Product category:
Gears, brakes, couplings and engines
News Release from: David Brown Engineering | Subject: Series G gearbox
Edited by the Engineeringtalk Editorial
Team on 10 October 2005
Replacement box provides operational
flexibility
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
This article was originally published on Engineeringtalk on 3 May 2004 at 8.00am (UK)
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Just-in-time service beats 24 hour deadline
A heavy-duty gearbox critical to a leading UK pigments producer was delivered by David Brown Engineering in less than 24 hours, preventing production losses of up to GBP 10,000 per hour.
Just 48 hours from a gearbox
Gearboxes available off the shelf in the UK following a deal struck with distributor that should reduce delivery times to less than 48 hours.
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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