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Geared Variable-Speed Couplings

Variable-Speed Drives
We are the experts in hydrodynamic variable-speed drives at Voith Turbo.
Voith Turbo, the specialist for hydrodynamic drive, coupling and braking systems for road,
rail and industrial applications, as well as for ship propulsion systems, is a Group Division
of VoithGmbH.
Voith is one of the largest family-owned companies in Europe with a workforce of around
39000, with sales of EUR 5.1 billion in the 2008/2009 fiscal year and 280 locations world
wide. The company is active in the energy, oil and gas, paper and raw materials industries,
as well as transportation and automotive markets around the world.

Geared variable-speed couplings

Precise control of maximum powers

How will you benefit?

Geared variable-speed couplings


with modular design

Geared variable-speed couplings


for high-speed driven machines
How to select the right coupling
How to operate the coupling

5
6-7
8

Product range
for high-speed driven machines

Geared variable-speed couplings


for low-speed driven machine

10-11

Precise control
of maximum powers
Voith Turbo is the largest manufacturer of geared variable-speed
couplings worldwide. Over 4000 drives have been supplied so far
and are operating successfully. Powers up to 60000kW and speeds
up to 20000rpm are possible. Drives with geared variable-speed
couplings are renowned all over the world for their outstanding
features and customer benefits in a wide range of applications,
i.e. in power plants, in the petrochemical industry, the chemical
industry, the iron and steel industry as well as many others.

Economical operation with excellent reliability is a priority in modern


power plants. Whether they are
installed in boiler feed pump or fan
drives, in thermal power stations,
in combined cycle power plants or
nuclear power plants, Voith geared
variable-speed couplings meet
these requirements, both in the
feed water and in the cooling water
circuit of the power plant.
Controlling the speed of the driven
machine provides accurate and
energy-saving adaptation of power
to the operating point of the plant.

In pump and compressor drives in


chemical and petrochemical industry, the geared variable-speed
couplings ensure that driven
machines operate more economically. Voith Turbo has the perfect
geared variable-speed coupling for
virtually all requirements be it the
smooth acceleration of motor and
driven machine or the precise and
dynamic adaptation of the speed of
driven machine.

Offshore or onshore, in extremely


hot or cold temperatures, on plat
forms, pipeline stations or in the
desert Voith geared variablespeed couplings have been
designed and built to withstand
rough and extreme conditions,
year after year, with a minimum
of maintenance and maximum
reliability and availability. Designs
to API specifications are available
also.

Applications
Power plants

Petrochemical industry

Chemical industry

n Boiler feed pumps


n Boiler fans
n Circulating pumps
n Coal mills

n Pipeline pumps
n Crude-oil pumps
n Injection pumps
n Pipeline compressors
n Process compressors

n Compressors
n Fans
n Centrifugal pumps

Combined with a robust squirrelcage motor, geared variable-speed


couplings have proven themselves
as the preferred choice when competing against alternative drive
systems.

How will you benefit?

n Power savings and extension of driven machine life


compared to throttle control; lower operating costs
n Precise load adaptation of driven machines due to
the high control accuracy and fast reaction times
n Reliability >99.9%
(Evaluation based on units in operation)
n Vibration damping
n Relieved motor start-up and smooth acceleration
of heavy masses
n Robust and compact design
n Easy maintenance, low maintenance costs
n Long service life

Geared variable-speed couplings


with modular design

Scoop tube with electro-hydraulic actuator and


mechanically operated oil circulation control valve:
improved dynamics, increased precision, low
auxiliary power, compact design, no electromechanical connecting members.

The modular geared variable-speed


coupling is a further development
of the proven geared variablespeed coupling design. The gear
stage and the hydrodynamic variable-speed coupling are provided
in a range of separate modules but
with a common interface so that
they can be combined to provide
the optimum solution for a particular
driven machine power and speed.

