Problem Solution
A CASE STUDY FROM YOUR FALK SALES ENGINEER
New Falk Quadrive® Solves Old Service
Headaches
BIRMINGHAM, AL -- A new
Falk shaft mount reducer design gave Vulcan Materials-Dolcito a time-saving
option when a twin-tapered shaft mount was replaced on a conveyor feeding a
crusher
Quick Installation!
A Falk Quadrive shaft mount reducer was installed in half
the time due to the unique "Torque Assist" TA Taper®
bushing.
"With the tapered bushing, all we
had to do was slide the bushing onto
the shaft," says Maintenance
Manager Jerry Champion.
With the bushing in place on the
shaft, the speed reducer's tapered
bore was placed over the bushing
and a threaded nut tightened. The
bushing design uniformly draws the
speed reducer onto the shaft.
The torque assist TA Taper bushing is a feature of the Quadrive, the
newest shaft mount reducer from Falk. The Quadrive is coupled to a 7.5 hp motor.
The low speed shaft turns at 70 rpm helping process 220 tons per hour (tph)
while operating at 330 feet per minute on Vulcan's conveyor with 1 8-foot pulley
shaft centers. More than 1.5 million tons of limestone, sand and gravel, and
other lightweight material are processed yearly.
Easy On With TA Taper Bushing!
"The Quadrive, with the torque
assist TA taper bushing, is easy to put
on with only one key to line up and
fewer parts than a twin-taper design,"
notes Champion.
"With twin-taper shaft mounted
drives, you have two bushings and
the gear box to line up in one
keyway," he adds. "And, there are six
to eight bolts to tighten and line up.
This can be very difficult, especially if you're in a tight spot on an
above-ground platform and pressed
for room."
Straight bore designs offer no simple solutions either,
since the shaft has to be in near perfect condition. Says Champion: "Straight
bore drives are difficult to install as well because you have to be sure that
the shaft is clean. And even then, straight-bore speed reducers often times
don't go on or off the shaft easily."
Easy Off!
While installation of the unit saved
time, removal of the Quadrive with
the new bushing takes far less time
compared to other drive designs.
The TA Taper bushing design
marks an end to the need for
hammering and the damaging results.
Mechanical Advantage Frees
Unit
The threaded nut set screw is loosened and an optional
removal tool (available from Falk) is attached to lock the bushing nut. (Standard
tools can also be used.) When the high-speed shaft is turned, the drive's
mechanical advantage powers the unit free from the bushing
taper.
This will come as welcome relief
to Champion, who confronted a host
of problems during removal of the
twin-taper shaft mounted drive.
"It took us well over an hour to
pound off the old unit from the shaft.
It would have taken us much longer
if we were higher up," Champion
remembers. "The biggest problem
with the twin-taper design is that
you have to wedge the drive off. If
you can get the bushings to move,
you've got it. But, a lot of times, the
bushings are frozen to the shaft."
Additionally, pounding or forcing
the drive from the shaft often leads
to damaged or ruined equipment.
"The bushings are often ruined.
Sometimes the oil seals are cracked. And, in extreme situations, the speed
reducer is damaged beyond repair," Champion notes.
A Time-Saving
Advantage
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Installing a Falk single-taper shaft mounted
speed reducer in half the time needed for a twin-taper design.
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Simplified
installation and removal play a critical role in the life of a shaft
mounted speed reducer. Forcing the drive on or off the shaft can cause
undue stress to the equipment, not to mention wasted time and energy. This
latest technological development in the design of shaft mounted speed
reducers will give Vulcan Materials maintenance crews a time-saving
advantage during future changeouts.
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New Falk Quadrive Simplifies Shaft Mounted
Drive Removal
Falk's new Quadrive features the
benefit of a "Torque Assist" TA Taper
bushing.
Removal is now made fast and
easy. The TA Taper bushing setscrew
is loosened and Falk's TA removal tool
(patent pending) is attached to lock
the bushing nut. When the high-speed
shaft is turned, the drive's mechanical
advantage frees the unit from the
bushing taper.
Installation is equally as easy.
During installation, the TA Taper
bushing assembly is placed on the
driven shaft. Once the reducer's
tapered bore is in place over the
bushing, the threaded nut and
setscrew is tightened. Falk's TA Taper
design provides a uniform draw onto
the taper in less time and with less
difficulty than twin-taper or
single-flanged bushings. Other features include:
- Available in 11 sizes.
- Bushing bores from 1 " to 6
1/2".
- Capacities up to 300 hp.
- Produces up to 320,000 in-lb. output
torque.
- 5 to
350 rpm output speed.
- Horizontal and vertical mountings.
- Adaptable for flange-mounted and
screw conveyors.
- Accessories like motor mounts,
backstops, cooling fans, vertical
breathers and V-belt guards.
- Interchangeable with other brands.
- Minimal shaft engagement required
for retrofit.
- An inboard bushing location prolongs
the life of high-speed bearings by
minimizing sheave overhang.
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