03MCHQD MACHINE DESIGN 2016-2017

TECHNICAL REPORT 1 - part 1- static design

Object of the report is the calculation of the gearbox (Figure 2) connected to the Kaplan turbine in a
hydropower plant (Figure 1).
The gearbox is a speed increaser. In Figure 1 it can be seen that the speed increaser is connected
to the low speed shaft coming from the Kaplan turbine and drives the high speed shaft (shaft1) that
goes to the generator.
The first stage of speed increment is obtained by means of a planetary gearing. The second speed
increment stage is obtained by means of two wheel-pinion stages.
In this report it is required to perform the static calculation of two shafts: the output shaft 1
and intermediate shaft 2, assuming gear efficiency equal to 1.

Table 1. Given data

Dimensions 1730 2748 2100 mm
Operating data
Input power (P) (mechanical power) 935 kW
Input speed (nI) 26.17 rpm
Gear data
Total gear reduction (i) 61.966
Gears
Pressure angle () 20
Helical teeth spiral angle () 15
Bearings and bore diameter (d)
Bearing A - series NJ 2322 ECMA (110) 110 mm
Bearing A - series QJ 222 N2MA (110) 110 mm
Bearing B - series NU 2322 ECP (110) 110 mm
Bearing C - series 30232 J2/DF (160) 160 mm
Bearing D - series NU 2322 ECM (160) 160 mm
Suggested material for the shafts
Quenched and tempered steel Rm = 1250 MPa, ReH = 1050 MPa,
36NiCrMo16 UNI EN10083

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 Turbine and generator

GENERATOR
Oil Pressure Unit
GEARBOX

GENERATOR

GEARBOX
Butterfly valve

Turbine

Figure 1 The hydropower plant, the turbine and electrical generator

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 THE GEARBOX
Generator side

A
A C

Shaft 1 Shaft 2

B D

Turbine side

Figure 2 The gearbox

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 planet planetary
carrier
sun

ring gear

Figure 3 Rotating parts: different colors correspond to different rotating speeds.

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Figure 4 Gearbox with bearings

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Figure 5 Scheme of the gearbox

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 SKETCH OF THE FORCES ON THE WHEELS

Kn4
Kp4
Ka4
Ka3
Kn3
Kp3

Kn2

Ka2
Kp1
Kp2
1 Ka1

Kn1

Table 2. Gear-tooth forces

INPUT and OUTPUT orques

P 60 1000
MtIN Nm Input torque from the rotor
n2
tIN Nm Output torque to the main generator
M
MtOUT
i
Gear-tooth forces (helical cut gears)
Mt
Kp
r
r pitch radius of the gear
K a K p tan

tan
Kn K p
cos

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Guidelines for the design

1) Calculate the torque on the shafts and the forces according to Table 2.
2) Estimate the dimensions of the wheels pitch radius from the sketch of Figure 2; consider as
reference the dimensions of the bearings bore diameters (d in Table 1).
3) Calculate the forces Kp, Ka, Kn between the mating gears according to the formulas of Table 2
4) Sketch the dimensional layout with the main dimensions and constrained as in the example
of the figure below which is referred to a similar gear .

- In choosing the direction (axial or radial) of the bearing reaction analyze which are the
bearing functions and which are the loads taken by each bearing;
- to estimate the length of the shafts from the sketch of Figure 2 consider as reference the
dimensions of the bearings bore diameters (d in Table 1).

5) Calculate the bearing reaction forces.

6) For each of the shafts
- calculate and plot the bending (2 planes) moments, the resultant bending moment, the
torsion moment and axial load;
- calculate and plot the section modulus W f for bending and W t for torsion and the area A;
- calculate and plot the stress values due to bending, axial force and torsion;
- calculate and plot the equivalent stress for static calculation;
- calculate the static safety factor.

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Example of diagrams

Presentation tips for the Technical Report. All the information from calculations is synthesized in
one figure. This is a drawing from a 2010/11 student report for a different shaft. The hand sketch is
very effective approach to the needs of an engineers communication. A good hand sketch is a very
impressive presentation card !!

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BEARINGS DIMENSIONS (FROM on line CATALOGUE)
SKF site: http://www.skf.com/portal/skf/home/products?lang=eg&maincatalogue=1&newlink=1
or
FAG site:
http://www.fag.de/content.fag.de/en/ina_fag_products/medias-search/index.jsp?section=productshortcut
Table 2. Bearings
Bearings A series NJ 2322 ECMA (110)

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 Bearing A - series QJ 222 N2MA

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 Bearing B NU 2322 ECP

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 Bearing C - - series 30232 J2/DF (160)

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 Bearing D - - series NU 2322 ECM (160)

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