geislinger gesilco shaft marine wind power power generation technical data torque range: 1 knm –...

GEISLINGER GESILCO® SHAFT

LIGHTWEIGHT

Significant weight reduction through integrated flange

Easy combination with different misalignment couplings

Carbon fibre filament windings at different angles and stiffness levels

D E S C R I P T I O N

Geislinger Gesilco® shafts are produced in one piece, meaning that the flange is not additionally linked to the shaft but is already a part of it. This unique design reduces the weight by approximately 50%. Due to its modular concept, the Gesilco® shaft can be adjusted and tailored to applications depending on their specific requirements especially in terms of transmitted power, length, bending stiffness and tor-sional stiffness. The stiffness levels of the shafts can be adjusted by altering the angles of the carbon fibre filament windings.The Gesilco® shafts can measure up to 10 meters in length. The lightweight shaft-lines show high chemi-cal resistance and superior stability throughout their lifetimes. From designing and manufacturing to calculating the rotation properties of the Gesilco® shaft lines, the entire production is carried out in an in-house process which ensures high quality products and solutions.

A D VA N TA G E S

Lightweight Maintenance free Long bearing distance Electrically insulating Non-magnetic Accommodation of radial misalignments No aging, resistant to heat, frost and oil Easy installation

A P P L I C AT I O N S

Marine Wind power Power generation

T E C H N I C A L D ATA

Torque range: 1 kNm – 700 kNm Ambient temperature: -45°C to 100°C Diameters: 80 mm – 600 mm

The Geislinger Gesilco® shaft product range is based on more than 20 years’ experience in developing fibre composite couplings and shafts. The maintenance-free Gesilco® shaft lines are made of advanced composite material and are characterized by their single-piece manufacturing and their integrated carbon fibre flange connection. The Gesilco® shafts can easily be adapted to the specific requirements of your application. Complete packages with in-house produced steel adapters, bearings, bulkhead seals and additional composite Gesilco® misalignment couplings are available. Their outstanding shock capabilities and good acoustic attenuation further underline the use of Geislinger shafts for high-speed vessels.

GEISLINGER GESILCO® SHAFT

Geislinger GmbH, 5300 Hallwang, Austria

Preamble

This catalog replaces all old catalog versions.

The content of this catalog is indicative and - based on new developments -Geislinger

reserves the right to change the content without prior notice.

All duplication, reprinting and translation rights are reserved.

Should you have questions, remarks or inquiries please contact us per e-mail

([email protected]) or telephone (+43 662 66999-0).

The latest version of all Geislinger catalogs can be found on our website Geislinger.com.

Geislinger GmbH, 5300 Hallwang, Austria Gesilco Shaftline Catalog 1.1 1 / 18 August 2016

Index

Gesilco Shaftline Description .................................................................................... 2

Designation ............................................................................................................. 5

Selection .................................................................................................................. 6

Technical Data ....................................................................................................... 11

Examples ............................................................................................................... 15


Gesilco Shaftline Description

Gesilco Shaftline Application

A Gesilco shaftline is a complete driveline system comprising advanced composite material drive shafts and accessory parts specifically designed for lightweight drivelines. Gesilco shaftlines offer outstanding weight advantages in comparison to steel shafts.

The lower density of Gesilco composite shafts results in higher critical speeds than conventional steel shaft solutions and allows for twice the spacing between support bearings. The installation of Gesilco shaftlines in the high-speed section of the driveline, e.g. between engine and gearbox, takes special advantage of these features.

Depending on the type of reinforcing fiber, the weight of the composite Gesilco shaft is approx. 15% of a solid steel shaft and approx. 30% of a hollow steel shaft. However, the overall weight of a Gesilco shaftline must take into account steel flanges and intermediate shafts for bearings.

Due to the extended support bearing distances, the radial stiffness of the Gesilco shaft system is significantly reduced. Therefore, hull deformations and engine transverse / vertical deflections can be accommodated by Gesilco shaftlines. Gesilco shaftlines, in combination with Gesilco couplings, offer interesting design solutions for lightweight drivelines with excellent deflection compensation capabilities (see chapter Examples).

