Services

Ball bearing slewing rims

Tenova TAKRAF supplies its partners throughout the world with top quality ball bearing slewing rims that are split upward of a diameter of 6 m or as rolled bearing races.

• Design
     - in segments
     - one-groove or multi-groove
     - hardened or naturally hardened raceway

• Ball bearing slewing rings consist of:
     - ball race segments made of heat-treated steel with a strength
       of about 1000 N/mm2
     - high-quality balls
     - ball race cover, if requested
     - ball cages without intermediate pieces

• Fabrication size
     - diameter: > 5000 mm
     - segment length: max. 4500 mm (chord)
     - min. groove diameter: 100 mm

Gear rims

Gear rims in all diameters between module 20 and module 40 are fabricated at the Lauchhammer works.

• Design
     - in segments
     - modules 20 to 40
     - straight involute toothing according to DIN 867
     - internally and externally toothed

• Gear rims consist of:
     - cast steel
     - forged material

• Fabrication size
     - diameter: > 5000 mm
     - segment length: max. 4500 mm (chord)
     - min. groove diameter: 100 mm

For further information please contact us.

Belt pulleys

Belt and rope pulley as major components of belt conveyors are fabricated by Tenova TAKRAF with maximum diameter of 2500 mm.

• Design
     - drive, take-up, return, snub pulleys
     - also in antimagnetic design
     - lagging: rubber or ceramic material
     - diameter: max. 2500 mm

• approx. 170 pulleys produced in the period between 2000 and 2004

Rope pulleys

• Design
     - left-handed and right-handed
     - with shaft or hub
     - diameter: max. 1800 mm
     - length: max. 10000 mm
• approx. 40 pulleys produced in the period between 2000 and 2004

For further information please contact us.

Ball supports

Tenova TAKRAF provides ball supports with special bronze shell and a maximum diameter of 1500 mm.

• Design
     - with bronze shell
     - with PTFE shell segments
     - with split ball

• Fabrication size
     - diameter: max. 1500 mm

• Max. load
     - from: Pperm= +490 KN / - 98 KN
     - to:  Pperm= +24518 KN / -3334 KN

For further information please contact us.

Bucket wheel gearbox

Tenova TAKRAF newly-developed bucket wheel drive units form the core of further modernizationprocesses.

• Design: one-line or multi-line
• Power range: 500 kW to 2500 kW
  

For further information please contact us.

Bucket wheels

For the enhancement of bucket wheel excavators productivity Tenova TAKRAF manufactures complete bucket wheels with diameters up to 25 m.

• Design
     - single-plate or two-plate
     - in one piece or in segments

• Bucket wheels consist of:
     - hub part
     - conical centre part
     - outside ring with bucket fastening
     - antiwear lining

• Fabrication size
     - diameter: up to about 25 m
     - weight: up to about 80 t per welding group

For further information please contact us.

Crawler travel gears

Complete crawler travel gears of welded design as single or group travel gears are manufactured by Tenova TAKRAF.

• Welded design
  Crawler travel gears consist of:
     - crawler girders- various two-, four-, six- or eight-wheel bogies
     - return and drive tumblers
     - hydraulic system and lubrication
      (conventional lubrication or lifetime lubrication)
     - take-up device and cover

• Fabrication size
     - total weight: max. 130 t
  Rail travel gears

• Design
     - as single-wheel travel gear in welded design
     - as group travel gear mounted in bogies
     - track wheels with slide bearings or antifriction bearings as requested
     - driven or non-driven travel gears

Rail travel gears

• Rail travel gears consist of:
     - travel gear frames/bogies made of structural steel in welded design
     - installed axles and track wheels
     - mounted drives, brakes, couplings and motors

• Fabrication size
     - weight: preassembled units max. 130 t

For further information please contact us.

- We offer optimum and use-related advice on and supply of spare and wear parts.
- We produce high-quality structural steel and mechanical component.
- Adapting of spare and wear parts is ensured for existing equipment and the modernisation of machines and plants.
- On the basis of documents submitted to us we are able to produce further spare and wear parts as well as complete subassemblies for our customers.

Crawler treads

• Design
     - welded type
     - one-link or two-link
     - die-pressed bottom plate
     - crawler links made of cast steel or
       chilled cast manganese
• Fabrication size
     - pitch:   250  - 1000 mm
     - WIDTH= 1000  - 4500 mm

Buckets

• Design
     - welded type
     - half-round or rectangular
     - with rip teeth or corner cutters
     - armoured or non-armoured or as requested by customer

• Fabrication size
     - content: 100-4000 l

For further information please contact us.

Regular inspections and maintenance

Our service is based on detailed engineering knowledge and decades of experience in the operation of individual machines and complete systems
We offer the following services:

• Regular inspections of machines and equipment in accordance with
  the mining regulations issued by the local mining authorities

• Preparation of informative inspection reports, including repair instructions

• Preventive repairs, including the replacement of spare and wear parts

On the basis of the specification of TAKRAF, inspections of bucket wheel excavators, belt wagons, spreaders, shipunloaders and various cranes were carried out in 20 countries during the past 10 years.

