Bonfiglioli Transmission Introduced Large Industrial Drives

The new HDP Parallel Shaft and HDO Bevel Helical units in sizes up to 72,000 Nm are the result of more than three years development to produce good reliability and torque densities to record values, says Bonfiglioli National Sales Manager Steve Samson.

“The new drives - which will be tailored to customer requirements through extensive assembly and service facilities in Australia and New Zealand - feature excellent torque distribution across their entire ratio range, with gear ratios laid out in close progression and the drives having a rugged capacity to cope with the shock and impact of intermittent loads.”

“Outstanding research and development has gone into producing these drives, with Finite Element Analysis and Multi Body Simulations conducted in order 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
A Boundary element method was used to reduce the noise emissions through the identification of all the direct and indirect vibration sources of the gear unit in actual operating conditions,” said Samson.

Reliability is enhanced by a high radial load capacity, with 100 % heavy duty bearings, and by reduced vibration and noise levels achieved by gears that are entirely ground-finished, said Samson.

Units up to size 120 (35,000 Nm) feature rigid monoblock housings while larger units feature a horizontally split housing.

Input shafts are supported by robust taper roller bearings. They may be coplanar, sitting 90 degrees apart, for optional mounting positions, or allow both a main and pony drive to be fitted.

New generation heavy duty roller bearings are used to withstand the forces generated internally and applied externally. Accurate proportioning of the shafts allows for lifetime balance of each axis.

Gears of optimised geometry and profile (entirely ground finished to quality class DIN 6) feature high load capacity, extended lifetime and reduced noise in operation.

Output shafts are robustly fabricated from hardened and tempered alloy steel. Shafts may be requested as keyed hollow, solid or as hollow with shrink disc coupling for ease of mounting and dismantling. Large covers allow inspection of gears at any time.

The drives’ versatility in service is enhanced by numerous mounting options suitable to their typical applications, such as materials handling (inc belt, apron, bucket, screw and chain conveyors), manufacturing, mining, quarrying and minerals processing, rural and food product processing, paper, pumps, steel, sugar, timber, wrapping and stacking applications, and water and waste water treatment.

The drives’ multi machined surfaces and symmetrical design allows them to be used in either left or right hand configuration.

Introduction of the HDP and HDO ranges follows the large expansion ever of Bonfiglioli range and service facilities in Australasia, where it has more than doubled the size of its headquarters Down Under.

The new ranges will be stocked at Bonfiglioli’s new $8 million facility located near the M7 Orbital in the Western Sydney.

In addition to the capital investment in its new Australasian headquarters, Bonfiglioli is spending a further $8 million on stock inventories in Australia and New Zealand to ensure the broad availability, and prompt deliveries of its drive technologies.

Bonfiglioli has branch offices around Australia, plus a new branch in Auckland, New Zealand, where the company has a joint assembly venture facility with its Partner, Saeco Bearings and Transmissions, says Samson.

Ideal is the high level of partnership with Bonfiglioli, which is a world leader in drives technology with sales of more than $650 million a year and more than 2500 staff with extensive operations in mainland Europe, the UK, USA, Canada, South Africa, India, China, South Asia and Australasia.

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