Corrugator operating speeds have increased as a result of the installation of high performance dry-end systems and new generation singlefacers. With this change, the original OEM doublebacker drive design often becomes the "weak link", limiting machine speed and reliability. Bull gear failure becomes more common as speeds and operating hours go well beyond the original corrugator design. This problem is compounded as additional doublebacker load is added as a result of installing popular thermal-transfer systems. An increased load of 20 to 30% can be enough to force a marginal bull gear drive to fail.

The Doublebacker Direct Drive Conversion from Chicago Converting Equipment reportedly eliminates the problems and limitations associated with bull gear drives to provide higher speed, greater efficiency, improved speed control, faster stopping and reduced maintenance.

According to the manufacturer, the product design is simple, compact and flexible. A new DC drive motor is connected to upper and lower right-angle high-efficiency gear reducers with individual timing belt drives. The reducers are connected to the head pulley drums with heavy-duty universal shafts, which allow for misalignment or runout of the existing journals. The gear units and drive motor are supplied in a pre-engineered frame designed to match the dimensional requirements of each application. The manufacturer notes that the system is comprised of standard components that can be obtained and serviced locally. No proprietary parts are used.

The Doublebacker Direct Drive Conversion is reportedly easy to install. The original bull gears, pinion gear, right-angle reducer and related components are completely removed. Taper-lock hubs are installed in place of the gears and connected directly to the individual upper and lower gear reducers with universal shafts. According to the manufacturer, no precision alignment is required and most applications require no modification of the existing journals. All guarding is supplied with the unit and complete installation is often completed in one day.

Chicago Converting reports that it has sold more than 30 systems since the product was introduced in the spring of 1995. All major brands of head pulley assemblies have been converted including Langston, S&S, Koppers, Peters and Uni- versal. Single- and two-motor designs have been supplied using both AC and DC drive technology. Systems are designed to fit the particular needs of the customer. The existing motor and controls can be used, or the company has the ability to provide a new package.

Several installations of the Doublebacker Direct Drive have included new motor control electronics from Chicago Electric. According to the company, modern digital drives further improve the performance and reliability of the corrugator. New drives reportedly provide 1,000 FPM capability with precise speed and torque control. Chicago Electric and Chicago Converting are both part of the Chicago Industrial Group. Together, these companies offer experience in applying new drive technology for the corrugator.

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