Gearboxes

BOGIFLEX

PRESENTATION

The BOGIFLEX is a floating (shaft-mounted) reduction gear with self-adjusting transmission(s) that allows the reduction of contact surface defects that occur in standard gear trains where the gears rotate in fixed bearings. This means that it is perfect for harsh environments such as high temperatures, severe shocks, deformed materials, vibrations, flexible bearings, etc. ...flexible bearings.

The BOGIFLEX allows the transmission of high torques at low speeds and has an extremely wide reduction range.

PROPERTIES
The range: 12 different sizes (from BFT6 to BFT28)
High torque range: up to 10 000 kNm.
Reduction ratio: up to 10 000.
Weight: Up to 50 tons.

APPLICATIONS

Steel industry : Converter (LD, AOD, ...), Steel ladle drive, Torpedo cars, Sintering line, Sinter crusher, Restraint systems ...

Heavy cylindrical furnaces : furnaces and converters for copper, nickel, cement, coal and various dryers...

Sugar industry : vertical diffusion tower (sugar beet), horizontal diffusion (sugar beet, sugar cane).

Heavy lifting : crane drums.

Mines, excavation : bucket wheel and bucket excavator.

Special drives with 0 clearance : large radars.

ADVANTAGES

Pressure and tension spread automatically over the teeth.
Absorption of energy caused by shocks and/or control of torque variation by means of: torsion bar and / or shock absorber (mounted on the shaft)
Smaller dimensions (module, volume) and lower weight.
Possibility of using one or more pinions per drive.
Possibility of a very wide passage of the slow-running shaft (use of a gear rim).
Possibility of a large passage of the hollow shaft (use of a wheel with hub).
Ability to absorb high short-term overloads.
Adaptable flexibility according to the application (shocks ...).
Can withstand bending, runout (up to 150 mm already observed!), displacement or deformation of the driven axis.
Numerous options (electronic control / preventive maintenance / safety devices).
Separate components for assembly - easier to ship and install on site.

CANEFLEX

CANEFLEX: CANEFLEX: REDUCTION GEAR UNITS FOR SUGAR TUBE MILL DRIVES


PRESENTATION


The CANEFLEX is a gear unit specially designed for driving sugar cane mills.
The new CANEFLEX Neo design replaces the former CMD CANEFLEX gearbox, which was developed in 1996 for output torques from 1300 to 2800 kNm and power ratings from 500 to 1800 kW.

ADVANTAGES

- High efficiency and availability
- Minimum maintenance
- Easy access to all gear stages in less than half an hour without changing the gear configuration during inspection
- LS shaft and bearings designed to withstand tail beam coupling effects
- Shock absorbing tooth engagement force compensation by elastically supported output sprocket
- Measurement and monitoring of the output torque absorbed by the mill

TECHNICAL DESCRIPTION


- Input speed up to 1800 rpm
- Gear ratio up to 500 : 1
- Bearings with a calculated life of L10h > 120 000 h according to ISO 281
- Integration of a CMD helical gearbox as primary CANEflex Neo gearbox to achieve gear ratios of more than 1000:1 in case of a turbine

ERMASTER

CMD has developed the new ERmaster range of gearboxes for driving heavy industrial machinery under tough operating conditions. This new generation meets customer requirements in every respect:

  • low noise emission

  • utmost availability

  • reduced maintenance costs

In the basic version from size 48 upwards, the gearboxes have two shaft ends on the actuator. They have a 2, 3 or 4-stage design with gear ratios from 6.3 to 500. Standardisation of some assemblies has reduced manufacturing costs and shortened delivery times.

Rolling bearings


The bearing dimensioning and the load distribution within the gear unit ensure optimum operating conditions for the rolling bearings and guarantee maximum service life.

Housing


The compact housings are made of high-quality grey cast iron FGL 250 (NFA 32-101). The design has been optimised by FEM calculations and guarantees maximum rigidity under high loads. Housings in welded steel construction are available on request.

