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MAAG Gear

Founded in Switzerland in 1913 by inventor Max Maag, MAAG Gear is now a global technological center for engineering drive solutions in the cement and mining industries. Our technical centers allow us to produce unique bevel gears with diameters up to 2800 mm, which only a few other manufacturers can achieve using the most advanced technologies available in the industry.

The company's success is rooted in the tooth design developed by founder Max Maag in 1910. His core concept is still used in the production of gears worldwide.

+100

Years

+320

Employees

+950

Projects

Mining

Cement

Geography

Kazakhstan

Almaty

Ukraine

Cherkasy,
Horishni Plavni

Poland

Gdynia

Applications in Mining and Cement Industries

GYRATORY CRUSHER

Bevel Gears

CONE CRUSHER

Bevel Gears

SAG MILL

Drive Solutions, Gear Rings, Pinion Shafts

HPGR

Planetary Gearboxes

BALL MILL

Drive Solutions, Gear Rings, Pinion Shafts

THICKENER

Drive Solutions, Gear Rings, Pinion Shafts

CONVEYORS

KA/KB Gearboxes

ROTARY KILN

Pinion Shafts, Open Gears, WA Drives

Bevel Gears

Details

Our company produces high-quality and durable bevel gears as replacement parts or components for power transmission in mining equipment, such as gyratory or cone crushers. We use advanced engineering tools to design bevel gears in compliance with DIN standards. We carefully select application factors and safety parameters to optimize wear resistance and enhance durability.

Manufacturing

Bevel gears are made from high-quality steel and formed on our state-of-the-art Klingelnberg gear hobbing machine. We also produce bevel gear sets using high-precision multi-axis milling machines, allowing us to manufacture any type of gear. The manufacturing process includes rough cutting, hardening, and finishing through hard cutting using the HPG method. Our gear cutting machines enable us to produce bevel gears with diameters up to 2.5 meters and modules from 10 to 30.

Custom Manufacturing with Fast Delivery

Our leading specialists in the design department use 3D modeling to align your requirements with the precision equipment standards, minimizing tooling costs and production time while ensuring maximum accuracy.

Designed for High Performance

The global standards of our manufacturing processes and the high-quality materials used allow us to create durable and reliable bevel gears.

High-Tech Equipment in Manufacturing

Our gear cutting machines are unique in Europe, enabling us to produce first-class components.

Horizontal Mills

DRIVE SOLUTIONS (WA, LGD, LGDX)

A reliable reduction gearbox for your horizontal mill. With over 100 years of experience in heavy industrial gearboxes, advanced manufacturing processes, and calculation methods, our gearboxes deliver impressive performance and reliability for your mill. The parallel shaft cylindrical reduction gearbox, single-stage WA, and multi-stage Temperex meet all possible requirements for grinding or other applications.

PINION SHAFTS

Manufactured with maximum precision and customized for your mill or kiln drive, our pinion shafts ensure smooth and stable operation of the open gear system, providing long-term reliable operation. The design features of the pinion shafts include the following layout options: self-aligning gear connection, straight, helical, or double-helical gears, bored and solid, forged from alloy steel, through-hardened, quenched and tempered, case-hardened and ground, induction hardened, nitrided, and more.

GEAR RINGS

Gear rings are manufactured using forged blanks for the working part of the gear ring and a welded construction for the body base. The production process is labor-intensive and unique, allowing for a more reliable product compared to gear rings made from cast blanks. The uniform and homogeneous crystalline structure of forged rings ensures identical material properties throughout the gear engagement, eliminating casting defects such as hot tears, porosity, or shrinkage, providing reliable and long-term operation for decades. Over 1000 MAAG® GEAR gear rings are in operation worldwide, ensuring optimal reliability for the mining and cement industries.

LUBRICATION AND OIL CLEANING SYSTEM

A quality lubrication system is essential for the reliable and long-term operation of your gearbox. However, not all lubricants have compatible characteristics. New high-viscosity lubricants increase the efficiency and expected lifespan of gearbox components, but to fully utilize these new lubricants, you need a precise lubrication supply system. The MAAG GGL gear lubrication system was developed to meet this challenge. This spray lubrication system ensures the delivery of the necessary amount of lubricant under any operating conditions, saving lubricant consumption, and significantly reducing operating costs and environmental impact.

High-Pressure Grinding Rolls (HPGR)

The design of the gearboxes for the high-pressure grinding rolls has been completely redesigned to improve reliability. As part of the upgrade of the original unit from 1987, in 2013, we reduced the weight of the PPU gearbox and simplified the range of components while expanding its potential for use in new applications. Our MAAG® GEAR PPU series gearboxes are reliable classic gearboxes with two planetary stages and a parallel cylindrical or bevel input stage. Covering torque ranges from 100 to 4200 kNm and gear ratios from 1:40 to 1:140, this robust gearbox has been used in roller presses for decades.

 The input speed can be adjusted within a range from 980 to 1800, allowing this traditional three-speed gearbox to adapt to your unique requirements. By reducing the number of components by 20%, we improved spare parts availability and reduced cost and maintenance complexity. For example, the new PPU Gear Unit uses only 5 types of rolling bearings, instead of up to 8 in other gearboxes of the same class of application. The lifespan of the bearings exceeds 100,000 hours, reducing the volume of maintenance work and lowering overall operating costs.

