Symetro Gear Unit

■ The ideal central drive for ball mills

■ Extremely long service life
■ Minimum maintenance
■ More than 1600 units in operation worldwide
 Highlights

Very long life compared Made to last The high-speed shaft is directly coupled to
S Y M E T R O® G E A R U N I T

with other gear systems, High efficiency, extremely long life and the motor. Speed is reduced in two stages
notably girth-gear negligible maintenance make the Symetro and in dual paths. The first reduction stage
systems. gear unit the ideal drive for both high-pow- is between the high-speed pinion and the
ered and low-powered mills. More than two gearwheels on the intermediate shafts.
Highly reliable in 1600 gear units all over the world operat- The second reduction stage is between the
operation: ing at efficiencies in excess of 99% testify two low-speed pinions and a large low-
• Simple design to the Symetro's reliability and cost-efficien- speed gear-wheel.
• High quality cy. Some of the earliest Symetro units The low-speed wheel, called the balance
• Case-hardened pinions installed nearly seventy years ago are still in wheel, is bolted to a set of membranes
• Optimised teeth con- service, and spare parts for all gear units mounted on the output shaft. The latter is
tact through profile supplied since 1926 are available based on an actual torsion shaft resting in a slide
and lead (helix angle) F.L.Smidth’s comprehensive documentation bearing (the balance bearing) which is
corrections as well as files. moveable both horizontally and vertically.
end relief. The free movement of the wheel in all
• Allows minor settle- Overall design directions automatically ensures even distri-
ment of gear and/or The Symetro is a compact central drive gear bution of the load on the two low-speed
mill foundations unit transmitting high motor output to a pinions. Guide rings rotating in the grooves
slowly rotating mill. The input and output of the low-speed pinions keep the low-
Easy maintenance of shafts are subjected to pure driving torque, speed wheel centered horizontally to avoid
gear unit and mill: and the low-speed pinion shafts are short shock-movements. The low-speed output
• Easy access for inspec- and solid with a minimum of deflection. shaft is connected to the mill by another set
tion of all gears, bear- The motor, gear unit and grinding mill of membranes.
ings, etc. are installed on a common centre-line.
• Barring device for A sturdy bottom frame supports the The gears
slow turning of the bearing housings and thereby all the mov- The first reduction stage gears have single-
mill even if the motor ing parts as well as the top part, while also helical teeth. The gears of the second stage
is dismantled acting as an oil-tight reservoir for the circu- are of the herringbone (double-helical) type.
• Simple lubrication lating oil. The top of the frame has built-in All pinions are made of high-grade case-
system markings for alignment checking. hardened steel and gear rims are made of
• Maintenance-free
couplings

Economical:
• Efficiency exceeds 99%
• Low power require-
ments for pumps, etc.
• Low cooling water
requirements
• Direction of rotation
can be reversed
 2 3

