tianjin shinway transmissions co., ltd

Tianjin SHINWAY Transmissions Co., Ltd.

SHINWAY Transmissions — A New Force in Transmissions

• Located in Xiqing Auto-Industrial Park, Tianjin, China.

• A wholly owned subsidiary of Beijing Jianlong Heavy Industry Group Co., Ltd.

• The 1st Phase investment amounts to 690 million RMB, covering an area of 213,333 ㎡.

• A R&D and manufacturing base of high-accuracy, large power and heavy-duty gear and gearbox products.

• Enterprise Spirit：Strive for Excellence, Start from Details.

• Core Value：Integrity, Regulation, Teamwork, Excellence, Win-Win Result

SHINWAY Transmissions — A New Force in Transmissions

Talent TeamAccording to the requirement of “internationalization, specialization and

standardization”, SHINWAY introduces key staff of management and technical R&D

from well-known companies at home and abroad.

Research, Development and Design Capability

• Three design departments.

• Rich experience in R&D and design.

• All participated in practical design for major projects.

• Have a profound understanding of gearbox application

in various industries.

Advanced software like Solidworks, Ansys, Kisssoft and B&K enable the configuration of gear trains, 3D design, finite element simulation, tooth profile and direction modification, bearing life calculation, vibration and noise diagnosis, etc.


Cooperation with Tianjin University in structure dynamic optimization design of wind turbine provides support for the design and finalization of 2MW gearbox, achieving good economic and social benefits.

Cooperation with Beijing Jiaotong University in stress and strain testing of wind turbine provides foundation for design and finalization of 2MW gearbox.

SHINWAY actively cooperates with universities in product research and development, continuously enriches the content and level of cooperation.


Gearbox Products — Vertical Mill GearboxBased on the severe work conditions of vertical

mill, SHINWAY reduces technical defects through reasonable data analysis and structure optimization.1、Optimal design and calculation of bevel gear strength by using KISSSOFT. Tooth profile can be optimized according to practical loads. 2、Finite element analysis of main structural components by using ANSYS. After optimization, axial loads can be completely born by axle wire of housing wall to avoid extra deformation.3、Design according to practical work conditions of mill. AGMA service factor≥2.5 to ensure safety and reliability.4、All rolling bearing are from SKF with service life of more than 100,000 hours. Bearing of common specification is easy to maintain. Bearings can be fueled by separated lubricating pipe to protect bearing lubrication.5、Radial and hydro-static bearing. Sufficient lubrication oil from low pressure ensures the cooling effect of engine bearing when up bearing the mine to required height.

2012

Tangshan DushiMachinery

3300KW vertical mill gearbox, 1 set

Tangshan Jianlong Steel

3000KW vertical mill gearbox for coldrolling mill, maintenance, 1 set

Tangshan GangluIron & Steel

355KW vertical mill gearbox,maintenance, 1 set

BrandsItems SHINWAY CSIC NGC

StructureBevel gear + dual planet（special floating technology of one-stage planet carrier）

Bevel gear + dual planet（one-stage sun gear floating）

Bevel gear + dual planet（one-stage sun gear floating）

Weight -128 tons（special transmission structure to reduce weight） -145 tons -135tons(surmise）

Bearing

Journal bearing to avoid low thermal speed of rolling bearing in overloading and low speed conditions

Rolling bearing’s problem of low thermal speed and short

service life.

Rolling bearing’s problem of low thermal speed and short

service life.

Bearing Design

Special bearing structure of big and small size to balance loads Only big size bearing. Only big size bearing.

Lubrication

Each lubrication point has branch pipe. Design and calculation of hybrid journal bearing indefinitely prolong its servicelife.

Lubricate rolling bearing through pressure feed lubrication. Low thermal speed leads to a sharp reduction of service life.

Lubricate rolling bearing through pressure feed lubrication. Low thermal speed leads to a sharp reduction of service life.

SHINWAY 5400KW Vertical Mill GearboxCharacteristics and Advantages

Gearbox Products — Vertical Mill Gearbox

Mail gearbox and pinion housing for CFHI Yanshan 1780 rolling mill.

Gearbox Products——Rolling Mill Gearbox

• Rolling mill gearbox for steel plant with features of large power, low speed and less vibration quantity – meet severe work conditions.• High quality alloy steel and high accuracy surface hardening treatment – improve gear loading capacity.• Bearing of imported brand-meet the work conditions of heavy loads and continuous operation.• Design of lubricant passage way and non-contact labyrinth seal structure – improve the continuous operation performance.

