Auteur
Révision
Date
D. BRUNEAU
08
22/04/2021
ABOUT US
• We are custom-made gearbox designer and manufacturer (new
project or replacement 100% interchangeable)
• More than 70 years of
experience
• Worldwide delivery and
support (80% of the total
sales)
• High quality products ISO
9001 : 2015
2
OUR PRODUCTS
HEAVY DUTY GEARBOX
HIGH SPEED TRANSMISSION
AND TEST BENCH
TURBOGEARBOX
+ Any specific gearboxes up to 30MW, 40t and 150 000rpm
+ High speed couplings
+ High Speed Bearings
+ Lubrication units
3
OUR SERVICES
Erection - Commissioning
Gearbox Testing
Vibration & Temp. Analysis
Maintenance - Overhauling
Diagnostic & Repair
Balancing
4
APPLICATIONS
PRODUCTION AND RELATED
TESTING (50% of our products)
Balancing
Aeronautics
Chemicals
BCSA
Products
Oil & Gas
Cement plants
Others
Automotive
Railway
Others
5
OUR STRENGHTS
Recognized for its:




High quality products
Strong Engineering department
Close cooperation with customers
Very flexible behavior and adaptability
Great design flexibility and manufacturing organization lead to
rapid adaptation to customer requirements. In particular :



Specific center distances
Specific base plates
Specific interfaces
YOUR NEEDS, OUR PRIORITY
What’s in your mind?
Center distance
Coaxial
Customization is our standard
Let us help you with your project
7
BRIEF HISTORY
• Our renown was built under different names over the year
ACMI
MAAG France
BOISSET & CIE
BCSA GEAR
1946
1984
1998
2017
Subsidiary of MAAG
Founded in 1913
MAAG Gear Holding
Group separation
8
OUR LOCATION
FRANCE
LYON urban district
Vaulx-en-Velin (69)
PARIS
20 min from the airport
LYON
MARSEILLE
9
OUR WORKSHOP CAPABILTY
2 300m²
workshop
530m² office
2 300m²
7m under hook
30t hoisting
10
SOME OF OUR ACHIEVEMENTS
TABLE OF CONTENTS
Automotive
Aeronautics
Railway
Balancing
Cement plant
Oil & Gas
Other industries
p.13-18
p.20-38
p.41-46
p.47-50
p.51-53
p.54-58
p.59-61
12
AUTOMOTIVE
Very high speed increaser
for F1 test bench
Gearbox type : SP 450 T4 C
Power : 220 kW
Input speed : 7 550 rpm
Output speed : 130 000 rpm
Max HS torque: 20 Nm
• ERS system (MGU-H)
• 150 000 rpm/s acceleration (15 710 rad/s²)
• More than 5 units in use
13
Ref BCSA: KR 5333
AUTOMOTIVE
T-shape gearbox for
transmission test rig
Gearbox type : SP 630 T4/2
Power : 2 x 300 kW
Input speed: 3 200 rpm
Output speed : 28 484 rpm
Max HS torque : 674 Nm
Max LS torque : 6 000 Nm
•
•
•
•
Low inertia design (0.05 kg.m²)
Split torque
Titanium custom-made flange
More than 24 T-shape gearboxes sold
14
Ref BCSA: KR 5884
AUTOMOTIVE
T-shape gearbox for
transmission test rig
Gearbox type : SP 900 T8 2I
Power : 2 x 375 kW
Input speed: 12 000 rpm
Output speed : 7 850 rpm
Max HS torque : 1 600 Nm
Weight : 1 100 Kg
•
•
•
•
•
Vertical offset
Speed sensor with phonic wheel integrated
50 000 hours lifetime
Low gear backlash
Torque sensor on HS side
15
Ref BCSA: KR 5817
AUTOMOTIVE
F1 thermic engine
test bench
Gearbox type : TU 320 V
Power : 2 MW
Input speed: 24 000 rpm
Output speed : 3 800 rpm
Max torque : 800 Nm