Shaftline Design and Materials

The Gesilco shaftline (Fig.1) is a highly integrated system consisting of: (1) Gesilco shafts, (3) steel intermediate shafts, (6) steel adapters, (4) bearings, (5) bulkhead seals and conceivably additional Gesilco misalignment couplings.

Fig. 1

The Gesilco shaft (1) is produced, by filament winding technology, from glass and/or carbon fibers and epoxy resin. The epoxy resin is cured at a high temperature, resulting in a service temperature of up to 100° C. It is possible to produce many fiber orientation angles, within the shaft laminate, by using the computer controlled filament winding technology. Fiber orientation controls the strength and stiffness properties of the shaft (i.e. torque and bending stiffness properties).


For standardization purposes, Geislinger presents two types of reinforcing fibers with two different fiber orientations in this catalogue. However, special designed shafts, with application specific optimized fiber orientations and fiber types, can be designed and delivered by Geislinger on request.

The Gesilco shaft (1), with its steel flanges (2), is connected to intermediate shafts (3) (for bearing support) and customer flanges. The joint, connecting the composite shaft (1) and the steel flanges (2), is made by mechanical load transfer. Either a bolted or press fitted joint is used for the connection. This design provides high level of resistance to temperature and other environmental conditions.

Another patented Gesilco shaft design is to produce shafts in one piece, meaning that the flange is not additionally linked to the shaft but is already a part of it.

A standard range of diameters is available for Gesilco shafts, covering nearly all applications in ship drivelines. Diameters vary between 80 mm and 600 mm with a corresponding nominal torque up to 700 kNm. Gesilco shafts with higher nominal torque are available on request. The diameters of the Gesilco shafts and the steel intermediate shafts are designed to fit commercially available bulkhead seals and bearings. If requested, seals, bearings and other components can be selected and offered by Geislinger.

Gesilco shafts can be supplied with a special fire resistant outer layer. In combination with a sprinkler system mounted above the Gesilco shaftline, SOLAS fire resistance requirements can be met without the need for an additional housing.

Shaftline Installation

Gesilco shaftlines can be adapted to standard installation requirements. As described above, Gesilco shaftlines are capable of accommodating radial misalignments. If special radial misalignment is required of a Gesilco shaftline, Geislinger must perform an analysis.

Geislinger Calculation Services

As a manufacturer of torsionally elastic damping couplings, Geislinger has a long history of experience with Torsional Vibration Calculations (TVC). Geislinger will perform and supply to the customer TVC’s for Geislinger shaftlines using proprietary Geislinger software.

In case of required accommodation of radial misalignments, Geislinger performs additional calculations such as Whirling Analysis and Finite Element Analysis.

Approvals

Gesilco shaftlines have been developed in line with DIN/ISO 9001. Gesilco shaftlines can be delivered with certificates from any of the major Classification Societies.


Shaftline Advantages

Low mass

Low thermal expansion

Accommodation of radial misalignments

Long bearing distances

Low radial stiffness system

Easy installation

Maintenance free

No corrosion

Long service life

Sound insulating

Non magnetic

Non conductive (electrically insulated by glass fibers)


Designation

The Shaft Designation has the following Significance

The Gesilco shafts (in this catalogue) have five standard diameters and two fiber types. Each shaft is offered in two different fiber orientations. The following shaft designation will identify these characteristics.

The fiber orientations are designated as Type 1 and Type 2. Type 1 offers higher torque resistance at lower bending stiffness and Type 2 lower torque resistance at higher bending stiffness respectively.

IS 33/104/1C

IS 33 shaft size 104 nominal torque of the Gesilco shaft 1 or 2 fiber orientation Type 1 or Type 2 C fiber type (C... carbon fiber, G... glass fiber)


Selection

Selection of Gesilco Shaftlines

The technical data for the standard Gesilco shafts mentioned above are given in the ‘Technical Data’ section (Table 1 and Table 2).

For a given driveline, data from Table 1 and 2 and the information bulleted below will help designers select and predesign a Gesilco shaftline with optimal weight and bearing distances.

nominal torque

shaft speed

required bearing distance

The selection of a Gesilco shaft is normally performed according to the sequence listed above and is described in the following chapters.

