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The mill’s gearbox

The mill’s gearbox. MAAG Gear: A pioneer of modern gear technology. MAAG Gear on the move. 1913 Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland 1927 Start of internationalisation (MAAG Italy, MAAG France, etc.) 1989 Foundation of MAAG Gear AG, Switzerland 1997 Acquired by FLSmidth

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The mill’s gearbox

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  1. The mill’s gearbox MAAG Gear: A pioneer of modern gear technology August 09

  2. MAAG Gear on the move 1913 Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland 1927 Start of internationalisation (MAAG Italy, MAAG France, etc.) 1989 Foundation of MAAG Gear AG, Switzerland 1997 Acquired by FLSmidth 2000 Acquisition of factory in Elblag/ Poland • Move to Winterthur, Switzerland • Sales of marine and turbo business 2009 Move into City of Winterthur MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  3. MAAG Gear is a leading global player and belongs to FLSmidth since 1997 Engineering, sales, marketing and project management in Winterthur Production in Poland and Winterthur Quality ISO 9001 certified More than 90 years of grown expertise Facts MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  4. Figures 2008 • Turnover: 115 mio CHF • Production capacity 80 –100 gear units • Employees: 280 • Engineers: 105 • Technicians: 78 • Service: 30 • Administrative: 45 • External Assistance: 14 • Trainees: 8 MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  5. Engineering experts Gearing technology - parallel gears Gearing technology - bevel gears Metallurgy FEA Antifriction bearings Journal bearings Toothed couplings Acoustics/vibration analysis CAD/PDM Integrated Logistic Support (ILS) / Reliability Availability Maintenance (RAM) Supporting tools CAD / Solid Works PDM-Systems / Team Center Ansys for FE-Analysis Various tools for material analysis MAAG Gear-developed program systems representing the unique experience of generations of gear exports Collaboration with our customer Cooperation with universities and research centers Know-how in engineering and technology MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  6. Cement Minerals FLSmidth FLSmidth Minerals FLSmidth Project Division FLSmidth Minerals Division FLSmidth Customer Services FLSmidth Dorr-Oliver EIMCO FLSmidth Airtech FLSmidth Krebs Pfister FLSmidth Buffalo Ventomatic FLSmidth Koch / MVT FLSmidth Möller Excel Foundry & Machine Dansk Eternit Holding FLSmidth RACHO FLSmidth ABON MAAG Gear, a member of FLS since 1997 FLSmidth & Co. MAAG Gear MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  7. Driving equipment for the cement industry MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  8. WPU/WPV Raw mill WPU Coal mill PPU Roller Press CPU/CPV/LGD Cemet mill Cement processes driven by MAAG Gear MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  9. Roller mills vertical drive WPV Roller mills vertical drive WPU Ball mills lateral drive LGD Ball mills central drive CPU/CPV Driving equipment for the cement industry MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  10. Roller mills drive, 2-stage (Type WPU) Benefits to customer • High operational reliability • Efficiency exceeds 96.5% • Customers-specific design of gear units • Very high efficiency Planetary stage and thrust bearing for grinding table with very long service life • Low-cost maintenance Technical overview • Fully developed compact two-stage design (bevel gear / planetary gear stage) • Case hardened or hardened and quenched tooth • Bevel gear stage with its own casing • Thrust bearing mill table hydro static and hydro dynamic lubricated • Power: 250 to 6,000 kW MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  11. Roller mills drive, 3-stage (Type WPV) Benefits to customer • Torque split for compact design • Flex pin solution for optimized load distribution • Efficiency exceeds approx. 95 % • Slide bearing application in bevel and planetary gear stage • Simple mechanism for assembly and adjustment of bevel gear stage without remove the gear unit Technical overview • 1st stage 3 planets, 2nd stage 5 planets • Toothing case hardened or quenched and tempered • Thrust bearing mill table hydro static and hydro dynamic lubricated • Power: 2,500 to 9,000 kW MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  12. Installation / Maintenance Installation and commissioning • Experienced and skilled service engineers • Timely managed Maintenance Preventive • Monitoring / short reports • Assessments • Service plan agreement Overhaul • Planning and project management • Execution and support Troubleshooting • 24/7 Hotline Tel +41 79 619 91 00 MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  13. Support Customer training • During installation and commissioning • In house / in MAAG Gear workshop • Tailor-made • On-site Expert reports • Vibration and operating readings • Material analysis and monitoring • Advisory opinion Service packages • Better performance for longer periods • Guaranteed productivity and profitability • Continued customer satisfaction • Enhanced reliability MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  14. WPU: The Gear Drive System Mill thrust bearing Thrustpads Thrust bearings lined with babbitt metal MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  15. The WPU Gear System Roller Mill Mill thrusts Annulus WPU gear reducer MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  16. Schematical Design Concept Spiral bevel gear set MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  17. Set of instrumentation for trend analysis MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  18. Set of instrumentation continue • Process signals – directly wired to CS 51.1: T1 – Bearing temperature (self-aligning roller bearing bevel pinion, coupling side) 51.2: T2 – Bearing tempersature (axial self-aligning roller bearing bevel pinion, gearing side) 51.3: T3 – Bearing temperature (self-aligning roller bearing bevel pinion, gearing side) 