Gearbox Products——Rolling Mill Gearbox

• Widely used in the field of mining machinery, metallurgy, ports, power plant, cement and other industry.• Modular design – assemble into different products with fewer components, meet the requirements of market diversity, shorten delivery time.• Variety installation and cooling methods to be chosen.• Can replace SEW M, ML / FLENDER FZG.• 2/3/4 stage horizontal shaft, 3/4 stage rectangular shaft• Product Type: 095 – 155.

Gearbox Products——V-Series Standard Gearbox

No. Item SHINWAY SEW/FLENDER SHINWAY Advantages

1 Material of Gear Steel

low carbon alloy steel18CrNiMo7-6

low carbon alloy steel18CrNiMo7-6 Raw material meeting DIN standards, consistent with imported products.

2 Suppliers of Gear Steel

Bao Steel /Fushun Special Steel

Bao Steel /Fushun Special Steel

Best raw material suppliers in China. Reliable quality of raw material with mechanical property meeting design requirements.

3 Material of Output Shaft 42CrMo4 42CrMo4 Raw material meeting DIN standards, consistent with imported products.

4 Design of GearsOptimal modification design,

analyzed and verified by a variety of professional software.

Common modification design, single software.

Optimal modification design - reliable engaging, even and stable load carrying, lower noise, longer service life.Simulation and finite element analysis-competitive advantages in product design.

5 Material of Housing

Cast iron GG20Ductile Iron GGG40Steel welded housing

Cast iron GG20Ductile Iron GGG40Steel welded housing

Select best housing scheme according to work conditions – ensure product reliability and cost reduction.Non-standard gearboxes mostly use steel welded housing.

6 Design of Housing Optimal design of housing Common design of housing Optimal housing design according to work conditions – increase load carrying capacity.

Increase contact surface of connecting link – reduce noises caused by vibration.

7 Bearing Imported bearingSKF/FAG/NSK

Imported bearingSKF/FAG/NSK

Imported bearing with reliable quality – longer service life, longer replacement cycle, lower failure rate, higher product precision, lower noise.

8 Seal Imported seal Imported seal Imported seal with reliable quality – sharply reduce oil leakage, ensure smooth operation.

9 Seal Structure Optimal seal structure Common seal structure Technology optimization of seal structure – sharply reduce oil leakage, effectively control temperature rise and noise of bearing.

10 Heat TreatmentHardening and tempering,

carburizing and quenching by process optimization.

Hardening and tempering,carburizing and quenching

Process optimization of heat treatment – increase finished product rate after heat treatment, increase production efficiency, ensure the final technical parameters to meet design requirements.

11 Processing Technology

High accuracy hobbing, carburizing and quenching, shot

blasting, grinding and modification.

Common hobbing, carburizing and quenching, shot blasting, grinding and

modification.

Imported equipments of latest model – machinery precision may reach DIN2.Heat treatment equipments including shot peening and blasting – increase the strength of tooth surface and root, longer service life.

12 Dimension Smallest Small High strength, small dimension, compact conformation – small dimension of complete gearbox.

13 Service Life Longer Long High precision and high strength – long service life, reliable quality.

14 Noise lower Low High product configuration, high process precision, strict quality control, optimization of seal structure, tooth surface modification and housing design – lower noise during operation.

15 Reliability High reliability, few oil leak. High reliability, few oil leak. Strict quality control during whole process – reduce failure rate.Optimization of technology – advantages in design concept and structure.

16 Price Low High Higher quality and lower price than SEW product.

Gearbox Products——V-Series Standard Gearbox

Gearbox Products—Two-stage planetary gearbox for hydraulic lifting platform

Type

Rated Lifting Force

Output speed

Speed Ratio

Layout Form

Design Life

HYPT-P100-A1

100T

380 rpm

317

one-stage planetary and one-stage small teeth difference planetary

1000 hours under rated lifting force

Design Parameters

Gearbox Product — Gearbox for power lifting machinery

Gearbox Products— 2MW two-stage planetary and one-stage parallel shaft wind turbine main gearbox

Type:WMG-P2-A1

Output Speed:1200 rpm

Rated Power:2160 KW

Speed Ratio: 78.04

Transmission Form: two-stage planetary and one-stage parallel

Design Life: 20 years

Shinway 2MW CSIC 2MW NGC 2MW

Strength Safety Coefficient of Gear

About 15% higher than industry average Industry average Industry average

Weight of Gearbox 19.2 tons About 22 tons About 22 tons

Oil Seal Design of Output Speed

Labyrinth seal+2 layer leak proof, Shinway patent to prevent oil leak Labyrinth seal Labyrinth seal

