Composite Long Shaft Coupling Design For Cooling Towers

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International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comComposite Long Shaft Coupling Design for Cooling TowersJunwoo Bae1,#, JongHun Kang2, HyoungWoo Lee2 , Seungkeun Jeong1 and SooKeun Park3,*JAC Coupling Co., Ltd., Busan, South Korea.Department of Mechatronics Engineering, Jungwon University, Chungbuk,, South Korea.3Korea Institute of Industrial Technology, Incheon, South Korea.*Corresponding author#Orcid: 0000-0003-2904-1984 & Scopus Author ID: 5719067401912AbstractIn this study, a structural analysis was carried out to optimizea composite material long shaft coupling by varying the discthickness and number of stacked plies. Then, performancetesting was conducted to verify reliability. The structuralanalysis of GRIP disc thicknesses from 2.5T-3T and 3-5 pliesrevealed that the stacking sequence of 4 plies with a thicknessof 2.75 was the safest. A prototype of the selected disc packwas manufactured for torsional performance testing underconditions of 2 mm axial displacement, an angulardisplacement of 1 , and torque of 6,200Nm. The performancetesting verified the analysis results. The final prototype of thelong shaft coupling was fabricated to verify the safety anddesign of the major components. The prepared final prototypewas verified for lifespan reliability with a 1,000,000 cycledurability test.Keywords: Cooling Tower, Element Analysis, Composite,Disc Coupling, Lighter WeightINTRODUCTIONCooling towers are mainly used in machinery and industrialprocesses to reduce heat and control temperature. The largescale cooling towers used in industry are connected to pipingthat circulates coolant, and the towers are typically installed inoutside open areas with access to air for circulation. Theircooling performance is usually enhanced by forcing largeamounts of air to circulate through the tower using rotatingblades. [1]A lightweight long shaft coupling composed of compositematerials is required to connect the motor and gearbox shaftswith the drive unit of the cooling tower. The axialmisalignment and transfer torque of such industrial couplingshave been characterized by. [2]In addition to the functionality of conventional industrialcouplings, the long shaft coupling needs to be durable in acorrosive environment, depending on the particular operatingenvironment, have robust structural characteristics, and beable to transfer power by connecting with a rotating axis. Theuse of composite materials for such cooling tower componentsprovides reduction in weight that can lead to reduction invibrations and bearing loads, and consequently extend thesystem lifespan.Numerous studies have been carried out using genericstructural mechanics to investigate the stress and safetyfactors related to the maximum torque and maximumdisplacement conditions of industrial couplings [3 6]. Theseinclude optimal configuration studies for long shaft couplingdisc packs using finite element analysis. [7] Moreover,various studies have been carried out on the application ofcomposite materials in the high speed shaft couplings of windturbines.[8 10]In this study, based on the results of optimum flexibilitystructure studies of the long shaft coupling disc pack, anoptimization structural analysis was carried out to investigatethe effect of the thickness and number of stacked plies of thedisc, which is a component of the composite material discpack. Then, performance testing was conducted to verifyreliability, and the results were used for a comparativeanalysis. Also, performance testing was used to evaluate thebonding strength of the flange in the spacer assembly,depending on the material, where the carbon fiber compositematerial applied to the winding tube and flange are bonded.Long Shaft Coupling Structural DesignFigure 1: Shape and position of composite coupling forcooling towerThe long shaft coupling is located between the driving motorand gearbox in the cooling tower and is a functional part ofthe cooling tower powertrain that transfers the high speedrotational force from the motor to the gearbox. Figure 2 showsthe structure of the long shaft coupling. The major structuresof the high speed shaft coupling include the stainless steel hub11555

