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The Mining and Aggregate industries face tough challenges every single day. The harsh environments are dirty, dusty, moist, and can be very cold or very hot. Further, the stop and start of much of the heavy machinery causes extreme stress on motors, drives, belts, and bearings. Maintenance is often difficult to manage, and often results in machine downtime. Downtime to switch out parts is frequent, and expensive.
Today, there are a wealth of new products on the market that aid the Mining and Aggregate industries through longer life and durability, and less maintenance requirements. From electric motors to bearings, optical encoders to belts, these products are available now.
Gates Poly Chain Carbon belt drive systems can replace old the old chain and sprocket. In heavy use environments chains and sprockets often break down after only a few months in service. Replacing chains and sprockets can take several hours, and result in thousands of dollars lost on downtime and man hours. The Gates Poly Chain Carbon toothed belt has a polyurethane body for abrasion resistance, and reinforcement that resists stretching, especially in shock loads.
The service life of the Gates Poly Chain Carbon belt system is typically double that of the chain drive. Parts replacement is less than half the chain and sprocket costs. All this minimizes downtime, makes your machinery more productive, and saves your company money.
TEFC motors from Emerson keep contamination out. Emerson's e-LINE totally enclosed fan cooled, electric motors are designed to protect the internal components of the motor, even in the most severe environments. The motor's cast iron frame, fan cover guide, and conduit box protect the internal components against rock damage. Zinc coated hardware, stainless steel nameplate, and chemical resistant paint combine to help resist rust in moist conditions. The V-ring shaft with umbrella seals protect the inside of the motor in heavy dust environments.
Emerson e-LINE motors have the added advantage of the Vacuum Pressure Impregnated Insulation System. The VPI system allows the motor to run longer and cooler, even when a variable frequency drive is being used.
Timken offers a spherical roller bearing that's designed to operate even if the shaft and housing are misaligned under load. They even run cooler. The Timken self-aligning spherical roller bearing is a combination radial and thrust bearing. This high-capacity bearing is the favored choice when conditions include heavy loads, difficulties in establishing or maintaining housing alignment, or when shaft deflection is expected. These bearings operate at a lower temperature, extending the life of your machines, which saves you money.
Harsh duty optical encoders from NorthStar eliminate downtime. In the mining industry bulk materials are moved out of the mine on conveyors which which require proper belt tension to ensure consistent speed. By providing reliable feedback to the motor, NorthStar encoders control the speed of conveyors reducing the possibility of downtime.
The NothStar HSD35 harsh duty encoder is built with an unbreakable Mylar plastic or stainless steel code disc rather than a fragile glass disc. It is environmentally sealed at both ends to prevent the penetration of dirt and moisture. This harsh duty encoder is tough enough for any mining application, and reliable enough for consistent speed control.
Bulk material handling conveyors in the Mining and Aggregate industries rely on rugged shaft mounted reducers to drive them. A more compact drive package is sometimes needed, and a right angle drive unit is more suited for the application. Efficiency is critical, and a helical bevel gear drive unit offers efficiencies of up to 95%.
That's where Hub City's Helical Bevel Drives come in. They are available in shaft mount or shaft output designs, and shaft or c-face input configurations. Direct coupling the drive motor with a quill (c-face) input can further reduce costs by eliminating hardware items such as sheaves, couplings, motor mounts, belts, and belt guards. With power ratings up to 130HP, and frame sizes ranging from 182TC to 364TC, Hub City Bevel Drives offer design flexibility and efficiency.
These new products are just a sampling of all the great products on the market to help Mining and Aggregate companies become more efficient and more profitable. There are a host of great products and solutions out there to help take the Mining and Aggregate industries forward into the 21st century.
Ted Hebert is a writer and Maverick Thinker who works with business of all sizes to grow their business. Contact Ted at ted@atunga.com or visit http://www.Atunga.com For more info on the products mentioned in this article visit http://www.kamanDirect.com
Advantages of using SolidWorks 3D for Mechanical Product Design
SolidWorks is revolutionary 3D Mechanical Design software developed for efficient and quicker design of Mechanical products and components. It helps Mechanical engineers, Product designers and Manufacturers to design new and better products faster and at lower cost.
SolidWorks 3D comes with excellent CAD tools that automates time-consuming detailing work and help diagnose and resolve issues related to mechanical relationships and the application of dimensions. It generates parametric 3D models from design sketches which can be used for presentations, sales proposals or material analysis - before creating any component. This helps in saving time, while scrapping the high costs of prototyping.
SolidWorks platform has comprehensive automated checks and autocorrect capability that ensures complete adherence to your company's fabrication standards - before you send your product designs for manufacturing or fabrication.
SolidWorks tools allow designers to compare components or drawings to find out exact differences between two similar designs. It simplifies the use of data from various CAD systems to work on same platform.
SolidWorks 3D tools visualize your product design right on-screen when you create assemblies, saving you the time and cost of physical prototyping. You can reproduce components by choosing individual surfaces, edges and curves; produce mechanical relationships between components; check interference/collisions and link the motion of pulleys/sprockets.
You can automatically assemble fasteners and related hardware; automate the assembly of commonly used parts and resolve conflicts such as over-constraining a component.
The software has various data translation tools for AutoCAD users, along with help documentation, so you can easily convert DWG files into 3D models.
Should you have any queries regarding 3D Mechanical design or SolidWorks Design services, please feel free to contact us. Find more at http://www.cadoutsourcingservices.com/cad-mechanical-design.php
About the Author
Richard Bothom is member of CAD Design services team at COS – an established offshore firm offering wide range of Civil, Architectural, Structural and Mechanical design services at affordable rates. For more information visit http://www.cadoutsourcingservices.com
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