Toothing


The ERmaster gearboxes are designed for an oil viscosity of 320 cst at 40°C, or 460 cst at 40°C. Depending on the application and operating conditions, different types of lubrication can be used: Splash lubrication or injection lubrication, optionally with oil heating, constant temperature or oil cooling Due to the low noise level, the lubrication systems are equipped with screw pumps. Through component standardization we offer high-quality elements at reasonable prices.

Lubrication


Die ERmaster- Getriebe sind für eine Ölviskosität von 320 cst bei 40°C, oder 460 cst bei 40°C ausgelegt. Je nach Anwendung und Betriebsbedingung können verschiedene Schmierarten zum Einsatz kommen: Tauchschmierung oder Einspritzschmierung, optional mit Ölheizung, Konstanttemperatur oder Ölkühlung. Wegen des niedrigen Geräuschniveaus sind die Schmieranlagen mit Schraubenpumpen ausgerüstet. Durch Bauteil- Standardisierung bieten wir hochwertige Elemente zu günstigen Preisen.

Seals


In most cases, maintenance-free, contactless seals are used. This allows perfect circulation of the oil, which flows back into the oil sump after lubricating the rotating parts.

Couplings

The ERmaster gearboxes are combined with FLEXACIER 9000 and FLEXIDENT couplings to guarantee homogeneity and smooth running of the drive train. Catalogues of these couplings are available on request


Accessories and options
are available:

  • additional output shaft end

  • Protective hoods

  • Backstop

  • Fan

  • Heating

  • Air Cooler

  • and so on …

as accessories for the gearboxes.

Controls


All products benefit from the following permanent tests:

  • Control of the suppliers

  • Inspection of incoming goods

  • Production controls

  • Final inspection with test run

  • Corrosion protection according to the environment or storage conditions.

All control criteria comply with the quality standards of ISO 9001.

ERMILL

ERMILL : SINGLE SIDE DRIVE FOR CRUSHING MILLS

PRESENTATION


From a traditional crushing mill drive system consisting of a reduction gear, couplings, bearings, etc., CMD has developed the ERmill drive system.
This completely new concept is not only more compact, but also cheaper than a conventional system.
Based on a more compact process, the ERmill is designed in such a way that the coupling is removed together with the coupling rod of the drive unit and the drive wheel and bearings are installed in the reduction gear.
The special feature of the ERmill is that it has a self-aligning, hardened, tempered and ground drive gear on the side, which can compensate for alignment errors.

ADVANTAGES


Compact solution
Smaller and simpler construction
Faster adjustment
Robust mechanically welded housing
Modular technical solutions (drive wheel assembly - gear rim lubrication)


TECHNICAL DESCRIPTION
Compliance with the design standards, procedures and instructions specified in ISO 9001.

Housing :

Robust, mechanically welded, hot oil resistant housing made of steel of grade S135 JR.

Gearings :

After cutting, the gears are hardened, tempered and ground.
In accordance with ISO 6336, the life of the gears is 100 000 hours.


Bearings :

The bearings are calculated to have a theoretical minimum life of 100 000 hours L10, without factor a23, in accordance with ISO 281.

Rear wheels :
The standard version is built with 1 self-aligning gear.


Oil lubrication.

HAFLEX

HAFLEX : SPLIT TORQUE GEARBOX FOR SHAFT MOUNTING OR FLOOR MOUNTING


PRESENTATION


The Haflex is a split torque reducer (2 or 4 pinions balanced under load drive the main wheel). Two types of mounting are possible: mounted on the shaft (HALFLEX suspended, hollow shaft for low speeds) or on the floor (with solid shaft for low speeds and mounting base).
The Haflex enables high torque to be transmitted at low speeds and offers an extremely wide transmission ratio range.

EIGENSCHAFTEN

The range: 10 different sizes
Torque up to 3 500 kNm
Ratio up to 10 000
Weight: Up to 56 tons
APPLICATIONS
Steel industry : converters (LD, AOD...), sintering plant, sinter crushers.
Sugar industry : horizontal diffusion, mixer, cane sugar mill.
Mines, excavation : bucket wheel, bucket dredger.
Miscellaneous :autoclave, vertical agitator, vertical separator, crane wire drum drive.

