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Alignment-free heavy-duty drives that integrate motor and gearbox are being custom engineered by Bonfiglioli for low-maintenance high performance in rugged, remote and demanding applications.

The new HD alignment-free drives (AFD) – one of the latest of which was engineered for an inclined ship-loading coal conveyor in Indonesia – join Bonfiglioli’s expanding range of Australasian-engineered mounting options for specific applications.

The HD AFD combinations, in capacities up to 1,722kW and 150,000Nm, offer an alternative to laser-aligned baseplate types while allowing the versatile use of close-coupled IEC B5 flange-mounted motors up to a 315 frame size.

The easily installed HD AFD drives complement Bonfiglioli’s HD Power Pack drives on base plates and Hi-Torque drives combining HD drives and Trasmital planetaries.

The HD drive combinations are particularly suited to conveyor drives and materials-handling applications across a range of industries, including manufacturing, mineral processing, primary processing, resources, energy and water, and waste water HD AFD models can save time and money in a range of applications because there is no need to laser align the motor and gearbox shafts.

In addition to reduced initial costs compared with traditional baseplate designs, the HD AFD configuration enhances serviceability by permitting high-speed components to be removed and replaced without the need for realignment.

Finite-element analysis and multi-body simulations were conducted extensively to identify the stress pattern on each of the main components and to optimise the design for: system structural stiffness; gear geometry; shaft deflection; extended gear and bearing lifetime.

Features of the HD drives include: ratios from 7:1 to 500:1; reduced noise emissions from fully hardened and ground-alloy steel helical and bevel gears to DIN Class 6; SG cast-iron housings and high-grade alloy steel shafts with induction hardened seal journals to ensure greater service life in demanding conditions; high efficiencies from fully hardened and ground-alloy helical and bevel gears in conjunction with premium high-speed bearings; superior lubrication achieved by combining splash lubrication with dedicated galleries and lubricant collection pockets incorporated into the internal walls of the housing and side covers; heavy-duty bearings; all units feature premium brand roller bearings, allowing high-load carrying capacities and consistent bearing lifetimes throughout gearbox stages; numerous mounting and shaft options resulting from the HD’s multi-machined case and symmetrical design; shaft options include hollow-keyed bore, single or double solid-keyed, shrink disc and male/female splines on request.

Bonfiglioli

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