Flender gear units for cement and mining industry, flender gear drives

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As a leading provider of drive technology for material extraction we are very familiar with all the requirements of mine operation. Whether it is over long distances, in confined space conditions or in hot, arid mountainous areas, extreme conditions are the right work environment for our Flender gear units for cement and mining, because our solutions are 100 per cent designed to cope with anything they are put through.

The comprehensive modular system for all drive requirements – Flender gear units for conveyor belts H series
Our special solution for difficult environmental conditions – Flender gear units for conveyor belts E series
The ready-assembled complete system for confined spaces – Flender gear units for conveyor belts A series

Flender gear units for conveyor belts H series

Our extensive module system offers drive solutions from standardized components for every conveyor belt. Due to the use of established standard components customers profit from short delivery times and an excellent price-performance ratio.

In case the environmental conditions allow it, it is reasonable to arrange cost-effectively a Drive from the highly-developed standard porftolio. This is due to the fact that the modular system with its wide range of gear-units, motors, bell-housings, swing bases and add-on parts does not leave any wishes unfulfilled.

The Flender H-conveyor gear units are compact, have a high power density and are available in 25 construction sizes. They are well suited for multiple drives to meet very high power requirements.

These belt drives have proved themselves in thousands of applications worldwide.

Your benefits at a glance

Large selection of 25 sizes with few component variants
Standardised components with an outstanding price-performance ratio
The modular system comprises comprehensive accessories (such as oil-supply systems, various shaft forms, backstops, brakes, fans, etc.)
Worldwide short delivery times
Highest power density
High reliability and operational dependability
Dustproof thanks to largely contactless and wear-free labyrinth seals
Flanged output shafts and flanged couplings enable easier gear-unit fitting combined with a small space requirement
High efficiencies
Outstanding noise characteristics thanks to ground bevel gears and sound-damping housings and especially high tooth contact ratios
IDS (Integrated Drive Systems) for perfect coordination and control

Flender gear units for conveyor belts E series

With the Flender gear units for conveyor belts E-series, FLENDER offers a gear-unit range that is at home in extreme ambient conditions. To guarantee a stable operating temperature, highly efficient fans are used. Specially designed air-guide hoods ensure that the air flows evenly over the entire housing. In combination with the optimised surface the best qualifications for outstanding heat regulation.

Cooling systems represent additional risk potential for many mine operators, as frequently there is no water supply available. One part of the solution lies in an extended housing surface, a second and more decisive part in intelligent air conveyance that ensures that the ambient air is guided directly over the housing and over as much of it as possible. FLENDER has invested a great deal of development work in the fluid mechanics bound up with this.

For special areas of application a technically optimised cooling air-guide hood is available with a fan that functions independently of the direction of rotation. This enables thermal capacity to be further markedly increased.

B3SE gear units are available in 10 construction sizes and can be operated outstandingly as multiple drives for drive applications with very high power requirements.

Your benefits at a glance

Extended operating conditions and outputs
No external cooling
Shorter delivery time (thanks to stock-holding concept)
Large selection of 10 sizes with few component variants
Highest power density
High reliability and operational dependability
Dustproof thanks to largely contactless and wear-free labyrinth seals
Flanged output shafts enable easier gear-unit fitting combined with a small space requirement
High efficiencies
Outstanding noise characteristics thanks to ground bevel gears and sound-damping housings and especially high tooth contact ratios
IDS (Integrated Drive Systems) for perfect coordination and control

Flender gear units for conveyor belts A series

Not every mine offers enough space for complicated measuring, alignment and installation work. Our Flender gear units for conveyor belts A series are delivered ready-assembled and require no costly and time-consuming alignment on site.

The patented self-aligning system is the answer to many drive problems which frequently crop up in confined space conditions of the kind, for example, often encountered under ground.

The A-conveyor drive series offers flexibility for initial start-up, either with regard to space conditions, location or assembly. No special know-how is needed either for modification or disassembly work. The entire drive unit does not need to be aligned. A direct connection between motor and gear unit makes alignment unnecessary. High production quality also ensures the necessary precise connection. The patented Clever Cooling System ensures outstanding heat dissipation.

With the FLENDER Self-Aligning System in eight sizes FLENDER covers a power range of up to 550 kW.

Your benefits at a glance

Space-saving, compact design
Unique, provem concept with many customer references
Easy installation on site and less maintenance work: no aligning on site
Simple transport
Increased thermal capacity: no external cooling required
Highest power density
High reliability and operational dependability
Dust-proof
Flanged output shafts enable easier gear-unit fitting combined with a small space requirement
High efficiencies
Outstanding noise characteristics thanks to ground bevel gears and sound-damping housings and especially high tooth contact ratios
IDS (Integrated Drive Systems) for perfect coordination and control

Reliable Gear Units for High Performance Vertical Conveyors

Bucket elevators serve to vertically transport large masses of bulk material to different heights without creating dust, then dump it. The height to be overcome is frequently more than 200 meters. The weights to be moved are enormous.

Flender gear units for bucket elevators

The carrying elements in bucket elevators are central or double chain strands, link chains, or belts to which the buckets are attached. The drive is located at the upper station. The features specified for the drives destined for these applications are similar to those for steeply ascending belt conveyors.

