Kiln Drive

Kiln drive consists of :
Single Pinion Dual pinion
4
6
7
8
 Girth Gear mounted on Spring Plates
attached to kiln shell.
9
 Spring Plates installed by :
 Welding in the kiln shell
 Installed with bolts in girth gear
10
Spring plates possess a high degree of
flexibility in the radial direction , This
should permit expansion of shell
without disturbing center distance
between gear and pinion.

11
Girth Gear Pinion
Kiln shell in cold condition
(not expand)
Spring plates in cold
condition
Kiln shell in hot condition
(Expand shell)
Spring plates in
hot condition
(bent to take expansion )
Spring plates permit

expansion of shell without Fixed
disturbing center distance
Between gear and pinion 12
Spring plates profile
Spring plates profile
Y Design
Assemble the gear on the kiln .
Adjustment radial runout and axial runout

are minimal .
 On Ground Preparation of the Gear :-
i. Place the gear segments on clean level timbers.
ii. Position the gear with marks “A-A” and “B-B (and “C-C and “D-D” if
applicable) in position for eventual joint connection work.
iii. Assemble the regular studs .
iv. Torque the Mechanical Tensioner jack bolts .
v. Insure that a 0.04mm feeler gauge will not enter the assembled joint.
vi. Inspect the alignment of the gear joints. Axial and radial steps at the
joints should be less than 0.05mm

 Install the spring mount pins :-
 Install all the chairs :-
I. Set all the chairs in appropriate positions on the gear web
in spaces between the springs. Locate chair at narrow zone
for spring, but avoid interference points.
II. Tighten the side bolts to hold the chairs in place.
III. Swing the tail ends of the spring mounts as far as possible
toward the gear web plate.
IV. Tie the spring mounts against the web with lengths of soft
heavy-gauge baling wire or an acceptable substitute to
secure the arrangement for crane handling maneuvers.
 Installing the Gear on the Shell :-
 Setting Chairs on the Shell :-
 Setting Chairs on the Shell :-
I. Back out the adjustment chair side bolts far enough to

allow for setting the chairs in relation to the guide lines.
II. Weld the support leg channels to the shell with a 5mm
size fillet weld.
III. Tighten the adjustment chair side bolts alternately and
gradually to move the gear into the best possible
position relative to the surface of the shell.
IV. Tighten the bottom bolt of the adjustment chairs
enough to support the gear when the crane is released.
 Preparation for Shell Rotation:-
I. Place the drive bar(s) about 25mm from the legs of the
chairs to allow for adjustment of the gear and such that
there is adequate clearance for welding the spring mounts
to the shell upon final alignment.
II. A single drive bar is usually adequate for a new gear on a
new machine, but when a gear is being reversed, or a new
gear is replacing a worn gear on an older kiln, it may be
necessary to place a drive bar at each chair in order to
handle the internal refractory and coating load at the start
of rotation.
 Preparation for Shell Rotation:-
III. Tack weld in place.
IV. Install the bridge arrangement(s).
V. Install bridge arrangement side bolts and top bolts tight
against the bar(s) for rotation of the gear for runout test
VI. Weld the bridge legs to the kiln shell.
VII. Installing the Pinion(s) Apply lubricant to the pinion
before turning .
 Checking Gear Axial Runout:-
I. Gear runout tests are not valid if the shell is, in any way,
affected by any source of heat, including sunshine.
II. Check the axial runout on the gear rim end face or the
proof surface if one exists.
III. Set dial indicator “A” on the surface to be aligned.
IV. Set dial indicator “B” on the same surface, at 180° apart
from dial indicator “A” .