Bearing Brand All from SKF From different brands From different brands

Electrical Components Compliance with UL CertificationsNot completed

compliance with UL Certifications

Not completed compliance with UL

Certifications

Parameter Brand

Gearbox Products—1.5MW one-stage planetary and two-stage parallel shaft wind turbine gearbox

Type: WMG-P1.5-A1

Output Speed: 1660 KW

Rated Power: 1800 rpm

Speed Ratio: 104

Layout Form: one-stage planetary and two-stage parallel


Shinway 1.5MW CSIC 1.5MW NGC 1.5MW

Strength Safety Coefficient of Gear

About 10% higher than industry average Industry average Industry average

Weight of Gearbox 15.2 tons About 16 tons About 16 tons

Oil Seal Design of Output Speed

Labyrinth seal+2 layer leak proof, Shinway patent to prevent oil leak Labyrinth seal Labyrinth seal

Bearing Brand All from SKF From different brands From different brands

Electrical Components Compliance with UL CertificationsNot completed

compliance with UL Certifications

Not completed compliance with UL

Certifications

ParameterBrands

Gearbox Products— 2MW one-stage planetary and two-stage parallel shaft wind turbine main gearbox

Type: WMG-P2-B1

Rated Power: 2250 KW

Speed Ratio: 102.8

Output Speed: 1750 rpm

Layout Form: one-stage planetary and two-stage parallel


Design Parameters

Gearbox Products—1.5MW Double Planetary and Main Shaft Gearbox

Shinway high speed gearboxes can be applied to steam turbine, gas turbine

generator, centrifugal and axial-flow fans, blower, compressor, high/low pressure pump,

oxygen making machine, etc.

Basic Structure: double helical tooth / single helical tooth, journal bearing

Gearbox Products — High Speed Gearbox

High speed gearbox for multi-shaft gear compressor (gearbox for H-type compressor)

is mainly used to separate oxygen, nitrogen and carbon dioxide by compressing air.

Basic Structure: parallel shaft, single input shaft extension, multiple output shaft

extension, single helical tooth, bevel thrust collar, journal bearing.


High speed gearbox for large power gas turbine is

mainly used to drive generator by gas turbine.

Basic structure: upper and lower structure, double

helical tooth, double layer design of housing, journal bearing,

non-contact mechanical seal.


Design Capability— High Speed Gearbox for Multi-shaft Gear Compressor

Technology Parameters:

• Gear Layout Form and Gear Profile: multiple parallel shafts, single helical tooth,

involute, hard tooth surface, single input shaft, multiple output shafts.

• Transmission Power ：2800kW

• Input Speed of Low-speed Shaft: 2983 r/min

• Output Speed of High-speed Shaft: 14580 r/min

• Output Speed of High-speed Shaft 2: 18700 r/min

• Output Speed of High-speed Shaft2: 24800 r/min

• Gear Accuracy Class: 3~4 GB10095

• Design Life: 100,000 hours• Continuous operation time under full ≮3 years

23

ShaanGu AV63-16 Axial-flow Compressor UnitTechnology Parameters:• Gearbox Layout Form: horizontal• Gear Layout Form and Gear Profile: parallel shaft, double helical tooth, involute, hard tooth surface.• Transmission Power ：18000 kW• Service Factor: 1.4• Transmission Efficiency: ≥98.0 %• Input Speed of Low-speed Shaft: 1486 r/min • Output Speed of High-speed Shaft: 5220.05 r/min；• Gear Accuracy Class: 4～5 GB10095• Design Life: 200,000 hours• Continuous operation time under full ≮3 years• Center Distance of Gearbox: 720• Linear Velocity of Gear: 85m/s 24

Design Capability— High Speed Gearbox for Blast Furnace Blower

25

Mine Safety Authentication

Product Certification — V-Series Standard GearboxSpecifications:VGR3R095, VGP3R105, VGP3R095, VGR3R105, VGR3K105, VGR3K095, VGP3K105, VGP3K095, VGR3S105, VGR3S095, VGP3S095, VGP3S105, VGR3R155, VGR3R145, VGR2R135, VGR3R125, VGR3R115, VGP3R155, VGP3R145, VGP3R125, VGP3R115, VGP3R135, VGR3K155, VGR3K145, VGR3K135, VGR3K125, VGP3K155, VGP3K145, VGP3K135, VGP3K125, VGP3K115, VGR3K115, VGR3S155, VGR3S145, VGR3S135, VGR3S125, VGR3S115, VGP3S145, VGP3S135, VGP3S125, VGP3S115, VGP3S155.

