Improving drive system efficiency for large-scale rotary kilns

Abstract

The objective of the present article is to ascertain the forces emanating from the interface between the girth gear and the pinion, which exert a direct influence on both the loading of the kiln supports and the selection of an optimal open-gear drive configuration for large-scale rotary units. Significance. Ensuring the straightness of the kiln shell axis constitutes a pivotal challenge in the design and operation of large rotary units. Deviations, even those measuring a mere millimeter, in long, heavily loaded kilns have been shown to redistribute support reactions, increase shell bending, raise radial loads in bearing assemblies, and induce noise and vibration. These phenomena, in turn, have been demonstrated to accelerate wear and increase the risk of failure. Mitigation of these adverse factors necessitates a thorough examination of gear-mesh loading to ensure stable, full-face tooth contact, as well as design solutions that are impervious to installation and assembly inaccuracies. This approach is a simple yet effective means of enhancing the reliability and service life of open-gear drives and their associated drive systems. Methodology. The study examined the loads generated in the gear contact zone and investigated how the geometric arrangement of the drive elements affected these loads. Results. The proposed mathematical relationships facilitate the evaluation of forces within the gear mesh, thereby establishing the dependence of mesh parameters on the geometric arrangement of the lever-mounted pinion. Scientific novelty. Mathematical relationships have been developed to quantify the influence of gear-mesh parameters and the geometric positioning of rotary-kiln open-gear drive elements on contact zone loads and their transmission to the support assemblies. The practical significance of the aforementioned topic is as follows: The paper presents an efficient open-gear drive configuration for a large-scale unit, providing calculation results to support the selection of appropriate geometric parameters, thereby ensuring effective operation.