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Gearbox for rolling
The client trusted IZDIT for the design, manufacture and installation of a large gearbox intended for a hot rolling mill.
From the bidding phase to the final development of the project, the technical and reliability requirements set by the client were extremely demanding.
Thanks to its highly qualified team with extensive experience in highly complex projects, IZDIT addressed the challenge with agility and flexibility, adapting precisely to the client's specific needs.
During the final run-in test, carried out at IZDIT's facilities, the client highlighted the excellent performance of the equipment, especially for the low levels of vibration and temperature achieved.
Technical specifications:
Total weight of the gearbox (empty): 51 tons
Push rack
The client contacted IZDIT to undertake the manufacture and assembly of a push rack for the tube rolling mill. The precision required both in the joints and in the rack alignment made IZDIT the best option for the client, given the high standards in design, manufacture and assembly.
The rack is 50 meters long divided into 5 sections of 10m each. The assembly of the shafts on the rack was carried out in cold using liquid nitrogen. The joining of the sections was carried out using links mounted hot with an interference of 1mm.
The precision required in the alignment was tenths of a millimeter in the total of 50 meters, a standard that IZDIT strictly complied with.
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Click on thumbnails to enlarge
Vertical mill repair
IZDIT was commissioned to repair a vertical mill drive gearbox that showed a high degree of deterioration due to lack of maintenance. Thanks to the agile and professional response of IZDIT's After-Sales Service, the project could be executed within tight deadlines.
A complete reverse engineering process was carried out to generate the gearbox drawings and critical components to be replaced were identified. Among other actions, a new worm-gear set was manufactured and deformations in the housing were corrected through precision reboring.
After the manufacture and reconditioning of the components, the final assembly and a sensorized run-in were carried out, successfully passing all functional tests.
Likewise, the gearbox was equipped with a permanent vibration and temperature sensorization and monitoring system.
Complete gearbox retrofitting
The client requested IZDIT to perform a global inspection and complete replacement of components of a gearbox belonging to a cement plant.
As a first step, an exhaustive analysis was carried out through reverse engineering of all components, identifying those that required renewal. After the manufacture of the necessary parts, the complete assembly of the gearbox and its test bench run-in were carried out.
Verifications included contact controls, vibration levels, temperatures and clearances. The equipment was delivered to the client with full satisfaction for the quality of the work and compliance with the highest technical standards.
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GSearbox for rolling
The gearbox for hot rolling mill box is a key component of the rolling mill. Its function is to transmit the torque and speed from the main motor to the work rolls, ensuring powerful, stable and synchronized rolling even under extreme conditions of load and temperature.
Main technical characteristics:
• Helical or straight-toothed hardened and ground gears, designed to support very high torques.
• Parallel or orthogonal shaft configuration, according to frame design.
• Welded steel housing, machined with high precision.
• High capacity bearings and forced lubrication systems by oil circuit.
• Capacity for continuous operation at high temperatures and intense vibrations.
• Possibility of direct coupling with cardan shafts or transmission shafts to the rolling cylinders.
Function: Ensure robust, precise and durable transmission between the main motor and the rolling mill box, maintaining the uniformity of the rolled product and process stability.
Planetary
The planetary gearbox for steel industry is designed to transmit very high torques in compact spaces, guaranteeing high efficiency, precision and reliability in extreme working environments such as rolling mills, winders, straighteners or feed lines.
Main technical characteristics:
• Multistage planetary configuration, with hardened and ground gears.
• High torque density, ideal for high power drives.
• Efficiency above 95% and quiet operation.
• Modular housing, robust and easily integrable into industrial systems.
• Forced lubrication or oil bath with optional cooling.
• Designed for continuous operation under severe load and temperature conditions.
• Possibility of integration with electric, hydraulic or servomotor.
Typical applications:
Rolling mills, winders, unwinders, roller conveyors, pickling lines, presses and straighteners.
