Leading Gearbox Manufacturers in India for Travelling Grate

If you are a Travelling Grate Manufacturer and are looking for a reliable supplier of Gearboxes then you are at a right place. This blog will give you a clear insight of reliable manufacturer of gearboxes for travelling grate. Top Gear Transmissions the leading manufacturer of Industrial Gearboxes in India is supplying highly efficient and reliable gearboxes for travelling grate application from last two decades. With more than 20000+ gearboxes installed all gearboxes are running satisfactory.  Efficiency of travelling grate is very important, inefficient travelling grate boilers causes a considerable energy waste. According to statistics there are >500 000 industrial boilers, representing about one-third of the total nationwide coal consumption. Most of these industrial boilers are coal fired travelling grate. The thermal efficiency of many of these boilers is only 60–70% which leads to a remarkable waste in energy. Use of hydraulic drives or inefficient gearboxes is also one of the factors that cause tremendous loss of energy. Hence if you are looking for highly efficient drives for your travelling grate, Top Gear Transmissions is one of the renowned suppliers of the gearboxes.

What is Travelling Grate?

The traveling grate is a conveyor that transports balled iron ore concentrate through cross-flow processing zones. The conveying element is a continuous loop assembly of slotted ferrous stainless steel grate plates, chain castings, and side plates to carry a bed of agglomerates. The upper, active, carrying portion of the conveying element is supported level and flat over a head shaft, intermediate upper supporting shaft/roller assemblies and a tail shaft. The grate is driven by a Gearbox and a variable frequency drive and motor or hydraulic drive at the head shaft, and sufficient speed variation is provided to maintain the required bed depth over a reasonable wide variation in feed rate. The processing zones consist of furnace over the active run, and wind boxes underneath. These are enclosures to contain and direct process gases as they flow through the grate. The elements of the conveyor and the upper and lower enclosures are supported on a frame of steel structural members. The frame, being a machine element, is meticulously set, rigidly braced, and force-air cooled in the preheat zone to assure the true alignment of the conveying element during operation, heat-up, and cool-down.

Why to prefer Top Gear as a reliable source of Travelling Grate Drives:

Case Study:

Challenge:

As discussed earlier the efficiency of travelling grate is the major concern for many manufacturers. Wherein earlier many of the manufacturers were using hydraulic drives which were inefficient in operation. The movement of travelling grate was not uniform which resulted into jamming and showed lot of wear and tear in rachet and pawl. This drives had more operating & maintenance cost for hydraulic oil pumps & accessories. There were lots of leakage problems observed due to use of these drives. Cost of these drives was also very high. Periodic Oil replacement was one of the factors accounting for huge maintenance. Taking into consideration these challenges Top Gear Designed Efficient range of Planetary Gearbox series which resulted into elimination of the challenges faced due to hydraulic drives with added benefits of planetary drives.

SOLUTION:

Top Gear Analyzed the application –Travelling Grate and accordingly designed the planetary drive series such that it would suit for various kinds of mounting requirements. Especially Top gear offered these series in Foot mounting and shaft mounting with high reduction ratios.  

RESULTS:

Uniform movement of travelling grate was achieved which eliminated Jamming and wear & tear of Rachet Pawl. Earlier energy conversion was from electric to hydraulic and from hydraulic to mechanical, in this arrangement energy conversion was directly from electric to mechanical which resulted in less energy losses and helped to achieve huge power savings (about 40%). Installation of direct shaft mounted drives eliminated the leakage problems. Compactness of drive resulted into more space saving. This drive also reduced initial cost of installation with negligible operating & maintenance cost.