 Checking Gear Runout:-
I. Dial indicator stems must be perpendicular to the surface
being aligned.
Dial indicator
measuring axial
runout
Dial indicator
measuring axial
runout
V. Rotate the Kiln to bring gear station number 1 in line with
dial indicator “A” .
VI. Zero both dial indicator “A” and “B”.
VII. Record station number, dial indicator “A” reading, and
dial indicator ”B” reading in Table 1.
VIII. Rotate the Kiln so that the next station is aligned with
dial indicator “A”.
IX. Record station number, dial indicator “A” reading and dial
indicator “B” reading in Table 1.
X. Continue this procedure through one complete revolution.
XI. Repeat readings at station number 1.
XII. Compare the first axial run out reading of station number
1 with the second reading.
XIII. If the value in column 5 is outside the range of 0.05mm to
-0.05mm dial indicator “A” or “B” may have been
inadvertently disturbed.
XIV. Accordingly, discard all readings and repeat process.
 Table 1: Gear Rim Axial Run out :-
Column 1 Column 2 Column 3 Column 4 Column 5
Dial Dial
Column 2 Add Take half
Station indicator Station indicator
with signs Columns of
Number A Number B
reversed 1&3 Column 4
Reading Reading
 Does second reading of Column 5 at station number 1 result in a value outside

the Range -0.05mm to 0.05mm?
Maximum Plus =
Maximum Minus =
Total Axial Run out = Maximum Plus - Maximum Minus
(Accept / Reject)
 Allowable Axial Run out :-
 Obtain the allowable axial runout from the gear

assembly drawing or calculate the allowable axial
runout per the following specification.
0.083 mm/m of Pitch Diameter
0.001″/ft. of Pitch Diameter

 Table 2: Example Axial Run out :-
Column 1 Column 2 Column 3 Column 4 Column 5
Dial Dial Column
indicator indicator 2 Add Take half
Station Station
A B with Columns of
Number Number
Reading Reading signs 1&3 Column 4
(mm) (mm) reversed
1 0 4 0 0 0 0
2 - 0.15 5 - 0.05 + 0.05 - 0.1 - 0.05
3 + 0.1 6 + 0.05 - 0.05 + 0.05 + 0.025
4 + 0.225 1 - 0.1 + 0.1 + 0.325 + 0.1625
5 + 0.05 2 - 0.15 + 0.15 + 0.2 + 0.1
6 - 0.15 3 + 0.075 - 0.075 - 0.225 - 0.1125
1 - 0.15 4 - 0.125 + 0.125 - 0.025 - 0.0125

 Table 2: Example Axial Run out :-
 The second reading of Column 5 at station number 1 = - 0.0125 mm

It is in the Range ( -0.05mm to 0.05mm )
Maximum Plus = + 0.1625
Maximum Minus = - 0.1125
Total Axial Run out = + 0.1625 – (- 0.1125 ) = + 0.1625 + 0.1125 = 0.275 mm
≈ 0.011 inch
 Pitch Diameter of this Girth Gear = 7.2m ≈ 23.6 Feet
 0.083 mm/m of Pitch Diameter
 0.001″/ft. of Pitch Diameter
 Allowable Axial Run out for this Girth Gear = 0.083 x 7.2 = 0.6 mm
= 0.001 x 23.6 = 0.024 inch
( 0.275 < 0.6 Accept  )

 Allowable Axial Run out :-
0.024 inch
 Checking
Gear Radial
Runout:-
Dial indicator measuring

radial run out placed near
the pinion
 Checking Gear Radial Runout:-
I. Check the radial run out over the tooth tips.
II. Record the data in Table 3.
Station Dial indicator
Number Reading
1
2
3
 Does a comparison of the first and second reading of run out at station 1
result in a value outside the range of -0.05mm to 0.05mm ?
Maximum Plus =
Maximum Minus =
Total Radial Run out = Maximum Plus - Maximum Minus
(Accept / Reject)
 Allowable Radial Run out :-
 Obtain the allowable radial runout from the gear

assembly drawing or calculate the allowable radial
runout per the following specification.
0.125 mm/m of Pitch Diameter
0.0015 ″/ft. of Pitch Diameter

 Allowable Radial Run out :-
0.035 inch
Backlash & Root clearance
BACKLASH
49
Backlash & Root clearance
ROOT CLEARANCE
51
Girth Gear & Pinion Pitch lines
Girth Gear
Girth Gear
Pinion
** Scribe Lines are Separate (Hot condition )