Vertical Roller Mills (VRM)

GEAR RINGS

Improving the energy efficiency of your vertical roller mill and reducing energy consumption are top priorities for both environmental and economic reasons. However, you cannot afford to lose VRM performance. Our MAAG® GEAR CEM Drive system achieves both, providing VRMs with up to 14,000 kW of power through a compact integrated motor, reducing power losses by more than 20%.

IRON DRIVE

A gearbox that helps you reduce operating costs in a simple way. Enhance operational stability with the new MAAG Iron Drive, our most efficient drive for vertical roller mills of all sizes. Reliable and safe, it is the ideal gearbox for all vertical roller mill applications, including coal grinding. This range of drives covers power ranges from less than 1000 to 9000 kW and is available for a wide range of mills and other installations.

WPU GEARBOX

The two series of models of the MAAG® GEAR WPU two-stage gearboxes include models that will meet your requirements and are suitable for a wide range of mills and installations. The large series covers power ranges from approximately 1300 to 5500 kW, while the small series is ideal for coal mills with power ranges up to 1500 kW.

MAX DRIVE

The high-power drive system is designed to ensure maximum performance in vertical roller mills. The three-stage cylindrical gearbox with torque split of the MAX Drive system uses two identical drive units to provide up to 15,000 kW of power for your vertical roller mill. The expertise in gear technology and manufacturing accumulated by us over the past 100 years is applied to the modular drive concept specifically for vertical mills.

Rotary Kiln

Master drive gears

Modernise your open gear drives with reliable gears to improve the smooth operation of your kiln. Manufactured to the highest precision, our gears are individually designed for the kiln drive and are designed to work harmoniously with the gears, ensuring smooth and reliable operation of the entire mechanism

Our factories utilise rigorous testing methods including non-destructive, ultrasonic, magnetic powder and capillary testing, as well as NDTQA inspection, to ensure that the manufactured parts are flawless.

Our products are fully compliant with applicable international standards including: UNI EN ISO, AWS, ASTM, ASME and DIN

Open Gear Transmission

The strength of MAAG® GEAR’s heavy-duty girth gears is due to the robustness of the original blanks and the impeccable stability of the manufacturing process. We use welded steel construction, forged rings, rolled plates, and ductile (nodular) cast iron to ensure uninterrupted operation of your kiln by working harmoniously with girth gears, providing smooth and reliable operation of the entire mechanism.

External Gears:

Maximum Diameter: 11 200 mm

Maximum Diameter: 11 200 mm

Maximum module: 45 during milling

External gears:

Maximum Diameter: 6 500 mm

Face width: 400 mm

Face width: 25,4

The precision and quality of the gear manufacturing process ensure accurate alignment, resulting in high-load gears that guarantee the smooth operation of your equipment.

WA / Temperex Drive

We have designed the MAAG® GEAR WA / Temperex gearboxes specifically for grinding equipment drives and pyroprocessing in mineral processing. These single and multi-stage gearboxes efficiently transmit torque from electric motors to the drive of rotary kilns, ball mills, rod mills, SAG mills, AG mills, or other types of horizontal mills, ensuring reliable output power.

In addition to a wide range of standard power and size configurations, we can also provide custom designs upon request, tailored to the required power and speed of your engine.

Conveyor Equipment

MAAG® GEAR KA / KB

Modular, reliable gearboxes designed for material handling tasks and similar purposes. Designed to transmit torque from the drive motor to the conveyor shaft, the KA / KB gearboxes are most commonly used for belt conveyors in the cement and mining industries.

For these gearboxes, the input stage is a bevel gear, followed by a reduction stage with one cylindrical gear (KA) or two reduction stages (KB).

High strength and wear resistance of the gearboxes and the entire range are ensured by a well-thought-out design, high-quality components, and top-grade materials.

Our gearboxes use cyclo-palloid gearing for the bevel stage with gears made from alloy-hardened steel. The roller bearings used in the KA / KB gearboxes depend on the type of transmitted load and have an extended service life.

 

Design and Software

The design department of our company, with over 100 years of experience in designing and engineering complex drive mechanisms, uses the latest software products to calculate devices of any complexity and size.

KISSsoft is used for standard and heavy-duty gearboxes, mill drives, servo drives, gear motors, spindle drives, and open drives or gears in the mining industry.

Features and Benefits

WPS Certificate

Welding Procedure Specifi cation

All gears are manufactured according to international welding quality standards with a certificate issuance.

Details

Materials and Technology

Gear manufacturing standard: AGMA 200-A88 Forging material is stronger than casting. Ribs and plates are made of high-strength steel.

AGMA Partner

American Gear Manufactures Association

Long-standing member of the international community of leading global transmission mechanism manufacturers.

> 950

Projects Implemented

In more than 100 years of company history, delivered worldwide.

Service Life

Calculated according to AGMA

The service life of the products is between 5 and 25 years.

Manufacturing

MAAG®

The history of MAAG is not just the history of our company; it is a global history of innovation and progress. It began over a century ago during the industrial revolution in heavy industry and continues to shape our present. With a global identity, thanks to our presence in many countries worldwide, our mission is focused on improving efficiency and reliability in various sectors of the mining industry.

Our plants in Switzerland, Italy, and Poland are in many ways benchmarks of excellence in technological processes, accumulated experience, and an impeccable reputation as a reliable partner for thousands of users on all continents.

TMS GROUP INTERNATIONAL" Sp.z o.o

NIP: 5783153425

VAT: PL5783153425