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The synchronised sets of industrial gearboxes, available from Bonfiglioli Transmission , are being used on Sydney’s important Harbour Bridge to drive two 60-tonne workmen’s gantries essential to an upgrade announced to extend indefinitely the lifespan of this bridge.
The compact and versatile A series bevel helical gearboxes, the same type used in manufacturing, mining, materials handling and primary processing applications, are used in sets of eight on each mobile platform to drive them along rails beneath the length of the 503m long main arch of the bridge.
Supplied by the prominent Australian Industrial Crane manufacturer Eilbeck Cranes, the platforms feature sophisticated encoders to ensure smooth synchronous operation of their A60 series Bonfiglioli Gearmotors, which, with 2.2kW installed motor power and 2117Nm output torque, drive four sets of wheels on each side of each platform.
The compact drives also feature stainless steel brake components especially fitted to the brake motors to ensure reliability of operation in marine environments.
The drives are designed to ensure longevity of service on the bridge, which was opened in 1932 and is one of Australia's well-known and photographed landmarks, along with the Sydney Opera House.
The Sydney Harbour Bridge is a large steel arch bridge (and is just 66cm shorter than the Golden Gate Bridge). The top of the bridge stands 134m above the harbour and has a total length of 2.3km, carrying eight road traffic lanes and two rail lines.
At the time of construction, 96 Steam locomotives were positioned in various ways to test the strength of the bridge.
During the bridge’s 75th anniversary last year, the NSW Minister for Roads, Eric Roozendaal announced the $A85 million structural and strengthening upgrades to maintain its good condition and to extend its lifespan.
“We want to be celebrating the Bridge on its 100 and 200 anniversaries. This work is designed to guarantee that,” said Eric Roozendaal.
The Managing Director of Bonfiglioli Transmission (Aust and NZ), Malcolm Lewis says the Bridge represents one of Australia’s big industrial and structural maintenance task, involving more steel (55,000 tonnes) than was used to build the ocean liner Titanic.
Painting alone required a total of 270,000 litres for the first three protective coats and the job has continued in a never-ending sequence, from end to end, ever since.
The current refurbishment programme, scheduled for completion next year, includes the two new gantries for which the Bonfiglioli drives were chosen.
“This a project of national importance, so it was a considerable distinction to have our drives chosen by Eilbeck Cranes to provide the high standards of performance and reliability required,” he said.
The highly durable Bonfiglioli A series, now available in 12 sizes from 0.9-55Kw and 150Nm-14000Nm torque, is well-known for its torque per dollar value for money and achieves its versatility by boasting a ratio range of up to 1700:1 in a single gearbox.
The A series covers an enormous range of small-to-medium-sized applications within industries such as construction and quarrying; cement; civil engineering; electricity generation; food processing; glass and bottle manufacture; general manufacturing; bulk materials handling; metal production, including foundries; mining; petroleum and gas production; printing; pulp and paper; timber processing; textile; clothing and footwear manufacture; pharmaceutical processing and water and sewage treatment.
Equipment in which the A series may be used includes conveyors, cranes, elevators, mixers, pumps, valves, winches and special purpose equipment.
Bonfiglioli Transmission’s A series drives feature FEA (Finite Element Analysis) procedures in its design and construction. These allow for lightweight construction whilst maintaining strength and durability from case-hardened nickel chrome steel gears, says Malcolm Lewis, who added that major features of the A series include high torque, high efficiency and low noise.
Operating efficiencies are enhanced by Bonfiglioli Transmission’s high performance patented hypoid bevel gear pair, which gives significant energy savings.
Low noise gearing is achieved by locating the bevel gear pair at the output stage of the gearmotor. This allows noise reductions significantly below similarly sized traditional bevel helical gearmotors. It allows the A series to conform to the most arduous of mechanical specifications.
The A series wide ratio range (with up to four reduction stages in the larger units) permit one A series to be used where previously two gear units increased dimensions and cost.
The A series is also available with compact motors, to further reduce overall dimensions and increase cost-effectiveness.
The recent expansion of the A series range follows large expansion ever of Bonfiglioli range and service facilities in Australasia, where it has more than doubled the size of its headquarters Down Under. The A series is stocked at this new $8 million facility located near the M7 Orbital in the Western Sydney.
In addition to the capital investment in their new Australasian headquarters, Bonfiglioli Transmission are spending a further $12 million on stock inventories in Australia and New Zealand to ensure the broad availability, and prompt deliveries of their drive technologies.