Chapter 1-5

 

1.0 INTRODUCTION

1.1  

Background study This project focus on designing a complete reliable an Open Gear

Lubrication pray yste! yste!,, this system function to supplied the lubricant to the Open Gear system. This Open gear is a huge gear which used to operate the horizontal ball mill. The Open gear contains 2 big gears which the biggest one we called it the Girth gear (Drien gear! and the smaller gear called it as pinion gear (Drie gear!. To operate the Open gear we need to lubricate the gears contact surface, so that the gear tooth flan"s contact is not running in the na"ed metal which can cause damage to the gear tooth flan"s surface. 1."

Open Gear  

Open or semi#enclosed gear dries, also "nown as heay duty gear dries it has been a common method of power transmission since the beginning of industrial reolution. Generally, open gear dries are the most economically type of gear drie alternatie for  use in applications where high load carrying capacity and long serice life under seere shoc" load condition are re$uired. %t is these characte characteristic ristic in addition to fle&ibility in the machine's design that hae made open gear dries the most common type of drie used for ball mills, and grinding mills, "ilns, dryers, draglines and shoels. ost of this gear is made from oerseas accept the pinion which it can be fabricate locally regarding to its size is smaller compare to the girth gear. This open gear is usually manufacture by cast iron in a big foundry the pinion is casted in 2 separate pieces which is the gear and the shaft. The big girth gear is also usually casted in 2 pieces which the gear is casted in half. This big gear than will need to undergo the heat treatment process to release the stress of the metal and also to produce re$uired properties.

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)igure *.* + all ill 1.#

Ba$$ %i$$

 - ball mill is a type type of grinder grinder used to grind materials into into e&tremely e&tremely fine powder powder for use in mineral dressing processes, paints, pyrotechnics and ceramics. ost of the machine is used on the cement industries and also in the mining industries. The conentional arrangement of the ball mill drie and transmission is usually comes from electric motor engage to the gearbo& by hydraulic coupling and after that, transmit the rotation to the pinion gear which is the drie gear to rotate the girth gear which is the drien gear. The girth gear is the largest gear in the system and it is attached to the ball mill to rotate the mill.

Girth

Main gear box From electric motor

Pinion gear

)igure *.2 + orizontal ball mill anatomy

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 - ball mill is a horizontal cylinder partly partly filled with with steel balls balls (or occasionally occasionally other other shapes! that rotates on its a&is, imparting a tumbling and cascading action to the balls. aterial fed through the mill is crushed by impact and ground by attrition between the balls. The grinding media are usually made of high chromium steel.

)igure *./ + Grinding edia The mill is usually diided into at least two chambers, (Depends upon feed input size presently mill installed with 0oller 1ress are mostly single chambered!, allowing the use of different sizes of grinding media. arge balls are used at the inlet, to crush clin"er  nodules (which can be oer 23 mm in diameter!. all diameter here is in the range 45+ 65 mm. %n a two#chamber mill, the media in the second chamber are typically in the range *3+75 mm, although media down to 3 mm are sometimes encountered. -s a general rule, the size of media has to match the size of material being ground8 large media can9t produce the ultra#fine particles re$uired in the finished cement, but small media can9t brea" large clin"er particles.   1.&

'rob$e! st state!ent

%nside the local mar"et at alaysia there is no local design for the open gear lubrication lubrication spray system, there is seeral systems design from outside of the country but it is 3

 

e&pensie. )rom that point of iew there is an opportunity to design a spray system which can be applied not only for the open gear but probably can be modified to supply grease to the bearings in the future and most important it is cheap.

ost common problem from e&isting product is it is e&pensie since the spray system consist components from oersea and the complicated of the system itself. The most e&pensie item in the e&isting spray system is the control deice for the system itself  this control deice will wor" as a brain to the system and there is 2 types of spray system control deice whether by using 1: which it is ery e&pensie or by using simple electrical relay switch which is ery big and bul"y . The e&isting system itself is ery difficult to maintain since the system is so complicated with the sensor and 1: control, not many people can understand how the system wor"ed. %n the real situation in the cement plant the spray system is usually handled by section leader and most of them the education bac" ground is not high and this will cause problem for them to handle the system. %f there is system failure and it is related to the 1: control we need the O; specialist from oersea to do the repair.

The system size is $uite bul"y and ery hard to do installation on the site for the normal engineer it is a challenge to locate the parts at the site. )rom the e&perience to install the e&isting spray system it is needed to hae 2 phases. The first phases it is needed to locate the spray system controller and do the piping of the system and when the mill is shut down than the second phase to locate the spray nozzle and the connection of  piping can be done.

1.(

Ob)ecti*es

The summaries of the objecties are as follows8 i.

To des design ign the Open Open Ge Gear ar ubri ubricati cation on