Nominal Torque KNT of the Gesilco Shaft

The mean / nominal torque T of the driveline is calculated from the engine power P and the shaft speed n by the following formula.

n

PT 55.9

T mean torque kNm P engine power kW

n engine speed min-1

The Gesilco shaft should be selected so that the nominal torque rating of the shaft KNT

is greater than the mean torque to be transmitted.

T>TKN

In Table 1 and 2 (see Technical Data), a Gesilco shaft can be found with a nominal torque rating greater than the application’s mean torque. For weight optimisation procedures, Table 1 and 2 offer Gesilco shafts with different diameters having equal nominal torque ratings. For selection of the final diameter, shaft speed and weight of the shaftline have to be considered.


Critical Shaft Speed and Bearing Distance

Typically designers know the shaft speed, rough shaft lengths and bearing distances needed for a given installation. These application requirements are then compared with the values shown in Diagram 1 and 2. A shaft is then selected which has bearing distance and shaft speed values greater than or equal to the applications requirements.

Table 1 and 2 also allow a designer to optimise the weight of a Gesilco shaftline.

It should be noted that safety factors do not need be added to torque and shaft speeds listed in the tables or represented in Diagram 1 and 2.

Permissible Vibratory Torque TV

In addition to the static nominal torque TKN

the Gesilco shaft can transmit vibratory

torques. The limit values for transient vibratory torques (i.e. when moving through a resonance) and continuous vibratory torques are shown in Fig.2. The lower the mean torque T is, the higher is the permitted vibratory torque T

V. The limit values, shown in

Fig.2, must not be exceeded (even in the case of cylinder misfiring).

Fig. 2

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

-1.40 -1.20 -1.00 -0.80 -0.60 -0.40 -0.20 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40

Vibratory torquecontinuous

Vibratory torquetransient

Y

X

Type U, fully reversible

torque nominal

torquevibratory el. perm.=

T

T=Y

KN

el

torque nominal

torque mean=

T

T=X

KN

0 X 1 Y = 0.6 – 0.3 X

1 X 1.3 Y = 1.3 – X


Service Life

Gesilco shaftlines are designed for a service life of 20 years in standard ship applications.

Permissible Shock Torque

Gesilco shafts are designed to take shock or peak torque loads as required by the Classification Societies.

Torsional Vibration Calculation

For torsional vibration calculation purposes, torsional stiffnesses, mass moments of inertia and undimensioned damping factors are provided in Table 1.

The undimensioned damping factor is defined as the ratio of the amplitudes of the damping torque Td to the amplitude of the elastic torque Te.

e

d

T

Tκ

undimensioned damping factor Td damping torque Te elastic torque Damping factors have the following values:

Undimensioned damping factor for carbon fiber Gesilco shafts (Table 1): = 0.01

Undimensioned damping factor for glass fiber Gesilco shafts (Table 2): = 0.005


Examples for the Selection of Gesilco Shafts

Example 1

Engine MCR: 6000 kW Shaft speed (between gearbox and water jet): 570 rpm Calculated mean torque T: 100.53 kNm Total length of the shaftline: 16 m Selected length for Gesilco shaft: 2 x 8 m Selected Gesilco shaft (Carbon fiber) from Table 1 IS 33/104/2C Mass per linear meter: 43 kg/m Max. permissible shaft length from Diagram 1 (shaft speed 570 rpm): 9.5 m > 8.0 m (required) Selected Gesilco shaft (Glass fiber) from Table 2 IS 38/104/2G Mass per linear meter: 52 kg/m Max. permissible shaft length from Diagram 2 (shaft speed 570 rpm): 8.2 m > 8.0 m (required) Note: This solution is not recommended due to higher weight


Example 2

Engine MCR: 1970 kW Shaft speed (between engine and gearbox): 1900 rpm Calculated mean torque T: 9.9 kNm Total length of the shaftline: 4.5 m Selected length for Gesilco shaft: 4.5 m Selected Gesilco shaft (carbon fiber) from Table 1 IS 19/13/2C Mass per linear meter: 9 kg/m Max. permissible shaft length from Diagram 1 (shaft speed 1900 rpm): 4.2 m < 4.5 m (not possible !!) This result makes it necessary to select a shaft with bigger diameter due to the bending natural frequency of the shaft. Selected Gesilco shaft (carbon fiber) from Table 1 IS 26/22/2C Mass per linear meter: 11 kg/m Max. permissible shaft length from Diagram 1 (shaft speed 1900 rpm): 4.8 m > 4.5 m (required) Selected Gesilco shaft (glass fiber) from Table 2 IS 26/22/2G Mass per linear meter: 16 kg/m Max. permissible shaft length from Diagram 2 (shaft speed 1900 rpm): 3.8 m < 4.5 m (not possible)

