Malmedie Drum Couplings

Malmedie Drum Couplings

Pioneering Torque Transmission Solutions

Malmedie Drum Couplings have transformed coupling technology with the invention of the world’s first barrel-roller drum coupling. Malmedie has led the way in innovation, consistently improving mechanical torque transmission systems. Their drum couplings efficiently combine high-capacity torque transmission with a compact design. As a result, they are crucial for key applications across various industries, especially in hoisting operations that encounter high radial forces.

Technical Overview

Innovative Design

Malmedie’s latest drum couplings, including the TTXL series, significantly advance from earlier models like RTT, NTT, TTX, and TTXs. These improvements highlight Malmedie’s dedication to setting new benchmarks in capacity and operational safety, which further strengthens its leadership in the industry.

Mechanism of Action

Malmedie drum couplings use a unique design to ensure efficient torque transmission. Hardened barrel rollers, placed precisely within dual circular gearings, manage force transmission even under extreme radial forces, like those in crane operations. This innovative design reduces the risk of sudden failures, a common issue with traditional gear couplings that often break under stress.

Operational Excellence

Malmedie’s drum couplings withstand high radial forces while maintaining reliable torque transmission. The external wear control mechanism allows for easy inspections without requiring disassembly. Additionally, some models include an automatic wear control system, which enhances safety, improves operational efficiency and supports predictive maintenance.

Versatile Applications

The German company’s products serve a wide range of industries, including ports, steel mills, mining, and hydropower. They perform exceptionally well in hoisting mechanisms, winching systems, and conveyor belt operations. Their versatility makes them a preferred choice in demanding industrial environments.

Custom Engineering Solutions

The innovative engineering firm excels in delivering custom-engineered solutions to complex challenges. With a modular manufacturing approach and complete in-house production in Germany, the company offers flexible designs and fast delivery, tailored specifically to meet client needs.

Commitment to Quality

Quality drives Malmedie’s operations, supported by  ISO 9001 certification. This rigorous quality management process ensures that every product meets the highest standards, providing the reliability and performance clients expect.

Conclusion

In conclusion, Malmedie drum couplings are more than just mechanical components—they are thoughtfully engineered solutions designed for optimal torque transmission, safety, and adaptability across a broad spectrum of industrial applications. Malmedie’s unwavering focus on quality and innovation solidifies its position as a leader in industrial coupling technology.

Optimizing Steel-Making: The U-ONE-(SAFETY-) Compact Encoder System

Key Benefits

The U-ONE-(SAFETY-) Compact encoder system offers several key advantages over older solutions. First, it allows direct mounting on the application shaft. As a result, this eliminates the need for extra gears, reducing mechanical issues and potential failures. Additionally, the system improves measurement accuracy by removing mechanical play caused by distribution gears. Furthermore, it is easier to set up than older mechanical switches, which helps reduce downtime during installation and maintenance. Moreover, the system allows for quick starts and restarts after adjustments. This, in turn, minimizes delays and enhances overall efficiency. These benefits make the U-ONE-(SAFETY-) Compact system an effective solution for improving control and precision in steel-making plants.

Before

In traditional setups, steel-making plants typically use mechanical cam limit switches and absolute encoders. These are mounted using extra gears. Consequently, this approach often leads to mechanical problems and inaccuracies. Extra gears can introduce unwanted movement and delays in signal transmission. Additionally, mechanical cam limit switches are difficult to adjust. As a result, they often lack the precision needed for modern industrial applications. This complexity and lack of precision can hinder efficiency and affect overall performance. Therefore, there is a need for a more reliable and precise solution. This solution must address these issues and improve operational efficiency in steel-making plants.

After

The U-ONE-(SAFETY-) Compact system offers a modern solution. It combines electronic position switches and an absolute encoder in a single unit. This unit mounts directly on the application shaft. Consequently, it removes the need for extra gears, significantly enhancing system accuracy and reliability. Additionally, the compact design simplifies installation and reduces the system’s overall footprint. This makes it more efficient and space-saving. By integrating these components into one unit, the U-ONE-(SAFETY-) Compact system provides a more streamlined solution. It effectively addresses the limitations of traditional setups and improves control in steel-making plants.

Task

In steel-making plants, accurately measuring and controlling converter angles is essential. Traditionally, this has been done using absolute encoders and mechanical cam limit switches. These are mounted with extra gears. However, this setup often results in inaccuracies due to mechanical play. Moreover, it is challenging to adjust mechanical switches, leading to inefficiencies. These issues can, therefore, compromise plant performance and reduce productivity. Thus, a solution that addresses these challenges is critical. Improving accuracy and reliability ensures smooth operations in steel-making plants.