Weight : 1 500 Kg
• Vertical offset
• Low noise and vibration emissions
• Very long life, operating since 2002
16
Ref BCSA: KR 3611
AUTOMOTIVE
Speed increaser for racing
thermic motor test bench
Gearbox type : SP 320 T2 C
Power : 800 kW
Input speed: 5 000 rpm
Output speed : 9 500 rpm
Max LS torque : 6 650 Nm
Weight : 350 Kg
• Low HS inertia (0.14 kg.m²)
• Split torque design
• 24h Le MANS engine testing
17
Ref BCSA: KR 5472
AUTOMOTIVE
Speed increaser for
e-motor test bench
Gearbox type : SP 320 T4C
Power : 700 kW
Overpower: 1 400 kW
Input speed: 10 000 rpm
Output speed : 28 000 rpm
Max HS torque : 1 070 Nm
Weight : 900 Kg
• Low HS inertia (0.09 kg.m²)
• Split torque design
18
Ref BCSA: KR 5868
AERONAUTICS
Speed increaser for
compressor test bench
Type : TU 1500 T4C
Power : 8 000 KW
Input speed: 1 800 rpm
Output speed : 30 000 rpm
Max HS torque : 3 060 Nm
Weight : 7,5 t
•
•
•
•
Coaxial split torque design
With 0.01% accuracy torque sensor integrated
1m shaft for volute integration
HS coupling with shear neck
20
Ref BCSA: KR 5337
AERONAUTICS
Gearbox for compressor
test bench
Type : TU 710 T4C
Power : 3 000 kW
Input speed: 12 000 rpm
Output speed : 52 000 rpm
Max HS torque : 690 Nm
Weight : 2,4 t
• Coaxial split torque design
21
Ref BCSA: KR 5106
AERONAUTICS
Gearbox for compressor
test bench
Type : TU 900 T4C
Power : 4,5 MW
Input speed: 10 000 rpm
Output speed : 50 000 rpm
Max HS torque : 840 Nm
Weight : 2,4 t
• Coaxial split torque design
22
Ref BCSA: KR 5156
AERONAUTICS
Compressor development
stand
Type : TU 1200 T4C
Power : 3 000 kW
Input speed: 2 176 rpm
Output speed : 45 000 rpm
Max HS torque : 3 060 Nm
Weight : 5,5t
• Coaxial split torque design
• With torque sensor integrated
• HS coupling with shear neck
23
Ref BCSA: KR 5324
AERONAUTICS
Compressor development
stand
Type : TU 900 T4C
Power : 1 900 kW
Input speed: 2 500 rpm
Output speed : 55 000 rpm
Max HS torque : 500 Nm
Weight : 2,6 t
• Coaxial split torque design
• With torque sensor integrated
24
Ref BCSA: KR 5754
AERONAUTICS
Compressor development stand
Gearbox type
TU 500 V TU 950 T4 C
TU 900 T4C
Power (kW)
5 000
5 000
3 000
Input speed
(rpm)
1 800
6 020
5 986
Output speed
(rpm)
6 020
40 000
60 000
Max HS torque
(Nm)
14 350
2 150
720
Weight (Kg)
5 400
2 500
2 500
•
•
•
•
2 gearboxes in a row design with common base frame
Last upgrade allows 60 000 rpm with the replacement of HS gearbox
Designed for 5X impact torque
With torque sensor
Ref BCSA: KR 5341 & KR 5464
25
AERONAUTICS
Compressor
development stand
Type : TUD 360 V
Power : 2,9 MW
Input speed : 3 000 rpm
Output speed : 16 200 rpm
• With lubrication unit and oil tank base frame
26
Ref BCSA: KR 5261
AERONAUTICS
Speed increaser for
compressor test bench
Type : SP 710 T4C
Power : 800 kW
Input speed : 3 000 rpm
Output speed : 65 000 rpm
Max HS torque : 120 Nm
Weight : 1 200 Kg
• All lines on high speed roller bearings
• HS coupling with shear neck spacer
• Efficiency > 96%
27
Ref BCSA: KR 5275
AERONAUTICS
Gearboxes for HP and LP