For further information please contact us.                                    

Reconstruction, modification, modernisation

Our service is based on detailed engineering knowledge and decades of experience in the operation of individual machines and complete systems
We offer:

• Performance-increasing modernisation

• Modernisation of subassemblies while maintaining the technical parameters to reduce the scope of maintenance and repair

• Adapting of equipment to new technological operating conditions

• Development and manufacture of special electromechanical and hydraulic drives.
  Since 1998 TAKRAF has refurbished 21 bucket wheel excavators with bucket wheel drives made in Lauchhammer throughout the world.

• Qualified training and instruction of the operating personnel by our specialists after completed refurbishment

For further information please contact us.

Training and instruction

Our service is based on detailed engineering knowledge and decades of experience in the operation of individual machines and complete systems

• Even before commissioning training programmes ensure the qualified training and instruction of the operating and maintenance personnel.

• We offer to carry out the training courses both at the jobsite of the equipment and at the locations of Tenova TAKRAF.

For further information please contact us.

Immediate service

Our service is based on detailed engineering knowledge and decades of experience in the operation of individual machines and complete systems.
In order to minimise any downtimes of the equipment and plants, we provide support around the clock a. o. by means of:

• Immediate response by dispatch of specialist personnel to analyse the malfunction and secure the equipment

• Technical evaluation of the components and subassemblies as to their reusability

• Preparation of a complete repair offer

• Rapid supply of all spares and subassemblies required for the repair

• Dispatch of specialist personnel for supervising the repair

For further information please contact us.

Work farmed out by industrial contructors

• Compact and welding-intensive steel structures with mechanical machining made of profiles, plates and castings with a material thickness up to 250 mm as well as with maximum component weights up to 130 t and with customized corrosion protection

• Highly loaded and calculation-intensive components made of alloyed steels, structural steels and high-tensile fine-grained steels with yield points up to 600 N/mm2

• Mechanical machining capacities on boring mills, large vertical turning and boring mills and special lathes

• Annealing of components

• Refurbishing of crusher components

• in fields, such as: 
     - transport installations
     - foundry equipment
     - steel works equipment
     - power plant equipment

For further information please contact us.

Work assemblies

Complex manufacture and functional test/test rig run
(hydraulic and pneumatic units) of:

Compact machines 

Surface Miners

Transport crawlers

For further information please contact us.

Erection

The TAKRAF erection division coordinates all supplies and services on site when erecting complex integrated plants worldwide.
the scope of services of TAKRAF includes:

• Structural and mechanical erection

• Highly qualified welding work

• Workmanlike riveting

• Technological planning and execution of complicated erection and dismantling

• Provision of specialists for erection supervision

• Commissioning and performance tests

 For further information please contact us.

Quality control

Tenova TAKRAF’s quality assurance is carried out in compliance with DIN EN ISO 9001:2000 in all phases of design, manufacture and erection.

The quality control comprises:

Quality monitoring parallel to manufacture

Material testing up to level 2

Non-destructive material tests

• Ultrasonic test

• Wall thickness measurement

• X-ray examination up to 50 mm material thickness

• Magnetic particle crack test, dye penetrant test

• Hardness test

• Testing of castings and forgings as well as welded joints

Ultrasonic test of ball race segments  

Magnetic particle crack test of axles

Ultrasonic test gearbox inner parts  

Magnetic particle crack test of pulley shells

 
 
Ultrasonic test of belt pulleys   

For further information please contact us.

Measuring techniques

Large-volume 3D measurement and length measuring technique

• Sokkia 3D measuring system
  Range: 100 m
  Accuracy: ± 1 mm

• Faro laser tracker
  Range: 35 m
  Accuracy: 0.02 mm +1.1 μm/m

• PC-aided evaluation with test sketches and data export

• Measurement of covered points
  All around measurement and change of position possible

Measurement of gearbox casings for large gearboxes by means of the Faro laser tracker 

Crane measurement by means of the Sokkia 3D measuring system

3D measurement of complex components after machining   

Measurement of inner parts of large gearboxes 

 
3D measurement of a 1000 t shipyard crane by means of the Sokkia measuring system

For further information please contact us.

Gearbox tests

• Trial runs and functional tests of large gearboxes in-house and outside manufactured, with and without load

• Testing of gearboxes with rated power up to 2 x 1250 kW, load simulation depending on gearbox power up to 2500 Nm at n= 1000 min-1

• Automatic recording of temperatures, speeds, load torques and other parameters

• Simultaneous testing of two gearboxes is possible by means of the BackToBack method
   
  

   
Gearbox test rig for large gearboxes 

Testing of oil flow and contact reflection on tooth flanks

     
  
Gearbox trial run of two gearboxes of the same design by means of the
BackToBack method with load reversal 

Process picture with parameter indication on gearbox test rig  

Testing of a 1000 kW bucket wheel gearbox

For further information please contact us.