AGMA-04FTM1-2004.pdf
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1、04FTM1 Gear Noise - - Challenge and Success Based on Optimized Gear Geometries by: Dr. F. Hoppe and Dr. B. Pinnekamp, Renk AG TECHNICAL PAPER American Gear Manufacturers Association Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/11111
2、11001, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:44 MDTNo reproduction or networking permitted without license from IHS -,-,- Gear Noise - - Challenge and Success Based on Optimized Gear Geometries Dr. Franz Hoppe and Dr. Burkhard Pinnekamp, Renk AG The statements and opinions contained her
3、ein are those of the author and should not be construed as an official action or opinion of the American Gear Manufacturers Association. Abstract For gear transmissions different levels of requirements with regard to noise excitation have to be matched. Industrialapplicationsforconveyorbeltsorcement
4、millsarewithoutdoubtmuchlesssensitivewithrespectto noise emission than military applications, e.g. for navy ship propulsion. However, also for industrial applications the air borne and structure borne noise behavior more and more becomes an important feature. RENKhasbeendevelopingoptimumgearunitsfor
5、allapplicationswithatransmittedpowerlevelrangingupto 145 MW. This paper describes requirements and solutions with regard to noise behavior focusing on examplestakenfromnavyapplicationsandwindturbinegeartransmissions.Theindividualapproacheshave to be a suit-able compromise to meet the challenge of no
6、ise requirement and cost optimization without any restriction on gear load carrying capacity. Therefore, there is no general but individual solution for optimum design. The paper comprises basic considerations with regard to gear noise, noise requirements and measurements at shop and field tests in
7、comparison to gear geometry and calculation results. Copyright 2004 American Gear Manufacturers Association 500 Montgomery Street, Suite 350 Alexandria, Virginia, 22314 October, 2004 ISBN: 1-55589-824-6 Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA License
8、e=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:44 MDTNo reproduction or networking permitted without license from IHS -,-,- 1 Gear Noise Challenge and Success Based on Optimized Gear Geometries Franz Hoppe, BSc, PhD: General Manager Marine Gears RENK AG, Germany Burkh
9、ard Pinnekamp, BSc, PhD: Engineer, Special Programs Marine and Industrial Gears RENK Corp, Duncan, SC 1 INTRODUCTION Power generation or Navy vessel propulsions are two examples for the application of advanced gear systems. Typical applications are wind turbine mul- tiple stage step up gears, or COD
10、OG and CODAG marine gears for up to 30 MW gas turbines and diesel engines up to 7 MW to controllable pitch propellers. In any case, the supplier of main reduc- tion gears has to provide the optimized technology for any kind of installation at utmost interface flexi- bility. This can only be achieved
11、 in close co- operation with power train suppliers, or Navies and shipyards. Furthermore, in continuous development of tech- nology enhancement, single components are sub- jected to increased refinement such as gear teeth as the heart of gear transmissions for the benefit of optimization of the load
12、 carrying capacity and low- est noise performance. To achieve optimum noise behavior, different criteria of gear design have to be observed, such as selection of bearings (damping features) and housing (mass, noise dissipation fea- tures) and gear geometry. In this respect, an ex- treme importance c
13、omes to the correct selection of macro geometry parameters as well as tooth cor- rection values, where the proper evaluation of both is supported by continuously adapted calculation methods. However, theory needs to be transferred to real operable gears with the required accuracy applied, and theref
14、ore production means such as heat treatment processing and grinding tools are simultaneously to be maintained on the latest stage of technology. In completion of a modern main transmission gears, the environmental demands on control aspects require an ongoing adaptation. Today, integral pro- grammab
15、le logic control (PLC) systems provide an utmost flexibility, safety and comfort for the opera- tion of reduction gears. The gear is not just a me- chanical transmission it is developed to a system with functional sub stations interfacing with the plants operational environment. 2 GEAR NOISE BASICS
16、2.1 Tooth Geometry Basics for Low Noise A main power transmission gear is subjected to various external influences, such as reaction loads from adjoined external couplings, foundation distor- tion, dynamic mass forces due to heavy sea states or transient wind forces, and, not lastly, heat ex- pansio
17、n due to the power loss generated by gear teeth and bearings. In view of all these impacts, and also respecting in most marine field cases low noise generation re- quirements, the tooth design is to be focused on in particular, as pinions and gears represent “the heart” of a gearbox. First priority,
18、 the decision on the basic type of gear teeth is of importance, where principally spur gears, single helical or double heli- cal gears are available. Figure 1 shows the principle coherence between tooth mesh noise excitation and overlap ratio, . With spur gears, equals zero, with low single helices,
19、 values up to 2 are achievable. High heli- ces are in practical sense realized only with double helical gears, achieving 3. Apart from signifi- cant noise reduction at increased , excitation ap- pears to be minimum with integer value of overlap ratio. The fundamental results as depicted in Fig- ure
20、1 are considered as state of the art and have been confirmed throughout the past 25 years with numerous research programs, supported by experi- ence with countless applications in service. Involute gears theoretically mesh without periodical angular deviation in rotation and without dynamic excitati
21、on. However, due to manufacturing devia- tions, misalignment and elastic deformations under load, this theoretical optimum is not achieved in reality. Manufacturing and alignment can be ad- dressed by optimum quality with regard to gear grinding, assembly and commissioning. Deforma- tion under load
22、cannot be avoided but addressed properly by smart design and appropriate flank modification. Above all, the macro geometry still is the decisive criterion on noise excitation. That Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/111111
23、1001, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:44 MDTNo reproduction or networking permitted without license from IHS -,-,- 2 means that only optimized macro geometry allows for optimum noise behavior. The basic background will be described in the following paragraphs. Gears will change th
24、eir geometric position under load due to the following influences: Deflection due to Hertzian pressure, bending of teeth, elastic deflection of gear bulks and shafts. Figure 1 Noise in dB generated in tooth mesh, dependent on basic layout and overlap ratio, , acc. to ref. (2) and (3). Note: Minima a
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