3. 14-Apr-14 Swati Gurav 3
• Sector gears are the mechanical
systems designed to reduce the motor
speed to the working speed of the
mill/kiln
Transmission is via gears
Gear units basically comprises of
1.Rotary parts- shafts and gears
2.Stationary parts- housings and bearings
4. 14-Apr-14 Swati Gurav 4
•Cement I Mills and Kilns
•Mining and Minerals I Mills, Kilns, Rotary Dryers
•Pulp & Paper I Kilns, Debarking Drums, Drum Pulpers
•Power Plants I Mills (Coal and Limestone Grinding/ FGD)
•Chemical I Fertilizer Industry I Kilns, Dryers
•Environmental Industry I Rotary Incinerators, Dryers
•Bulk Material Handling I Rotary Wagon Tippers
•Metal Industry I Converters, Smelters
•Food Industry I Rotary Ovens, Dryers
Applications
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aspects1.Selection of Service Factor
Higher service factor provides necessary rating to
prevent tooth breakage from starting and peak shock
loads
Critical aspectsCritical Factors
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aspectsCritical aspectsCritical Factors
• Previously load distribution factor was a fixed value
based on the face width
• Load distribution factor is one of the parameters that
goes directly into the horsepower calculation
• It accounts for uneven load across the face as a result
of misalignment, deflection and bending of teeth as well
as torsional twist and bending of pinion shafts.
2.Selection of load distribution factor
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aspectsCritical aspectsCritical Factors
3. Lubrication of gears
Asphaltic lubrication- a spray lubrication system that will provide
warnings of clogged nozzles or lines that are not providing
any lubricant
Grease lubrication- heavy oil base to provide a thick lubrication
film even at high temperature
Fluid lubrication- continuous lubrication which needs a pump
and a sump for recirculation of oil
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aspectsCritical aspectsLubricant analysis
Higher lambda value represents lower wear and higher
gear operating life
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aspectsCritical aspectsCritical Factors
4. Alignment
• The main purpose of maintaining proper alignment is
providing equal load distribution along gear teeth and
maintain it
• If misalignment occurs, one side of the pinion will be
overloaded causing tooth scuffing or scoring at the tooth
end
• To avoid all these problems the preventive action to be
taken is periodic checks for the alignment
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aspectsCritical aspectsCritical Factors
5. Improper joints of segments
• Pitch error at the joints causes knocking, vibration and
slackening of nuts
• Due to deformation in joints axial runout comes into
picture
• Remedy-
Proper heat treatment
i.e.
• Slowly heat upto 600oC
• Soaking at 600oC for 6-10 hours
• Cooling upto 300oC at the rate of 25oC per hour
• Cool down to ambient temperature in still air
13. Progress
• Catalogue Preparation
o Technical Content for catalogue was collected by referring
various catalogues of competitors.
o Images to be displayed in catalogue were segregated.
o Prototypes for catalogue front pages were discussed with
ODC creations.
• Reference Papers
Reference papers to be referred for bolt strength and thermal
analysis of a sector gear were obtained from internet.
14-Apr-14 Swati Gurav 13
14. Progress
• Standards
o Parameters to be taken into account during manufacturing
were noted.
o Types of lubrication systems to be provided were studied.
• Visit
o Pushpak trademech Ltd.
Ahmedebad.
14-Apr-14 Swati Gurav 14
15. Development
• Catalogue
o Refining for the catalogue content.
o Images to be edited for catalogue.
• Analysis
o Bolt strength analysis is to be done.
o Standard calculations and manufacturing techniques for
Sector gear are to be studied.
• ANSYS
Thermal Module of ANSYS software is to be studied and learnt
for thermal analysis of a sector gear.
14-Apr-14 Swati Gurav 15