Solution

The U-ONE-(SAFETY-) Compact encoder system effectively addresses these challenges. It integrates an absolute encoder and electronic position switches into one compact unit. This mounts directly on the application shaft, thereby eliminating the need for extra gears. This reduces mechanical issues and improves accuracy. Furthermore, Hübner Giessen’s special torsion-resistant couplings ensure precise operation. Additionally, the system’s easy setup and quick restart after adjustments streamline operations. Moreover, the system is available with optional safety certification, meeting SIL 2 / PL d standards. This makes the U-ONE-(SAFETY-) Compact system ideal for enhancing accuracy, efficiency, and safety in steel-making plants.

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.

Industrial braking systems for safety and efficiency

Industrial braking systems for safety and efficiency

Understanding Industrial Braking Systems: Beyond Cars

Many people are unfamiliar with industrial braking systems, even though they play a critical role in various industries. These systems ensure the safety of both human lives and machinery.

Bolstering Machinery Resilience with Storm-Proof Brakes

Braking systems are essential in manufacturing, mining, marine, and engineering sectors, where heavy machinery operates. These brakes are crucial for maintaining safety and efficiency in these industries. Let’s explore the workings of industrial braking systems in more detail.

Back to Basics

Brakes absorb kinetic energy by pressing two surfaces together, which brings an object to a halt. Operating at high speeds, brakes endure significant wear and tear and generate substantial heat during the process.

A Brief History

About half a century ago, drum brakes were the standard. However, drum brakes often led to heat buildup during heavy braking, as there was only one surface to dissipate energy and heat. The automotive industry recognized the need for a better system and transitioned to disc brakes in the 1970s. Disc brakes offered more efficient cooling since the rotor remained exposed to outside air. This improvement reduced the risk of brake fading and overheating. In manufacturing, this change significantly decreased machine downtime, improved maintenance efficiency, and enhanced operations in challenging environments.

Now that we’ve covered the basics and history of braking systems, let’s explore the different types of brakes you might encounter.

Different Types of Braking Systems

  • Hydraulic Brakes: Industrial applications such as mining equipment, cranes, and winches commonly use hydraulic brakes, which transfer pressure from the control to the brake mechanism via braking fluids.
  • Fail-safe Brakes: Fail-safe brakes activate automatically during a power interruption, making them invaluable in areas prone to power outages. Elevators, for example, use this system to prevent catastrophic falls.
  • Pneumatic Brakes: Also known as air brakes, pneumatic brakes use compressed air stored in a reservoir. A valve releases the compressed air when the lever or pedal is actuated, engaging the brake.
  • Electromagnetic Brakes: These advanced brakes use electromagnetic force to create friction, which stops the moving object. Trains, trams, and aerospace programs frequently employ this technology.
  • Spring-Applied Brakes: Similar to fail-safe brakes, spring-applied brakes stop or hold a load if power is cut off. Hoists commonly use this braking system.
  • Storm Brakes: Designed to prevent cranes from moving unintentionally during seismic activity or massive windstorms, storm brakes protect lives and equipment from damage.

Brakes are indispensable in today’s machinery. They often go unnoticed despite their critical role in keeping production plants running smoothly. A machine breakdown can lead to significant production delays, costing both time and money.

The Makeup of Brakes

Manufacturers create brakes from various materials tailored to specific applications. Some brakes withstand moisture better and last longer, while others offer a smooth, gentle performance on the rotor but may have a shorter lifespan. In the industrial market, ceramic and semi-metallic brakes are common. Metallic brakes, known for their aggressiveness and cost-effectiveness, suit heavy-duty applications. Ceramic brakes handle heat better, wear down more slowly, and are gentler on the rotor.

Where to Go for Your Industrial Brakes

When searching for an industrial brake supplier, Heubner Speed Monitoring offers a range of brakes and solutions designed to minimize machine downtime. They provide high-quality braking supplies and services, making them an ideal partner for any machine-driven enterprise.

Heubner Speed Monitoring stocks a variety of braking systems, including:

  • Wheel and Gantry Brakes
  • Drum and Band Brakes
  • Disc Brakes
  • Motor Mounted Brakes

Heubner Speed Monitoring aims to partner with you, providing reliable solutions and products that enhance your business operations.

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