Acceptable
52
Girth Gear
Girth Gear
Pinion
Pinion
** Scribe Lines are Tangent ( Hot condition )

Acceptable
53
Girth Gear
Pinion
** Scribe Lines are Overlap ( Hot condition )

Unacceptable
54
55
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 Spray Pattern :-
 An important factor for operational reliability is a perfect spray pattern

without any gaps, i.e. the lubricant must be distributed evenly over the
entire height and width of the tooth flanks .
 Inadequate spray pattern's; the individual patterns do not overlap .
 The spray nozzles should not be installed in an upward direction since
the spray heads would become clogged by returning used lubricant.

57
Preferable orientation of a spray nozzle
(X = 200 ± 50 mm)
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59
60
61
62
63
 The hydraulic motor is mounted directly onto
the pinion drive shaft. As there are no high-
speed elements, which need reducing in
speed, the hydraulic motor can develop its
exceptionally high torque from zero speed,
indeed it can maintain full shaft torque from
stall to full speed condition.

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M
71
72
73
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Friction drive through support
rollers:
(This type of drive is only suitable for two station kilns )
 MECHANICAL:
Planetary gears with built in barring
devices, cardan shafts and electric motor
drives.
 HYDRAULIC :
Hydraulic motors with pump station
75
 Friction drive through support rollers:
(This type of drive is only suitable for two station kilns )
• Planetary gears with
MECHANICAL
built in barring devices,
cardan shafts and
electric motor drives.
• Hydraulic motors with

HYDRAULIC
pump station
76
Mechanical friction drive
77
78
Traditional support
___________________________________________________________
Self-aligning support
___________________________________________________________
Hydraulic friction drive
82
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Kiln Drive

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Kiln drive consists of :

Single Pinion Dual pinion

flexibility in the radial direction , This

should permit expansion of shell

without disturbing center distance

between gear and pinion.

Spring plates permit

Adjustment radial runout and axial runout

i. Place the gear segments on clean level timbers.

applicable) in position for eventual joint connection work.

iii. Assemble the regular studs .

iv. Torque the Mechanical Tensioner jack bolts .

joints should be less than 0.05mm

I. Back out the adjustment chair side bolts far enough to

III. Tack weld in place.

IV. Install the bridge arrangement(s).

V. Install bridge arrangement side bolts and top bolts tight

VI. Weld the bridge legs to the kiln shell.

VII. Installing the Pinion(s) Apply lubricant to the pinion

affected by any source of heat, including sunshine.

proof surface if one exists.

III. Set dial indicator “A” on the surface to be aligned.

from dial indicator “A” .

 Does second reading of Column 5 at station number 1 result in a value outside

 Obtain the allowable axial runout from the gear

0.083 mm/m of Pitch Diameter

0.001″/ft. of Pitch Diameter

1 - 0.15 4 - 0.125 + 0.125 - 0.025 - 0.0125

 The second reading of Column 5 at station number 1 = - 0.0125 mm

( 0.275 < 0.6 Accept  )

Dial indicator measuring

 Obtain the allowable radial runout from the gear

0.125 mm/m of Pitch Diameter

0.0015 ″/ft. of Pitch Diameter

** Scribe Lines are Separate (Hot condition )

** Scribe Lines are Tangent ( Hot condition )

** Scribe Lines are Overlap ( Hot condition )

 An important factor for operational reliability is a perfect spray pattern

entire height and width of the tooth flanks .

 Inadequate spray pattern's; the individual patterns do not overlap .

 The spray nozzles should not be installed in an upward direction since

the spray heads would become clogged by returning used lubricant.

the pinion drive shaft. As there are no high-

speed elements, which need reducing in

speed, the hydraulic motor can develop its

exceptionally high torque from zero speed,

indeed it can maintain full shaft torque from

stall to full speed condition.

• Hydraulic motors with

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