51.4: T4 – Bearing temperature (roller bearing bevel wheel, below wheel) 51.5: T5 – Bearing temperature (roller bearing bevel wheel, above wheel) 50.1: T11 – Bearing temperature – Segment of axial thrust bearing 46: T12 – Oil temperature at gearbox outlet • Vibration Sensors – directly wired to CS 86.1: VS1 – Ring Gear (Annulus) of the planetary stage 86.2: VS2 – Ring Gear (Annulus) of the planetary stage (perpendicular to 86.1) • Note: Wiring between gearbox and centre control room shall be done by the customer MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  19. WPV sectional drawing MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  20. Selection chart for vertical mill gearbox WPU WPV Maximum P/nt MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  21. WPV - Concept Main advantages: • Torque split 30% to 70%, => 2nd stage with smaller dimension • 5 Planets on the 2nd PV-Stage, => smaller dimension of the stage • Planets on the 2nd Stage with flex pin, => much better load distribution • No housing integrated Planetary stage => standard components possible => casing optimised to the axial load • Only slide bearings used => unlimited lifetime of bearings • Adjustment of bevel gear=> No need of gearbox disassembly MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  22. Slide bearings in the bevel gear stage Advantages of the slide bearings: • Short delivery time • Unlimited lifetime => high availability of plant • Higher damping compared to anti- friction bearings => less vibration • easy installation and highly service friendly • high know-how basis at MAAG Gear through an enormous amount of deliveries for the Cement, Turbo, and Marine applications MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  23. Easy adjustment of bevel gear Advantages of the improved adjustment method: • Tooth contact easy to adjust • Bevel pinion is adjustable from outside • Bevel gear wheel is adjustable through conic shoe • Fast removal of bevel pinion, without need to remove gear • Service friendly through large dimensioned man hole => short maintenance stops=> no pull out of the gearbox MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  24. WPV 360 – Bevel Gear Stage MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  25. Summary MAAG new developed WPV gearbox show several important advantages in investment and operation: • First Test run results and assembly show very encouraging results • High potential for optimisation of investment cost • Improvement on maintenance and service friendliness increasing the gearbox availability • Lower transport weight and consequently easier erection and reduced transport costs • The independent gearbox modules allow a more flexible and faster production • Lower delivery time for spares due to the smaller gear parts • The gearbox is build up with long term approved technologies MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  26. Maintenancephilosophy - Permanent surveillance, daily checks (by site personnel) - Checks after every 1‘000 h of operation (by site personnel) - Checks after every 6‘000 h – and 12’000 h of operation (annually)(under supervision of MAAG Service personnel) - Special checks after approx. 80‘000h of operation, or 12 years (under supervision of MAAG personnel) MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  27. Daily checks Permanent surveillance/daily checks (by site personnel) - Quick check of the whole drive group - Checking and recording of operating data - Checking of drive group and accessories for eventual leaks (reducer, couplings, lube oil supply unit, etc.) - Checking of oil level in lube oil reservoir - Check p of lube oil filter (if not monitored) MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  28. Routine 1’000 h checks Checks every 1‘000h of operation (by site personnel), (additionally to the aforementioned daily checks) - Record and check operating data (complete checklist 1 of the instruction manual) - Check lube oil filter and filter/breather for contamination, cleaning or replacing at need MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  29. Regular 6’000 h check Checks every 6‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned routine checks) - Check all important bolt connections (reducer, lube oil supply unit, coupling, etc.) - Check and if necessary re-tighten gearbox anchoring - Check lube oil for water content/contamination, Analysis of lube oil by the supplier (replacement according to recommendation) - Visual check of lube oil-sample from axial bearing casing MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  30. Regular 12’000 h check Checks every 12‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned regular checks) - Checking of alignment to driving- and driven machine - Inspection of central bearing no. 1 (input shaft) - Check of instruments and interlocks, record setting points (complete checklist no. 2) - Inspect and clean lube oil cooler (if required) - Partial disassembly and inspection of in- and output coupling, replacing of lubricants and seals - Functional and alignment check of auxiliary drive - Inspection of spare parts (if available), special tools MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  31. Special checks - Overhaul Special checks, overhaul after approx. 80‘000 h of operation, or 12 years (under supervision of MAAG personnel) • Disassembly of the entire reducer, inspection of all parts. Ultrasonic bonding test of all bearings. (replacement of parts if required) • Maintenance of components (motors, instruments, etc.) (according to the individual supplier) Estimated shutdown time 2 weeks, depending upon accessibility, availability of facilities as well as findings and results of the inspection. MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  32. Customer Service Products Overview Customer Service Products Service & Spare Parts Contracts Easy – Training Concept Performance – Gear Box upgrade Prevention – Security thanks obviating Speed – Security thanks fast information flow MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 32

