DRIVES & CONTROLS
performance and efficiency ;
ABB medium voltage variable drive solutions for mining customers are designed to provide reliability and flexibility in meeting mining application needs ; while ABB Motion Services helps customers maximise uptime , extend product life cycle and enhance the performance and energy efficiency of motors , generators and drives . ABB Motion OneCare and Partnered Solutions provide data , analytics , recovery , modernisation and performance improvement services , enabling innovation and success through digitalisation by securely connecting and monitoring customers ’ motors and drives .
With a broad spectrum of power classes , sizes , and designs , Flender One gear units ensure optimal coverage of various mining applications
Flender One gearboxes expand reach
Earlier this year , Flender announced the global launch of the next extension of its Flender One gearboxes . After the models for pumps and paper applications , Flender One expands its reach , offering versatile solutions for over one hundred different applications .
The new gear units are designed to meet a wide range of application needs , many of which are relevant to mining including bucket elevators , belt conveyors , and hoisting applications . With a broad spectrum of power classes , sizes , and designs , these gear units it says ensure optimal coverage of various industrial requirements .
Flender states : “ Flender One stands out with its tailored solutions . Customers only purchase what they need , eliminating unnecessary components and maximising efficiency . This customisation reduces operating expenses and enhances performance , providing a perfect fit for each specific application . Additionally , the gearboxes offer a wide range of add-on parts and customisable output shafts .”
It says the Flender One design saves both time and money in planning and plant operations . “ The new configuration process can be completed in minutes with just three parameters . Combined with instantly accessible 3-D data , prompt quotations , and shorter delivery times due to automated manufacturing processes , project timelines are accelerated from the
ABB ’ s NEMA Motors DP200 Crush +
Looking in more detail at ABB ’ s NEMA Motors DP200 Crush + severe-duty motor , Oscar Palafox , ABB NEMA Motors Global Portfolio Product Manager states : “ ABB has designed and manufactured the DP200 Crush + motor to meet or exceed our customers ’ needs for energy efficiency and reliability . The modular design offers a high level of flexibility for our customers and makes it easy to upgrade or retrofit existing systems in the field or implement future equipment designs and requirements .”
Built on ABB ’ s trusted SD200 , three-phased motor platform , Crush + optimises performance , efficiency and long-term maintenance costs while delivering high starting and breakdown torque . With a power range of 100 to 600 horsepower , a robust , cast-iron design , Class H insulation and a multi-position conduit box , Crush + allows for customisation to meet diverse operational needs . ABB ’ s solutions are engineered to meet the highest industry standards , including IEEE 841 , API661 and NEMA Super Premium efficiency .
The heavy-duty frame , available in NEMA 440 to 580 sizes , ensures Crush + can endure harsh operating conditions , while its high-strength 4140 steel shaft reduces the risk of damage under high-stress loads . Crush + is safeguarded against dust , water and other contaminants with its IP65 ingress protection and non-contact labyrinth seals .
Its flexible and oversized conduit box allows for adjustable positioning and mounting options to simplify installation . With 4- and 6-pole options and compatibility with 460V and 575V at 60Hz ( with custom options for 50Hz ), Crush + is versatile for use across multiple regions .
Crush + is compatible with the ABB Ability Smart Sensor for digital powertrain monitoring in hazardous environments , transforming motors into smart , wireless devices . This enables proactive maintenance to maximise safety and efficiency . The sensor ’ s durable enclosure withstands vibration , dust and water and is certified for ATEX , IECEx and NEC500 to meet the strictest standards for explosive atmospheres .
Full Class H insulation and Division 2 hazardous location certifications further guarantee safe operation in environments with flammable gases or combustible dust , making it a confident choice for hazardous industrial settings .
planning phase .” Flender added that plant operators can achieve up to 25 % time savings in planning through simplified processes .
In operation , the Flender One platform reduces operating expenses . All gearboxes are equipped with performance-optimised Metaperform ® gearing , reducing power dissipation by up to 20 % compared to previous models and a 30 % higher thermal capacity . Also , the bearing lifetime increases by 80 %. “ This results in faster cost amortisation for industrial gearboxes from Flender than ever before .”
Flender One offers built-in gear unit intelligence straight from the factory . Each unit comes with an integrated AIQ Core sensor , providing digital monitoring and intelligent onboard analytical functions . This allows for increased plant availability and process optimisation , reducing unplanned downtime by up to 70 %. Data- and need-based maintenance intervals can decrease service costs by up to 40 % and service-related downtime by up to 50 %. The optional torque measurement function allows for process and operating point optimisation . The AIQ Core torque can be easily selected via the configurator .
Rouven Daniel , President Industrial Gear Units at Flender , also once again stresses the fact that with the help of collected data and AI models , Flender is now able to size the gearboxes only as large as needed for the respective application . “ Most industrial gearboxes from all manufacturers in the field , including Flender , are oversized by up to 50 %. With Flender One and AIQ , we have the right tools to continuously eliminate this oversizing together with our customers . As a result , we will realise massive savings in raw materials , energy consumption , delivery times and installation space . Any waste is eliminated in terms of the environment and costs .”
In the future , further expansions of the Flender One platform will make it possible to configure
22 International Mining | NOVEMBER / DECEMBER 2024