: . : Mechatronics - Crystalliser : . :

Crystalliser Drives

Low Power Consumption
High efficiency planetary transmission ensures at least 60% reduction in installed power as compared to the conventional worm gear system.

Shaft Mounting Construction
Compact, single unit, shaft mounted drive configuration goes directly on the Crystalliser shaft. No couplings, bulky foundation, and base frames are required.

Longer Life
Enclosed construction ensures uniform lubrication of rotating elements and results in longer life.

Reduced Maintenance Cost
Routine maintenance is limited to re-lubrication, that too once a season.

Dynaspede offers easy-to-fit, shaft-mounted Magtorq Crystalliser drives rated up to 7.5 HP, and for output speeds 1 to 0.3 RPM to cover the standard range of horizontal Sugar Crystallisers of capacities 45 T to 100 T, and vertical crystallisers up to 300 T capacity. Developed after an in-depth study of typical Crystalliser installations, the Magtorq Crystalliser drive employs high efficiency spur and helical gearing instead of conventionally used worm gearing. The overall efficiency of Magtorq Crystalliser drives is 90%, leading to optimal use of the installed motor rating, which results in sizable power savings.

The drive arrangement consists of an electric motor, a multi-stage planetary gear reducer and a single-stage helical gear transmission. The electric motor is flange mounted to the input of the planetary gear reducer, which in turn is flange mounted on the input of the helical gear transmission. The hollow output shaft of the helical transmission can be keyed directly onto the Crystalliser shaft. The drive unit can be aligned in a convenient direction with respect to the Crystalliser axis, and its torque arm structure bolted at the convenient place. No other additional structures such as base frames or any couplings are required. The drive unit is completely enclosed and oil-tight. All internals including bearings are oil-lubricated, and oil change is recommended only once a season.

Crystalliser

COMPARISON OF MAGTORQ DRIVE WITH OPEN TYPE WORM AND WORM WHEEL

ARRANGEMENT FOR CRYSTALLISER APPLICATION

	Open type Worm and Worm Wheel arrangement	Magtorq Crystalliser Drive
Motor rating	Generally motor ratings will be from 10 to 30 HP	Maximum motor rating will be within 7.5 HP
Efficiency	Highly inefficient; losses in the gear system are very high and efficiency very poor and going down to 30%	Efficiency is very high – about 90%
Labor requirement for operation while the gear unit is running	As gears are open type and hence one person is always required to attend the oil filling	As the unit is totally enclosed, no need of frequent oil filling. Oil to be changed only once in a season
Cleanliness	The surrounding area is very unclean due to oil overflowing	As there is no oil overflow; surroundings will remain clean and free of oil spread
Operation by hand during power failure	Very difficult to rotate it by hand	Very low power is required and one person can rotate the shaft easily
Alignment-related problems	Due to wear in the bush bearing provided in the crystalliser shaft, the worm wheel tends to bend downward and sit on worm shaft, adding to the load and reducing life of worm and worm wheel. Also, one coupling is required between the motor and worm gear unit, which needs to be aligned properly	Since the entire gear unit is mounted on the crystalliser shaft (weight of the total gear unit is less than weight of the worm wheel), wear of the bush does not pose any problem. With no couplings and base plates, alignment-related problems are unlikely
Annual Maintenance	Generally motors and gear units are dismantled and bearings are changed during off-season. This is a major involving a high cost	No special annual maintenance is needed. Maintenance is limited to only changing the oil once in a season
Life of the gear unit	Since the gears are the open type and the surroundings are dirty due to overflowing of Massecute, life of the gear unit life is short. Higher frictional losses, improper gear meshing, contamination in lubricants etc reduce the gear life	Totally enclosed construction ensuring continuous lubrication, and there is no scope for entry of foreign material inside the gear unit, which extends the life of the gear unit

MAGTORQ CRYSTALLISER DRIVE
TYPICAL ARRANGEMENT

An ISO 9001:2008 Certified Company