System and special solutionsfor heavy industrywww.pfaff-silberblau.com

Safety - Made by Pfaff-silberblau

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System and special solutions for heavy industryIn steelmaking and other heavy industries, drive technology is expected to lift, move and precisely position heavy loads under extremely adverse conditions, something that requires special solutions and technical expertise. Pfaff-silberblau has both, and for many years has been one of the world's leading providers of special drive technology components for steel-making and heavy industrial applications.

• Standard screw jacks for loads ranging from 0.5 t to 75 t• Heavy-duty screw jacks for loads ranging from 100 t to 200 t• Special screw jacks for special solutions• Special screw jacks for repositioning tundishes • Complete pot lifting systems for coating lines

The highest levels of automation and productivity are required, particularly in plant construction. This in turn means more

individual lifting and lowering mechanisms, feed drives and swivel actuators, together with their interfaces to electronic control systems.

Particularly in heavy industry, the drive technology must function reliably under the harshest conditions for years and years. Pfaff-silberblau supplies individual components as well as complete solutions for lifting systems in the steel industry. The products and services available extend from individual standard screw jacks to the development and manufacture of complete lifting systems, including the structural steel, control system, commissioning and service. The customer benefits from the highest levels of transparency in all phases of the project, starting with the conclusion of the contract to the handover of the system.

Pfaff components integrated in the "Steel" process chain

Tundish adjuster

Cold roller adjustment

Hot roller adjustment

Coil handling

Semi-finished product handling

Pfaff components in continuous galvanizing lines

Brush adjustment belt cleaning

Coil handling

Adjustmentof air knife system

Zinc pot lifting mechanism

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Screw jacks for heavy industryThe advantages of screw jacks compared with a hydraulic solution are obvious.

• Self-locking trapezoidal screw (the load does not lower in the event of a system failure) • High repeat and positional accuracy• Robust and reliable• Total synchronism in the case of multi-screw lifting systems (even if individual screws are subjected to uneven loading), no electrical synchronisation control necessary• Easy to install

Refer to the "Compendium Screw Jacks" catalogue for the dimensions of the 35 to 75 t screw jacks and other technical data.

Screw jacks SHE �5.1 SHE 50.1 SHE 75

Max. lift load 350 kN 500 kN 750 kN

Ratio N 10 2/3:1 10 2/3:1 12:1

Ratio L 32:1 32:1 36:1

Trapezoidal screw Tr 100x16 Tr 120x16 Tr 140x20

Technical data: �5 to 100 t screw jacks

Screw jacks SHE 100.1 SHE 150.1 SHE �00.1

Max. lift load 1000 kN 1500 kN 2000 kN

Ratio N 12:1 19:1 17,5:1

Ratio L 36:1 On request On request

Trapezoidal screw Tr 160x20 Tr 190x24 Tr 220x28

Buttress-thread screw S 160x20 / 180x20 S 190x24 / 200x24 S 220x24

Technical data: Heavy-duty screw jacks >100 t

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Screw jacks for roll pass system in a rolling mill

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Screw jacks for roll pass system

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Screw jacks for a sizing stand

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Screw jacks for heavy industry

Dimensional drawing heavy-duty screw jack SHE 100

Ball screw, planetary roller screw

Buttress-thread screw

Options Anti-turn device

Long safety nut with speed monitoring

Design A Design B

Lift

+ 6

5mm

min

. 520

5

Screw jacks for heavy industry

Dimensional drawing heavy-duty screw jack SHE 150

Lift

+ 8

0mm

min

. 625

Design A Design B

Ball screw, planetary roller screw

Buttress-thread screw

Options Anti-turn device

Long safety nut with speed monitoring

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Screw jacks for heavy industry

Dimensional drawing heavy-duty screw jack SHE �00

Design A

Lift

+ 1

25m

m

Design B

min

. 600

Ball screw, planetary roller screw

Buttress-thread screw

Options Anti-turn device

Long safety nut with speed monitoring

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Complete system solutionsMore and more companies involved in engineering and plant construction no longer just order individual components from their suppliers, but entire assemblies that the contractors themselves mount and commission. The advantages for the OEM in ordering complete• They can concentrate on their core activities: less pressure on internal departments• Systems are coordinated • Everything comes from a single source, fewer interfaces• Best possible assembly solution results in best possible overall solution• One point of contact• Simpler guarantee handling• Fast response times in the event of a stoppage• Responsibilities clearly defined

Pfaff-silberblau provides proven complete solutions for a broad cross-section of plant construction, for example• Rail Technology• Stage engineering• Petrochemical industry

Zinc pot adjustment

For steelmaking and heavy industry, Pfaff-silberblau has joined forces with an OEM to develop a furnace lifting system capable of handling furnaces filled with liquid zinc and weighing up to 750 t. As part of this process, Pfaff-silberblau has designed an extremely reliable mechanical lifting device that is used in continuous galvanizing lines (CGL) all over the world. The advantages of this furnace lifting system with screw jacks compared with hydraulic solutions are as follows: • Total mechanical synchronism• No forced synchronisation necessary• Optional oil cooling extends duty ratios• Long-life due to oil lubrication in worm gear• Self-locking buttress-thread screw• Low vibrations and oscillation, therefore no damage to the furnace insulation• High levels of safety thanks to nut breakage and synchronism monitoring• Can be customised to suit individual requirements• Comprehensive sensor system available as option• Trialled extensively

The focal point of the linear lifting system are the ultra-precise and proven screw jacks from Pfaff-silberblau. Four screw jacks with a special thread are used to lift and lower the zinc pot. These are mechanically attached and synchronised using a bevel gear system and connecting shafts. The low twisting angle of just ¼ degrees per linear metre in the drive and connecting shafts, coupled with the gear ratio reduction in the worm gear, results in extremely accurate synchronisa-tion within the lifting system - deviation is less than 0.1 mm.

