DS-JUN24-PG46+47_Layout 1 18/06/2024 10:11 Page 1
FEATURE GEARS & GEARBOXES
FROM WATERWHEELS TO ROTA CHOOSING THE RIGHT GEARBOX TO
Gearboxes from Apex Dynamics are used in a huge range of applications. Here we take a look at the two of the latest
waterwheel – the largest in Europe. The gearbox has provided the wheel with near-perfect alignment, high efficiency and minimal power loss through transmission to ensure as much electricity as possible is generated. The groundbreaking new hydro project is from
A
family-owned self-drive plant hire company Buckland Newton Hire (BNH). To achieve the required head for the project, BNH raised one of the lakes on the family farm by around 11m. The galvanised steel waterwheel, which has 92 individual buckets carrying a total of six tonnes of water at a time, now delivers an average flow of approximately 150 litres per second 24/7 nearly all year round, supplying an average of 150 kWh per day. This contributes around one-third of the total electricity needed for the site, which includes more than 20 industrial units, many with large power demands, five properties, and offices – and even more in summer when daily consumption is lower.
GEARBOX SPECIFICATION For this application, an Apex Dynamics NB series linear 3 stage planetary gearbox is in line with the waterwheel shaft and is connected to the generator via a pulley and belt system. The waterwheel rotates at 4.5rpm and the Apex gearbox provides additional flexibility to fine tune the speed up to 450rpm at the 48mm gearbox output shaft. The high torque from the waterwheel is accommodated at the 140mm diameter input shaft of the gearbox. Getting the shaft
size to match was very important to the project. Incorporating a flexible grid coupler into the system design to accommodate any misalignment has proven unnecessary because the NB servo gearbox perfectly aligned with the input and output shafts, but this has been retained as a safety feature. The pulley and belt connection delivers the required
46 DESIGN SOLUTIONS JUNE 2024
pex Dynamics UK has supplied an inline planetary gearbox to control a 9m diameter electricity-generating
The 9.0m diameter
electricity-generating waterwheel is the largest in Europe
turbine, but we wanted to do something a bit different that showcases our capabilities and our green credentials as a company. We think we could replicate this project in the future to provide similar lake-based energy generation projects for clients.” Adding to this, John O’Malley, Apex Dynamics UK, said: “It is great to be involved in Europe’s biggest electricity generating waterwheel project, supplying a core component. Apex Dynamics is a pioneer in the gearbox industry, with our high-value motion control solutions, and the NB Series was the ideal fit, capable of handling up to 45,000 Nm of torque. Partnering with the team from BNH on their landmark project was a rewarding experience and showcases what is achievable with our precision servo gearbox technology.” The grounds around
the waterwheel will be landscaped by BNH so that visitors can come and view the pioneering electricity generation project from summer 2025. Perrett continued: “As
the lake is in front of his home on our family farm, my father wanted to watch a huge waterwheel from his window – and we have made his dream come true, building the biggest wheel we can for him! Apex Dynamics UK has been
1500rpm to the generator. “Having looked at other
gearboxes from different companies, we found that the Apex Dynamics NB-series was the only one to meet our specification, build and delivery time requirements, while easily achieving our 25-30,000 Nm maximum torque requirements, which was a key consideration for us,” explained Brad Perrett,
BNH manager and director. “It has been a really positive experience for
us working with Apex Dynamics and the NB Gearbox could not have worked better or been more straightforward. It has now been running perfectly, non-stop, 24 hours a day for more than three months without a hitch. “We could easily have installed a cross-flow
an excellent partner for this project.”
A REPLACEMENT GEARBOX With lead times rising sharply following the Covid-19 pandemic, rotary measurement specialist Rotary Precision Instruments (RPI) UK began looking for a reliable supplier that could meet its very specific requirements for high accuracy measuring and angular positioning. The company needed a replacement gearbox with minimal vibration that could be delivered fast so that it could continue to meet its customers’ needs. To meet requirements, it turned to Apex Dynamics, which provides delivery times of just two to three weeks. For this application, the gearbox needed to
fit into the existing design of a rotary table for coordinate-measuring machines (CMM), which are used for measuring components. CMMs cut down inspection times and costs for aerospace
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