| Customization: | Available |
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| Application: | Metallurgy, Building Materials, Petrochemical, Cem |
| Function: | Change Drive Torque, Change Drive Direction, Speed Changing, Speed Reduction, Speed Increase |
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High-speed gearboxes designed and manufactured in MASPTT are designated primarily for power generation industry, compressor and pump applications. The manufacture is carried out on the modern machine tools and gearboxes are assembled using own components or components supplied by professional manufacturers. All products undergo thorough testing on a dynamic test bench.
The design and gear strength calculation are performed according to API 613 5th Edition and AGMA 6011(Other standard can be applied if requested.).
The gearbox is self supporting and does not need any reinforcement. It has a foot flange for mounting to a foundation and jack bolts (levelling bolts) for easy installation. The gearbox does not require any special maintenance. It is recommended to change the oil on regular basis or when changing the climate conditions - see the Operating Manual for details.
Standard gearbox is adjusted for high speed operation in the temperature range between -50 / +50°C provided the oil preheating at low temperatures and oil cooling at high temperatures. Should the gearbox be operated in hazardous area or under other special conditions, it has to be contractually agreed. The standard gearbox effi ciency is usually higher than 98,5%. Total efficiency depends on plenty of factors, such as mesh losses, bearing losses, windage losses etc. Wikov is capable to prepare customized solution to increase the gearbox effi ciency up to 99,5%.
Mesh losses
gearing is sized based on the transmitted power. Power is given by a customer. It is not possible to reduce mesh losses considerably, however MASPTT aims to optimize the losses to achieve the best compromise together with gear life, durability and NVH behaviour.
Bearing losses
these losses have the biggest influence on the gearbox efficiency. It is necessary to design and size the bearing properly.
Windage losses
Windage losses have big influence on the gearbox efficiency if the gear circumferential velocity is high. It is possible to reduce these losses (up to approx 50%) by using the windage cover.
Other losses
gearbox efficiency is also affected by the oil pump losses (if used), oil injection loss etc.
Main Gearbox Components
Housing
The housing consists of 2 parts: the upper and the lower case. It is fabricated steel construction. The housing is optimized by CAE methods to ensure for good stiffness, low noise emissions, excellent cooling properties and minimum weight.
In the lower part there are feet for fixing the gearbox to the foundation equipped by jack bolts and with provision for mounting of earthing screw (if the gearbox is determined to the hazardous area). There is also located the oil input/output fl ange and provision for temperature detectors conduction to the junction box. In the upper part there is an inspection cover, checking the proper lubrication of meshing gears, a breather and provision for vibration probes. Split face of the casing is horizontal, parallel to shaft axis. Both parts are connected by bolts and fixed by dowel pins.
Shafts and gears
Both shafts are forged pieces. HS shaft is forged from one piece along with gearing. LS shaft and the gear are forged separately and the gear is heat assembled on the shaft. The backsplash ring is usually forged from one piece with the shaft or heat assembled. Both gears are ground to high precision. Teeth fl anks of HS pinion have special modifi cations to reduce the noise level and compensate the deflection of shafts due to heavy load.
A hunting tooth combination exists for mating gears when a tooth on the pinion does not repeat contact with a tooth on the gear wheel until it has contacted all the other gear wheel teeth.
The shape of shafts ends depends on customer's request (cylindrical, tapered, fl anged etc.).
Both shafts are dynamical balanced according to ISO 1940 or API 613.
Bearings
Solely hydrodynamic bearings with more sliding faces are used due to high speeds and bearing load. These bearings are divided into bearings with:
• fixed geometry - there is no movement of sliding faces • tilting pads - sliding faces are moving.
LS (low speed) shaft is usually placed in plain journal bearings with cylindrical clearance (fi xed geometry). One of the bearings is radial (on the non-driving 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 usually tilting pad type due to high speed and pitchline velocity and both of them are radial bearings.
Tilting pad bearings usually have 4 or 5 pads and static load direction goes either on one pad or between pads. Lubrication of these bearings can be reached by overflowing the space between pads or oil injection between pads by means of several nozzles which also protects pads against circumferential movement. When oil injection is used it is possible to reduce friction losses considerably. These bearings have the highest resistance against rotor instability because they do not generate any load causing instability.