ADVANTAGES

Compact and robust (main housing closed).
Shock absorption and/or control of torque fluctuations through:

Torsion bar and/or shock absorber (shaft mounting)
dynamometric damper (floor mounted)
electronic control (option)
Resists bending, runout etc. of the driven shaft (shaft mounting)

DESCRIPTION TECHNOLOGY

Main components within
are the main accommodations:

 

 The slow running wheel and its sprockets (2 or 4),
Sometimes a parallel shaft primary reduction gear on each pinion.


Additionally: 2 floating bevel gear primary reduction gears connected by a sliding cardan joint and 2 reaction arms for compensation.

JUMBOFLEX

Size 560 to 1250

Our gearboxes can be equipped with numerous accessories
and options can be equipped:

  • Special output bore (shaft-mounted gearbox with hollow shaft)

  • Second shaft end with standard or

  • Special dimensions

  • Hollow output shaft with shrink disc

  • Torque support to absorb the reaction forces of the transmission

  • Dynamometric shock absorber (with safety switch)

  • Transducers for force, torque, temperature,...

  • Backstop, freewheel

  • Clutch, torque limitation

  • Lubrication system with accessories

  • Fan, heat exchanger

  • Motor mount (gear motor)

  • Special centre distance and special reduction ratios

JUMBOREX

JUMBOREX : CENTRAL DRIVE FOR CEMENT MILLS


PRESENTATION


The JUMBOREX is a split torque reducer for centrally driven cement and raw mills. It is a coaxial reduction gear with parallel axle gears and 3 reduction stages.

TECHNICAL DESCRIPTION

10 Sizes from JC20 to JC62
Power from 1500 kW to 6500 kW
Weight from 40 tons to 115 tons
Torque from 130 kNm to 4000 kNm


VORTEILE


Reliability :
The JUMBOREX was designed for a long life.
The gear wheels are hardened, tempered and ground.
The housing and shafts have been optimized using finite element modeling to minimize deformation under load.

Easy maintenance :

The upper housing can be removed within an hour to allow direct access to all gears.
To obtain reliable and easily usable information about the condition of the JUMBOREX, 3 standard instrumentation levels are available.

They are designed to be easily and quickly assembled on site, with the possibility of mounting most of the centrally driven reduction gears currently available on the market in the same location. The JUMBOREX standards have been designed to adapt to the industrial standards that apply to the cement industry worldwide.

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MILLREX

MILLREX : DOUBLE SIDE DRIVE FOR MILLS


PRESENTATION


The MILLREX is a split torque reduction gear unit designed for side drives of cement mills and raw mills.

ADVANTAGES

Compact solution
The smallest and simplest form of civil engineering
The fastest adjustment
Although mechanically welded housing


TECHNISCHE DESCRIPTION


Compliance with the design standards, procedures and instructions specified in ISO 9001.

Housing :

Robust welded housing

Toothing:

All Millrex gears, including the 2 drive gears, are made of 18 CrNiMo7-6 case hardened steel.
After cutting, the gears are hardened, tempered and ground.
In accordance with ISO 6336 the life of the gears is 100 000 hours.

Bearings :

The bearings are calculated to have a theoretical minimum life of 100 000 hours L10, without factor a23, in accordance with ISO 281.

Rear wheels :
The standard version is built with 2 self-aligning gears.

.

Oil lubrication

PINION STAND

PINION STAND : ROLLING MILL REDUCTION GEAR


PRESENTATION


With our many years of experience, CMD designs and manufactures drive and gear cages for steel mills to customer specifications. These can be extremely large.
Tools to calculate the tooth geometry for optimum load application characteristics.
Possibility to use finite element modelling to calculate roll stand cages.
Design and modifications with special materials on customer request :special extensions, lubrication, possibilities to control the pinion position, etc.

