 rpm)
Impact of the process conditions (thermal expansion)
Impact of the kiln deformation
Natural frequency in the drive
Poor lubrication of the girth gear
The first Bogiflex drive will be tested in 2007 at the San
Sebastian plant
At that stage of the project, the design of the Bogiflex
should be the same for all kilns with a inner shell
diameter between 4.0 m up to 4,6 m.
Overview 2
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Bogiflex displacements: The meshing on the girth
gear is optimum and constant
Axial Radial

How is it working? 3
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Bogiflex: Main components
Spring plates
Girth gear
Bogi-pinion
Torque arm
Primary gearbox
Baring unit
Lubrication unit
Housing & Sealing

New technologies

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Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Design approach (must be confirmed)
Single motor (420 kW, 1000 rpm)
with VFD
Girth gear and pinion:
340/23 teeth, module 20, helix angle = 0,
pressure angle=20
T shape girth gear (almost identical):
adjustment of the web height
Spring plates set
Floating gear set: 560HD
72/30 teeth, module 11, helix angle = 0
Standard Reducer:
Ermaster R2HC40 with a speed ratio of 7.15
Universal joint and reaction arm
Two lubrication units and one baring
unit
Comparison with SB Could be different 5
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Design approach: pre-requisite data
Operating values (Power(kW) and associated kiln speed
(rpm)):
During stable condition
During high filling degree operation: ring(s) in kiln
Temperature (average, max) at:
The girth gear meshing
The close tire and rollers
The shell underneath the girth gear
Drawings of the kiln with the shell thickness and tires,
the present drive, the pier (with cross section)
Axial moving range of the kiln

6
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 General figures (must be confirmed)
New kiln capacities
3.9 rpm at 50 Hz
4.6 rpm at 60 Hz (power calculated with the B. Saxer
formula)
The production rate is increasing proportionaly to the
speed until the kiln speed is the bottleneck of the line
Cost approach:
Bogiflex KGD20 incl. CMD supervision and inspections (3
years): ~600 kEuro
New motor with VFD: ~110 kEuro (250 Euro/kW)
Monitoring of the KGD20: ~30 kEuro
Foundation modification and steelwork (local): ~40 kEuro
Erection cost: same as a girth gear replacement
Erection time: ~2 weeks in the critical path of the shutdown

7
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 The new type of spring plates has better
performance

8
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 New housing design to avoid oil leakage

9
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 The floating gearbox follows all the movements of
the girth gear
girth gear

internal roller

bearing 1

LS pinion

U joint

concentric
roller
primary drive
wheel
bearing 4

bearing 2

concentric roller bearing 3

primary drive
pinion

10
Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 The position of the reaction arm is always pushing
the pinion against the girth gear
Torque arm Rollers on the pinion (rings) support the load, keep the tip-to-root
Force Pushing effect clearance constant and drive the position of the floating gear set

Girth gear / pinion

Meshing reaction of the

wheel to the pinion

Position of the torque arm

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Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Axial displacement
Cardan keeps distance between the pinion and the reducer
The bogi-pinion follows the girth gear and displaces the floating
gearbox
The floating gearbox moves on its pinion

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Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt
 Application Overview
Power of PC4, PC5 and PC6 kilns related to the shell diameter
Installed Power Calculated power 4.5 rpm Power (Installed Power) Power (Calculated power 4.5 rpm)
2'800

2'600

2'400 SMALL MEDIUM

KGD 20 ?KGD 26?
2'200

2'000

1'800 ~10'000 t/d

1'600
kW

1'400
~8'000 t/d
1'200

1'000
~6'000 t/d
800

600 ~4'500 t/d

400
~2'500 t/d
200

0
3.6 3.8 4 4.2 4.4 4.6 4.8 5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6
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Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
Bogiflex_KGD20.ppt