Partner to the wind industry - Deutsche Messe...

Gearbox Development

Gear and bearing technology

Engineering analysis

Design reviews

Test planning and witnessing

Failure analysis

www.EES-KISSsoft.ch

_______________________________________________________________________________________________________ Brochure version 2016 / 2017 2 of 8

Services offered Work with EES KISSsoft GmbH to get: Gearbox concepts, specifications, design

Gear and bearing technology Technology surveys

Detailed gear, bearing and FEM calculations Certification assistance

Sourcing and quality control assistance Gearbox assembly supervision

Components and gearbox test witnessing Failure analysis, dispute assistance

Industries served Professionals in these industries request our services: Wind industry: main, pitch and yaw gearboxes /

main, pitch and yaw bearings

Mill drives, winches and cranes Aerospace gears and gearboxes

Roller and slewing bearing manufacturers Industrial gearing, actuators and geared motors

On- and off-road vehicle transmissions, axles and engine gear trains

Plastic gear industry

Expertise Our key expertise are in the fields of

Gear geometry, gear strength Bearing rating

Gearbox concepts Engineering analysis for certification

Planetary gears

Location Offices are located in central Switzerland: 45 minutes from Zurich airport

Easy to reach by train or road In the centre of the Italian, French, German and

Austrian gear industry hubs

Mr. Martin Schweinberger, Sales Manager Wind Energy, ESK Ceramics GmbH & Co. KG,

Germany:

“… Guten Morgen Herr Dinner,

wir haben Ihren Bericht durchgelesen und – um es auf den Punkt zu bringen – wir sind

begeistert. Das geht genau in die Richtung, wie wir es uns vorgestellt hatten…

Viele Grüße aus Kempten, Martin Schweinberger“


Projects: Wind industry 8MW gearbox (Germany)

– Conceptual and overall design – Engineering analysis

3MW gearbox (China) – Design review, testing supervision – Engineering analysis for certification

3MW gearbox (Spain) – Design and engineering analysis review – Test witnessing and assessment at supplier site

3.xMW drive train (Germany) – Overall design, cost calculation – Engineering analysis

6.xMW main gearbox (Germany, China) – Design, gear technology – Engineering analysis, FEM – Parts drawings, part lists

1MW main gearbox (India) – Engineering analysis for certification – FEM analysis – Gear detail design

1.6MW main gearbox (India) – Preliminary design, gear and bearing selection – Mass tables, gear and bearing data

3.xMW main gearbox (Germany, China) – Design, gear technology – Engineering analysis, FEM – Parts drawings, part lists

1.75 MW main gearbox (Germany) – Bearing rating for certification for different ratios – Calculation of modified reference rating life – For four variants of the same gearbox

675 kW main gearbox (Germany) – With integrated main shaft – Overall design, gear optimization – Bearing selection

1.x MW main gearbox (Germany) – Overall design, technology consultancy

660 kW main gearbox (Germany – Analysis for certification, dynamic analysis) – Gear modifications – Testing specifications, testing

3.x MW drivetrain concept (Switzerland) – Overall design, model – For cost and feasibility analysis

2.x MW main gearbox (Germany) – Overall design, detail design, manufacturing drawings – Engineering analysis, certification assistance – Components and back-to-back test

Various projects on pitch and yaw drives – Gearbox analysis (gears, bearings, shafts, bolts FEM) for certification – Slewing bearing analysis for certification – For turbines from 750kW to 5.5MW

Jose-Luis Roman, Head Mechanical Design, Alstom Wind, Spain:

“Hello Mr. Dinner, All test with new gear corrections until now

have shown vibration level reduction.

best regards,

Jose-Luis Roman”


Projects: Industrial, mining, … UAV and RGB gearbox technology (Korea)

– UAV helicopter main gearbox technology survey – UAV turboshaft turbine reduction gearbox technology survey – Flap actuator technology survey

Cement mill gearbox (India) – Overall design and rating – Gear modifications – Installation and commissioning assistance