Pinion stand gears hardened and tempered with ground teeth.
Wheels with a diameter up to 4500 mm, weight up to 40 tons.
Perfect geometry of the teeth through our control methods.

Power from 4 000 kW to 11 700 kW
centre distance of the shafts from 600 mm to 1 300 mm
Weight up to 215 tons

ROLLEREX

ROLLEREX: REDUCTION GEAR UNIT FOR VERTICAL MILL DRIVES


PRESENTATION


CMD has developed the range of ROLLEREX reduction gears for driving vertical mills with rolls. These ROLLEREX reduction gears are designed to withstand all the stresses and strains caused by the grinding process when driving the vertical mill. In this context, CMD has decided to combine performance and reliability in the design of the ROLLEREX series.

TECHNISCHE DESCRIPTION
 

Size 20 sizes
Power 150 to 3000 kW
ratio of 19 to 51
Torque from 35 kNm to 1300 kNm
Static vertical effort 21 000 kN
Dynamic vertical efforts 35 kNm to 1300 kNm


ADVANTAGES


Size adaptation to most vertical mills currently in use
Extremely compact
Extremely low noise level
Ability to withstand with great certainty the axial stresses and vibrations generated by the mill
A very safe and efficient hydraulic and electrical system
Lubrication units adapted to each reduction gearing of the series
A design and production quality recognised throughout the mechanical world

 

FEATURES


Input spiral bevel gear, cut on a Klingelnberg machine
Output planetary gearbox with sun and satellites made of forged steel type 18CrNiMo7-6 with gear teeth hardened, tempered and ground.
Axial forces are supported by several independent, oscillating thrust pieces
Lubrication The independent central unit consists of a high-pressure circuit and a low-pressure circuit.

WORM GEAR UNITS SERIES N

Sizes 160 to 500

Our gearboxes can be equipped with numerous accessories
and options can be equipped:

  • Special output bore (shaft-mounted gearbox with hollow shaft)

  • Second shaft end with standard or

  • Special dimensions

  • Hollow output shaft with shrink disc

  • Torque support for mounting the

  • Reaction forces of the gearbox

  • Dynamometric shock absorber (with safety switch)

  • Transducers for force, torque, temperature,...

  • Backstop, freewheel

  • Clutch, torque limitation

  • Lubrication system with accessories

  • Fan, heat exchanger

  • Motor mount (gear motor)

  • Special centre distance and special reduction ratios

ZAFLEX

CMD offers a range of ZAFLEX worm gear reduction units and geared motors with or without primary helical gearing in a power range from 0.18 kW to 90 kW.
These reduction gearheads and geared motors are available with hollow output shafts or standard output shafts with diameters ranging from 25 to 140 mm.
The cast iron housing is extremely well ventilated and has been designed to be used in any operating position without accessories.
The possibility of coupling them together allows an extremely wide range of output speeds to be achieved.


Options

Backstop
Reaction arm for shaft-mounted model
Torque control using dynamometric dampers

Advantages

  • Silent: The functional principle of worm gears by creep gearing, combined with a high drive ratio, results in the lowest noise level of all gear transmission systems.

  • Compact: For many applications a compact reduction gear unit is essential. DURAND reduction gear units were developed to reduce the size:

  • Orthogonal arrangement of shafts

  • Hollow shaft

  • High ratios with small size

  • Robust: An extremely rigid housing and the use of high-quality components with well-dimensioned dimensions ensure extremely robust devices. DURAND reduction gears can transmit high torques without taking up much space.

ERSUN

The ERSun® is a planetary gearboxes range. It has been designed to meet the needs of the most demanding applications of heavy industry, such as sugar industry.

  • Input Speed : from 600 rpm to 1800 rpm

  • Reduction ratio: from 40:1 to 2500:1

  • Nominal torque : from 130 000 Nm to 4 000 000 Nm

Advantages:

  • Bearings selection ensuring important lifetime

  • Optimized design for the best capacity/dimension ratio

  • A robust casing including the two last gear stages in order to achieve a good rigidity, essential for shaft mounted configurations

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