38 n MECHANICAL POWER TRANSMISSION June 2024 www.drivesncontrols.com Gearbox-motor combination cuts conveyor running costs Industries such as quarrying and recycling are evolving in response to climate change pressures and soaring energy costs. The analyst McKinsey estimates that the mining sector alone needs to cut its emissions by 85% by 2050. Switching to efficient mobile electrified equipment, such as conveyors, will be a key to this transition. Electric conveyors tend to be larger and heavier than comparable hydraulic equipment. There is thus a growing demand for compact electric motor-gearbox combinations that can reduce footprints and weight, while maximising energy efficiency. In response to these pressures, the Northern Ireland drives specialist, Technidrive, has produced a compact track drive gearbox for heavy-duty conveyors which, it says, has 53% less mass than a typical bevel-helical gearbox of the same power, torque and speed. It also claims the total cost of ownership is up to a third lower than using conventional bevel-helical gearboxes. The Drum Drive range was originally developed for low-speed, high-torque feeders. It has since been expanded to suit high-speed, low-torque conveyors, using small-frame motors with high power ratios. Because of its small size and weight, the Drum Drive can be installed inside a conveyor head drum – unlike helical gearboxes. It acts as a bearing, eliminating the need for shafts and bearings that need regular lubrication. Fewer parts mean lower upfront costs, reduced maintenance and extended lifespans. The drive is also claimed to achieve 20% higher service factors, and 60% higher shaft radial load ratings. Oil seals in helical gearboxes can fail in arduous environments such as quarries and recycling plants because of their exposure to dust and water. To eliminate this risk, the new drive uses enclosed oil seals. The drive can be fitted with permanent magnet (PM) or hybrid motors containing PM, ferrite or neodymium magnets, as well as synchronous reluctance (SynRM) machines. Technidrive’s motor partner is WEG. n A Drum Drive for high-speed, low-torque conveyor applications Industrial gearbox market forecast to hit $45.7bn by 2032 Gearboxes are essential for transmitting power and regulating the rotational speed of machinery in a variety of industrial settings. Their primary function involves managing torque and loads to ensure reliable equipment operation. Industrial gearboxes are critical components in a variety of applications including conveyors and heavy machinery, and contribute to the efficiency, reliability and performance of industrial machinery. Growth in the market is being driven by a variety factors including the wider use of automation and the need for enhanced torque transfer capabilities. According to a recent report from the analyst Adroit Market Research, the prospects for the global industrial gearbox market are promising, with steady growth expected, driven by the expansion of manufacturing and construction activities around the globe. Adroit predicts that the industrial gearbox market will expand from around $30bn in 2022 to reach $45.7bn by 2032 – a CAGR of 5.4%. It expects the Asia-Pacific region to dominate the market because of a combination of the “robust” industrial development in the region, a surge in demand for machinery, and growing investments in infrastructure. The dominant industrial gearbox technology is the helical box, known for its high efficiency, smooth operation and low noise levels. These gearboxes can handle heavy loads, while transmitting high levels of torque. Recent advances have led to the creation of compact, lightweight helical gearboxes, further bolstering their popularity. Adroit expects the helical industrial gearbox to maintain its stronghold. Parallel-axis gearbox designs that allow efficient power transmission are usually employed in machinery requiring high torque and precision. Their straightforward construction and ease of maintenance have made them a popular choice. Angled-axis designs are also widely used, typically in applications such as automotive and aerospace where there are space constraints and specific functional requirements. In terms of end-use, Adroit expects the material-handling sector to dominate the global industrial gearbox market due to the growing demand for advanced materialhandling equipment for a wide range of industries. Industrial gearboxes play a critical role in moving materials efficiently. The increasing emphasis on optimising supply chains and streamlining logistics is helping to fuel the demand for gearboxes. www.adroitmarketresearch.com/ contacts/request-sample/3044 Photo: Nord
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