The Gears that Grind: Essential Mechanical Parts in Quarry Equipment

Quarries are the industrial giants that provide the raw materials for construction, infrastructure, and countless other applications. But these massive operations rely on a complex network of machinery, and within that machinery lies a world of essential mechanical parts working tirelessly. Let’s delve into some of the key equipment found in a quarry and the mechanical parts that keep them functioning.

1. Drilling and Blasting:

Drill Rigs: Powerful rotary or hammer drills use high-strength drill bits and robust bearings to penetrate rock. Hydraulic cylinders power the drill’s movement, while valves control fluid flow. Here, different types of couplings come into play:

-Rigid flanged couplings: These couplings connect the drive shaft from the engine or motor to the gearbox of the drill.

-Power Locks: Heavy duty shaft locking devices are also used on rigid flanged couplings. They provide easy, strong, and secure connections between shafts and hubs without backlash.

-Jaw couplings: Fenner Jaw couplings are perfect for absorbing shock and misalignment between the engine and gearbox, protecting the drivetrain.

2. Excavation and Loading:

Excavators: These versatile machines feature a hydraulic arm with a powerful bucket attached. The arm’s movement is controlled by a network of hydraulic pumps, motors, and valves. Tracks or wheels provide traction, while slewing rings allow the excavator to rotate its upper body. The excavator’s performance relies heavily on:

-Gearboxes: Excavators require gearboxes to increase the torque from the hydraulic motors to provide the necessary digging force at the bucket. These heavy-duty operations often use a planetary gearbox. Check out the SITI Planetary gearbox – used commonly in quarries, this gearbox is compact, and has a high power density with high efficiency continuous operation.

-V-belts: These are often used to drive auxiliary systems on the excavator, like the cooling fans. Check out Fenner V belts as they used commonly in quarries and one of longest-lasting belts out there.

3. Crushing and Screening:

Jaw and cone crushers: Jaw crushers use massive jaws with replaceable wear plates and leverage shafts, bearings, and eccentric mechanisms to break down rocks. Cone crushers, on the other hand, rely on a spinning cone and a fixed wall, using conical bearings and shafts for size reduction. Motors drive the cone’s rotation, and similar to jaw crushers, they likely utilize couplings and gearboxes to achieve the perfect crushing speed and force. Both crusher types then use screens to sort the crushed material into desired sizes.

-Couplings: Similar to drill rigs, jaw crushers likely use flange or jaw couplings to connect the motor to the crusher’s main shaft.

-Gearboxes: Gearboxes are crucial in jaw crushers, as they step up the motor’s speed and torque to create the immense crushing forces.

-Crusher Jamming: Crusher jamming incidents are a frequent headache in quarries, caused by things like big rocks, stray metal, or even wet material. These jams can quickly ruin the crusher’s belts by overheating and burning them. To keep downtime to a minimum during these emergencies, it’s important to have the right replacement belts on hand and ready to swap in. In this case, the Fenner PowerTwist Plus belt is a problem-solver and a game-changer. They are built to replace those old metric SPZ, SPA, SPB and SPC wedge belts, and they work perfectly on existing pulleys. One huge advantage is that these “link belts” work like a chain- you can add or remove links during installation and adjust to get the exact length you need for your machine. they also conquer tough environments with oil, grease, water, most chemicals and solvents. They resist abrasion better and can handle a wider temperature range, from a frigid -40°C to a scorching 116°C.

4. Conveying Systems:

Belt Conveyors: Belt conveyors are the most prevalent type of conveyor system employed within the mining and quarrying industries.

-Gearboxes: These conveyors, sometimes referred to as feeders, utilize shaft-mounted gearboxes to facilitate material transportation along inclines of minimal grade. The Fenner SMSR Gearbox (shaft mounted speed reducer) is used commonly in this application, with torque capacity up to 45,000Nm. It consists of a taper-Grip bush for easy removal and fitting. Additionally, bevel helical and worm gear reducers find application in these belt conveyor systems. Shafttech has assisted many quarries in using SITI bevel helical and SITI worm gearboxes (Italy) for high quality and reliable operations.