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Gearbox for sheet straightener
Precision gearbox with parallel shafts for 7-roller sheet straightener.
- It is the mechanism responsible for transmitting and adapting the speed and torque from the motor to the straightening rollers.
- It is usually a gearbox or multiplier with helical or planetary gears.
- Its function is to synchronize the rollers and guarantee uniform sheet straightening through hardened and ground gears.
- It has variable speed adjustment, according to the type and thickness of the sheet.
Synchronized transmission through hardened and ground gears.
Shear - Gearbox
The gearbox for circular shear is responsible for transmitting movement from the main motor to the blade carrier shafts, guaranteeing adequate speed and torque for the thickness and type of material to be cut.
It is usually composed of helical or ground gears, housed in a cast body machined with precision.
Common features:
- Transmission through hardened and ground gears.
- High capacity bearings to support radial and axial loads.
- Forced lubrication or oil bath.
- Synchronized output shafts to maintain cutting precision.
- Possibility of incorporating integrated variators or geared motors.
Main function: Ensure perfect synchronization between the upper and lower blades, obtaining clean and precise cuts even at high speeds.
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Click on thumbnails to enlarge
Pull rolls
The gearbox for sheet pull rolls is responsible for transmitting the torque and speed necessary to drag the sheet continuously and controllably throughout the process (straightening, cutting or rolling).
It is designed to offer high precision, high torque and synchronized operation, guaranteeing constant advance without slippage or deformation.
Common technical features:
- Hardened and ground helical gears.
- Robust machined steel housing.
- Parallel or coaxial shafts, according to roller arrangement.
- High radial and axial load capacity.
- Possibility of direct coupling to motor or through elastic coupling.
- Oil bath or forced circuit lubrication.
Function: Ensure smooth and constant transmission of movement to the pull rolls, maintaining adequate tension on the sheet throughout the process.
Winder and dryer
Orthogonal gearboxes for dryer battery drives are used in paper machines to transmit movement precisely and synchronously to the dryer cylinders, guaranteeing uniform advance of the paper web during the drying process.
These gearboxes must withstand demanding working conditions: high temperatures, continuous operation and variable loads.
Main technical characteristics:
- Orthogonal configuration, with hardened and ground helical bevel gears.
- Nodular cast or welded steel housing, machined with precision.
- High efficiency and low noise level, even at high speeds.
- Output shafts designed for direct coupling with dryer cylinders.
- Forced lubrication and optional integrated cooling.
- Possibility of integration into synchronized drive lines with connection shafts.
Function: Ensure robust, reliable and synchronized transmission of movement to each dryer, maintaining tension and paper uniformity throughout the battery.
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Click on thumbnails to enlarge
Winder
The paper winder drive gearbox is the element responsible for transmitting the torque and speed from the motor to the winding shaft, allowing controlled and uniform winding of the paper web coming from the main machine.
It must guarantee variable speed, high torque at low revolutions and precise synchronization with the rest of the production line.
Common technical features:
- Hardened and ground helical gears.
- Housing machined in cast iron or steel, with high rigidity.
- Output shafts designed to support high radial and axial stresses.
- Possibility of integration with electric motors or servomotors.
- Forced or oil bath lubrication system.
- Prepared for paper tension control and automatic reel change.
Function: Ensure smooth, efficient and adjustable transmission, guaranteeing uniform winding and no paper breaks, even at high speeds.
Speed multiplier
Our client requested the development of engineering and the manufacture of a speed multiplier for the use of gas generated in coke batteries. The objective is to partially reduce coke as fuel for the blast furnace, reducing CO2 emissions by 125,000 tonnes per year.
Some notable features:
- Input speed of 1500 rpm and output of 8000 rpm.
- White metal bearings that allow high working speeds.
- Labyrinth seals. There is no direct contact between moving and fixed parts, reducing wear. The choice of oil viscosity required for the process is important.
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