Safety and ef­fi­ciency for ma­jor Aus­tralian port fa­cil­ity

DEMM Engineering & Manufacturing - - NEWS -

A SE­RIES OF seven Bon­figli­oli slew drives cus­tom- en­gi­neered in Aus­tralia for safety, dura­bil­ity and per­for­mance are be­ing in­stalled to power a stacker re­claimer for the stockpile area at a ma­jor Aus­tralian shipload­ing fa­cil­ity.

The spe­cially de­signed Bon­figli­oli 316 plan­e­tary bevel gear­box slew drives have sev­eral unique fea­tures and parts that have been de­signed and man­u­fac­tured in Aus­tralia, com­ple­mented by high- qual­ity parts sourced from Bon­figli­oli’s head­quar­ters and state- of-the art fa­cil­i­ties in Italy.

Bon­figli­oli’s Cus­tomer Ap­pli­ca­tion En­gi­neer­ing (CAE) team spe­cially de­signed the drives, which the cus­tomer (which can­not be named due to com­mer­cial con­fi­den­tial­ity rea­sons) will use to power the stacker re­claimers at the port, which is one of the largest in Aus­tralia, with ex­pand­ing through­put year- on-year. Three drives will be used on each of the two slews, with one spare al­ways avail­able to min­imise down­time and pro­duc­tion losses.

“We de­signed the drives to boost ef­fi­ciency, con­sume less en­ergy and pro­vide ul­ti­mate re­li­a­bil­ity,” says lead project en­gi­neer, Bon­figli­oli, Harry Singh.

“We had a quick turn­around time from re­ceiv­ing the or­der to de­liv­ery, to have the drives de­liv­ered dur­ing a sched­uled shut­down win­dow. This was a big chal­lenge, be­cause we sourced only high- qual­ity parts through­out the en­tire drive, which of­ten means longer lead times. Ad­di­tion­ally, de­spite en­gi­neer­ing com­plex­ity and spec­i­fy­ing all top- qual­ity parts from Aus­tralia or Italy, Bon­figli­oli’s drives were still more cost- ef­fec­tive than the older drives they were re­plac­ing.”


The slew drives are vi­tal to op­er­a­tional ef­fi­ciency, and to en­sure their smooth op­er­a­tion at all times, Bon­figli­oli’s slew drives of­fer dou­ble back- up for en­hanced safety.

“In ad­di­tion to the usual torque lim­iter found on most drives, these cus­tom-en­gi­neered slew drives have a se­condary en­coder on the bevel stage, which has sen­sors to mea­sure the drive at slow speeds and send data to the PLC (Pro­gram­mable Logic Con­troller), which will stop the drive if any prob­lems are de­tected,” said Singh.

“To pro­vide an ad­di­tional safety for the has­sle-free op­er­a­tion, these drives fea­ture a se­condary sens­ing de­vice ( proxy sen­sors), which can iden­tify any mar­ginal speed er­rors be­tween the mo­tor and gear­box shaft. The sen­sors, as well as all com­po­nent parts of the drive, were sourced from glob­ally proven and ISO- cer­ti­fied brands,” he said.


Bon­figli­oli slew drives, with typ­i­cal torque out­puts of up to 130,000 Nm, are de­signed to be in­dus­try bench­marks of safety, ef­fi­ciency and re­li­a­bil­ity. They fea­ture a re­in­forced bear­ing out­put shaft, an ec­cen­tric mount­ing flange op­tion for pinion/girth gear ad­just­ment and a huge shock load up to 2,000,000 Nm.

Mal­colm Lewis, Manag­ing Di­rec­tor, Bon­figli­oli Aus­tralia says that al­though these slew drives were highly cus­tomised to suit the cus­tomer’s unique ap­pli­ca­tion re­quire­ments, they were all de­signed to the top- qual­ity stan­dards of the in­ter­na­tional Bon­figli­oli Group, which has more than 3,650 em­ploy­ees in 22 coun­tries.

“When de­sign­ing these drives, our CAE en­gi­neers built upon a safe, durable and re­li­able base – the 316 slew drive – and added ad­di­tional safety and ef­fi­ciency fea­tures to suit the cus­tomer’s re­quire­ments,” he said. “All Bon­figli­oli slew drives are easy to in­stall, and have a pre­cise torque con­trol to en­sure smooth, ac­cu­rate per­for­mance in a wide range of ap­pli­ca­tions.”

The Bon­figli­oli drives will be de­liv­ered in two stages, the first of which was re­cently com­pleted. The first stage in­volved four drives that were in­stalled in Septem­ber dur­ing a planned shut­down.

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