4 2

high-grade heat treatable steel. The pinions and an oil cooler, before reentering the bot- External lubrication system
are tooth-flank ground with profile and lead tom frame. A small amount is lead to the 1. Coarse filter. 2. Oil pump
3. 20-micron filter. 4. Oil cooler
(helix-angle) corrections to obtain equal high speed bearings. A cooling water valve
load distribution on the teeth and to reduce opens if the oil temperature reaches 55ºC.
noise. All the gearwheels are high-precision Filtration of the oil is essential because
hobbed and machined under rigorous tem- small and hard metal particles in the oil
perature and humidity control. may cause serious wear, especially in roller
bearings.
Bearings
The high-speed pinion shaft and the two Testing
intermediate shafts are mounted in heavy- Our quality assurance system is certified to
duty spherical roller bearings. The two high- the ISO 9001 standard. F.L.Smidth uses
speed shaft bearings are mounted in a com- state-of-the-art equipment to carefully
mon bearing housing while the bearings of check and inspect all gear unit components International lubrication system
the intermediate shafts are mounted in indi- during manufacture.
vidual housings. The low-speed slide shoe Gear blanks are checked not only by the
bearing has unlimited life. steel supplier but also by F.L.Smidth’s labo-
ratories that perform hardness, macro and
Lubrication micro-structure and ultrasonic tests of the
The bottom frame acts as an oil reservoir. steel.
All bearing housings contain a relatively Trial-assembled gear units are test run
large amount of oil, which means that all in the workshop. Teethcontact check and
bearings are continuously oiled. During other tests are also performed.
operation the gears dip into the oil and F.L.Smidth uses a computer-controlled
splash it into a socalled service trough in Barring device measuring machine to ensure the high
quality of its gear units.
the top part of the gear unit from which An F.L.Smidth-designed barring device
the oil flows down to the intermediate allows slow turning and exact positioning of
bearings, to the low-speed bearing and the mill. It makes the mill easier to service,
over the gearwheels. for example when changing grinding
Before start-up and during operation of media, replacing machine parts, and
the gear unit, oil is pumped via a separate inspecting the mill. The barring device is a
starting system into another trough above separate unit fitted between the main
the gearwheels and to the high speed bear- motor and the gear unit and can be used
ings. At temperatures below approximately even if the motor is dismantled for repair.
10ºC (50ºF) the oil is heated before being Such a barring device is indispensable for
pumped to the gear system. On reaching a the maintenance of today’s large grinding
temperature of 55ºC / 122ºF, another oil mills. For further details on the F.L.Smidth
pump in the conditioning system is activat- barring device, see separate brochure.
ed and the start-up pump is stopped. On its
way from the reservoir in the bottom frame,
the oil passes through a coarse filter, a
bypass, a 20 micron (absolute) fine filter
 Bottom frame

Split torque

Guide ring

Symetro®
Balance wheel

Torsionshaft
 Inspection window

Balance bearing
Motor
High-speed
bearing housing

High-speed pinion
Intermediate wheel

Low-speed pinion

Intermediate
bearing housing Test assembly in workshop
Balance bearing

Mill
 Measuring for:
• Differential pressure in oil filters
• Oil level in through
• High-speed bearing temperatures
• Oil sump temperatures
• Vibration level

Safety system
The Symetro is provided with built-in safety
devices to prevent
• inadequate oil supply and oil level
• too low or too high temperature
• unacceptable vibration
Inadequate oil supply and oil level is pre-
vented by a sensor in each trough in the grammed to take the necessary action to
top part which automatically prevents start- prevent damage of the machinery and to
up of the main motor or stops it if the oil alert the operator in the control room.
level is too low.
The temperatures in the high-speed shaft Maintenance
bearings and in the oil reservoir are moni- The Symetro gear unit is extremely reliable
tored by sensors that stop the main motor in operation and requires very little checking
if the temperature rises above a preset val- or monitoring. The gears and bearings of
ue or start/-stop the heaters (optional extra) the Symetro gear unit are very easy to
under low temperature conditions. The sen- inspect. Maintenance is confined to check-
sor in the reservoir is also used to start / ing the oil level and – about twice a year –
stop the oil pumps and to open the cooling laboratory analysis of the oil.
water supply when cooling is necessary.
The main motor also stops if the gear Plant Services
vibrations exceed a preset level. To meet customers’ need for comprehensive
The safety devices are integrated with the gear inspection, F.L.Smidth offers a special
F.L.Smidth central control system. All record- service provided by gear unit experts using
ings of oil level, temperature and vibrations advanced measuring equipment, see sepa-
are fed to the control system which is pro- rate brochure.