The advantages of this design


are obvious:
n Increased technical flexibility
n Optimum adaptation by combining
gearbox and coupling
n Integrated rapid-start device
n Compact design, short delivery
times
n Easy maintenance

Geared variable-speed couplings


for high-speed driven machines

Design and function

Voith geared variable-speed couplings combine mechanical gears


and a hydrodynamic variablespeed turbo coupling in one common housing. The oil reservoir is
bolted to the bottom of the housing.
Depending on the application or
the design, the gear stage is either
arranged on the input or on the
output side of the coupling.

Type R..K..M

PDS

11

PI PS PS

5
8

Oil supply

Both working and lube oil are


supplied from the integrated oil
tank, but have separate circuits.
The oil system can also be used
to supply both the motor and the
driven machine with lube oil.

Design

12

The coupling fill can be varied as


needed during operation by means
of the scoop tube. As a result, the
speed and power transmitted to the
driven machine can be controlled
steplessly.

Voith geared variable-speed


coupling type R..K..M

10

The design of a geared variablespeed coupling is essentially


determined by the power and the
speed of the driven machine.

420 mA

3
4

1 Gear stage
2 Hydrodynamic variable speed coupling
3 Scoop tube
4 Electro-hydraulic positioning
control (VEHS)
5 Working oil cooler
6 Lube oil cooler
7 Main lube oil pump
8 Oil circulation control
valve
9 Working oil pump
10 Auxiliary lube oil pump
11 Duplex filter
12 Oil reservoir

How to select
the right coupling

The power diagrams show the


powers transmitted in relation to
the input and output speed for the
various coupling types and sizes.

Input speed = 1800rpm (60Hz countries)


60
50
40
30

0
12
11

R 119/118 GS

600
550
500
450

R
7

10

11

R 118/117 GS

400

11

5
4
3

R 110/111 KGS
R 18/19 KGS-14
R 16/17 KGS

Power [kW x 1000]

20

R 120/119 GS

11

11

1K

0 K 630
R
19 630
R K
18 M
R K
17 M
R K
16 M
R K
15
M
K
M
R
14
K
M
R
12
K
M
R
10
K
M

0,3
1

7 8 9 10

R 8 K...M
15

20

Speed [rpm x 1000]

Input speed = 1500rpm (50Hz countries)


60
50
40
30

0
12
9

R 119/118 GS

11

R 110/111 KGS
R 18/19 KGS-14

11

550

500
450

11

10

R 16/17 KGS

400

5
4
3
2

63
K 0
M
R K
17 M
R K
16 M
R K
15
M
K
M
R
14
K
M
R
12
K
M
R
10
K
M
18

19

0K

0,3

11

11

1K

63

Power [kW x 1000]

600

R 118/117 GS

20

R 120/119 GS

R 8 KM

7 8 9 10

15

20

Speed [rpm x 1000]

Design to API standard are also


available. The size of the machine
then depends on the specified API
service factor.

Input speed = 3600rpm (60Hz countries)


60
50
40
30

R 115 GS
R 115 GS
R 114 GS 550
R 110/111 KGS

R 114 GS
R 113 GS 500/450
5

10

R 18/19 KGS-14
R 16/17 KGS

11

11

400

5
4
3

11

R 19 GS...M

R 18 GS...M

Power [kW x 1000]

20

R 17 GS...M
R 16 GS...M
R 15 GS...M

11
1
11 K 6
0 K 30
R
19 63
0
R K
18 M
K

R
17 M
R K
16 M
R K
15
M
K
M
R
14
K
M
R
12
K
M
R
10
K
M
R
8K

0,3
1

7 8 9 10

15

20

Speed [rpm x 1000]

Input speed = 3000rpm (50Hz countries)


60
50
40
30

R 115 GS
R 115 GS
R 114 GS 550
R 110/111 KGS

R 114 GS
R 113 GS 500/450
5

10

R 18/19 KGS-14
R 16/17 KGS

11

11

400

5
4
3

11

R 19 GS...M
R 18 GS...M

R 17 GS...M
R 16 GS...M
R 15 GS...M

11
1
11 K 6
0 K 30
R
19 63
0
R K
18 M
R K
17 M
R K
16 M
R K
15
M
K
M
R
14
K
M
R
12
K
M
R
10
K
M
R
8K

Power [kW x 1000]

20

0,3
1

7 8 9 10

15

20

Speed [rpm x 1000]

How to operate
the coupling

The performance diagram shows


the transmittable coupling torques
TK at different scoop tube positions
as a function of the output speed.

