DYNAMIC POSITIONING CONFERENCE October 11-12, 2016 THRUSTERS Michael Potts Schottel High Torque Gear (HTG) - The New Premium Class in Azimuth Thrusters Gear Technology
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DYNAMIC POSITIONING CONFERENCE October 11-12, 2016
THRUSTERS
Michael Potts Schottel
High Torque Gear (HTG) - The New Premium Class in Azimuth Thrusters Gear Technology
High Torque GearNew premium class in azimuth thrusters gear technology
Michael Potts, October 2016
YOUR PROPULSION EXPERTS
WELCOME ABOARD!
YOUR PROPULSION EXPERTS
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSSTRUCTURE
(1897 – 1973)
01 INTRODUCTION
02 APPLICATION
03 MANUFACTURING
04 DEVELOPMENT
05 TESTING
06 CALCULATION
07 RUDDER ECOPELLER SRE
YOUR PROPULSION EXPERTS
Josef Beckerfounds Schottel
1921
SCHOTTEL Rudderpropeller
1950
Elmer A. Sperry Award 2004
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSINTRODUCTION
YOUR PROPULSION EXPERTS
SCHOTTEL PRODUCTS
High qualityPropulsion Systems
up to 30 MW
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSINTRODUCTION
YOUR PROPULSION EXPERTS 6
APPLICATION
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSAPPLICATION
YOUR PROPULSION EXPERTS 8
MANUFACTURING
Quelle: Wikov
YOUR PROPULSION EXPERTS
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSMANUFACTURING
GrindingConventional Machining5-Axis-Free-Form-Milling
P=600 kW
Tin=3.800 Nm
de2=455 mm
P=2.300 kW
Tin=37.000 Nm
de2=950 mm
P=5.500 kW
Tin=90.000 Nm
de2=1.650 mm
YOUR PROPULSION EXPERTS
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSMANUFACTURING
Conventional Machining 5-Axis-Freeform-Milling
toe heelfoot toe heelfoot
YOUR PROPULSION EXPERTS 11
DEVELOPMENT
Pythagoras: Eternal Change
„Everything changes,
nothing dies…“
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
Manufacturing quality 5-Axis-Freeform-Milling
waviness
shape & position tolerance roughness
milling strategy
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
Idea 1: Asymmetrical profil
αD=30°
αC=18°
αD=20°
αC=20°
pH =FN � E
2π � 1− ν2 � l�
1ρ1
+1ρ2
pH αw = 45° → minimal
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
Idea 2: Addendum coefficient
heel foot toe
h = 36,67 mm
lbm = 201 mm
khap = 1,0 khap = 1,2
h = 39,93 mm
lbm = 222 mm
Pinion Pinion
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
Conventional MachiningStandard flank modification
5-Axis-Freeform-MillingIdea 3: Free flank modification
heel toe heel toe
σH = 1.279 MPa σH = 1.195 MPa
YOUR PROPULSION EXPERTS
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
σH = 1.101 MPa
Reduction Hertzian pressure σH = 16 %
SH = 1,51
Increase safety against pitting SH = 16 %
Conventional MachiningReference
5-Axis-Freeform-MillingHTG
YOUR PROPULSION EXPERTS
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSDEVELOPMENT
Reduction maximum sliding velocity vg = 12 %
Increase safety against scuffing SB = 29 % and micropitting Sʎ = 37 %
vg = 3.252 mm/s
SB = 3,55
Conventional MachiningReference
5-Axis-Freeform-MillingHTG
YOUR PROPULSION EXPERTS 18
TESTING
Source: Skipwebworld
YOUR PROPULSION EXPERTS 19
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSTESTING
Testing Method
Endurance run
Identical materialIdentical heat treatment
12 gearsmn=7,35mm
18 gearsmn=4,47mm
HTG
Ref
eren
ce Symmetrical profilStandard flank modificationStandard addendum coefficientStandard foot curve
Asymmetrical profilFree flank modificationOptimised addendum coefficientOptimised foot curve
YOUR PROPULSION EXPERTS 20
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSTESTING
700
800
900
1,000
1,100
1,200
1,3001,4001,5001,600
6001.E+06 1.E+07 1.E+08
Pini
onTo
rque
T 1[N
m]
Number of cycles NL
T50%= 1.113 Nm
T50%= 917 Nm
+21 %
HTG- No damage
HTG- Pittings Reference- Pittings
Reference- No damage
YOUR PROPULSION EXPERTS 21
CALCULATION
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSCALCULATION
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ISO 10300DIN 3991
Rules
Tooth fracture Sf>1,55
Scuffing SSS>2,00
Tiff SS>1,2
Pitting SH>1,20
Micropitting Sλ>2,00
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSCALCULATION
Stem: Fx = - 23 kNFy = - 123 kNFz = - 28 kN
Nozzle:Fx = 70 kNFy = - 227 kNFz = 16 kN
displacement:∆max=16 mm
YOUR PROPULSION EXPERTS 24
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSCALCULATION
YOUR PROPULSION EXPERTS
(1897 – 1973)
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSTHE RUDDERPROPELLER
YOUR PROPULSION EXPERTS 26
geardiameter
Using HTG gear:• diameter gain• increased torque• allows even better, leaner hydrodynamic shape
=> >1,5% efficiency gain
H T G
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSRUDDER ECOPELLER SRE
+
YOUR PROPULSION EXPERTS 27
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSRUDDER ECOPELLER SRE
pitch max. aheadpitch max. back full feathering
YOUR PROPULSION EXPERTS 28
Offshore Optimization of Proven Principle Outstanding Efficiency Enviroment-friendly Superior Course Keeping Capability Advanced Gear Design
(Higher Safety, More Torque) FP / CP (Full Feathering optional) Mechanical Simplicity Easy Installation Most Flexible Dimensions ICE-Classes 1A, 1B and 1C
HIGH TORQUE GEAR IN AZIMUTH THRUSTER GEARSRUDDER ECOPELLER SRE
YOUR PROPULSION EXPERTS 29
MANY THANKS FOR YOUR ATTENTION!
Source: Sigma Report
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