Robust Encoders

Robust Encoders for Complex Applications

  • Greater functional component reliability
  • Higher converter plant availability
  • More precise measurement signals despite shock and vibration loads
  • Easy and time-saving programming

Before: Old skip-car control mechanism with two mechanical geared cam limit switches.

robust encoders

After: More precise signals because of robust encoders, combining bearing block and heavy-duty encoders

The skip-car control system used until now had two mechanical, geared cam limit switches that are slow to program. The mechanical overspeed switch can be unreliable when exposed to shock and vibration. These parts don’t have the needed accuracy, making them unsuitable for the modern needs of steel mill operations..

Upgrading to modern standards needs parts that are accurate, reliable, and easy to program. Hübner Giessen improved the system by replacing a geared cam limit switch with an FG 4 K incremental encoder and an AMS 4 K absolute encoder with an SSI interface. These encoders were mounted on a bearing block, boosting resistance to shock and vibration while compensating for slight mechanical differences in the current gearbox. In the next phase, the second cam limit switch will be replaced, along with the mechanical overspeed switch, which will be upgraded to a programmable electronic version. This plan ensures a stronger, more precise, and adaptable system, meeting the needs of modern applications.

In any case, you can count on our support for the complete project.
From the first discussion to the installation support on site. Contact us if you have questions about our robust encoders,

 

94 / Metals / Converter / Hoist
Case Studies

 

GN series motors

GN Series Motors

  • Rugged DC shunt-wound motors feature infinitely variable control
  • Designed for 20 journeys per shift (8h)
  • Short-term 3-fold overload permissible
  • Battery powered, automated guided vehicle system

Heavy-load transporters are used to transport the casting ladles from the warehouse to the casting house.

Battery powered and robust DC shunt-wound motor GN 17.17.4 for trouble-free operation without trailing cable.

To drive a 100-ton transport vehicle for casting ladles, the system needs adjustable DC motors powered by a 48V battery. These motors, connected to a gearbox, not only reach a speed of 10 m/min but also give full torque across the entire speed range, with a 3-fold short-term overload ability. Furthermore, the vehicle’s 625 Ah battery provides at least 200 minutes of runtime, allowing for 20 trips per shift. Therefore, the motor output must meet these needs effectively and reliably.

For each transport vehicle, Johannes Hübner Giessen supplied two low-voltage shunt-wound DC motors from the GN 17 series, along with a built-in spring-loaded brake. Additionally, these motors include a fan for cooling and are specifically designed for on-and-off use (S3 42% CDF). Moreover, they provide a rated torque of 17 Nm and can also handle a short-term overload of up to 50 Nm. Furthermore, a BAMOBIL battery controller effectively manages power to the DC motor, ensuring smooth and efficient operation.

 

88 / Metals / Casting / Ladle Transporter
Case Studies

 

Encoder solutions

Hot and Cold Rolling Mills – Encoder solutions

Hot and Cold Rolling Mills

Encoder solutions:

 

  • Easy exchange or extension of existing encoder solutions
  • Cost-efficient, as encoders can be exchanged selectively
  • Implementation in the shortest possible time, optionally SIL certified
  • Planning, delivery and mounting support from a single source

Exploded view

Exploded view

All around the world Hübner Giessen encoder solutions are installed at main drives of Hot and Cold Rolling Mills.

These large motors often run for many years and after a while the question about a possible encoder modernization arises to provide new or additional electrical outputs.

Our encoder solutions minimize the need for modernization. For example, the FGH 6 and FGH 8 encoders include an integrated mounting flange, which simplifies adding an additional encoder to the existing system.

You can add a freely programmable overspeed switch, a universal encoder system with fiber optic signal transmission (both optionally SIL certified), or an incremental encoder with a different pulse rate.

We provide full support throughout the entire project, from the first discussion to on-site installation assistance.

Keeping an Eye on Your Equipment

August through October is known as the windy season in South Africa. During this time, we have all witnessed the windstorms sweeping across the country, bringing with them the much-anticipated rain and the onset of summer.

When the weather turns unpredictable, companies in the engineering, agriculture, and mining sectors must stay vigilant about their equipment. Notably, a breakdown or potential injury on duty concerns everyone involved. Therefore, regularly checking all equipment is crucial to ensure no potential dangers are looming.

Neglecting the operational aspects of a plant leads to dangerous errors. Consequently, routine safety checks are vital to the success of any plant and the safety of its employees, ensuring that everything runs smoothly.

Moreover, mining equipment endures significant stress due to the workload it handles, which causes wear and tear on all the components that keep the plant operational. Thus, a strict maintenance schedule is essential to prevent downtime caused by equipment failure.

Furthermore, strong winds can blow dust and sand into a plant, damaging intricate parts of the operation that are not always visible to the naked eye.

To help you maintain your industrial equipment effectively, here are a few tips:

Five Tips for Successfully Maintaining Your Mining Equipment

First, Keep Machinery Lubricated at All Times
Without proper lubrication, any machine will eventually fail. Indeed, lubrication is as critical as the moving parts themselves. Regular and correct lubrication reduces excess friction, which in turn extends the machine’s lifespan and prevents premature deterioration. However, over-lubrication can cause issues such as energy loss, damage to seals, and an excessive buildup of grease. Therefore, always use the appropriate type of lubrication for each machine to avoid breakdowns.

Second, Clean Heavy Machinery Thoroughly
Heavy machinery has special seals to protect its intricate parts. If dirt and grime infiltrate these seals, they can cause catastrophic damage and loss, often unnoticed by the untrained eye. Therefore, immediately replace broken or torn seals, and keep breathers free from debris. Additionally, change filters as soon as they become dirty or clogged. Covering or storing machinery indoors during heavy winds or rain also prevents dirt and grime from causing trouble.

Third, Keep Up with Regular Maintenance
Inspecting or repairing only when something goes wrong isn’t enough to keep heavy machinery in top condition. For this reason, establish a regular inspection plan, and take detailed notes on any inspections performed. Regularly check gaskets, seals, belts, and pulleys for proper alignment. Moreover, continually monitor moving parts, such as gears, for wear and tear or damage, and apply proper lubrication to keep them functioning optimally.

Fourth, Monitor Wear and Tear
During normal operations, you may notice wear and tear on parts or machines. Addressing these signs promptly is crucial as they may indicate more severe problems, especially with braking systems. For instance, common signs of wear and tear include heat, vibration, and changes in belt shape. Overheating often results from improper lubrication, and vibration may signal misaligned gears or belts.

Finally, Train Operators Thoroughly
One of the most effective ways to keep heavy machinery operational is through thorough staff training. New employees should undergo intensive training to ensure they understand how everything works and know what to look for in case of a problem. Meanwhile, current employees should attend refresher courses and receive inductions on any new machinery or parts. Consequently, regularly scheduled training courses ensure that all operators are equipped to handle machinery correctly, reducing the risk of downtime or costly accidents.

If you want to extend the lifespan of your heavy machinery, the tips above will certainly guide you in the right direction.

When you need new equipment, parts, or assistance, Huebner Speed Monitoring is the partner you need. With years of experience in the mining and agricultural industries, Huebner prioritizes the safety of your workforce and equipment. Additionally, they tailor solutions for each customer. So, contact their friendly staff today to start a long and successful business partnership.