Performance diagram
125

40%

50%

60%

70% 80%

III

smin
1

100

The desired output speed becomes


a stable intersection between coupling torque TK and load torque
(load curve).

TK [%]

75

30%

2
II

50
20%
25

10%
IV

0%
0

Operating Ranges:
I, IV Starting Range
II
Control Range
III
Overload Range
The shape of the coupling characteristic curves is given for information only, since there may be minor
deviations if coupling sizes, circulation oil flows, oil viscosity, etc. vary.

100%

50
Output speed [% of input speed]

Parameters:

Typical load characteristics:

Scoop tube position in %


of the full scoop-tube stroke.

TK

Transmitted coupling torque

smin

Minimum slip required


for torque transmission

n
1 n2
s=

1

100 [%]

n 1

input speed

n 2

output speed

1 constant torque
(e.g. positive displacement
pumps and compressors).
2 decreasing torque
(e.g. boiler feed pumps
operating at varying pressures).
3 parabolic torque
(e.g. resistance parabola,
pumps with back pressure,
blowers).
4 decreasing torque
(e.g. boiler feed pumps
operating at fixed pressure).

100

Product range
for high-speed driven machines
Coupling types for specific applications depend on the respective
arrangement of gearbox and coupling and the power and the speed
of the motor and the driven machine.

Type R..K..M (see page5)

Type R..GS

A combination of step-up gear and


variable speed coupling with high
power density, step-up gearing.
Special advantages due to modular
design.
Type R..KGS

A step-up gear is integrated both


at the input and the output side for
particularly high output speeds,
e.g. for high-speed compressors.

Type R..KGS

Type R..GS

The coupling is direct-driven by the


motor and adapted to the required
speed of driven machine by the
step-up gear located at the output
side of the coupling; ideal for high
powers and extremely high speeds.

Geared variable-speed couplings


for low-speed driven machines
The control requirements of low-speed driven machines such
as coal mills, I.D. fans or crude oil pumps, vary greatly.
Depending on the application and for optimum adaptation to
the existing space conditions, the gear stage is designed as
a helical gear or bevel gear.

Voith geared variable-speed


coupling type R..A:

Design and function

Oil supply

For low-speed driven machines, the


turbo coupling is fitted with a reduction gear on the output. Coupling
and gear stage are situated in a
common housing, the lower part
of which serves as an oil reservoir.
By adding a Voith hydrodynamic
brake (optional), with an appropriate breaking torque characteristic, heavy masses of the driven
machine can be rapidly decelerated.

Both working and lube oil are supplied from the integrated oil tank.
The oil system can also be used
to supply both the motor and the
driven machine with oil.

Type R..A

1 Gear stage
2 Hydrodynamic variable speed coupling
3 Scoop tube (adjustable)
4 Hydrodynamic brake
(optional)
5 Oil supply
6 Working oil cooler
7 Duplex filter
8 Oil pump

2
1

Type R..A

The variable-speed coupling is


fitted with a helical reduction gear
on the output side. Typical driven
machines are coal mills, crushers,
low-speed pumps and fans.
10

5
7

Type R..B

Type R..B

This type of turbo coupling is fitted


with a step-up gear on the output
side. Geared variable-speed couplings for low-speed driven machines
with high inertia, e.g. coal mills.

Type R..KGL

Type R..KGL

Geared variable-speed
coupling type R..B

A step gear at the input side and


a reduction gear at the output side
make this type into a fast reacting
and compact coupling used e.g. for
fast respones times, loading pumps
and high powers.

11

cr269en, aik-S&F/SVG, 11.2010, 3000. Dimensions and illustrations without obligation. Subject to modifications.

Voith Turbo GmbH & Co. KG


Variable-Speed Drives
Voithstr. 1
74564 Crailsheim, Germany
Tel. +49 7951 32-261
Fax +49 7951 32-650
vs.drives@voith.com
www.voithturbo.com/variable-speed