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Submersible geared motors solution for state-of-the-art wastewater treatment plant

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Delfluent Services BV is a consortium of specialised companies working on wastewater treatment facilities in The Hague, Netherlands. One of the plants, located in Houtrust, covers 5 hectares and, on average, can treat nearly 79,000 cubic metres of waste water a day.

The treatment process at Houtrust begins with the removal of large, solid material. Subsequently, the wastewater goes through pre-sedimentation tanks, activated sludge, biological treatment and post-sedimentation tanks.

The wastewater treatment plant was originally built in 1967 and needed to be refurbished to be in line with current environmental regulations. Included in the maintenance project was the replacement of a gear unit that was used to drive the chainwheel in one of the sedimentation tanks. The original equipment gear had always required a high degree of maintenance, demanding the tank’s basin be emptied twice a year to carry out regular services. This level of ongoing maintenance resulted in production losses and high maintenance costs. Delfluent chose to use the refurbishment as an opportunity to upgrade the system to a solution that could be easily maintained.

The original supplier had designed a solution which employed a single stage bevel gearbox fully submerged in the water. A connection tube was used to connect the gearbox to the rest of the power train, positioned above the water level. The tube connected to a pre-stage gearbox and an overload coupling, with a 0.55 kW motor driving the application.

In order to replace the existing motors and gears, Delfluent contacted Bauer Gear Motor, worldwide supplier of high quality, reliable geared motors, and part of Altra Industrial Motion Corporation.

Bauer has a proven track record of developing geared motors for challenging conditions and was particularly suited to help design a replacement to the original equipment. In particular, Bauer produces IP68-rated versions of its motors, which are fully submersible and impervious to water and dust ingress.

To provide the optimal service, Bauer conducted the replacement operations with its strategy partner Vos Gekas & Boot (VGB), expert in rotating equipment, including pumps – a supplier familiar to the wastewater treatment facility where the activity took place.

The solution provided by Bauer consisted of a drive belonging to the BK series of bevel geared motors (type BK70G20X-82W/DHEU09SA4/SP) that can operate continuously underwater. This motor series is available with power ratings between 0.03 kW-75 kW and operates at 110-690 V and 50/60 Hz.

From two one-stage gears, Bauer moved to a multi-stage geared motor. The bevel gearbox range can withstand torque of 80 Nm up to 18,500 Nm and gear ratios of 3.67-108.60 for two-stage gears or 7.29-441.3 for three-stage gears. In this way, the equipment was simplified, making future maintenance easier.

In addition, by removing the gear, the tube and the coupling, Bauer reduced the oscillations in the system and provided a more energy efficient solution.

Specific advantages of the BK series, besides IP protection against dust and water, include simple and cost-effective installation, high energy efficiency, robustness and durability, low maintenance requirements and low running costs.

This particular application runs at a set speed and so there was no need for a variable speed drive that might prove advantageous in other situations. Using a lower power-rated 0,37kW IE2 direct on line (DOL) motor offered the most energy efficient and cost-effective solution for this application.

I manage the editorial affairs for MONETA Tanıtım, which produces specific publishing, specially for the sphere, Turkey industry. We work for content development through digital and print media, with a new generation, dynamic publishing intellection.

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Motors

Hygienic drum motors with Interroll

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Charoen Pokphand Foods (CPF) is the largest feed and shrimp producer and one of the three largest poultry and pork producers in the world. For hygienic material flow and increased productivity, Interroll, together with three system manufacturers, has installed belt conveyors with drum motors.

The company, based in Bangkok, Thailand, was faced with the challenge of meeting rising global demand. The solution was to significantly increase the production capacity for automated food processing, using belt conveyors with drum motors. And since the machines were to run without downtimes, it was also necessary to keep energy costs as low as possible in continuous operation. 

158 drum motors for 400,000 chickens per day

For CPF, food safety is a business-critical factor: the company places the highest value on ensuring that all poultry products are manufactured absolutely hygienically and 100% safe for human consumption. Therefore, the material flow solution to be installed had to meet the strictest hygienic requirements and guidelines. 

The 158 Interroll belt drives now installed at CPF has increased production capacity by up to 400,000 chickens per day. And they meet all hygiene and operating cost requirements with top marks. A study carried out by the Institute for Food Research at the University of Parma (Italy) in 2016 confirmed that drum motors offer significant advantages over gear motors in terms of hygiene and on-site cleaning. 