Planetary gearbox, four stages (Italy) – Failure investigation – Gear optimisation – System deformation analysis

Auxiliary drive for helicopter (UK) – Gear design and rating – Lubrication and scuffing rating review

Vertical roller mill gearbox (France) – Concepts comparison

– Gear modifications

Plastic gear based actuator (China) – Tooth form optimisation – Strength rating for elevated temperature

Bevel-helical gearbox for mining (Germany) – Gear modifications – Final strength rating with load spectrum

Crane planetary gearbox (China, Finland) – Overall design, components rating – Gear detail design

Tractor transmission – Gear and bearing rating and optimisation

Aerospace actuator gearboxes (China) – Material selection for low and high temperature, vacuum – Design, manufacturing drawings, tolerance analysis – FEM, gear and bearing rating

Technologies Gearing

Overall design, optimisation, modifications Manufacturing drawings

Supplier assessment, sourcing Gear manufacturing specifications

Shot peening, materials, super finishing Tooling, grinding temper measurement

Flexible planet support

Flexpin design, deformation / strength analysis Materials, heat treatment, manufacturing

Strength and deformation testing

James Deferranti, General Manager, Denis Ferranti Group, UK:

“… We are very respectful of the output you have provided, it is excellent. We are very

lucky on this project that we have such good people working on it, yourself, the motor

guys, the power electronic experts, commercial experts and thermal experts. We have

every confidence this will get onto the airframe.

Best regards, James”


Recent projects: Bearings Pitch and yaw bearing assessment (Germany)

– Supplier assessment – Engineering analysis review

Main bearing assessment (Germany) – Supplier assessment – Engineering analysis review

Slewing bearing, 5.5MW turbine (Korea) – Static, life and stress rating, hardness depth – For DNVGL certification

Investigation of wear effects (Spain) – slewing gears for wind turbines – optimisation of the gear properties

Gearbox / main shaft bearings (Germany) – 1.6MW wind gearbox – integrated main shaft – for a bearing supplier

Calculation for certification (Germany) – GL certification for four gearboxes – For a bearing supplier

Calculation of pitch bearing (China) – Calculation along NREL DG 03

Re-calculation of main bearing (India/Japan) – For direct drive wind turbine – Supplier analysis assessment

Analysis of a >5m slewing bearing (Korea) – Ship unloader application – FEM calculation combined with ISO16281

Re-calculation for certification (India/Italy) – Wind turbine pitch/yaw bearing – Supplier analysis assessment

Analysis review (India/Korea) – Certification assistance of pitch/yaw bearing

Comparative analysis (Germany) – For wind turbine pitch and yaw bearings – For different suppliers with unified approach

Training on analysis techniques (USA) – Static and dynamic rating methods, stress rating methods – For surface mining shovels

Bearing analysis Bearing rating Analytical, FEM and combined calculations

Bearing selection or optimisation with suppliers For slewing or rolling bearings

Life rating, static rating

ISO76, ISO281, ISO/TS 16281, NREL DG03 Basic, modified and reference rating

Elastic structures influence by FEM analysis

Mr. N. D. Kulkarni, General Manager, Premium Transmission Limited, India

“Thanks to our engineer team being assisted by EES KISSsoft GmbH, we were able to

complete this project on time and were able to confirm optimal contact patterns in the

gears during test, as predicted by EES to deliver the best in class product to our

customer.”


