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Design and Development of Close-Coupled, High Performance Epicyclic Gear Unit For Gas Turbines at 4600-HP Rating and 10:1 Ratio
Design and Development of Close-Coupled, High Performance Epicyclic Gear Unit For Gas Turbines at 4600-HP Rating and 10:1 Ratio
D. W. DUDLEY
The new epicyclic gear unit for the large Centaur gas turbine at 4600 hp employs the proven
design features of the smaller epicyclic gear unit for the Saturn gas turbine. Hundreds of the
Saturn units (at 1100 hp, 22,300-1800 rpm) are now in service. The reliability has been
exceptionally good. Many units have now run more than 20,000 hr. The new gear unit is a
"star compound" arrangement instead of the star first stage, planetary second stage used
with the Saturn. The star compound arrangement is new to the gas turbine power field.
Certain unique arrangement details are involved. The resulting design has fewer parts and is
easier to assemble and disassemble than more conventional high-ratio epicyclic gear
designs used in steam and gas turbine applications. Perhaps more important, the new
design is very compact and it facilitates a much more integrated package of gas turbine,
gear unit, and generator than has been seen so far in the gas turbine industry at this power
rating. The testing of this unit reveals new insights into the internal dynamics of an epicyclic
gear system.
Contributed by the Gas Turbine Division of The American Society of Mechanical Engineers for
presentation at the Gas Turbine Conference & Products Show, Houston, Texas, March 2-6, 1975.
Manuscript received at ASME Headquarters December 6, 1974.
Copies will be available until December 1, 1975.
THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS, UNITED ENGINEERING CENTER, 345 EAST 47th STREET, NEW YORK, N.Y. 10017
Design and Development of Close-
Coupled, High Performance Epicyclic Gear
Unit for Gas Turbines at 4600-HP Rating
and 10:1 Ratio
INTRODUCTION
Some years ago, the Saturn Gas Turbine was For either ratio the casings, carrier,
equipped with an improved design of heavy-duty bearings, and second stage are all the same design
epicyclic gear unit for continuous-duty applica- of parts. The only change made is in the first-
tions. Hundreds of these units are in service stage gearing.
now and many have more than 20,000 hr of operating The epicyclic gear unit is designed to meet
time (Fig. 1). the following rating:
The Saturn application made an interesting
comparison (1), 1 since a complete production de- • Power -- 4600 hp
sign and substantial field experience was obtained o Life -- 30,000 hr between overhauls
using both conventional parallel axis gears and o Service factor — 1.10 for generator
the smaller epicyclic gear unit to do the sane application; 10 short circuit.
job.
History is repeating itself (at Solar) with
new Centaur continuous-duty generator sets. The
Centaur gas turbine was originally put into ser-
vice with a conventional parallel axis type of
double-reduction high-speed gear unit.
The new epicyclic design for the large
Centaur engine accomplishes the things that were
accomplished on the smaller Saturn when this en-
gine was equipped with a compact epicyclic gear
unit designed for long life.
This paper has been written to explain the
design concept and the engineering developments in
the new epicyclic gear unit.
DESIGN FEATURES
1
New Solar Centaur Gas Turbine Generator Set
A
Fig. 2 Epicyclic gear unit supports turbine at Fig. 3 Comparison of the new GS- 11-000 arrangement
air inlet. Note accessory drive pads built into with an epicyclic gear drive to the former GS-
main drive gear unit 3000 with a conventional double reduction gear
drive
2
CONNECTION
T TURElNE
FIXED RING TPINAT ING
fA GEAR G GEAR
1^ - r
FIXED
CAGE
iJ
FES
"EPICYCLIC" CHARACTERISTICS
FII
CAf Fig. 5 Details of gear arrangement used in star
compound unit for GS-14-000
3
Table 1 Tooth Data for Solar GS-4000 Star
Compound Gear Unit
have a proven record of long life and high relia- all the gearing. The Centaur gears are being made
bility. At the end of 1973, there were almost to the same exacting metallurgical and geometric
200 of these units in service. The average unit limits used in Saturn continuous-duty gear units.
had already accumulated over 25,000 hr of service:
Premature overhaul of these units was very limited. RESUMM OF ENGINEERING TESTS
Less than a dozen instances had occurred.
The Solar philosophy in designing epicyclic An extensive development test program has
gear units has involved these changes: been carried on for the new epicyclic gear unit.
Since the configuration was a "star compound"
• Floating sun pinion rather than the more conventional planetary or
• Flexible and floating ring gears star designs, it was appropriate to fully investi-
• High geometric precision in the gearing gate the internal dynamics of the unit before put-
• Rigid control of metallurgical quality ting it into production.
of the gears Previous experience (2) with high-speed
• Special sleeve bearings for the planets epicyclic gears has shown that the bearings 2 are
• Carrier designs of unusual rigidity.
2 Solar experience with bearings being criti-
The Centaur epicyclic unit follows this cal in high-speed gears is similar to that reported
philosophy. Vacuum arc remelt steel is used in by others.
4
1
p.