Relationship between mill speed and power consumption of gear

Mill rpm
22
21
20
19
25 0

0
H -1

35

18
H-1
TSH

-1 4 0
A

0A
0
00
-14

17
TSH

46

0A
HH

0A A
0A
-1

0A

20
74 0A
HH

53

60
HH
TS

18
67

16 -1 - 90
A
-1

80
-1

-1
TS

HH
TS

-1
HH

H 19
HH

H TS H -
H

TS 0A A
TS

15 SH HH 60
TS
TS

T TS 07 21 A
-2 H- 260 360
A A
14 SH
H
TS
H H-2 460
T TSH H -2 H -2
TSH TSH
13
12
11
10
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 kW
F

E
G

B Anormal D
End of mill flange
A
C C

1 1 2 3 4
Motor Motor Dimensions in mm
speed speed Net
(50Hz) (60Hz) P weight
rpm rpm n2 Anormal A B C D E F G ton
TSHH-1250 750/740 720/710 74.6 4000 4081 1680 1250 5010 1960 1255 1389 34
TSHH-1350 750/740 720/710 93.2 4000 4081 1750 1350 5390 2100 1491 1355 40
TSHH-1400 750/740 720/710 102.2 4000 4091 1990 1400 5610 2200 1571 1415 44
TSHH-1400A 600/595 600/595 113.3 4000 4091 2020 1400 5580 2260 1566 1405 46
TSHH-1460A 600/595 600/595 128.3 4000 4096 2068 1460 5820 2355 1613 1460 54
TSHH-1530A 600/595 600/595 141.7 4000 4096 2093 1530 6090 2405 1689 1530 58
TSHH-1600A 600/595 600/595 158.1 4200 4291 2263 1600 6360 2535 1724 1605 67
TSHH-1670A 600/595 600/595 179 4200 4291 2330 1670 6620 2670 1813 1670 73
TSHH-1740A 600/595 600/595 197.6 4500 4596 2375 1740 6900 2760 1885 1735 82
TSHH-1820A 600/595 600/595 221.5 4800 4896 2518 1820 7210 2825 1975 1825 92
TSHH-1900A 600/595 600/595 247.6 5000 5096 2553 1900 7520 2895 2009 1900 101
TSHH-1980A 600/595 600/595 276.7 5200 5306 2700 1980 7820 3090 2075 1975 114
TSHH-2070A 600/595 600/595 308.7 5600 5706 2798 2070 8170 3265 2184 2060 131
TSHH-2160A 600/595 600/595 346 5800 5906 2845 2160 8520 3360 2265 2145 142
TSHH-2260A 600/595 600/595 387 6100 6206 2875 2260 8900 3420 2361 2245 154
TSHH-2360A 600/595 600/595 432.5 6200 6306 2995 2360 9300 3580 2459 2335 174
TSHH-2460A 600/595 600/595 484 6400 6510 3090 2460 9700 3700 2560 2415 194

Smaller or bigger sizes are available on request

Dimensioning Standard equipment in all sizes of Symetro

1 Synchronous/asynchronous motor gear units:
2 P = maximum power consumption • Temperature measuring device
of drive • Vibration monitoring device
n2 = revolutions of low-speed shaft • Oil pumps
= mill speed • Oil filter
• Oil cooler using water
At a mill speed of 14.8 rpm the gear unit • Oil cooler using air is available on
TSHH-2260A will transmit a load of 387.0 x request
14.8 = 5730 kW
3 Standard length. Can be adapted to The oil preheater unit is an optional extra.
individual requirements. The correlation between mill diameter
4 Weight includes gear unit, foundation inside the lining (D) and mill speed applies
rails and specified accessories, but not oil. at 77% critical speed.
MAAG Gear A/S production of high-quality gear units is certified to DS/EN ISO 9001.

Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice.
12-01-286 Gramstrup Design ApS

USA INDIA DENMARK

F.L.Smidth Inc. Fuller India Limited F.L.Smidth A/S
2040 Avenue C Capital Towers Vigerslev Allé 77
www.flsmidth.com
Bethlehem, PA 18017-2188 180, Kodambakkam High Road DK-2500 Valby
Tel: +1 610-264-6011 Nungambakkam Copenhagen
Up-to-date addresses of worldwide
subsidiaries and sales offices are Tel: +1 800-523-9482 Chennai 600 034 Tel: +45 36 18 10 00
available from our website
Fax: +1 610-264-6170 Tel: +91 44-827-6030/8228623 Fax: +45 36 30 18 20
E-mail: [email protected] Fax: +91 44-827-9393 E-mail: [email protected]
E-mail: [email protected]