Geislinger GmbH, 5300 Hallwang, Austria Gesilco Shaftline Catalog Version 1.1 11 / 18 August 2016

Technical Data

Table 1: Technical Data of Carbon Fiber Gesilco Shafts

Designation Nominal torque

Nominal diameter

Mass per linear meter

Torsional stiffness per linear meter

Mass moment of inertia per linear meter

Mass of one steel flange

Mass moment of inertia of one steel

flange

Intermediate steel shaft diameter = bearing

diameter

Mass of intermediate steel shaft

Mass moment of inertia of intermediate

steel shaft

Recommended nominal diameter of

bulkhead seal

kNm mm kg MNm/rad kgm² kg kg mm kg kgm² mm

IS 19/13/2C 13 198 9 1.37 0.099 13 0.152 100 19 0.106 230

IS 19/22/2C 22 198 15 2.52 0.183 13 0.152 120 32 0.255 230

IS 26/22/2C 22 263 11 2.96 0.215 30 0.623 120 32 0.255 290

IS 26/36/1C 36 263 14 5.72 0.273 30 0.623 140 53 0.579 290

IS 26/36/2C 36 263 19 5.14 0.374 30 0.623 140 53 0.579 290

IS 26/53/2C 53 263 27 8.12 0.590 30 0.623 160 77 1.103 290

IS 26/53/1C 53 263 21 8.88 0.424 30 0.623 160 77 1.103 290

IS 33/53/1C 53 330 18 11.39 0.544 60 1.955 160 77 1.103 380

IS 33/53/2C 53 330 22 9.15 0.665 60 1.955 160 77 1.103 380

IS 33/76/1C 76 330 24 15.28 0.729 60 1.955 180 111 2.011 380

IS 33/76/2C 76 330 31 13.77 1.001 60 1.955 180 111 2.011 380

IS 33/104/1C 104 330 32 21.85 1.043 60 1.955 200 152 3.392 380

IS 33/104/2C 104 330 43 19.97 1.451 60 1.955 200 152 3.392 380

IS 38/104/1C 104 381 28 23.81 1.137 93 4.010 200 152 3.392 470

IS 38/104/2C 104 381 37 21.38 1.553 93 4.010 200 152 3.392 470

IS 38/138/1C 138 381 37 32.72 1.563 93 4.010 220 202 5.435 470

IS 38/138/2C 138 381 49 29.71 2.158 93 4.010 220 202 5.435 470

IS 38/179/1C 179 381 48 44.27 2.114 93 4.010 240 262 8.385 470

IS 38/228/1C 228 381 62 59.27 2.830 93 4.010 260 333 12.549 470

IS 38/285/1C 285 381 77 78.47 3.747 93 4.010 280 417 18.203 470

IS 59/285/1C 285 592 55 109.21 5.215 347 36.318 280 417 18.203 n.a.

IS 59/350/1C 350 592 61 123.16 5.881 347 36.318 300 512 25.636 n.a.

IS 59/510/1C 510 592 89 187.52 8.955 347 36.318 340 745 48.012 n.a.

IS 59/710/1C 710 592 124 275.70 13.166 347 36.318 380 1038 83.336 n.a.

All technical data are without warranty. Modifications of dimensions and design reserved.


