Gearbox arrangement for providing a partial vacuum within a gearbox arrangement, and method for efficiently providing and maintaining a partial vacuum and use thereof - Patents.com

Abstract

The present invention relates to a gearbox arrangement comprising at least one turbo gearbox arrangement, configured to provide a partial vacuum within the gearbox arrangement, the gearbox arrangement comprising a vacuum pump, a vacuum oil tank, an oil pump connected to the vacuum oil tank, and a plurality of valves, a sensor unit, and a control unit configured to control at least the vacuum pump and the oil pump, respectively, in response to instantaneous sensor data. The vacuum oil tank and the at least one valve provide a switchable siphon arrangement, such that a preset vacuum level is ensured in the internal volume by the vacuum pump and the vacuum oil tank and by controlling the vacuum pump in response to instantaneous sensor data. The present invention further relates to a method for providing and maintaining a partial vacuum with such a gearbox arrangement.

Description

[Technical Field]

[0001] The present invention relates to a gearbox arrangement representing at least one turbo-gearbox unit, the gearbox arrangement providing a partial vacuum in the gearbox unit (in particular in an internal volume / cavity defined in the gearbox housing), the gearbox arrangement comprising a vacuum pump, a vacuum oil tank, an oil pump coupled to the vacuum oil tank, a plurality of valves, piping connecting the vacuum oil tank, the gearbox unit, and the vacuum pump, a sensor unit, and a control unit for controlling at least the vacuum pump and the oil pump. The present invention also relates to a gearbox coupled to / with a vacuum component for ensuring a partial vacuum in the gearbox. Furthermore, the present invention relates to a method for providing and maintaining a partial vacuum in at least one turbo-gearbox unit of a gearbox arrangement, the method comprising: a vacuum pump communicating with an internal volume (cavity) of the gearbox unit; an oil pump coupled to the vacuum oil tank supplying oil to the gearbox unit and, optionally, to lubrication piping; and a control unit controlling at least the vacuum pump and the oil pump. In particular, the present invention relates to a gearbox arrangement and a method according to the respective independent claims. [Background technology]

[0002] Gearbox devices are often installed in high-power drivetrains. Particularly in highly efficient, high-speed / high-power gearbox devices, effectively reducing power losses is considered a strict requirement. Conventionally known gearboxes, particularly fixed ratio transmission gearboxes, are capable of providing partial vacuum at the gear / tooth area, which is considered an effective measure, particularly in turbo gearboxes, where efficiencies of 99% or more are required. The present invention addresses further improvements in providing such partial vacuum.

[0003] It is already known that losses are caused by lubricants and coolants present between the gear teeth, and / or turbulence caused by gear parts moving at high speeds, and / or friction between the gear teeth and the teeth of the bearings supporting the rotating shaft. A partial vacuum can significantly reduce losses due to turbulence caused by the high peripheral speed of the teeth. The present invention focuses on the type of pump operation involved in creating and maintaining said partial vacuum while ensuring high efficiency. Specific uses of lubricants and coolants may also be involved.

[0004] US Pat. No. 6,374,949 B2 describes a safety device for a transmission lubrication system in which a partial vacuum is maintained by a vacuum pump and the pressure and oil fill / volume are monitored by sensors.

[0005] French Patent No. 3035164 B1 describes a transmission device for partial vacuum operation in which the gear lubricant can be at least partially separated from the bearing lubricant (in partial vacuum operation) and fed by a delivery pump to an oil recovery container external to the gear unit, and in which the gear lubricant can also be conveyed to the oil recovery container via a check valve (in atmospheric pressure operation).

[0006] WO 96 / 15392 A1 describes the concept of supplying gas or creating a partial vacuum in a gearbox, where air can be evacuated from the gearbox by means of a pump that is also suitable for oil removal, the gears being mounted in radial bearings and preferably also in an additional internal housing.