  33. Customer Service Products MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. Easy – Training Concept - training of customers service personnel Challenge – Gear Box upgrade - exchange of an existing gear box, incl. gear boxes from competitors Prevention – Security thanks obviating - checks via vibration measuring, incl. gear boxes from competitors Speed – Security thanks fast information flow - 24 h/day vibration measurement thanks direct access of customers data’s via internet. 33

  34. Gearbox Damage How to handle material availability August 09

  35. Source of information and procedures • Emergency situation: • a) Customer contacts Field Service Dept: Emergency description, detailed information • b) Customer contacts Sales: availability of spare parts, delivery schedules • Service report at customer • Sales travel report at MAAG Gear • Customer / Agency request once procedure defined • Monitoring system MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  36. Material planning for repair (1) • Emergency case: • Damage assessment and evaluation • Material selection (parts, spares) • Availability at customer site • Service report: • History of the gearbox • Detect background of failure • Recommendations for repair • Sales travel report: • Spare parts already delivered • Identification of spares required • Contact persons • Express delivery • Quotes MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  37. Material planning for repair (2) 4. Customer / Agency request: • Contact Field Service Dept. for details / history • Proceed standard spare parts quotation • Monitoring system • Data exchange • Analysis • Recommendations • Follow up after repair MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  38. Information flow Customer address Contact name; e-mail; phone No. Plant code name Gearbox type & ex. Order No. Parts description Drawing No. SAP No. (If available) Quantity Reason for material request Time frame ServiceReport Basic Info Material Info Gen. Info MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  39. Repair options (1) • On site repair by MAAG Gear Field Service Engineers • Field Service Dept. to contact customer & make proposal forservice intervention (material inspection on site) • If damage material is already specified, then standard part quotation is issued • If defective material is already inspected, then procedure according to inspection report recommendations MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  40. Repair options (2) • In house repair at MAAG Gear production site • Delivery of damaged parts • Quote for damage assessment and inspection • Quote for repair • Repair by 3rd. Party • Cooperation under customer responsability MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  41. MAAG Gear locations and service centers • MAAG Gear locations for development, production and sales • Winterthur, Switzerland / Elblag, Poland • Bethlehem, North America / sales office • Beijing, China / sales office • Service Centers including agents and FLS partner offices world wide (MAAG Gear service centers in USA, Mexico, Poland and Denmark) MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  42. MAAG Gears in operation around the world MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

  43. MAAG Gear‘s vision Core Elements of our Corporate Strategy • Sustainable sales growth • Dynamic, relevant innovation pipeline • Operational excellence • Winning organization • Ensure we have the right people and the right working environment to deliver our vision • Constant willingness to innovate and close collaboration with our customer MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document.

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