The component parts are subject to the highest quality standards during manufacturing, a prerequisite for achieving this level of precision. The entire production process of the screw jacks is logged and is completely traceable. At the end of the production line, each gear mechanism receives an acceptance certificate that documents dimensions and func-tional parameters.

The reliable and ultra-precise screw jacks in the modular drive systems form the basis for tailored solutions. Pfaff-silberblau utilises them to create complete lifting systems capable of lift forces of up to 7500 kN. Special requirements and individual installation situations can also be catered for.

Regarding safety, the screw jacks comply with national and international regulations as set out in EN 280. This is achieved through the use of safety nuts and speed monitoring.

Numerous options are also available, such as an electric oil cooling feature that permits temperature-control operation, thus increasing duty ratios.

Max. lifting load up to 7500 kN

Motor speed 1500 1/min

Total ratio 25:1

Lifting speed 0,01 m/min

Lifting height up to 2,2 m

Duty ratio > 60 %

Technical data: Pot lifting system

Pot changing system lifting device

Functional diagram of pot lifting system

Working position

Maintenance position

POT �

POT 1

8

Pot lifting system

Complete system solutions Complete system solutions

700 t Pot lifting system

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Complete system solutions Complete system solutions

Standard Option

Buttress-thread screw ✘ -

Safety trap nut ✘ -

Nut breakage monitoring ✘ -

Wear monitoring ✘ -

Oil lubrication (wet sump) ✘ -

Oil temperature monitoring ✘ -

Spindle temperature monitoring - ✘

Electric oil level monitoring - ✘

Electric speed monitoring - ✘

Central lubricant sensor - ✘

Electric oil cooling - ✘

Control system - ✘

Structural steel incl. rails - ✘

Complete lifting system construction - ✘

Commissioning - ✘

Designs and options:

References:

525 ton pot lifting system in Jiangyin, China

520 ton pot lifting system in Caofeidan, China

520 ton pot lifting system in Mexico

500 ton pot lifting system in Brazil

500 ton pot lifting system in Hirohata, Japan

480 ton pot lifting system in Finnentrop, Germany

480 ton pot lifting system in Beijing, China

400 ton pot lifting system in Belgium

400 ton pot lifting system in Salzgitter, Germany

400 ton pot lifting system in South Korea

300 ton pot lifting system in Austria

Test configuration for trialling a 200 t screw jack type SHE 200 before use in a pot lifting system

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Screw jacks in special customer-specific designs Screw jacks in special customer-specific designs

Features:

• Planetary roller screw

• Totally encapsulated

• Visual lifting position display

• Oil-lubricated worm gear

• Integrated anti-turn device

Screw jacks for tundish adjuster

The lifting gear mechanisms that were developed and con-structed by Pfaff-silberblau in close collaboration with a re-nowned German steelmaker for use in a foundry comprise a transport unit that conveys molten steel from the smelter to the casting plant. Four lifting cylinders lift a 150 t casting gutter filled with molten steel by two metres in just one mi-nute - reliably and safely even under the harshest production conditions.

Max. lifting load per screw jack up to 500 kN

Motor speed 1500 1/min

Total ratio 18,5:1

Lifting speed 2,03 m/min

Lifting height 0,7 m

Duty ratio up to 40 %

Technical data: Tundish adjuster

Special solutions are used to deal with situations where stand-ard screw jacks can no longer be used due to plant-spe-cific considerations (installation space, lubrication, dirt, high temperatures, etc.).

These special solutions can, up to a point, be realised at rel-atively low cost using the modular system from Pfaff-silber-blau. Some of these solutions may, with the exception of a few components, require all the modules to be manufactured from scratch. To produce a lifting gear mechanism that is matched perfectly to the application in question, these special gear mechanisms are designed and developed in close cooper-ation with the customer's own development department.

The buggy is first lifted into its highest position and then positioned over the ceramic pipe, through which the molten material flows from the furnace into the buggy. Afterwards the rolling steel container is lowered so that the molten steel can be taken to the casting moulds. A special design, based on a modified version of the modular system, was required for this lifting mechanism. In addition to reinforced supports and guidance systems, extremely robust planetary roller screw were used to achieve a maximum lifting speed of 2 m/min. At 82 %, the degree of efficiency of this lifting mechanism is extremely high, allowing the input power from the drive motors to be reduced. The completely sealed construction ensures complete safety, even the extreme con-ditions in a steelworks.

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Screw jacks in special customer-specific designs Screw jacks in special customer-specific designs

Adjuster with tundish. Photo: Thyssen-Krupp

Photo: Thyssen-Krupp Photo: Thyssen-Krupp

Photo: Thyssen-Krupp

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Pfaff-silberblau Hebezeugfabrik GmbHAm Silberpark 2-886438 Kissing / GERMANYantriebstechnik@pfaff-silberblau.comwww.pfaff-silberblau.comPhone + 49 / 8233 / 2121-887Fax + 49 / 8233 / 2121-885

Lifting & Material Handling Equipement

Actuator Technology

Rail Technology

Stage Technology