Products

CEMENT INDUSTRY, POWER PLANTS

Requirements

Employed primarily in the cement industry and in coal-fired power plants, vertical mills are used to grind lime stone, clinker brick, and coal. The bevel gears used in these grinding processes are not only subjected to tremendous impact loads and environmental loads, they must also exhibit a high degree of efficiency in order to reliably ensure a continuous power transmission of up to 6,000 kW.

Solution

From the initial calculation and design of the gear sets all the way to practical simulations and production, Klingelnberg offers its customers just the right gear solution for these special applications. As early as the design phase, Klingelnberg makes provisions for easy disassembly in order to ensure short downtimes during the required maintenance operations. This further increases equipment uptime, and with it the availability of the entire production chain.

THE KLINGELNBERG ADVANTAGE

  • World's largest, most modern production facility for large bevel gears in Hückeswagen, Germany, operated according to lean production and lean management principles.

  • Cost-optimized production based on lean management principles.

  • Certification to DIN EN ISO 9001 / DIN EN ISO 14001.

  • Unsurpassed expertise in the calculation, configuration, simulation, and optimization of bevel gears.

  • State-of-the-art monitoring of the heat treatment process in company-owned hardening shop.
  • Oerlikon Spiral Bevel Gear Cutting Machine C 300, the world's largest bevel gearing machine for dry-machining of large bevel gears with ring gear diameters up to 3,000 mm.

  • Gearing loops for bevel gears with ring gear diameters up to approx. 1,000 mm.

  • Closed-loop method for every process step guarantees transparency and documented quality for every phase in the manufacturing process and enables cost-effective production in batch size 1.

  • Extensive measuring devices for determining and documenting the macro and micro geometry, also for large components.
  • Systematic use of Klingelnberg's KIMoS calculation software in all process chain steps relevant for gearing.

  • Optimal bearing pattern geometry through surface modifications, taking account of in-process displacements in the bevel gear stage.

  • Determination of in-process displacement parameters of a bevel gear set through static and dynamic analysis of the complete system.

  • Digital documentation of all production data.