turbine test bench
Type : TUD 710 V
Power : 14 MW
Input speed : 3 500 rpm
Output speed : 1 726 rpm
Max HS torque : 70 000 Nm
Poids: 11t
Type : TUD 360 V
Power : 8 MW
Input speed : 12 000 rpm
Output speed : 4 364 rpm
Max HS torque : 10 000 Nm
Weight : 7,5t
• Embedded torque sensor flanged on casing
28
Réf BCSA: KR 5760
AERONAUTICS
Bearing test bench
Type : SP 190
Power : 127 kW
Input speed : 6 988 rpm
Output speed : 45 000 rpm
Max HS torque : 27 Nm
Weight : 700 Kg
• Radial load up to 2500N on each bearing
• 4 bearings tested at once
• Several bearing types on the same casing
• No axial load
• Misalignment: 0 or adjustable for 2 bearings
• Specific lubrication unit for test bearings
• Lubrication flow rate controlled on each bearing
• Calculation of bearing losses
• Bearing monitoring (each one): temperature, radial vibration, cage speed, lubrication flow rate
• System monitoring: radial load, temperature (housing, ambient, lubrication in/out), shaft speed, shaft torque
29
Ref BCSA: KR 5177
AERONAUTICS
Bearing test bench
Type : SP 450 T4C
Power : 110 kW
Input speed : 2 965 rpm
Output speed : 85 000 rpm
Max HS torque : 26 Nm
Weight : 5 t
• Delivered with base frame
and lubrication units
• HS coupling with
mechanical fuse
30
Ref BCSA: KR 5840
AERONAUTICS
APU and VFG drive for
A380 Iron bird
Type : SP 320 T2M
Power : 265 kW (VFG) 180 KW (APU)
Input speed : 2 000 rpm
Output speed : 25 000 rpm
Acceleration : 3 000 rpm/s (APU)
2 600 rpm/s (VFG)
Weight : 3 800 Kg (VFG) 2 750 Kg (APU)
• Drive unit with frame support including lubrication system
• 10 units delivered
31
Ref BCSA: KR 3924 / KR 4282
AERONAUTICS
A380 generator test stand
Type : SP 400/2
Power : 317 kW
Max power : 425 kW
Input speed : 3 485 rpm
Output speed : 30 000 rpm
Ref BCSA: KR 4466
• Similar projects for A320, A350, A400M
Type : SP 400/2
Power : 458 kW
Max power : 643 kW
Input speed : 1 858rpm
Output speed : 16 000 rpm
32
AERONAUTICS
Helicopter MGB test bench
Mechanical close loop test bench
Simulated Power : ● 2 X 2 200 kW
● 3 500 kW (OEI)
● 1 300 kW (Tail rotor)
Nominal turbine speed : up to 23 000 rpm
Turbine over speed: 27 000 rpm
Nominal mast speed : up to 395 rpm
Mast torque : up to 191 000 Nm
•
•
•
•
•
•
Ref BCSA: KR 4450
Multipurpose test bench, capable of testing
different types of MGB
MGB installation in less than 2 hours
Single or twin turbine input
Hydraulic loading devices
600KW e-motor drive
Delivered with several adaptor gearboxes
and mast / tail force application systems:
Thrust: 150 000N
Shear: 20000N
Bending moment: 52000Nm
35
AERONAUTICS
Helicopter MGB test bench
•
•
•
•
Multi-purpose Back to Back test rig
Twin Turbine input
Contra-rotating mast shafts
Drive Power : 800 kW
•
Rig Power : 2 x 1 875 kW
1 x 2 132 kW (OEI)
3 073 kW (Lift off)
•
Max turbine Speed : 18 000 rpm
•
Main rotor torque: 93 750 Nm
MGB LS shaft Speed : 375 rpm
•
•
Mast loading device for each shaft
o Thrust load : 202 500 N
o Horizontal force : 24 000 N
o Shear force: 4 125 N
36
Ref BCSA: KR5509