Shaft sealing
Shafts sealing is provided by means of labyrinth seals and backsplash rings. Sealing design generally depends on the shaft revolution, operating conditions and environment. The advantage of labyrinth seal is that it is not exposed to friction scuff . That is very eff ective way of touch free sealing proper particularly for high speed and relatively dusty environment. It is possible to use it for low and high temperatures without any special provisions.
Labyrinth seal shall operate in horizontal position. It is necessary to size the oil drain from bearing space the way to prevent the oil leakage.
Case sealing
The gear case sealing in the split face and under all lids is ensured by LOCTITE or another similar sealant.
Lubrication
Lubrication of gears is performed by internal piping with spraying nozzle. Bearing lubrication is provided through internal oil passages in the gearbox casing. Oil drain from bearing space is ensured by means of adjustment of gearbox casing.
The nominal oil pressure is in the range of 0.1 - 0.15 MPa. Oil viscosity is ISO VG 46 or 32. Oil working temperature at bearings should be between 80° and 95°C at maximum.It is necessary to prevent mechanical impurities getting in the lubrication system. The permitted size of oil impurities behind the oil fi lter is 10 - 25 µm.
Cooling
Sufficient cooling of the gearbox is ensured primarily by natural radiation, i.e. the heat accumulated in the oil is released into the surrounding area by radiation and convection. The temperature of oil entering the gearbox shall not exceed 50°C. Unobservance of this temperature results in reduced service life of the product. Standard lubrication unit (incl. cooler, fi ltration etc.) shall be used for gearbox cooling and lubrication.
Sensors and monitoring
Gearboxes can befitted with various temperature, vibration, speed and shaft axial displacement probes. Remote gearbox diagnostics is optional equipment of the gearbox.
Get the right gearbox for your equipment.
PTT knows gearbox. As the leading industry gearbox manufacturer, PSS offers the best power transmission solutions to perfectly meet your specific industry application. On gearbox, PTT has a lot more to share.
We always satisfy all industries with our gearbox
PTT strives for 100% satisfaction from customers of all industries. We welcome challenges to offer tailored design or special solution to satisfy customers' Special needs on applications. We like to make impossibility become possibility.
Key features
Turbine gearboxes and planetary gearboxes are our advantages. Most companies can only manufacture Helical Bevel gearboxes, and we have a strong design team that has now designed turbine gearboxes up to 70, 000 rpm.
Diversity
PTT offers a vast diversity of gear reducer, geared motor and gearbox. No doubt you are able to find what you need with PTT.
Reliability
PTT is a trustworthy manufacturer you can rely on, no matter in terms of quality, delivery, pricing, service, etc. It becomes our name tag during our history of servicing our customers.
Capability
PTT is able to manufacture 200, 000 sets of gear reducers yearly and keeps investing on development of new series product.
We have a large list of our satisfied clients
Among the large list of our satisfied clients, there are many trend-setting top brands in various industries.
Mian products
Helical Gear Units
Bevel-Helical Gear Units
ZYJ Series Gear Units
DY Series Gear Units
P Planetary Gear Units
MLX Series Mill Gear Units
High Speed Gear Units
Non-stand Gear Units
Q:Are you trading company or manufacturer?
A: We are manufacturer with over 20 years' experience.
Q: How long is your delivery time?
A: Generally it is within 10 days if the goods are in stock, for goods produced as per order, it is within 35 days after confirmation of order.
Q: How long should I wait for the feedback after I send the enquiry?
A: Normally within 12 hours.
Q: What information should I give you to confirm the product?
A: Model/Size, Transmission Ratio, Speed, Shaft directions & Order quantity etc.
Q: Hong long is your product warranty?
A: We offer 12 months warranty from departure date of the goods.
Q: What is your payment terms? T/T 100% in advance for amount less than USD10000.-, 30% T/T in advance , balance before shipment for amount above USD10000.
If you have any other questions, please feel free to contact us below:
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