-Idlers and rollers: These support the conveyor belt and ensure smooth movement of the material.

-Scraper blades: These remove excess material buildup on the belt to prevent slippage and belt damage

Ensuring your quarry runs smoothly requires reliable and efficient equipment. Our team of experts can assist you in selecting the right compressors, crushers, conveyors, and other essential equipment to maximize productivity and minimize downtime.

Contact Shafttech today and let us be your partner in achieving your quarrying goals.

Shafttech is the no. 1 heavy industry expert in Southeast Asia.

Why You Need an Industrial Gearbox Overhaul

One of the most common services that we do at Shafttech is gearbox overhaul. In this article, we will break down the gearbox overhaul process.

In the heart of any factory, gearboxes orchestrate the movement of machinery by transferring power from motor to equipment, ensuring production lines run efficiently. Without a well-functioning gearbox, even the most powerful motors cannot translate to productive output. But industrial gearboxes are susceptible to wear and tear over time. To maintain optimal performance and prevent costly downtime, a proactive approach to gearbox maintenance is crucial. This is where gearbox overhaul come in.

What is an Industrial Gearbox Overhaul?

An industrial gearbox overhaul is a planned, comprehensive service that involves the complete disassembly, cleaning, inspection, and repair or replacement of all gearbox components. Unlike minor repairs that focus on specific issues, an overhaul addresses the overall health of the gearbox, extending its lifespan and preventing unexpected breakdowns.

Benefits of a Gearbox Overhaul

Doing a gearbox overhaul allows you to extend the gearbox lifespan. By proactively replacing worn parts, you minimize the risk of sudden gearbox failures that can halt production lines. Catching and addressing problems early on also prevents more extensive (and expensive) repairs down the road, reducing maintenance costs.

The Industrial Gearbox Overhaul Process

A typical industrial gearbox overhaul follows these key steps:

Pre-Overhaul Inspection: Our technician will assess the gearbox’s overall health through vibration analysis, oil sampling, and a visual inspection. This helps determine the extent of the overhaul needed.

Gearbox Removal and Disassembly: The gearbox is carefully removed from the production line and disassembled in a clean environment. Each component is meticulously documented and tagged. We will then provide an investigation report on the condition of individual parts within the gearbox.

a. Check the gears

b. Check the Shaft for the bearing seat and oil seal seat

DE = Drive end. NDE = Non-drive end

c. Check the bearings and bearing housings

d. Check oil seal housings

Repair or Replacement: Depending on the condition, parts may be repaired or replaced with high-quality components.

Reassembly and Testing: The gearbox is meticulously reassembled, ensuring proper alignment and torque specifications are met. The reassembled gearbox undergoes rigorous testing to confirm smooth operation and proper gear changes under load.

Gearbox Reinstallation and Commissioning: The overhauled gearbox is reinstalled on the production line, and final adjustments are made to ensure proper alignment with connected equipment.

Factors to Consider for Gearbox Overhaul Frequency

The recommended frequency for gearbox overhauls depends on several factors. One of them is the operating duration. Gearboxes operating for extended periods will require more frequent overhauls. Lead conditions also affect overhaul frequency as, gearboxes subjected to heavy loads will experience wear and tear faster.

Preventive measures like regular oil changes and proper lubrication practices can help to extend the lifespan between overhauls. Consulting with a qualified gearbox service provider can help you determine the optimal overhaul schedule for your specific equipment and operating conditions.

Conclusion

By incorporating gearbox overhauls into your preventative maintenance plan, you can ensure your factory operates at peak efficiency. Reduced downtime, enhanced reliability, and extended gearbox life all contribute to a more productive and cost-effective manufacturing environment.

Reliable Gearbox Overhauls, Every Time – Contact Shafttech for a reliable and detailed inspection of your gearbox.

The Vital Mechanics of Chemical Production: Essential Equipment and Unsung Heroes

Chemical plants are the lifeblood of many industries, producing everything from fertilizers and plastics to pharmaceuticals and cleaning agents. But behind the complex chemical reactions lies a hidden world of essential mechanical products. These workhorses, both the well-known and the less-celebrated, keep the processes running smoothly, efficiently, and most importantly, safely.