Ref BCSA: KR 5509
Main gearbox
helicopter test rig
AERONAUTICS
Gearbox type
Top gearbox
Engine multipliers
Power (kW)
2 X 1 100
1 100
Input speed
(rpm)
1 000
3 000
Output speed
(rpm)
365
6 000
Max torque
(Nm)
56 186
1 751
Weight (Kg)
1 500
2 100
• Electrical regeneration
• TGB loading
• Delivered with tail shaft and
mast force application devices
• With lubrication units
Ref BCSA: KR 5389
Mast force application:
• Thrust : 49 000 N
• Horizontal load : 9 800 N
• Shear load : 7845 N
Tail force application:
• Thrust : 3 920 N
• Longitudinal : 680 N
• Shear : 245 N
37
Main Gearbox Helicopter Test Rig
•
•
•
•
•
AERONAUTICS
Electrical regeneration
Power : 2 x 3 150kW
Turbine speed : 26 000rpm
Mast torque : 232 000 Nm
Mast speed: 260 – 350rpm
Engine multiplier adaptor
Top gearbox (Mast load)
Engine multiplier (turbine shaft drive)
Ref BCSA: KR 5876
High Speed Bearing
with torque meter
38
RAILWAY
Complete test bench
for e-motors
Gearbox type : SP 710 T2M
Power : 2 215 kW
Input speed : 1 500 rpm
Output speed : 4 950 to 6600 rpm
Max torque : 5 625 Nm
Weight : 90 t
41
Ref BCSA: KR 3899
RAILWAY
•
•
•
•
•
Possible use of 1 to 9 outlets
Each line could be engage, locked or
disengaged by hydraulic actuators
Lubrication unit with heaters
embedded on the gearbox
Mechanical driven oil pump for
bearings safety
Vibration and temperature monitoring
system
Scope of supply:
•
•
•
•
Design
Manufacturing
Critical speed analysis
Tests with customer and report
•
•
•
Quality documents
Operation and maintenance manual
Erection and commissioning
42
Ref BCSA: KR 3899
RAILWAY
Gearbox for e-motor test bench
Gearbox type : TU 630 T2 X
Power : 2 500 kW
Input speed : 1 500 rpm
Output speed : 27 000 rpm
Max HS torque: 1 256 Nm
Weight : 3 800 kg
• Delivered with lubrication unit
43
Ref BCSA: KR 3776
RAILWAY
High speed planetary for tramway
geared motor development
Gearbox type : AS 80
Power : 210 kW
Input speed : 28 000 rpm
Output speed : 4 067 rpm
Weight : 55 kg
•
•
•
•
Embedded system
Aluminium casing
Compact epicyclical design
Coaxial
44
Ref BCSA: KR 5103
RAILWAY
Speed increaser for e-motors development
Type : SP 3600/4
Power : 2 100 kW
Input speed: 1 500 tr/min
Output speed (a): 5 000 tr/min
Output speed (b): 7 500 tr/min
Max HS torque : 5 590 Nm
Max LS torque : 40 000 Nm
•
•
•
•
•
Ref BCSA: KR 5863
Delivered with 20 t base frame and lubrication unit
4 outlets
1 MW per output
2 speeds with automatic clutch
Efficiency > 95%
45
RAILWAY
Speed increaser for traction motor
test bench
Type : SP 250
Power : 800 kW
Input speed : 2 777 rpm
Output speed : 5 000 rpm
Weight : 1 200 kg
Scope of supply :
• Gearbox
• Lubrication unit
• Couplings
• Coupling safety covers
• Custom frame and fixations
46
Ref BCSA: KR 5218
BALANCING
Type : TU 630 T3 BV3
Power : 10 MW
Input speed : 1 800 rpm
Output speed 1 : 2 250 rpm
Output speed 2 : 4 500 rpm
Output speed 3 : 6 500 rpm
Max LS torque : 115 000 Nm
Weight : 17 t
• Rotor balancing up to 200 tons
• 3 different speed on the same HS shaft
49
