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 production gears and mechanical gearboxes. Our purpose is to keep delivering state-of-the-art products to our customers through intensive primary engineering and product development. We apply a maximally planetary gearbox innovative approach while addressing specialized 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 on the basis of a thorough comprehension of every concrete software. We supply high-speed equipment units particularly for thermal power station, heat plants, coal and oil sector or sugars refineries. High rate gearboxes are a crucial component for applications such: • Turbogenerator drives • Steam and gas turbine drives • Turbocompressor drives • Pump drives • Test benches Ever-power has tradition in high swiftness applications since 1977. The worldwide installation foot of the parallel shaft gearboxes totals over 800 products. The calculation and design software KISSsoft and a 3D CAD program SOLID-EDGE and also other instruments allow us to be maximally fast and versatile. Our team of style engineers cooperates with universities, analysis institutes and leading experts from all around the globe. Ever-power uses state-of-the-artwork finite element method (FEM) software equipment for determining and optimizing gear units properties.
2.1 Product introduction High-quickness gearboxes designed and manufactured in Ever-power are designated primarily for power generation industry, compressor and pump applications. The manufacture is carried out on the modern machine equipment and gearboxes are assembled using personal components or components given by European manufacturers. All products undergo thorough testing on a powerful test bench. The design and gear strength calculation are performed in accordance to API 613 5th Edition and AGMA 6011*. Product types: RS and RU gearbox type is designed to endure forces from meshing of dual helical gears. They are not made to withstand any external axial or radial load. R1T and R2T gearbox type is designed to endure forces from meshing of one helical gears and exterior axial and radial load. The transmission of exterior axial load from HS shaft to LS shaft is certainly by way of thrust collars. The gearbox is certainly self supporting and does not need any reinforcement. It includes a foot flange for mounting to a basis and jack bolts (levelling bolts) for easy installation. The gearbox will not require any unique maintenance. It is suggested to change the essential oil on regular basis or when changing the environment conditions – start to 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 temperature ranges and oil cooling at high temps. Should the gearbox be managed in hazardous region or under other unique conditions, it needs to be contractually agreed. The standard gearbox efficiency is usually higher than 98,5%. Total efficiency depends upon plenty of elements, such as for example mesh losses, bearing losses, windage losses etc. Ever-power is competent to prepare personalized solution to boost the gearbox effi ciency up to 99,5%. mesh losses gearing is definitely sized predicated on the transmitted power. Power is certainly given by a customer. It is not possible to lessen mesh losses considerably, nevertheless Ever-power aims to enhance the losses to achieve the best compromise as well as gear life, sturdiness and NVH behaviour. bearing losses these losses have the biggest influence on the gearbox performance. It is necessary to design and size the bearing correctly. windage losses windage losses possess big influence on the gearbox performance if the apparatus circumferential velocity can be high. You’ll be able to reduce these losses (up to approx 50%) by using the windage cover. various other losses gearbox efficiency is also 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 consists of 2 parts: the upper and the low case. It really is fabricated steel building. The housing is definitely optimized by CAE methods to ensure once and for all stiffness, low sound emissions, excellent cooling properties and minimal weight. In the lower part there are feet for fixing the gearbox to the foundation outfitted by jack bolts and with provision for installation of earthing screw (if the gearbox is determined to the hazardous area). There is also located the oil insight/output fl ange and provision for temperature detectors conduction to the junction container. In the upper part there can be an inspection cover, checking the proper lubrication of meshing gears, a breather and provision for vibration probes. Split encounter of the casing is usually horizontal, parallel to shaft axis. Both parts are linked by bolts and fi xed by dowel pins. 2.3.2 Shafts and gears Both shafts are forged parts. HS shaft is certainly forged in one piece along with gearing. LS shaft and the apparatus are forged separately and the apparatus is temperature assembled on the shaft. The backsplash band is usually forged from one piece with the shaft or high temperature assembled. Both gears are floor to high precision. The teeth fl anks of HS pinion have got special modifi cations to lessen the sound level and compensate the defl ection of shafts due to large load. A hunting tooth combination exists for mating gears whenever a tooth on the pinion will not repeat contact with a tooth on the apparatus wheel until it provides contacted all the other gear wheel teeth. The form of shafts ends depends upon customer’s demand (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 an increase of 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 motion of sliding faces • tilting pads – sliding faces are moving
LS (low quickness) shaft is generally placed in basic journal bearings with cylindrical clearance (fi xed geometry). One of the bearings is certainly radial (on the non-generating end) and the various other one (on the driving 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 due to high swiftness and pitchline velocity and both of these are radial bearings. Tilting pad bearings usually have 4 or 5 5 pads and static load direction goes either using one pad or between pads. Lubrication of the bearings could be reached by overflowing the space between pads or essential oil injection between pads through a number of nozzles which also defends pads against circumferential motion. When oil injection is used it is possible to reduce friction losses considerably. These bearings have the highest level of resistance against rotor instability because they don’t generate any load leading to instability
2.5 Gearbox Testing 2 Item explanation and key features 3 Gearbox selection 1 Introduction 2 Item description and key features 2 Product description and key features 2.5.1 Load tests of high-acceleration gearboxes Testing laboratory for high-quickness gearboxes is a camera monitored contemporary workplace at Ever-power manufacturing plant in Pilsen. The Dynamic Test Bench is a testing facility equipped with a computer controlled 1 MW engine with increase to 3.600 rpm, controlled load by a generator up to 710 kW of power, auxiliary gearboxes enabling testing of the primary gearbox with speed up to 35.000 rpm. The check bench possess 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 case of power outage. The testing process is instantly recorded while oil and bearing temperature, pressure, noise, total and relative vibrations are measured and transferred to a control area for evaluation by a specialized software.