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Energy saving rebuild for tyre shredder
ERIKS UK has recently applied its engineering know-how to the re-manufacture of a tyre shredder used at one of the UK's largest tyre recycling centres. ERIKS specified and sourced a complete range of power transmission products for the in-house build, ensuring a more efficient and productive finished machine.
The tyre-recycling centre in question is capable of recycling up to five million individual tyres each year and reducing them to a fine quality crumb which can be used for a range of products including sports surfaces and children's playgrounds. The operator had a requirement for a damaged tyre shredder to be fully overhauled. A large number of components needed to be repaired or replaced including the motors, gearboxes, couplings, bearings and drive chains; due to the high energy usage of the machine the client also saw this as an opportunity to up-date the shredder and make it more energy efficient.
Following approval from the client, ERIKS engineers completed a detailed strip-down and inspection of the entire machine. Mahesh Patel, Technical Manager at ERIKS, says: "Once we had seen the damage that had been caused we could identify which parts could be repaired and which needed to be replaced. We then worked with the customer throughout the project, specifying and supplying the best components for the job to rebuild and update the shredder; not having to outsource jobs to other companies allows us to drastically reduce lead times and manage costs."
Large 75kW WEG high efficiency motors were chosen to drive the main shears that reduce the tyres to a fine crumb, smaller WEG motors were also chosen to drive the primary handling rotors that feed the tyres into the shears. One of the benefits of WEG's W22 range is its energy efficient performance, which reduces losses by 10-40% compared with typical motors. Fenaflex Tyre Couplings were used to connect the motors to the inline gearbox. The couplings are highly efficient and have excellent shock absorbing properties, isolating the motors from vibration and torsional oscillations. The Tyre couplings have zero backlash, which is ideal for reversing applications, especially when using geared drives. Wear can be detected through visual inspection.
The two in-line reduction gearboxes in the main drive system were stripped and assessed, due to the significant wear present on the gear teeth, all gear internals were replaced with new case carburised gears manufactured in-house. Seals and bearings were replaced or upgraded as necessary using leading brand components with high wear factors and lower friction coefficients for maximum efficiency. Right-angle Fenner gearboxes were used to drive the handling rotors and the opposing ends were mounted on SKF housed bearings, reducing the maintenance requirements and maximising robustness in the design.
In addition to the motors, couplings and gearboxes, ERIKS also supplied components such as seals, gearbox bearings, drive chain and sprockets.
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