GL Certification

Product Certification — Wind Power Gearbox

Learn mature manufacturing technology from world’s leading wind gearbox

manufacturer, and form SHINWAY manufacturing features:

• Reliability of gear steel/forging

• High quality and less deformation of carburizing and quenching

• Reliability of ring gear induction hardening

• Control of gear grinding on tooth modification

• Prevention of tooth flanks burn and its testing

• High efficiency of ring gear processing equipment

Manufacturing Features

28

Manufacturing CapabilityNC equipments of world-class brand in every key link (machining, heat

treatment, procession test and product inspection) - meet mass production requirement of high-precision gearbox, ensure product quality fundamentally.

Equipment Name Country/RegionHigh-efficiency Gear Hobbing Machine Germany

Manufacturing Capability

Equipment Name Country/RegionHigh Precision Gear Grinding Machine Germany


Equipment Name Country/RegionNC Vertical Lathe Center Taiwan


Equipment Name Country/RegionNC Horizontal Lathe Center Japan


Equipment Name Country/RegionCarburizing Furnace Austria


Equipment Name Country/RegionHardening Machine for Gear Ring Germany


• Carburizing Heat Treatment Line is equipped with Aichelin products, including: 4 pit carburizing furnaces(Φ1.2mX1, Φ1.6mX2 and Φ2.0mX1), 2 Pit Tempering Furnaces(Φ2.0m),1 Slow Cooling Furnaces(Φ3.0m) and 1 Hardening Oil Groove fitting it, 1Cleaning Machine and other Auxiliary Equipments.

• Using PT9800 and PE600 systems to ensure the accuracy of parameters.

35


Equipment Name Country/RegionHorizontal Boring and Milling Machine Center Germany


Equipment Name Country/RegionVertical Gantry Machine Japan


Testing Capability

38

Equipment Name Country/RegionCoordinate Measuring Machining Germany

Place of Production: Germany

Measuring Range: 3000×3000×2000 mm

Accuracy: 3.0+L／400 µm

Maximum Weight of Workpiece: 15000 KG

• Leitz ultrahigh precision CMM

• The most precise CMM in the same industry

Equipment Name Country/RegionGear Measurement Center Germany

Place of Production: Germany

Measuring Range: 0～3000mm

Accuracy: VDI 2612 1stage

Maximum Weight of Workpiece: 15000 KG

Testing Capability

7.2MW Test Bench adopted the latest measurement system of Brüel & Kjær. As a world-leader in the industry, B&K Sound and Vibration Measurement A/S supplies us integrated solutions for measuring and analyzing the sound and vibration of wind turbine.

7.2MW Test Bench

Testing Capability

7.2MW Test Bench

Testing Capability

TUV ISO9001:2008 Certificate

Quality Control System

43

TUV ISO9001:2008 Certificate


Incoming Material Quality Control• The steel for Industrial Gearbox is customized in Shanghai Bao Steel and Fushun

Steel, in strict accordance with the standard of EN10084 and EN10083.

• The steel for wind power gearbox is only from Shanghai Bao Steel, in strict

accordance with the standard of En10083 ,En10084 and meeting ISO6336-5 ME class.

• Casting parts for industrial gearbox are customized in casting factory according to the

standard of EN1561 AND EN1563.

• Casting parts for wind power gearbox are only customized in professional factories of

wind power castings, in strict accordance with the standard EN1563 and other special

requirements.


100% test with the 30 consecutive batches of incoming materials to ensure quality stability.

44

45


HB3000B Brinell Hardness Testing Machine ERNST Hammer Hardness Testing Machine

OLYMPUS Metallographic Microscope+LECO Graphics Analysis System Japanese LST Portable Metallographic Microscope

46


SPECTROTEST

Quality Control System UT Testing Standard• Forgings: Test standard JB/T5000.15-98• Forged Rods: Test standard JB/T5000.15-98• Customer Requirement: Test according to customer requirement• Wind Power Castings: Test standard JB/T5000.15-98100% incoming test

47

Ensure the quality of heat treatment - advanced apparatus, 100% sample test,

furnaces controlled by computer automatically, regular check on thermodynamic

instruments and thermocouples.


48

Automatic Micro Vickers Hardness TesterLECO AMH433AVANCM

Infrared Carbon and Sulfur AnalyzerLECO CS230HC

49


Magnetic Particle Test

100% MT test according to the standard of JB/T5000.15-98

51


Grinding Burning Test

52

Standard: ISO 14104/AGMA2007

100% test according to inspection plan.


Testing Field LayoutQuality Control System

100% assembly test-run of Industrial Gear Units

Contact Area Test Backlash Test

Input Shaft Rotational Speed Test Output Shaft Rotational Speed Test

Thermal Change Test

Noise Level Test


tianjin shinway transmissions co., ltd

Documents