FleXeDrive – saving time and setting new standards

In a world that seems to be constantly speeding up, heavy industries like mining are subject to rapid fluctuations in commodity prices. When that happens, they need to quickly ramp up production to meet the changing demand. And that can mean acquiring new infrastructure to support their operations, just as fast. Responding to this kind of demand, SEW-EURODRIVE has introduced FleXeDrive, an industrial drive solution that sets new standards in drive technology and is typically available in four to six weeks.

FleXeDrive is a new product, consisting of robust, industrial-scale motors and gearboxes available in a multitude of combinations. As the name implies, FleXeDrive is all about flexibility. Drawing from stock items, held for the purpose in Australia by SEW-EURODRIVE, OEMs and end users have access to 72 different FleXeDrive solutions. The various options cover: six motor platform sizes; 17 motor sizes; five stocked gearbox base sizes; and 10 gearbox sizes.

According to Guido Wagner, SEW-EURODRIVE National IG, Engineering and Projects Manager, OEMs stand to benefit from these simple, catalogued selections and the wide range of options to choose from. With drawings and 3D models readily available, and standardised interface dimensions, there is no waiting for engineering design – the work has already been done.

Likewise, heavy-industry end users in sectors such as mining, bulk handling, and cement production enjoy a short concept-to-production cycle. They also receive all the benefits of SEW-EURODRIVE’s new-generation industrial gearbox, Generation X.e. Further, due to the modular nature of FleXeDrive, end users can upgrade easily and make savings with reduced spares holdings.

Ex-stock delivery

The FleXeDrive range is backed by short delivery, built-in quality and reliability, and levels of support that SEW-EURODRIVE clients have come to expect, including a 24/7 helpline.

?“The main advantage of the FleXeDrive is time,” says Wagner. “Traditionally, it would take 12 to 18 weeks for a locally manufactured solution, but with FleXeDrive, we are now looking at delivery times of approximately four to six weeks.”

In addition to SEW-EURODRIVE’s investment in large amounts of stock, the short delivery times are possible because of the groundbreaking design of FleXeDrive. Industrial drives have traditionally been mounted on a custom-fabricated steel base. It takes time to design and manufacture these bases. But SEW-EURODRIVE has revolutionised the process by introducing an interface to the base that allows assemblers to connect the gearbox and motor bases from stocked items.

Fast engineering

Wagner says this saves customers a lot of time because they can engineer their solutions without having to wait for customised designs. “They only need to select from standard items. The components are ready to go,” he says. There is also a cost advantage because the components are manufactured and stocked in large quantities.

An added benefit is that users of FleXeDrive need fewer spares. Because of the modularity and commonality of the new drive family, they can share spare components between different drives and reduce spares holdings.

Modifications are far easier too, says Wagner. If a conveyor drive motor needs to be upgraded from 55 kW to 90 kW, for example, it’s a simple matter with FleXeDrive. “They just change a stocked component and its done. This is another big benefit,” he says.

Designed to be flexible

Mounted on a swing base, the FleXeDrive covers a broad power range – from 37 kW to 630 kW. Its gearbox base incorporates the gearbox itself, the gearbox cover, coupling, the guard and the torque arm. The motor section has components such as coupling, brake discs and guards. However, there is flexibility around these configurations. Aside from the conventional options regarding size, power, speeds and ratios, users can also specify whether or not to include a brake or coupling.

With this flexibility comes simplicity. Wagner says that if users are familiar with traditional drive bases, they will certainly be able to design solutions using FleXeDrive. “Everything is at their fingertips, because all parameters are standardised and predesigned. The dimensions and different models are all specified – it’s easier to work with FleXeDrive than traditional drives, so there's no special training required,” he says.

Nevertheless, SEW-EURODRIVE’s hotline support is always available, around the clock, every day of the year. “And of course, we are always open to having one-on-one discussions with customers to answer their questions and provide further information,” says Wagner.

?All the benefits of Generation X.e

Included with FleXeDrive is SEW-EURODRIVE’s Generation X.e gearbox, which has taken over from the X series as the new standard industrial gearbox. The new-generation gearbox has five key improvements.

Firstly, it has contactless sealing-system options that eliminate the chance of leaks from the high-speed shaft. It has thermally improved oil levels, which enable the gearbox to run cooler. This means the oil lasts longer and the gearbox lasts longer. It is a more efficient gearbox.

Optimising the bearing preload reduces the formation of hot spots and improves bearing service life by up to 220%. Gearing topology is also optimised, improving safety, reducing noise, and enabling increased static overhung loads.

To complete the package, an improved bevel pinion housing enables optimised oil flow. This gives a 30% reduction in system power loss, increased operational reliability, and improved cold-start behaviour. It also increases the overall limit rating by up to 153%.

Wagner describes Generation X.e as a tailored-to-suit gearbox. For example, if an application requires absolute mechanical safety but thermal performance is less important, higher oil levels and tighter bearing loads can be specified. On the other hand, there will be cases where thermal properties are prioritised ahead of mechanical strength. Another application may prioritise bearing life. “We can optimise the X.e to whatever the requirement is,” he says.

Tested and ready to go

SEW-EURODRIVE has thoroughly tested the design elements and physical characteristics of the new drive solution. Using computer aided design and finite element analysis, the Australian team has checked the drive bases for stresses, deflections and similar parameters. The data gathered from load testing a fully built prototype has shown that the FleXeDrive performs exactly as expected when tested for thermal properties, vibration, air flow, noise and other characteristics.

The testing shows that FleXeDrive is now ready for use in heavy industrial applications like mining, bulk handling, cement or quarries. It is a robust system, suitable for harsh Australian conditions.

Having established dimensional and other standards for smaller motors in the past, SEW-EURODRIVE has taken the lead again, this time in the heavy-industry sector. FleXeDrive – a new and unique product – is ready to set the standards for industrial-scale drives.?

Find out more: FleXeDrive | SEW-EURODRIVE