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comof the axial connection, glass fiber composite material discpack, flange, and carbon fiber composite material windingtube bonded spacer. Stainless steel and glass fiber compositematerials can be applied to the spacer flange. In this study, theprototypes of various materials were bonded for fabricationand then tested. The disc pack absorbs displacements resultingfrom axial, radial, and angular misalignments, and transfersthe rated power in the operating environment of the coolingtower. The spacer structure has low specific gravitycharacteristics compared to steel materials, and this weightreduction allows a connection with inter-axial distances of amaximum 6,000 mm without bearing support. The long shaftcoupling, composed of composite material, can withstand thecorrosive environment typically found within the coolingtower due to water vapor produced by the evaporation of thecoolant.Figure 2: Structure of the long shaft couplingOptimal Design Through Disc Pack Structural AnalysisFinite element analysis was conducted to assess the structuralsafety and optimal design of the long shaft coupling disc pack.The 3-dimensional design program CATIA V5 was used tomodel the parts of the disc pack, followed by a structuralanalysis using the finite element analysis software ANSYS.To carry out the structural analysis, the disc pack structureswere selected according to the thickness and number ofstacked plies of the glass fiber composite discs, as shown inTable 1.Table 1: Disc pack structures for analysisCase2.50 T2.75 T3.00 T3 SheetCase 1Case 4Case 74 SheetCase 2Case 5Case 85 SheetCase 3Case 6Case 9Table 2: Boundary conditions for the analysisCaseLoad / DisplacementValues1Torque6,200 [Nm]2Axial Misalignment2 [mm]3Angular Misalignment1 [deg]4Combination 1 2 3The load boundary conditions included the 3 load conditionsof torque, axial misalignment, and angular misalignment. Also,the final structure and its stability were assessed using thesafety factor determined from the maximum equivalent stresswhen the combined load of the 3 loads was applied. Table 2shows the input values of the structural analysis. Here, valueswith a safety factor of 1.5 applied to the design conditionswere inputted as structural analysis load conditions, so thatharsh conditions were applied to the design of the optimal discpack structure.Figure 2 shows the finite element model of the long shaftcoupling disc pack. The basic structure of the disc pack iscomprised of multiple glass fiber composite discs stackedtogether and assembled with SOKET and BUSH of SUSmaterial.For the load analysis of the disc pack component, each sidewas connected to the SUS flange using bolts and the analysiswas configured so that analysis could be carried outconsidering the actual operating environment.(a) Torque boundary condition(b) Axial misalignment boundary conditionFigure 3: Disc pack finite element model11556

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.com(Case 1) 2.50T, 3Sheet(Case 2) 2.50T, 4Sheet(Case 3) 2.50T, 5Sheet(Case 4) 2.75T, 3Sheet(Case 5) 2.75T, 4Sheet(Case 6) 2.75T, 5Sheet(Case 7) 3.00T, 3Sheet(Case 8) 3.00T, 4Sheet(c) Angular misalignment boundary conditionFigure 4: Boundary conditions of the long shaft coupling discpackTable 3 shows the material properties of the glass fiberreinforced polymer (GFRP) disc and SUS bush parts whichwere used in the disc pack analysis.Table 3: Input value for FE AnalysisPart nameDiscBushMaterialGFRPSUSElastic modulus [GPa]33.12193Poisson’s ratio0.280.31Yield strength [MPa]-207Tensile strength [MPa]210586Table 4 and Fig. 5 show the structural analysis results for thecombination 1 2 3 according to cases 1 9 of the long shaftcoupling disc pack. The structural analysis results for the discpack for each load condition of the long shaft couplingshowed that the structure with 2.75T thickness and 4 stacks ofthe GFRP disc had the highest safety factor from the yieldstrength to maximum stress ratio, and this structure wasapplied to the final design.Table 4: Maximum Stress & Safety Factor(Combination 1 2 0.965193.751.086202.361.04(Case 9) 3.00T, 5Sheet7218.180.968196.641.07Figure 5 : Long shaft coupling disc pack structural analysis(Combination 1 2 3)9224.680.9311557