Recent projects: FEM Analysis Helical wind gearbox housing for certification

– Welded housing, static and fatigue rating – Considering main shaft, bearing and bolt forces

Flexpin analysis – Fatigue strength verification using time series – Stiffness optimisation

Planetary carrier fatigue rating – For 1MW wind turbine gearbox – Along GL guideline

Complete wind turbine drive train, deformation – Including DRTRB stiffness – Influence of main bearing deformation on LSS planetary stage

Housing, worm gearbox – Stress distribution and strength assessment

Forged bevel gears for differential – Contact stress calculation for whole meshing cycle

Planetary gearbox, load distribution – Calculation of Kγ considering random manufacturing errors – Using FEM model controlled by scripts

Rating for certification, pitch and yaw drives – Static and fatigue strength of housing and carriers – For GL approval

FEM Analysis Analysis types, through partners

Static or modal analysis Non-linear (deformation, contact, material)

Using ABAQUS implicit / explicit and FEMAP Using ANSYS and ANSYS Workbench

Tooth contact analysis, bearing modelling

Technologies Fatigue analysis of welded, machined, cast parts

Synthetic S-N curves

Load spectra and time series Planetary gearbox load distribution analysis

Assembly simulation to consider e.g. bolt pre-tension or press-fit

Coupled thermal-mechanical analysis to consider e.g. thermal growth of parts

Partners

Ingenis AG, Switzerland MET GmbH, Germany

Mr. Chang-kyu Shin, Haisung Good Three Co., Ltd., Korea:

“Sometimes, getting the certificate for a new product is difficult due to the technical

requirements and also because of the deep technical discussions required with the

certification agency. Also, performing all calculations accurately and as per the standards

is a major task, which we are happy to outsource to EES KISSsoft GmbH”.


Failure analysis Approach On site inspection

Analysis and reporting Root Cause Analysis

Gear failure analysis and classification FMEA

Probabilistic life rating

Projects Wind gearbox vibration (Germany, Spain)

Turbo planetary gear failure (Switzerland) Tunnel boring machine winch (Switzerland)

Four stages planetary gearbox (Italy)

Shaft breakage (India) Planetary gearbox, oil platform (Norway)

Supplier development The objective is to assist in the following Sourcing of machined parts

Gear manufacturing through selected partners Quality assurance, assembly supervision

Assessment of gearbox suppliers on technical level

Furthermore, we offer

Design FMEA Prototype assembly

Assembly and acceptance documentation Assembly instructions and manuals

Assembly supervision

Final inspection Staff instructions

Documentation Inspection after testing or after operation

Ing. Giovanni Patini, Operations Sales Manager, Dinamic Oil Spa, Italy

“… we like your work very much, it will help us in our discussion with the customer. We

like not only the technical result but also how you explain it and the reports are easy to

understand.

Cordialement, Giovanni Patini”


Trainings Several hundred engineers have undergone training with EES KISSsoft GmbH on

Technology for wind gearboxes, slewing bearings Plastic gears

KISSsoft and KISSsys software Shaft and bearing rating, bearing theory

Publications Key conference publications “Gear strength … operation in resonance”, DMK

2015 “Flexpin design”, SMK 2014

„Analytical assessment along NREL DG03 of tower and blade bearings”, DMK2013

“Wind turbine drive train concepts”, IQPC 2011

“Micropitting: calculation and optimisation of gear geometry for the wind industry”, Xian

2011 „An algorithm for robust gear modifications

design”, Gear Solutions 2012 „KISSsoft gegen Micropitting im Windbereich“,

Konstruktion, 2009 More: www.ees-

kisssoft.ch/index.php/downloads

Software Sales, support and trainings on KISSsoft and KISSsys

in Asia, with regional partners India: Kadkraft Systems Pvt. Ltd., Chandigarh

Korea: STech&H Pvt. Ltd., Seoul

China: KISSsoft China Pvt. Ltd., Suzhou

Contact EES KISSsoft GmbH 0041 41 755 33 20 (Phone)

Hauptstrasse 7 Skype: ees-h.dinner 6313 Menzingen [email protected]

Switzerland www.EES-KISSsoft.ch

Tiziano Cividino, Chief Engineer (Heavy Duty Transmission), PMP PRO-MEC S.p.A, Italy:

“Thank you for the training it was very interesting for all of us. You have been very clear,

you have touched interesting topics and I really appreciate the rigorous approach in the

exposition and in the resolution of the problems.”

Partner to the wind industry - Deutsche Messe...

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