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https://www.magicmag-tech.com/disc-basic-permanent-magnet-couplings.html
Panorama of the application of disc basic permanent magnet couplings in various industries
Disc basic permanent magnet couplings have been widely used in many industrial fields by virtue of their core advantages such as non-contact transmission, high efficiency and energy saving, buffer and vibration reduction, and maintenance-free. This innovative transmission technology based on the principle of magnetic coupling is gradually replacing traditional mechanical couplings and fluid couplings and is ideal for industrial equipment upgrading.
From the perspective of application industry distribution, mining (25%), metallurgy (20%), electric power (15%), cement industry are the main demand side, accounting for nearly 60% of the market share of the coupling industry. Flexible couplings (such as snake spring couplings, diaphragm couplings) accounted for 65% of the coupling industry in 2023 and increased to 68% in 2024, and disc permanent magnet couplings, as an innovative product, are rapidly increasing their market penetration with their unique advantages.
The following are the application cases of disc basic permanent magnet couplings in the cement industry:
Raw material mill system of a large cement enterprise
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Application background: In the raw material grinding system of the cement enterprise, the traditional coupling originally used has the problems of low transmission efficiency and frequent maintenance, which often leads to equipment downtime due to coupling failure, affecting the continuity and output of cement production and increasing maintenance costs.
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Transformation measures: The original coupling is replaced by a disc basic permanent magnet coupling, which works based on the principle of magnetic coupling between permanent magnets to achieve contactless transmission.
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Application effect: The transmission efficiency has been increased from about 92% to more than 98% of the previous conventional coupling, significantly reducing energy consumption. The operation stability of the equipment has been greatly improved, and the average time to stop due to coupling failure in the past is 2 to 3 times a month, and after the renovation, there is almost no downtime due to the coupling. At the same time, due to the absence of mechanical contact, wear and tear are reduced, and the maintenance interval is extended from once a month to once every six months, reducing maintenance costs by about 70%.
Belt conveyor for cement production line
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Application background: Belt conveyor is the key equipment for material transportation on the cement production line, and the original coupling has a greater impact on the motor and belt conveyor in the process of frequent starting and braking, resulting in motor failure and belt wear intensifying, affecting the material conveying efficiency and equipment service life.
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Retrofit measures: Install disc type basic permanent magnet coupling, which has flexible transmission characteristics and can effectively buffer the impact load during starting and braking.
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Application effect: The belt conveyor starts and brakes more smoothly, the impact on the motor is reduced by about 60%, the failure rate of the motor is significantly reduced, and the number of repairs is reduced from about 10 times a year to less than 3 times. The wear of the belt has also been improved, and the replacement interval has been extended from the original 6 months to 10 months, improving the stability and reliability of material handling and ensuring the efficient operation of the cement production line.
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