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The Development of a Cable Drive with Demountable Split Cable Drums for Special-Purpose Machines in Water Intake

Aqseptence Group GmbH, located in Karlsruhe (Division and Competency Centre for Water Intake Systems by GEIGER® and Johnson Screens®)

Technology/Process Technology:
Special Purpose Machinery Manufacturing, Energy, Environment and Water Technology, Desalination of Seawater

Measure:
Optimizing the Drive Assembly of a Bar Cleaning System

Starting Position and Objective
The Aqseptence Group GmbH in Karlsruhe is an internationally recognised manufacturer of machines for the mechanical filtration of water in water intakes.

As a company that processes stainless steel, the further development of products’ focus is on the economic and responsible handling of the valuable raw material stainless steel, as well as manufacturing the components as efficiently as possible. With the growing importance of the sustainable handling of raw materials, manufacturing processes and construction types have to be optimized constantly.

As a starting point for this strategy Aqseptence Group GmbH chose the modification of the drive assembly of the GEIGER® Cable-Operated Grab Cleaner. In the past the drive shaft and the cable drum of the GEIGER® Cable-Operated Grab Cleaner were manufactured in one piece from a raw steel pipe. The material used for this is stainless steel or, alternatively, carbon steel. The source material used for the drive shaft has a specially designed diameter and wall thickness, and is manufactured especially for the Aqseptence Group GmbH.

The drive’s cables are also made of stainless steel. These run in an upwards and downwards movement through the three grooves marked on the drive shaft. This ensures permanent contact to the waters on hand at the plant. The frictional force on the cable grooves, and also environmental factors and unfavourable combinations of materials have increasingly caused wear and corrosion in the corresponding places.

Implementation
The implementation concept includes a bare shaft of a standard size. This has a significantly smaller diameter than a conventional tubular shaft. In order to attach the synthetic cable drums, washer discs are welded onto the bare shaft. Prior to this the washer discs are manufactured using laser technology, and shaped. The modular set-up shortens the manufacturing process and reduces the materials costs by approximately half.

The cable drums are manufactured from a synthetic cast material as half shells that are split horizontally. This is an innovation in cable winch technology.

The cable drums have an integrated cable grommet and, depending on requirements can be exchanged individually, simply and safely, helping to save time and materials. It is now no longer necessary to disassemble the complete drive unit.

Using synthetic components and a considerably leaner shaft significantly reduces the total weight of the group of components. This increases the ease of servicing and assembly as well as the efficiency of resources. Furthermore, the downtimes of the machines are also reduced for the customer.

A further point that also speaks in favour of the use of synthetic cable drums is the reduction in friction between the cable and the groove. This prevents excessive wear and corrosion in the relevant places, the durability of the steel cables is increased and the maintenance intervals required are prolonged considerably. Finally, by using the connecting area of existing plants, we can guarantee the exchange of the cable drive in old plants. This extends the service life of the plants and positively influences the products’ sustainability.

Results
Aqseptence Group GmbH managed this leap in innovation thanks to their holistic approach to construction regarding resource efficiency. Modern manufacturing techniques have made it possible to develop an innovation in cable winching, giving the Aqseptence Group GmbH another unique selling point on the market. This measure considerably improves the product with regard to saving materials, and reducing transport costs to building sites across the world. As far as the service and operation of the plants is concerned, this new development reduces wear and tear and increases the service life of the components.

Company
The headquarters of Aqseptence Group GmbH (previously Bilfinger Water Technologies GmbH) are located in Aarbergen, Germany. Aqseptence Group GmbH currently employs 1,600 members of staff, 106 of those in Karlsruhe. In 2015 there was a turnover of just under 300 Mio. Euro. The managing directors are Joachim Foerderer (CEO), Mark Stegmayer (CFO), Rosario Eduardo Tagliavini (COO), Rudolf Bogner and Baldassare La Gaetana. Mr. Lars Späth leads the Water Intake Systems Division with its global competence centre in Karlsruhe.

Since 2000, the Aqseptence Group GmbH in Karlsruhe has been certified according to DIN ISO 9001:2008. Their customers are power station operators (coal, gas, nuclear), seawater desalination plants, chemical plants, refineries and drinking water plants across the world, as well as international large-scale plant constructors.