Table 2: Technical Data of Glass Fiber Gesilco Shafts

Designation Nominal torque

Nominal diameter

Mass per linear meter

Torsional stiffness per linear meter

Mass moment of inertia per linear meter

Mass of one steel flange

Mass moment of inertia of one steel

flange

Intermediate steel shaft diameter = bearing

diameter

Mass of intermediate steel shaft

Mass moment of inertia of intermediate

steel shaft

Recommended nominal diameter of

bulkhead seal

kNm mm kg MNm/rad kgm² kg kg mm kg kgm2 mm

IS 19/13/2G 13 198 12 0.85 0.143 13 0.152 100 19 0.106 230

IS 19/22/2G 22 198 21 1.61 0.270 13 0.152 120 32 0.255 230

IS 26/22/2G 22 263 16 1.83 0.308 30 0.623 120 32 0.255 290

IS 26/36/1G 36 263 21 2.48 0.417 30 0.623 140 53 0.579 290

IS 26/36/2G 36 263 26 3.22 0.542 30 0.623 140 53 0.579 290

IS 26/53/1G 53 263 31 3.92 0.659 30 0.623 160 77 1.103 290

IS 26/53/2G 53 263 38 5.17 0.870 30 0.623 160 77 1.103 290

IS 33/53/1G 53 330 24 4.42 0.743 60 1.955 160 77 1.103 380

IS 33/53/2G 53 330 31 5.68 0.955 60 1.955 160 77 1.103 380

IS 33/76/1G 76 330 35 6.65 1.118 60 1.955 180 111 2.011 380

IS 33/76/2G 76 330 44 8.65 1.454 60 1.955 180 111 2.011 380

IS 33/104/1G 104 330 48 9.65 1.622 60 1.955 200 152 3.392 380

IS 33/104/2G 104 330 60 12.72 2.139 60 1.955 200 152 3.392 380

IS 38/104/1G 104 381 41 10.33 1.736 93 4.010 200 152 3.392 470

IS 38/104/2G 104 381 52 13.37 2.248 93 4.010 200 152 3.392 470

IS 38/138/1G 138 381 55 14.35 2.412 93 4.010 220 202 5.435 470

IS 38/138/2G 138 381 69 18.78 3.158 93 4.010 220 202 5.435 470

IS 38/179/1G 179 381 71 19.66 3.306 93 4.010 240 262 8.385 470

IS 38/179/2G 179 381 89 26.08 4.385 93 4.010 240 262 8.385 470

IS 38/228/1G 228 381 91 26.73 4.494 93 4.010 260 333 12.549 470

IS 38/228/2G 228 381 114 36.00 6.053 93 4.010 260 333 12.549 470

IS 59/350/1G 350 592 90 53.22 8.948 347 36.318 300 512 25.636 n.a.

IS 59/510/1G 510 592 131 82.15 13.813 347 36.318 340 745 48.012 n.a.

IS 59/710/1G 710 592 182 122.84 20.654 347 36.318 380 1038 83.336 n.a.

All technical data are without warranty. Modifications of dimensions and design reserved.


Diagram 1: Critical Shaft Speed and Bearing Distance of Carbon Fiber Gesilco Shafts

0 rpm

500 rpm

1000 rpm

1500 rpm

2000 rpm

2500 rpm

2,0 m 3,0 m 4,0 m 5,0 m 6,0 m 7,0 m 8,0 m 9,0 m 10,0 m 11,0 m 12,0 m 13,0 m 14,0 m 15,0 m

bearing distance

sha

ft s

pee

d

IS19/../2C

IS26/../2CIS26/../1C

IS33/../2C

IS33/../1C

IS38/../2CIS38/../1C

IS59/../1C


Diagram 2: Critical Shaft Speed and Bearing Distance of Glass Fiber Gesilco Shafts

0 rpm

500 rpm

1000 rpm

1500 rpm

2000 rpm

2500 rpm

2,0 m 3,0 m 4,0 m 5,0 m 6,0 m 7,0 m 8,0 m 9,0 m 10,0 m 11,0 m 12,0 m 13,0 m 14,0 m 15,0 m

shaft speed

bearing distance

IS19/../2GIS26/../2GIS26/../1GIS33/../2GIS33/../1GIS38/../2G

shaft speed


Examples

Gesilco BF and CS Coupling and Geislinger Couplings


Gesilco Shaftlines, Gesilco CI Couplings and Geislinger Couplings


Gesilco Shaftlines with Geislinger Flexlinks


Gesilco Shaftlines and Gesilco BF Coupling

Geislinger GmbH, Hallwanger Landesstrasse 3, 5300 Hallwang/Salzburg, Austria, Tel. +43 662 669 99-0, Fax +43 662 669 99-40, [email protected]

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geislinger gesilco shaft marine wind power power generation technical data torque range: 1 knm –...

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