1.1 Company introduction 1.2 Application range of Ever-power high rate gearboxes Ever-power has been active in mechanical engineering for 25 years. For nearly 25 years, we have been manufacturing gears and mechanical gearboxes. Our goal is to keep providing state-of-the-art products to our customers through intensive core engineering and product advancement. We apply a maximally creative approach while addressing technical problems and specific needs of our clients. Our goal is constant development of items with a higher degree of practical and quality parameters. We propose optimal solutions based on a thorough comprehension of every concrete program. We supply high-speed equipment units particularly for thermal power station, heat plants, oil and gas sector or sugar refineries. High speed gearboxes are a crucial component for applications this kind of: • Turbogenerator drives • Steam and gas turbine drives • Turbocompressor drives • Pump drives • Test benches Ever-power has tradition in high acceleration applications since 1977. The worldwide installation foot of the parallel shaft gearboxes totals over 800 devices. The calculation and design software KISSsoft and a 3D CAD program SOLID-EDGE and also other instruments enable us to become maximally fast and flexible. Our team of style engineers cooperates with universities, study institutes and leading experts from all over the globe. Ever-power uses state-of-the-artwork finite component method (FEM) software tools for determining and optimizing gear devices properties.
2.1 Item introduction High-quickness gearboxes designed and manufactured in Ever-power are designated mainly for power generation industry, compressor and pump applications. The manufacture is carried out on the present day machine tools and gearboxes are assembled using very own components or components given by European manufacturers. All products undergo thorough testing on a dynamic test bench. The look and gear power calculation are performed in accordance to API 613 5th Edition and AGMA 6011*. Item types: RS and RU gearbox type is made to withstand forces from meshing of double 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 exterior axial and radial load. The transmission of exterior axial load from HS shaft to LS shaft is by way of thrust collars. The gearbox is self supporting and doesn’t need any reinforcement. It includes a foot flange for installation to a base and jack bolts (levelling bolts) for easy set up. The gearbox will not require any particular maintenance. It is recommended to change the essential oil on regular basis or when changing the environment conditions – see the Operating Manual for details. Regular gearbox is adjusted for high speed operation in the temperature range between -50 / +50°C provided the essential oil preheating at low temperatures and essential oil cooling at high temps. Should the gearbox be managed in hazardous region or under other particular conditions, it needs to be contractually agreed. The typical gearbox efficiency is normally higher than 98,5%. Total efficiency depends upon plenty of factors, 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 can be sized based on the transmitted power. Power is usually given by a customer. It isn’t possible to lessen mesh losses considerably, however Ever-power aims to enhance the losses to attain the best compromise together with gear life, sturdiness and NVH behaviour. bearing losses these losses have the biggest influence on the gearbox performance. It is necessary to planetary gearbox create and size the bearing correctly. windage losses windage losses have got big influence on the gearbox performance if the apparatus circumferential velocity can be high. It is possible to decrease these losses (up to approx 50%) utilizing the windage cover. various other losses gearbox efficiency can be affected by the oil pump losses (if utilized), oil injection loss etc.
2.3 Key specialized features Turbo Gear Units Catalogue © Ever-power Industry a.s. 2016, EN1604 Main Gearbox Components 2.3.1 Housing The housing includes 2 parts: the upper and the lower case. It really is fabricated steel structure. The housing is usually optimized by CAE solutions to ensure once and for all stiffness, low noise emissions, superb cooling properties and minimal weight. In the lower part there are foot for repairing the gearbox to the foundation equipped by jack bolts and with provision for mounting of earthing screw (if the gearbox is set to the hazardous region). Addititionally there is located the oil insight/result fl ange and provision for temperature detectors conduction to the junction box. In the upper component there can be an inspection cover, examining the proper lubrication of meshing gears, a breather and provision for vibration probes. Split face of the casing can be 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 items. HS shaft is usually forged from one piece along with gearing. LS shaft and the gear are forged separately and the apparatus is heat assembled on the shaft. The backsplash band is usually forged from one piece with the shaft or warmth assembled. Both gears are surface to high precision. The teeth fl anks of HS pinion possess special modifi cations to reduce the noise level and compensate the defl ection of shafts due to weighty load. A hunting tooth mixture exists for mating gears when a tooth on the pinion does not repeat contact with a tooth on the gear wheel until it offers contacted the rest of the gear wheel the teeth. The shape of shafts ends depends upon customer’s demand (cylindrical, tapered, fl anged etc.). Both shafts are dynamical balanced in accordance 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 divided into bearings with: • fi xed geometry – there is no motion of sliding faces • tilting pads – sliding faces are moving
LS (low quickness) shaft is normally placed in simple journal bearings with cylindrical clearance (fi xed geometry). One of the bearings is radial (on the non-traveling end) and the other one (on the driving end of the shaft) is combined radialaxial bearing. The design and calculation of the bearings are performed according to the latest methods. Bearings on HS (high speed) shaft are often tilting pad type because of high rate and pitchline velocity and both of these are radial bearings. Tilting pad bearings will often have 4 or 5 5 pads and static load path goes either on one pad or between pads. Lubrication of the bearings can be reached by overflowing the area between pads or oil injection between pads by means of several nozzles which also shields pads against circumferential movement. When essential oil injection is used it is possible to decrease friction losses substantially. These bearings possess the best resistance against rotor instability because they do not generate any load leading to instability
2.5 Gearbox Testing 2 Item explanation and key features 3 Gearbox selection 1 Introduction 2 Product description and key features 2 Item explanation and key features 2.5.1 Load checks of high-rate gearboxes Testing laboratory for high-quickness gearboxes is a camera monitored modern place of work at Ever-power manufacturing plant in Pilsen. The Dynamic Test Bench is a screening facility equipped with a computer controlled 1 MW motor with speed up to 3.600 rpm, managed load by a generator up to 710 kW of power, auxiliary gearboxes enabling testing of the main gearbox with increase to 35.000 rpm. The test bench have a lubrication centre with adjustable essential oil fl ow from 10 to 1 1.600 liters/ minute, controllable oil temperature and water cooling up to 800 kW of power. The lubrication is certainly supported with pneumatic pumps supplying full volume of oil in the event of power outage. The tests process is automatically recorded while essential oil and bearing temperature, pressure, noise, total and relative vibrations are measured and transferred to a control space for assessment by a specialized software.