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comDisc Pack Performance TestPerformance testing was conducted on the disc pack prototypemanufactured with 4 stacks of 2.75mm thickness GFRP discs,based on the structural analysis results, to verify its reliability,and perform a comparative analysis with the structural results.Figure 6 shows the manufactured disc pack prototype.Figure 7 : Disc pack torsional test resultFigure 6: Disc pack prototype (2.75mm, 4 plies)Prototypes #1 and #2 were manufactured to have the samestructure as the designed structure, while a rubber coating of 1mm was applied to the designed structure for prototypes #3and #4, for enhanced external quality.Table 5 shows the test results for the 4 prototypes. It wasobserved that all the prototypes underwent failure anddeformation above 6,200Nm, verifying the stability of thedesigned products. Also, it was determined that the rubbercoating on the prototypes had virtually no effect on the testresults.Torsional testing was carried out by applying an axialmisalignment of 2 mm and an angular misalignment of 1 andthe torque at the point of failure and deformation wasmeasured.Table 5: Maximum Torque of Torsional TestCaseMax. Torque [Nm]#1766#2806#3730#4807(a) #1 after testing(b) #2 after testing(c) #3 after testing(d) #4 after testingFigure 8 : Disc pack prototypes after testing11558

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comEq. (3) can be simplified so that Eq. (4) can be applied.CFRP Spacer Design Considering VibrationThe design and product selection of a long shaft coupling witha large distance between each end requires considering notonly the static strength of the product but the resonance fromthe rotation. The lateral natural frequency of a long shaftcoupling fixed on both ends can be obtained using theRayleigh-Ritz method.N c k 946 1 (4)k compensation coefficient according to the support type oneach endk 1 when only supported so that rotation is possible (k 1 forlong shaft coupling k 1)k 1.3 when both ends are fixed and assembled with arotating disc or flywheelFigure 9: Lateral deflectionNc 30g (1)g gravitational acceleration ( 9.81 m s²)δ vertical static deflection of the shaft when placedhorizontallyNc rpmSince no mass is attached to the center of the shaft, the lateraldeflection can be calculated as shown below using theequation for beam deflection under a distributed load.Figure 11: Amplitude ratioThe allowable number of rotations under normal operationcannot exceed 75% of the critical rotational speed.N a 0.75 N c(5)Figure 10: Deflection of beam 5wL35qL4 384 EI 384 EIThe long shaft coupling must only be used after calculatingthe critical speed and maximum length according to theoperating environment, and Table 6 briefly shows themaximum rotational speed calculation data for the long shaftcoupling designed using the above equation.(2)w Shaft weightq specific weightL Shaft LengthTable 6: Maximum rotational speed calculation for the long shaftcouplingE Young’s ModulusI Moment of InertiaFrom Eqs. (1) and (2), the critical speed from the resonancedue to the rotation can be calculated.Nc 30 384 gEI 5wL3(3)11559NoDescriptionValues1Tube Outside Dia.159 mm2Tube Thickness5.5 mm3Max. Length4,350 mm4Deflection0.16 mm5Critical Speed (Nc)2,379 rpm6Na 75%Nc1,784 rpm

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comA study that performed the natural frequency analysis andcritical speed evaluation based on the critical speed calculatedfor the cooling tower long shaft coupling was previouslycarried out.[7]CFRP Spacer Torsional TestLong Shaft Coupling Durability TestThe final prototype for the cooling tower long shaft couplingwas fabricated and the design safety of each part was verifiedthrough analysis and testing. In order to investigate thevalidity of the final design, a 1,000,000 cycle static durabilitytest was conducted.The torsional strength of the carbon fiber reinforced polymer(CFRP) spacer used for the cooling tower long shaft couplingwas investigated to determine whether failure and deformationoccurred at the maximum torque of 6,200Nm for theprototype, which was manufactured according to the designeddimensions. The testing was carried out with a torque limit ofabout 6,800Nm considering the allowable strength of the jigand bolts.Figure 13: Prototype for the long shaft coupling durabilitytestThe prototype with the assembled GFRP disc pack and CFRPspacer was installed in the testing machine and the test wascarried out under conditions of 2 mm axial misalignment, 1 angular misalignment, and 2,000Nm operating torque, where1 cycle was 200 2000Nm (R 0.1).(a) Initial Angle(b) Final AngleFigure 12: CFRP spacer torsional test resultTable 7: Maximum Torque of Torsional TestCaseMax. Torque [Nm]#16,787#26,928(c) Feedback TorqueThe test results showed that failure and deformation did notoccur at the maximum torque of 6,200Nm, verifying thesafety of the CFRP spacer with regard to torsional strength.Figure 12 and Table 7 show the test results.11560

