Replacement box provides operational flexibility
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David Brown Engineering product story
Edited by the Engineeringtalk editorial team
Oct 10, 2005
Federal Mogul Friction Products has upgraded its heavy duty mixing operation using a David Brown Series G gearbox as part of a solution created by Jackson Power.
A UK leader in the manufacture of brake pads and composition blocks used primarily in the automotive and rail industries, Federal Mogul Friction Products has upgraded its heavy duty mixing operation using a David Brown Series G gearbox as part of a solution created by Jackson Power.
The plant at Chapel-en-le-Frith in Derbyshire operates a high shear mixer to compound the material used in automotive brake pads.
The unit was driven by a gearbox originally installed more than 50 years ago and which after a motor upgrade several years ago was under-rated for the power source.
Spare parts would have been extremely difficult to source, adding to reliability problems.
Federal Mogul was seeking a more reliable compact solution with a smaller footprint that would also deliver more efficient power use and better control of the torque and the energy being put into the mix - control vital to ensure product integrity and protect the quality of the mix.
Peter Jackson of Jackson Power surveyed the existing equipment and designed a replacement system mounted on a single frame and incorporating a 400kW inverter with a 315kW AC motor and a David Brown Series G 19 triple reduction helical gear unit.
The new Series G gearbox is rated at around 600kW compared with a rating of only 112kW for the unit it replaced, thus providing greater operational flexibility.
Jackson's also manufactured a base frame that fitted the original footprint and mounting locations and was also compatible with existing drive connections.
Maximum power readings were taken from the existing system and the new drive arrangement was designed with a reserve of power and current limiting in order to prevent the drive system being overloaded.
The mixer operates 24 hours a day, 6 days per week, so the replacement of the drive gear had to be carried out within a tight work schedule to avoid compromising production.
The whole operation was completed on time and within the estimated budget.
Maintenance Manager Jason Hobson explains: "The new installation has substantially improved process robustness and provided the opportunity to refine still further the quality of the product through more precise control of the mixing operation".
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