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 Voith GmbH.

Voith is one of the largest family-owned companies in Europe with a workforce of around
39 000, 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 2

How will you benefit? 3

Geared variable-speed couplings

with modular design 4

Geared variable-speed couplings

for high-speed driven machines 5

How to select the right coupling 6-7

How to operate the coupling 8

Product range
for high-speed driven machines 9

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 4 000 drives have been supplied so far
and are operating successfully. Powers up to 60 000 kW and speeds
up to 20 000 rpm 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 excel-
lent 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 indus-
try, the geared variable-speed
couplings ensure that driven
machines operate more economi-
cally. 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 variable-
speed 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.

2
 Applications

Power plants Petrochemical industry Chemical industry

n Boiler feed pumps n Pipeline pumps n Compressors

n Boiler fans n Crude-oil pumps n Fans
n Circulating pumps n Injection pumps n Centrifugal pumps
n Coal mills n Pipeline compressors
n Process compressors

Combined with a robust squirrel- How will you benefit?

cage motor, geared variable-speed
couplings have proven themselves
as the preferred choice when com-
peting against alternative drive
systems.
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

3
Geared variable-speed couplings
with modular design
The modular geared variable-speed
coupling is a further development
of the proven geared variable-
speed coupling design. The gear
stage and the hydrodynamic vari-
able-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.
Scoop tube with electro-hydraulic actuator and
mechanically operated oil circulation control valve:
improved dynamics, increased precision, low
auxiliary power, compact design, no electro-
mechanical con­nect­ing members.
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
4
 Geared variable-speed couplings
for high-speed driven machines

Design and function

Type R..K..M
PDS
Voith geared variable-speed cou-
plings combine mechanical gears
PI PS PS 11
and a hydrodynamic variable-
speed turbo coupling in one com- 6
mon housing. The oil reservoir is
bolted to the bottom of the housing.
Depending on the application or
1 10
the design, the gear stage is either 7

arranged on the input or on the

9 12
output side of the coupling.
2

The cou­pling fill can be varied as

needed during operation by means
5
of the scoop tube. As a result, the
speed and power transmitted to the 3 4…20 mA
8
driven machine can be controlled 4

steplessly.

Oil supply 1 Gear stage

Voith geared variable-speed
coupling type R..K..M
2 Hydrodynamic variable-
speed coupling
Both working and lube oil are 3 Scoop tube
supplied from the integrated oil 4 Electro-hydraulic positioning
control (VEHS)
tank, but have separate circuits.
5 Working oil cooler
The oil system can also be used 6 Lube oil cooler
to supply both the motor and the 7 Main lube oil pump
8 Oil circulation control
driven machine with lube oil.
valve
9 Working oil pump
10 Auxiliary lube oil pump
11 Duplex filter
Design
12 Oil reservoir
The design of a geared variable-
speed coupling is essentially
determined by the power and the
speed of the driven machine.

5
 How to select
the right coupling

The power diagrams show the

powers transmitted in relation to Input speed = 1800 rpm (60 Hz countries)
the input and output speed for the
various coupling types and sizes. 60
50
40 R 120/119 GS
30

0
12
R 119/118 GS 600

R
20

9
R 118/117 GS 550

11
R 110/111 KGS

R
500 R 18/19 KGS-14

8
Power [kW x 1000]

11
10 450

R
7
400 R 16/17 KGS

11
R
5
4
3
2

1
0 K 630
19 630
18 M
17 M
16 M
M

M
M
1K

R K…
R K…
R K…
R K…

K…

K…

K…
K…
11
11

14

12

10
15
R

R 8 K...M
R
R

R
0,3
1 2 3 4 5 6 7 8 9 10 15 20
Speed [rpm x 1000]

Input speed = 1500 rpm (50 Hz countries)

60
50
40 R 120/119 GS
30
0
12

R 119/118 GS
R

20 600
9

R 118/117 GS
11

550 R 110/111 KGS

R

R 18/19 KGS-14
8
Power [kW x 1000]

11

10 500
R

450
7

R 16/17 KGS
11

5 400
R

4
3
2

1
0
63

K… 0
M
17 M
16 M
M

M
63

M
1K

R K…
R K…
R K…

K…

K…

K…
K…
0K
11
11
19
18

14

12

10
15

R 8 K…M
R
R
R
R

0,3
1 2 3 4 5 6 7 8 9 10 15 20
Speed [rpm x 1000]

