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Agitator Drive
Mixing Solutions Drive
For Top and Bottom Entry Applications
All Mixing Solutions Agitator Gear drives are designed specifically
for mixing service offering field proven performance and reliability.
Whether your application is 0.25kW or more than 2000kW our range of standard
and custom designed gear drives will meet your needs.
Modular design construction techniques allow a wide variety of configurations to be tailored quickly and effectively to meet your needs.
Common Features
All housings are machined in one operation to exacting tolerances on computer
numerically controlled, machining centres, ensuring the accurate alignment
and angular displacement of housing bores, providing a stable rigid foundation
for the location and support of all Major Gear Drive Components; critical
to the overall performance and reliability of the mixer drive. Interchangeability
of future spare parts is assured.
The co-axial flanged motor mounting bell
housing used by Mixing Solutions:
• guarantees motor alignment without the need for spacer or shims,
• greatly simplifies maintenance
• reduces noise and vibration often associated with foot mounted
motor configurations
• accepts a wide range of standard motor / variable speed drive
options
Rigorous quality control of component manufacture,
test running and checking of tooth contact on all drives ensures gear
drive efficiency and reliability is maintained. Higher efficiency means:
• Quieter operation
• Cooler operation
• Longer lubricant life
• Extended gear drive reliability
Drywell
The "No-leak" output shaft drywell feature
isolates the low-speed output shaft from the oil to prevent
lubricants from leaking down the output shaft and contaminating the product.
Dynamic lip seals are fitted to retain grease lubricant and provide secondary
sealing.
Most industrial drives would not be able to offer this.
Gear Shafting
Rigidity and accuracy of gear support shafts is extremely important to
the efficient and reliable operation of any agitator drive.
The Mixing Solutions drives avoid the use of taper fit gears and overhung shafts to support primary high speed input shaft pinions. The elimination of the overhung shaft design concept avoids misalignments often associated with taper mismatch and allows the high speed input pinion to be mounted between bearing supports for maximum rigidity, reducing deflection and vibration due to gear tooth separation forces.
The
large section output shaft drive quill provides high rigidity and prevents
harmful gear deflection ensuring quiet and efficient operation of the
bevel gears under the most arduous mixing conditions.
Right Angle drives
- 3800 Series
Casing
A
one piece gear case produced in high quality close grained
cast iron.
Bearings
The high load carrying capacity back to back mounted taper roller bearings
are used throughout the 3800 SERIES. The Mixing Solutions design standard
calls for a minimum B10 life of 100,000 hours ensuring long and trouble
free operation of equipment. Output shaft bearings are independently grease
packed and sealed.
Gears
High
efficiency through hardened and helical primary change gears with case
hardened and matched lapped spiral bevel final reduction gears. All
gears are designed and manufactured strictly in accordance with the latest
AGMA standards.
Strength Durability and Quality of manufacture are key factors in Drive Design. 3800 Series Mixer Drives currently have the highest strength and durability ratings available for this type of drive consistent with the use of specific alloy steels and modern manufacturing techniques.
Helical change gear sets are simple to fit and permit 12 standard output speeds to be used without major disassembly of the gear reducer.
Lubrication
Efficient splash lubrication provides a reliable and copious supply of
oil to gears and high speed bearings under all climatic conditions. All
output shaft bearings are independently grease lubricated. The drive is
provided with a visible indication of oil level.
Mounting
Regardless of drive of motor size, all 3800 agitators require only the
nozzle for mounting, no additional supports or steadies of any kind are
required.
Parallel Shaft Drives
– PVE Series
Casing
Gear housings comprise a two piece cast steel (fabrication on
larger drives) suitably reinforced and stress relieved
to withstand all static and dynamic loading generated in operation.
Bearings
Back to back taper roller bearings are incorporated giving a minimum design
life of 100,000 hours B10 on all bearings when operating continuously
at most design speeds and powers.
Gears
Gears are designed to the latest AGMA Standards to withstand all shock
loading associated with agitator service. Mixing Solutions' PVE Reducers,
available as top or bottom-entry, parallel gear configurations, actually
exceed all current industry standards. So you get more dependable service,
lower maintenance costs, and greater efficiency.
Mounting
Regardless
of drive of motor size, all PVE agitators require only the nozzle for
mounting, no additional supports or steadies of any kind are required.
Seal Options
All drives can utilise the Mixing Solutions Modular arrangement
to incorporate vessel lip seals, packed glands or single / double mechanical
seals.
Lubrication
Immersion of gears in an oil bath provides splash lubrication to all rotating
components within the agitator drive housing ensuring long and trouble
free operation of the equipment as an added safety feature. (In PVE-D
gear drives a subsidiary shaft driven pump is also included to safeguard
against operation with low oil levels.) Due to the above feature lower
output shaft bearings are grease lubricated on larger units, sealed for
life bearings for the smaller drives.
Large
oil capacity lowers operating temperatures, so oil retains a higher viscosity
and gear, bearing and seal life are extended.
Auxiliary cooling systems are available for larger high speed units, subject to application.
Covers, shims, gaskets and blind-tapped end cover holes retain lubricant, eliminating oil and contaminant leakage, reducing maintenance and downtime.
Magnetic oil drain plug.
Gear Drive Service
Factors
The
service factor of a gear drive is defined as the lowest A.G.M.A. mechanical
rating (strength or durability) of any pinion or gear in the drive divided
by the full motor nameplate power. The initial design rating and selection
of the correct service factor has a direct effect on the long term reliability
of any mixer and its initial purchase price.
A change in service factor for any given load condition will affect the life expectancy of both bearings and gears within the gear drive.
Increased Service Life
Bearing L10 life varies inversely to the load raised to the 10/3 power
for roller bearings and to the third power for ball bearings, therefore,
an increase in service factor from 1.25 to 1.5 will increase the expected
service life of the mixer by approximately 80%. This increase could also
be expected to increase the purchase price by approximately 10%.
Depending upon initial design rating, higher
service factors should be applied to standard industrial gear reducers
to ensure long term reliability in addition to which gear reducer output
shaft bearing capacity should be checked with the manufacturer.
Reduced Ratings
Since A.G.M.A requires that anti-friction bearings are selected to yield
an average life of 25,000 hours or not less than 5,000 hours L10 life
at a service factor of 1, many standard industrial gear reducers are designed
with lower bearing life ratings than purpose-built agitator drives.
Service Factor Selection
In order to select the correct service factor for any mixer drive system
a detailed knowledge of the loadings associated with the particular process
application must be known.
The table below gives some examples of typical service factors applied to particular applications. Mixing Solutions engineers will advise the correct factor to be applied for your specific duty condition.
Service Classification Guide
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U = Uniform Load
M = Moderate Load
H = Heavy Load
