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Gearbox upgrade minimises downtime

A Brevini product story
Edited by the Engineeringtalk editorial team Aug 1, 2008

Planetary gearboxes are capable of producing reduction ratios as high as 15,000:1, meaning that they are ideal for driving large, slow-moving rotors.

Anglian Water PLC sewage treatment works (STW) in Benfleet has replaced its obsolete gearboxes with Brevini planetary gearboxes.

When the old Varatio Strateline gearboxes began to fail on two half-bridge scrapers Anglian Water found that Brevini wasthe only company able to meet all the requirements for a new gearbox.

Brevini was able to offer a low-cost solution providing compact and highly efficient gearboxes without the need to replace or re-engineer the half-bridge scraper.

When a half-bridge scraper stopped working and another was found sounding distressed at Benfleet STW, Anglian Water had to make a decision whether to repair the existing, dated gearboxes or to re-engineer the half-bridge scraper to accommodate a new gearbox.

Both of these options were expensive and would have resulted in a lengthy downtime.

Fortunately Brevini was able to provide an alternative solution to drive the bridges using the existing structure.

Using its range of planetary gearboxes Brevini designed a drop-in solution that provided cheaper running costs and minimal maintenance throughout its lifespan.

Any standard motor can be directly mounted onto the gear units so the gearboxes can be installed straight into any existing system.

Jon Snaith, General Manager of Brevini UK, visited the site to develop a planetary solution to meet the criteria of the STW and bring the site up to date.

Planetary gearboxes are capable of producing reduction ratios as high as 15,000:1, meaning that they are ideal for driving large, slow-moving rotors.

Producing up to 800kNM of torque the gearboxes are able to produce the same power as large "worm and wheel" gearboxes despite being far smaller.

Brevini gearboxes have a lifetime over 100,000 hours when they are in constant use.

Only one oil change a year is required.

As Brevini's gearboxes are smaller than conventional gearboxes they are driven by a far smaller motor, which reduces running costs.

Each stage has three planetary gears, mounted on two rows of needle roller bearings.

This reduces point pressure and internal friction in the gears, this means that Brevini gearboxes run at 98% efficiency per stage, compared to many other high-reduction gearboxes which will run with less than 50% efficiency.

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