Ref BCSA: KR 4900
BALANCING
Type: TU 710 T4 BV3
Power : 500 kW
Input speed : 1 800 rpm
Output speed 1: 8 000 rpm
Output speed 2: 15 000 rpm
Output speed 3: 30 000 rpm
Type : TU 710 T4 BV3
Power : 1 000 kW
Input speed : 1 800 rpm
Output speed 1: 8 000 rpm
Output speed 2: 15 000 rpm
Output speed 3: 25 000 rpm
50
Ref BCSA: KR 4913 & KR 5584
CEMENT PLANT
Gearbox for kiln drive
Type : ULS 2500 P
Power : 935 kW
Input speed : 1 000 rpm
Output speed : 10.2 rpm
Max LS torque : 875 800 Nm
Weight : 26t
•
•
•
•
In place of existing gearbox, 100% interchangeable
Embedded lubrication system
High temperature and dusty environment
100 000 hour design
51
Ref BCSA: KR 4484
CEMENT PLANT
Gearbox for fan drive
Type : TU 560
Power : 4 800 kW
Input speed : 1 000 rpm
Output speed : 5 862 rpm
Max LS torque : 45 840 Nm
Weight : 7,1 t
• In place of existing gearbox, 100%
interchangeable
• Embedded lubrication system
52
Ref BCSA: KR 5283
CEMENT PLANT
Other applications
• Speed reducer for:
o
o
o
o
o
o
o
Ball mill
Dynamic separator
Bucket elevator
Belt conveyor
Mill turning device
Hammer crusher
…
53
OIL & GAS
Centrifugal
compressor gearbox
Type : TU 450
Power : 4 850 kW
Input speed : 1 490 rpm
Output speed : 4 710 rpm
Weight : 4 600 Kg
54
Ref BCSA: KR 3808
OIL & GAS
Gas compressor
gearbox
Type : TU 560
Power : 5 810 kW
Input speed : 1 488 rpm
Output speed : 9 234 rpm
Weight : 4 t
• API 613
• Offshore platform
55
Ref BCSA: KR 1824
OIL & GAS
Compressor turbo
gearbox
Type : TU 500
Power : 620 kW
Input speed : 1 480 rpm
Output speed : 367 rpm
Weight : 2 t
• API 613
• ATEX
• Replacement gearbox
56
Ref BCSA: KR 4925
OIL & GAS
Turbo blower fan
gearbox
Type : TU 320
Power : 3 564 kW
Input speed : 3 888 rpm
Output speed : 12 150 rpm
Weight : 1 000 Kg
• Replacement gearbox
57
Ref BCSA: KR 4452
OIL & GAS
Pump drive
Type : UJS 1075
Power : 600 kW
Input speed : 985 rpm
Output speed : 309 rpm
Weight : 4 760 Kg
• Replacement unit gearbox, 100% interchangeable
• 15 t axial trust
58
Ref BCSA: KR 4824
OTHER INDUSTRIES
Energy
E-motor test rig
Type : TU 500/2
Nominal power : 8 300 kW
Overload : 16 000 kW
Input speed : 1878 rpm
Output speed : 3700 rpm
Maximum torque: 42 000 Nm
Ref BCSA: KR 4677
Waterway
Gate winches
Type : ULS 945 P
Power : 3.9 kW
Input speed : 950 rpm
Output speed : 0.157 rpm
Maximum torque: 88 000 Nm
Ref BCSA: KR 4868
59
OTHER INDUSTRIES
Elevating
Hoisting winch
Type : A 8000 DI
Nominal power : 2.35 kW
Input speed : 1 500 - 500 rpm
Gear ratio : 1/209 & 1/1 755
Maximum torque : 80 000 Nm
Ref BCSA: KR 5257
Nuclear
Upending devices
Type : ALC 300
Power : 4 kW
Input speed : 1 420 rpm
Output speed : 25 rpm
Maximum torque: 1 120 Nm
Ref BCSA: KR 5463
60
OTHER INDUSTRIES
Hydroelectricity
Turbine and generator
Type : HY 640 T1M
Power : 1 600 kW
Input speed : 160 rpm
Output speed : 750 rpm
Weight : 6,5 tons
• With shaft driven oil pump
Ref BCSA: KR 373
61
Feel free to contact us for more
information
David BRUNEAU
Sales Engineer
04 72 14 90 93
dbruneau@bcsa.fr
63
ISO 9001 CERTIFICATION
64