1.1 Company introduction 1.2 Application selection of Ever-power high quickness gearboxes Ever-power has been energetic in mechanical engineering for 25 years. For nearly 25 years, we’ve been production gears and mechanical gearboxes. Our purpose is to keep delivering state-of-the-art products to your customers through intensive primary engineering and product advancement. We apply a maximally creative approach while addressing specialized problems and specific needs of our customers. Our goal is continuous development of products with a higher degree of practical and quality parameters. We propose ideal solutions on the basis of an intensive comprehension of each concrete program. We supply high-speed gear units especially for thermal power station, heat plants, oil and gas sector or glucose refineries. High velocity gearboxes are a important component for applications such: • Turbogenerator drives • Steam and gas turbine drives • Turbocompressor drives • Pump drives • Test benches Ever-power has custom in high acceleration applications since 1977. The worldwide installation foot of the parallel shaft gearboxes totals over 800 models. The calculation and design software program KISSsoft and a 3D CAD program SOLID-EDGE and also other instruments allow us to be maximally fast and flexible. Our team of style engineers cooperates with universities, research institutes and leading professionals from all around the world. Ever-power uses state-of-the-artwork finite element method (FEM) software tools for determining and optimizing gear units properties.
2.1 Item introduction High-swiftness gearboxes designed and produced in Ever-power are designated primarily for power generation industry, compressor and pump applications. The manufacture is completed on the present day machine equipment and gearboxes are assembled using own components or components supplied by European producers. All products undergo thorough testing on a powerful test bench. The look and gear strength calculation are performed in accordance to API 613 5th Edition and AGMA 6011*. Item types: RS and RU gearbox type is designed to endure forces from meshing of dual helical gears. They are not designed to withstand any exterior axial or radial load. R1T and R2T gearbox type is designed to endure forces from meshing of solitary helical gears and external axial and radial load. The transmission of exterior axial load from HS shaft to LS shaft is definitely by means of thrust collars. The gearbox can be self supporting and does not need any reinforcement. It includes a foot flange for installation to a basis and jack bolts (levelling bolts) for easy set up. The gearbox does not require any particular maintenance. It is recommended to change the oil on regular basis or when changing the environment conditions – see the Working Manual for details. Standard gearbox is modified for high speed procedure in the temperature range between -50 / +50°C provided the essential oil preheating at low temperatures and essential oil cooling at high temps. If the gearbox be operated in hazardous region or under other unique conditions, it needs to be contractually agreed. The standard gearbox efficiency is generally greater than 98,5%. Total efficiency depends upon plenty of elements, such as mesh losses, bearing losses, windage losses etc. Ever-power is capable to prepare customized solution to boost the gearbox effi ciency up to 99,5%. mesh losses gearing is definitely sized predicated on the transmitted power. Power is given by a customer. It isn’t possible to reduce mesh losses considerably, nevertheless Ever-power aims to optimize the losses to achieve the best compromise together with gear life, sturdiness and NVH behaviour. bearing losses these losses possess the biggest planetary gearbox influence on the gearbox performance. It is necessary to create and size the bearing properly. windage losses windage losses have big impact on the gearbox efficiency if the gear circumferential velocity is definitely high. You’ll be able to reduce these losses (up to approx 50%) by using the windage cover. various other losses gearbox efficiency can be affected by the oil pump losses (if utilized), oil injection reduction etc.
2.3 Key technical features Turbo Gear Units Catalogue © Ever-power Industry a.s. 2016, EN1604 Main Gearbox Components 2.3.1 Housing The housing contains 2 parts: the upper and the lower case. It really is fabricated steel construction. The housing can be optimized by CAE methods to ensure for good stiffness, low noise emissions, superb cooling properties and minimum weight. In the low part there are ft for repairing the gearbox to the building blocks outfitted by jack bolts and with provision for installation of earthing screw (if the gearbox is determined to the hazardous region). Addititionally there is located the oil insight/result fl ange and provision for temperature detectors conduction to the junction package. In the upper part there can be an inspection cover, examining the proper lubrication of meshing gears, a breather and provision for vibration probes. Split encounter of the casing is certainly horizontal, parallel to shaft axis. Both parts are connected by bolts and fi xed by dowel pins. 2.3.2 Shafts and gears Both shafts are forged parts. HS shaft is definitely forged from one piece along with gearing. LS shaft and the gear are forged separately and the gear is temperature assembled on the shaft. The backsplash ring is usually forged from one piece with the shaft or warmth assembled. Both gears are surface to high precision. Teeth fl anks of HS pinion have special modifi cations to lessen the noise level and compensate the defl ection of shafts due to heavy load. A hunting tooth mixture exists for mating gears whenever a tooth on the pinion will not repeat connection with a tooth on the gear wheel until it provides contacted the rest of the gear wheel tooth. The form of shafts ends depends upon customer’s ask for (cylindrical, tapered, fl anged etc.). Both shafts are dynamical balanced according to ISO 1940 or API 613. 2.3.3 Bearings Solely hydrodynamic bearings with more sliding faces are used due to high speeds and bearing load. These bearings are split into bearings with: • fi xed geometry – there is absolutely no movement of sliding faces • tilting pads – sliding faces are moving
LS (low swiftness) shaft is usually placed in basic journal bearings with cylindrical clearance (fi xed geometry). One of the bearings is definitely radial (on the non-generating end) and the additional one (on the traveling end of the shaft) is combined radialaxial bearing. The look and calculation of the bearings are performed based on the latest methods. Bearings on HS (high speed) shaft are often tilting pad type because of high speed and pitchline velocity and both of them are radial bearings. Tilting pad bearings usually have four or five 5 pads and static load path goes either using one pad or between pads. Lubrication of these bearings can be reached by overflowing the area between pads or oil injection between pads through several nozzles which also defends pads against circumferential motion. When oil injection is used it is possible to reduce friction losses significantly. These bearings possess the best level of resistance against rotor instability because they don’t generate any load leading to instability
2.5 Gearbox Testing 2 Product explanation and key features 3 Gearbox selection 1 Introduction 2 Product explanation and key features 2 Product explanation and key features 2.5.1 Load exams of high-swiftness gearboxes Testing laboratory for high-acceleration gearboxes is a camera monitored modern place of work at Ever-power manufacturing plant in Pilsen. The Powerful Check Bench is a assessment facility equipped with a computer managed 1 MW electric motor with increase to 3.600 rpm, controlled load by a generator up to 710 kW of power, auxiliary gearboxes allowing testing of the primary gearbox with increase to 35.000 rpm. The test bench possess a lubrication centre with adjustable oil fl ow from 10 to at least one 1.600 liters/ minute, controllable oil temperature and water cooling up to 800 kW of power. The lubrication is definitely supported with pneumatic pumps supplying full level of oil in case of power outage. The examining process is immediately recorded while essential oil and bearing temperature, pressure, noise, absolute and relative vibrations are measured and used in a control space for evaluation by a specialized software.