6
 Design to API standard are also
available. The size of the machine Input speed = 3600 rpm (60 Hz countries)
then depends on the specified API
service factor. 60
50
40 R 115 GS
30 R 115 GS
R 114 GS 550
20
R 114 GS R 110/111 KGS
R 113 GS 500/450 R 18/19 KGS-14

Power [kW x 1000]

10

5
400

11
R 16/17 KGS

R
4
11
5

R
4
3 R 19 GS...M

3
11
R 18 GS...M
2
R
R 17 GS...M
1
R 16 GS...M
0 K 30
0
11 K 6

18 M
17 M
16 M
M

M
19 63

M
R 15 GS...M
R K…
…
R K…
R K…

K…

K…

K…
K…

…
1

K
11

8K
14

12

10
15
R
R
R

R
0,3
1 2 3 4 5 6 7 8 9 10 15 20
Speed [rpm x 1000]

Input speed = 3000 rpm (50 Hz countries)

60
50
40 R 115 GS
30 R 115 GS
R 114 GS 550
20
R 114 GS R 110/111 KGS
R 113 GS 500/450 R 18/19 KGS-14
Power [kW x 1000]

10
5

400
11

R 16/17 KGS
R
4
11

5
R

4
3 R 19 GS...M
3
11

R 18 GS...M
2
R

R 17 GS...M
1
R 16 GS...M
0 K 30
0
11 K 6

18 M
17 M
16 M
M

M
19 63

R 15 GS...M
R K…
R K…
R K…
R K…

K…

K…

K…
K…

…
1
11

8K
14

12

10
15
R
R
R

0,3
1 2 3 4 5 6 7 8 9 10 15 20
Speed [rpm x 1000]

7
 How to operate
the coupling

The performance diagram shows

the transmittable coupling torques Performance diagram
TK at different scoop tube positions 125
40% 50% 60% 70% 80% 100%
as a func­­tion of the output speed.
III smin
1
100
The desired output speed becomes
a stable intersection between cou- I

pling torque TK and load torque 75

30% 2
(load curve).
TK [%]

II
3
50
20% 4

25
10%
IV
0%
0
50 100
Output speed [% of input speed]

Operating Ranges: Parameters: Typical load characteristics:

I, IV Starting Range Scoop tube position in % 1 constant torque

II Control Range
III Overload Range
The shape of the coupling charac-
teristic curves is given for informa-
tion only, since there may be minor
deviations if coupling sizes, circula-
tion oil flows, oil viscosity, etc. vary.
of the full scoop-tube stroke. (e.g. positive displacement
pumps and compressors).
TK Transmitted coupling torque 2 decreasing torque
(e.g. boiler feed pumps
smin Minimum slip required operating at varying pressures).
for torque transmission 3 parabolic torque
(e.g. resistance parabola,
n
s=
1 – n2
1
( ) • 100 [%] pumps with back pressure,
blowers).
n 1 input speed 4 decreasing torque
(e.g. boiler feed pumps
n 2 output speed operating at fixed pressure).

8
 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 page 5)

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.

9
 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.

Design and function Oil supply

For low-speed driven machines, the Both working and lube oil are sup-
turbo coupling is fitted with a reduc- plied from the integrated oil tank.
tion gear on the output. Coupling The oil system can also be used
and gear stage are situated in a to supply both the motor and the
common housing, the lower part driven machine with oil.
of which serves as an oil reservoir.
By adding a Voith hydrodynamic
brake (optional), with an appropri-
ate breaking torque characteris-
tic, heavy masses of the driven
ma­chine can be rapidly decelerated.

Voith geared variable-speed Type R..A

coupling type R..A:

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

Type R..A

The variable-speed coupling is 3

fitted with a helical reduction gear
on the output side. Typical driven 5
machines are coal mills, crushers, 7
low-speed pumps and fans.

10
 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 cou-
plings 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
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

cr269en, aik-S&F / SVG, 11.2010, 3 000. Dimensions and illustrations without obligation. Subject to modifications.