The Flow of Power: Pumps, Compressors, and their Transmission Partners

At the heart of material movement are pumps, the tireless champions of liquid and slurry transfer. But a pump’s success story relies on its supporting cast:

Couplings

The critical link between the pump shaft and the motor’s driveshaft.

1.Gear couplings ensure smooth power transfer for applications with perfect shaft alignment. ESCO Gear Couplings are known in the market for its ability to transmit high torque despite a small coupling size, reducing stress on on machinery.

2.Tyre couplings or Disc Couplings are often used to accommodate shaft misalignment while dampening vibrations. Fenner Tyre coupling is the market standard for tyre couplings; Installation is easy and you only require to change tyres every 1-2 years, which makes it perfect for most pumps. If the torque capacity and speed is higher, ESCO Disc Couplings will come in handy. ESCO Disc couplings are designed for infinite life, and no lubrication is needed. For chemical plants, ATEX certification is sometimes required, and ESCO Disc couplings can offer an ATEX disc couplings for hazardous environments. When high shock loads are anticipated, jaw couplings with their interlocking teeth provide a robust connection.

Gearboxes

When a pump requires a change in speed or torque output from the motor, gearboxes step in. These marvels utilize a series of precisely machined gears to achieve the desired speed or torque multiplication, allowing the pump to operate at its optimal efficiency. Helical gearboxes offer smooth, quiet operation, while helical-bevel gearboxes provide a right-angle power transfer with high efficiency. The Fenner (UK) Bevel Helical gearbox is popular for chemical plants due to its high quality and cost-effectiveness.

The Art of Mixing: Mixers, Agitators, and their Unsung Heroes

Many chemical reactions rely on constant, thorough mixing to guarantee proper ingredient interaction. Mixers and agitators come in various forms, but their operation hinges on:

Shafts

These long, rotating rods act as the power conduit, transmitting torque from the motor or gearbox to the mixing impellers. Stainless steel shafts are a popular choice for their corrosion resistance in many chemical applications. For especially harsh environments, exotic metal alloys may be necessary.

Bearings

These unsung heroes support the rotating shaft, minimizing friction and wear. Chemical plants often rely on heavy-duty bearings designed to handle high loads and withstand the corrosive nature of the processed chemicals. Self-lubricating bearings and Oilless Bushings, can be crucial in applications where external lubrication is impractical. One big exporter of Oilless Bushings is Shafttech. Shafttech carries a wide range of Oilless Bushings.

Separation Science: Centrifuges, Filters, and their Control Network

Chemical processes frequently involve separating components with distinct physical properties. Centrifuges and filters play a vital role in this separation, but they often require additional components for precise control:

Clutches and brakes

These engage and disengage power to the centrifuge or filter, enabling smooth start-up, controlled operation, and safe stopping. Magnetic particle clutches provide a non-contact, wear-free solution for high-speed applications, while pneumatic clutches offer a simple and reliable option for lower-speed requirements. Disc brakes deliver precise stopping power for a controlled deceleration of the centrifuge or filter.

Speed reducers

In some centrifuges, meticulous control over rotational speed is paramount. Planetary gear reducers or Planetary Gearboxes provide a compact and high-ratio speed reduction solution, while worm gearboxes offer a self-locking feature for applications requiring shaft hold during downtime. SITI (Italy) is a champion in this range of products, specialising in high quality worm gearboxes and and the bigger planetary gearboxes for chemical plants.

These are some of essential mechanical products that keep chemical plants running. From the powerful pumps to the precisely designed valves and their supporting cast, each piece plays a vital role in the safe and efficient production of the chemicals that underpin our modern world.

If you encounter any technical failures or wish to upgrade any part of your plant, you can contact our team of technical engineers salesco1@shafttech.com who can assist you with replacement, selection and recommendation of new parts, frequent failure inspection, cost-down maintenance. Shafttech is one of the most trusted providers for heavy industries in Southeast Asia.