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 12, Number 21 (2017) pp. 11555-11561 Research India Publications. http://www.ripublication.comREFERENCES[1]G. B. Hill, “Cooling Tower Principles and Practice”,Butterworth-Heinemann, 1990.[2]"Power transmission engineering, Flexible shaftcouplings - Parameters and design principles", 1975,DIN740 Part 2.Figure 14: Long shaft coupling durability test result[3]No failure or deformation were observed for the finalprototype of the long shaft coupling. The test results verifiedthe endurance life and reliability of the final prototype.Jon R. Mancuso, 1999, "Couplings and Joints-Design,Selection and Application", 2nd Edition, MarcelDekker, Inc.[4]S.M Jung and D.C Han, 1983, "Standard of MachineDesign”, Chapter 2 Screw, bolt, Dongmyeongsa,pp.91 98.[5]William D. Callister, Jr. Material Science andEngineering, The Univ. of Utah, JOHN WILEY &ONS, Inc., 1993.[6]D.K. Lee, K, S. Jung, and J. H. Choi, CompositeMaterial: Dynamics and Production Technology,Sigma Press, pp.19-20, 1998 (in Korean).[7]J.W Bae, etc., 2016, “A study on Long ShaftCoupling Using a Finite Element Analysis”,International Journal of Applied EngineeringResearch, Vol.11, No.20, pp. 10146 10153[8]J.H Kang etc., 2014, "Development of high speedcoupling for 2MW class wind turbine", Journal of theKorean Society of Marine Engineering, Vol. 38, No.3, pp. 262 268[9]B.J Woo, 2015, "Research on the design of Flexibledisc pack and adhesive Bonding Structure of HighSpeed Coupling for Wind Turbine", Pusan NationalUniversity, M.S.[10]H.W. Lee, etc., 2016, "A study on high speedcoupling design for wind turbine using a finiteelement analysis", Journal of Mechanical Scienceand Technology, Vo1. 30, No. 8, pp. 3713 3718.CONCLUSIONA design process, finite element analysis, and verificationtesting were performed for various GFRP disc packs andCFRP spacers, which are major components of the long shaftcoupling for cooling towers. The following conclusions wereobtained.1) The finite element analysis was conducted for 9 designcases of GFRP discs with varying thicknesses andnumbers of stacking ply. The analysis result revealed thatthe 2.75mm thickness and 4 ply structure was the moststable among them.2) The disc pack prototype was manufactured based on thedesign selected from the analysis results. Torsionaltesting was carried out on the prototype with an axialmisalignment of 2 mm, an angular misalignment of 1 ,and torque of 6,200Nm, and the test results verified andvalidated the analysis results.3) The Rayleigh-Ritz method was used to design thedimensions of the CFRP spacer considering vibrationsand to calculate the critical speed.4) Torsional testing was conducted on the prototype of thedesigned CFRP spacer, which verified the safety of thedesign.5) The final long shaft coupling prototype was manufacturedand part designs verified for safety, and the endurance lifeand reliability of the final prototype was verified during1,000,000 cycle durability testing.ACKNOWLEDGEMENTThis study was performed as part of the "The development of6MW class high speed shaft coupling for offshore windturbine over 120kNm maximum torque" under the EnergyTechnology Development Project (20143030021090).11561

Long Shaft Coupling Structural Design . The long shaft coupling is located between the driving motor and gearbox in the cooling tower and is a functional part of the cooling tower powertrain that transfers the high speed

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