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

This image cannot currently be displayed.

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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