5
Table 2 Typical Steady-State Temperatures When
Running GS-4000 Epicyclic Unit at 2800 kW
Oil in - - - - 131 F Oil out - - - - 166 F Flow 34,5 gpm P i = 50 psi
No. 1 Star bearing oil out temperature 157 F No. 1 Star pinion, pin 174 F 167 F
No. 2 Star bearing oil out temperature 156 F No. 2 Star pinion pin 186 F -----
No. 3 Star bearing oil out temperature 157 F No, 3 Star pinion pin 193 F 173 F
Output shaft ball bearing 185 F
floating ring gear. Chart A shows the sun's radial of "a" at No. 1 and imagining that at that instant
motion characteristic, as measured at the thrust in time there is no position error at Nos. 2 or
runner. Chart C shows the ring gear as measured 3.
on the outside diameter right over the gear teeth. The analysis of Fig. 9 shows that the mesh
The chart shown is for vertical motion. The at No. 2 would be deeper by about 0.67 a. Meshes
chart for horizontal motion (not shown) was almost Nos. 1 and 3 would be slightly shallower. The
the same. greatest misalignment would occur at mesh No. 1
The ring gear has its primary vibration at since the direction of motion of the pinion
30 Hz -- which is its rotational frequency. The center is almost perpendicular to the tooth side
amount is 0.0038 in. This movement is really not of this mesh. Misalignment effects at the other
a vibration -- even though it is measured with two meshes would be quite slight since the motion
vibration equipment. What is happening is that at the pinion center is close to being parallel
the ring is shifting as it rotates to accommodate to the tooth sides.
slight errors in the gear teeth and the bearings. The misalignment effect at No. 1 comes out
The sun pinion is executing several orbits to be approximately 0.67 a. Its severity is
simultaneously. At the ring gear frequency of equal to 0.67 a/L where "L" is the pinion length
30 Hz, the sun is orbiting 0.0015 in. At the from pivot point.
frequency of the star assembly, 95 Hz, the sun is The result just shown is quite favorable.
shifting 0.0012 in. At its own rotational fre- An out of position due to accumulated spacing
quency, the sun is shifting 0.002 in. Chart B errors has only a small effect in causing misalign-
shows an instantaneous oscilloscope trace of the ment. This means that precision tooth accuracy
motion pattern of the sun. Note the complex mo- in an epicyclic of these dimensions should cause
tion pattern. Note also that the pinion is spend- no serious alignment troubles.
ing most of its time within 0.001 in. of center. Inspection of these gears after load runs
The data just presented indicates that both bears out the validity of the Fig. 10 analysis.
floating members are indeed moving about to pro- The spacing errors and the amplitude of floating
perly divide the power between the three branches. resulting from these errors have no noticeable
What are the meshing conditions at the effect on the tooth bearing pattern across the
first stage? Possibly the teeth will suffer from face width. The tooth fit of this unit is governed
serious end loading due to alignment shifts of by lead accuracy almost exactly the same as would
the sun pinion. (The sun assembly must pivot from be the case of a simple pinion and gear on parallel
the flexible coupling at the end of the turbine axes. The inherently narrow face of the epi-
shaft.) cyclic, of course, makes it easier to get suitable
Fig. 10 shows an analysis of how a position lead accuracy for a good tooth fit.
error at No. 1 pin would shift the floating sun. With the pinion jumping around in various
The accumulated spacing errors of the gear teeth, orbits, there could be a worry that acceleration
plus bearing runouts and flexible spline runouts, forces required to move the pinion short distances
will constantly introduce and remove position very quickly would be great enough to disrupt the
errors at each of the three mesh points. The pinion's load sharing tendency. Calculations have
general nature of what is going on can be under- been made to see what the greatest acceleration
stood by taking a simple case of a position error force would be to move the pinion the distances
6
;4 ..... .
I 4q o, ''may.
^GL r
rs ^j^^{ c ` ^irio v^ac.: ,
CNAR T R
} t^
1/IW lAll
9 .
QCLJSCOP
..'°
00
OF RIRJtf St v t3' 'l of
.i30i ....... M'O77t?,ir
by heat radiation from the gear casing.) The calcu- SHIFT OF LOAD
REACTION AT 2
lations show that this epicyclic gear unit runs at (1R H INAL F ENTER
In recent years, there has been a very sub- POSITION TO ACCCMMODATE CHANGE AT 1^1.
stantial increase in the use of epicyclic gearing RESULTS: - TEETH MESH DEEPER AT S2
K. SHIFT IS APPROXIMATELY .67 a.
- TEETH MESH SHALLOWER AT #3. SHIFT IS APPROXIMATELY ,S
in the industrial field by steam and gas turbines. - CENTER OF PINION SHIFTS ABOUT .F7
At the present time, there is probably close to - GREATEST MISALIGNMENT EFFECT IS AT #I, THEORETICAL
SLOPE CHANCE .67 a/L.
30 million hp installed in turbine applications
Fig. 10 Error study of floating sun
around the world.
It has been amply demonstrated that the
dimensional precision and the metallurgical
quality -- now available for larger, high-speed described in this paper has been developed to
gears — make the industrial epicyclic gear unit take its place with other proven epicyclic gear
an excellent choice for compact, economical power units.
packages. Although only a small amount of engineering
The new star compound epicyclic gear unit data can be presented within the limitations of a
7
short technical paper, the results shown bring Life Epicyclic Gearing for Industrial Gas Turbines,"
out these things: AGMA 219.07, Oct. 1970.
2 Ehrlenspiel, K., "Statistical Investiga-
• The new star compound design functions in tion on High-Speed Gear Failures -- Possibilities
a manner similar to others, better known, planetary to Reduce Failures," ASME Paper No. 72- PTG -32, Oct.
and star arrangements. Its internal dynamics are 1972.
good, and it accomplishes a high ratio with a 3 Jones, T. P., "Fifteen Years Development
minimum number of parts. of High-Power Epicyclic Gears," Transactions of
• The efficiency of the star compound is the Institute of Marine Engineers, Vol. 79, No. 8,
good -- as is characteristic of the epicyclic 1967, pp. 273-303.