Hygienic advantages through compact drum motor design

The compact design of the drum motors increases the cleaning capability enormously. The design with fewer parts without cooling fins or fan wheels offers advantages in the wet area of meat processing: Salmonella, listeria, E. coli bacteria and other harmful microorganisms cannot settle in hard-to-reach niches or joints. The number is reduced to a minimum in the entire production environment – the risk of dirt accumulation and cross-contamination is decreased. By reducing the amount of cleaning required, CPF is able to save significant costs over the entire life cycle and increase ROI.  

Cleaning according to highest standards

All Interroll drum motors of the latest generation are equipped with the highest degree of protection IP69k for housings. This simplifies cleaning and speeds up setup. Thanks to the PTFE seal, high-pressure cleaning with chemicals approved in accordance with ECOLAB guidelines is also possible. This enables CPF to clean and disinfect both the drum motors and the entire system to the required hygiene standards, while at the same time saving energy and costs thanks to shorter cleaning phases: The best prerequisites for remaining competitive in a highly competitive market in the long term.

Less installation time, more satisfaction

A further criterion for choosing Interroll drum motors was the shorter installation time, trouble-free continuous operation and reduced space requirements for a more compact system. The three OEM-cooperation partners involved in the project – Mechanical and Food Process Engineering, Thai Mech Tech and Cheetah Engineering Systems – also emphasize the flawless installation. Charoen Pokphand Foods now benefits from a future-proof material flow solution that is efficient, hygienic and easy to clean – and thus meets the high demands placed on food safety.

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Motors

Nidec Develops Fully Integrated Traction Motor System (E-Axle)

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Today, Nidec Corporation, a Kyoto-based leading global manufacturer of electric motors, announced the successful development of a new fully integrated traction motor system (e-axle) comprising an electric motor, reduction gear box and inverter. This new system is the latest and most advanced iteration of the company’s e-axle developed to respond to the growing demand for automobile electrification.

In addition to integrating the inverter, a separate component in Nidec’s first e-axle design announced in September 2017, the torque output capability has also been improved; the lightweight system weighs in at only 83 kg while achieving a maximum power output of 150 kW and a maximum torque output of 3,900 Nm. Furthermore, the new fully integrated design obviates the need for wiring between components, resulting in a more compact system that increases design flexibility.

The new traction motor system covers a wide array of applications, ranging from compact cars to SUV platforms, and is compatible with AWD vehicles due to an optional clutch mechanism that can be disengaged when only two of the wheels need to be powered. Production is scheduled to begin in 2019, starting in China and later expanding globally.

Nidec was founded in Kyoto, Japan 45 years ago by four engineers and has since grown into a world-leading comprehensive motor manufacturer encompassing approximately 300 subsidiaries employing over 100,000 people throughout the world. After becoming the first company in the world to successfully commercialize a direct drive spindle motor for HDDs using brushless DC motor technology, the company branched off into the automotive motor market which now constitutes its fastest growing business segment. Nidec’s electric power steering motors, in particular, have captured the largest global market share and helped cement the company’s position in the industry.

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Motors

Nidec Develops Fully Integrated Traction Motor System (E-Axle)

Published

on

Today, Nidec Corporation, a Kyoto-based leading global manufacturer of electric motors, announced the successful development of a new fully integrated traction motor system (e-axle) comprising an electric motor, reduction gear box and inverter. This new system is the latest and most advanced iteration of the company’s e-axle developed to respond to the growing demand for automobile electrification.

In addition to integrating the inverter, a separate component in Nidec’s first e-axle design announced in September 2017, the torque output capability has also been improved; the lightweight system weighs in at only 83 kg while achieving a maximum power output of 150 kW and a maximum torque output of 3,900 Nm. Furthermore, the new fully integrated design obviates the need for wiring between components, resulting in a more compact system that increases design flexibility.

The new traction motor system covers a wide array of applications, ranging from compact cars to SUV platforms, and is compatible with AWD vehicles due to an optional clutch mechanism that can be disengaged when only two of the wheels need to be powered. Production is scheduled to begin in 2019, starting in China and later expanding globally.

Nidec was founded in Kyoto, Japan 45 years ago by four engineers and has since grown into a world-leading comprehensive motor manufacturer encompassing approximately 300 subsidiaries employing over 100,000 people throughout the world. After becoming the first company in the world to successfully commercialize a direct drive spindle motor for HDDs using brushless DC motor technology, the company branched off into the automotive motor market which now constitutes its fastest growing business segment. Nidec’s electric power steering motors, in particular, have captured the largest global market share and helped cement the company’s position in the industry.

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