Bucket elevators require a comparatively high input power. Flender gear units for bucket elevators must be soft-starting because of the high starting power, and this is achieved by means of fluid couplings in the drive train. Bevel helical gear units are normally used for this purpose as single or twin drives on a base frame or swing base.

As world market leader for bucket elevator drives, FLENDER has standardized the complete application-specific drive system, thus combining the advantages of proven and reliable components with fast availability. Flender gear units for bucket elevators are a crucial element of the drive train. They are characterized by maximum performance and operational reliability as well as optimal availability. Auxiliary drives (maintenance or load drives) and backstops are supplied as standard. The gear unit and the auxiliary drive are therefore perfectly matched.

Your benefits at a glance
Maximum power capacity
Maximum operational reliability
Fast availability
Modular design principle

Technical data
Types: Bevel helical gear unit FLENDER
Sizes: 15 sizes from 04 to 18
No. of gear stages: 3
Power ratings: 10 to 1,850 kW (auxiliary drive power from 0.75 to 37 kW)
Transmission ratios: 25 – 71
Nominal torques: 6.7 to 240 kNm
Mounting positions: Horizontal

Applications
Lime and cement industry
Powders
Fertilizers
Minerals etc.
Suitable for transporting hot material (up to 1000°C)

With a power requirement of up to 30 MW, tube mills belong to the largest driven machines. They crush minerals, ores, coal, or cement clinker by impact and friction until the material is pulverized. The tube mills, which can have a diameter of up to 15 m and a length of up to 20 m, are installed horizontally. With tube mills, a distinction is made between different drive variants. Flender gear units for tube mills particularly specializes in:

Single pinion drives
Central drives
Load sharing girth gear units

For all three variants, FLENDER offers the entire drive system: Motor, gear unit, couplings, pinion, and girth gear, as well as auxiliary drive, safety devices, and diagnostic systems.

Flender single pinion drives

Ball mills and rotary kilns are most challenging applications that demand a big deal from the drive system. High performance and reliability are very important. When it comes to milling of iron ore, limestone and clinker large axial and radial forces occur. Single-pinion drives and Flender gear units for tube mills must be able to withstand the acting forces permanently.

FLENDER MDSS is a standardized gear unit that was optimized to meet the high requirements of the application. For the girth gear/pinion drive, a FLENDER gear unit with input shaft on both sides from the standard range is generally used as the main gear unit. The main motor is connected to one side of the gear unit, while the auxiliary drive is connected to the other side.

The pinion at the mill’s girth gear can be connected via a double-jointed coupling with spacer to ensure the adjustability of the pinion. Single pinion drives are supplied in both fixed and self-aligning design. MDSS offer flexibility and precision for the optimum tooth mesh.

Your benefits at a glance
Optimized gear teeth geometry
High rigidity of housing
High manufacturing quality
Minimum noise generation
Highest efficiency

Applications
Crushing of minerals, ores, coal, or cement clinker in the building materials industry and coal preparation

Flender central drives

Harsh working conditions and high dust concentrations in the production of cement, limestone and gypsum place high demands on the drive system In the case of central drives, the mill is driven from the end face.

Since there is no girth gear transmission, relatively large gear units are required even for low power rating ranges. The FLENDER load sharing gear units such as our DUORED 2 and FLENDER planetary gear units such as Planurex 2 and Planurex 3 series, offer the high power capacities demanded.

PLANUREX 3 central drives (HCCP) are low-maintenance and reliable. Their compact design offers a good price-performance –ratio. Moreover the less space requirement leads to cost savings when designing mills and their supporting structures.

Your benefits at a glance
Low-weight and compact drive
Save running costs through high efficiency and optimized maintenance intervals
High manufacturing quality
Low noise emission
Optimum power/weight ratio
Easily combined with other gear units such as upstream helical, worm, bevel or bevel-helical gear units
Optimized gear geometry
Low acquisition costs per newton meter
Long service life
First-class quality
Short delivery times
Very good price-performance ratio

Applications
Crushing of minerals, ores, coal, or cement clinker in the building materials industry and coal preparation

Flender girth gear units

Particularly innovative are the direct meshing FLENDER girth gear units (DMG2). This Flender gear units for tube mills was developed for driving tube mills with girth gears.

Here, the gear unit forms a single unit with the girth gear with which it meshes directly. Compared to the traditional pinion/girth gear variant with external pinion and girth gear, the system with the gear unit for the girth gear is by far more favorable. Tried and tested elements were brought together in an optimal combination. Fewer parts are required, and consequently the space requirements, and the installation and operating costs are reduced.

The current generation of DMG2 gear units is available in four sizes. Consistent standardization results in a high availability of individual components. The DMG2 Flender gear units for tube mills cover the entire power range from 1,200 to 10,000 kW in stand-alone operation and up to 20,000 kW with the use of a dual drive. Worldwide, over 400 of these large gear units have already been deployed successfully.

Your benefits at a glance
Compact and efficient drive
More effective use of the girth gear
Perfect load distribution across the entire girth gear width

Applications
Crushing of minerals, ores, coal, or cement clinker in the building materials industry and coal preparation

FLENDER