[0007] WO 2003 / 074903 A2 describes a gear mechanism configured to generate a lean atmosphere, comprising means for reducing the gas pressure in a casing housing containing at least two gear components, a first container communicating with a second container communicating with a storage tank, the container and the storage tank being arranged so that oil flows in succession by gravity flow.

[0008] U.S. Patent No. 5,101,936 discloses a vacuum-operated dry sump system comprising a gearbox assembly, a vacuum oil tank, an oil pump connected to the vacuum oil tank, and a valve. The vacuum oil tank and valve provide a selectable / switchable siphon arrangement to ensure a predefined vacuum level within the internal volume of the gearbox assembly via the vacuum pump and vacuum oil tank.

[0009] In this context, the present invention focuses on improving the efficiency of gearbox arrangements that accommodate partial vacuums and explores improvements that ensure functionality / operation in both partial vacuum and atmospheric operation.

[0010] [Summary of the Invention] The present invention aims to provide a concept that allows for high efficiency in gearbox arrangements that operate in partial vacuum and, optionally, under atmospheric pressure conditions, thereby improving the function / operation of the pump technology involved and, optionally, the use of lubricating or cooling media. In particular, the present invention aims to ensure high efficiency and high system safety in transmission devices that operate primarily in partial vacuum (e.g., approximately 500 mbara or approximately 50% below ambient or surrounding pressure). In particular, for turbo transmissions, both operation in partial vacuum and at atmospheric pressure are preferably considered and optimized. Turbo transmissions, in particular, operate at very high speeds.

[0011] The object of the invention is solved by the features of the independent main claim. Advantageous features are set out in the auxiliary claims. Features of the auxiliary claims may be combined with features of the main claim and with features of further auxiliary claims.

[0012] One aspect of the present invention relates to a gearbox arrangement that includes an improved pumping system (and process).

[0013] In particular, this object is solved by a gearbox arrangement representing at least one turbo-gearbox apparatus, in particular a high-efficiency turbo-gearbox apparatus, configured to provide a partial vacuum within the gearbox apparatus, the gearbox arrangement comprising: a vacuum pump in communication with an internal volume (partial vacuum cavity) of the gearbox apparatus, a vacuum oil tank separate from a main oil tank of the gearbox apparatus, an oil pump connected to the vacuum oil tank, a plurality of valves, and piping connecting the vacuum oil tank with the gearbox apparatus and the vacuum pump, the gearbox apparatus further comprising a sensor unit consisting of at least one sensor, and a control unit configured to control at least the vacuum pump and the oil pump (and optionally further associated valves and / or instrumentation), respectively, depending on actual sensor data of the at least one sensor, wherein at least one of the vacuum oil tank and the valve provides a selectable / switchable siphoning arrangement, such that a predefined / definable vacuum level is ensured within the internal volume (partial vacuum cavity) via the vacuum pump and the vacuum oil tank. Here, the predefined / definable vacuum level is controllable / controllable (controllable according to a predefined operating mode) by controlling the vacuum pump according to actual sensor data of at least one sensor. The sensor data includes at least one of the following types of data: pressure sensor data related to the vacuum level in the internal volume (partial vacuum cavity), air leakage sensor data related to the gearbox device. Such a configuration ensures efficient and effective operation of the vacuum pump, especially taking into account the actual situation.

[0014] In other words, the present invention also provides a type of efficiency improvement device, especially for turbo gearboxes (high-speed, high-power gearboxes). In particular, the present invention can be advantageously implemented in any turbo gearbox where an overall efficiency of, for example, 99% or more is required and where the initial efficiency is close to, for example, 98.5%. This efficiency level is already achieved in some types of gearboxes, especially in the power generation sector and the oil and gas industry. The present invention therefore provides a further improvement in relation to the remaining 1% of losses (which may not be negligible, especially in high-power configurations). Some of the advantages of the present invention are summarized below: The present invention can effectively reduce power losses (especially wind losses and pumping losses), especially at efficiency levels of at least 99%. The present invention can effectively and efficiently reduce the atmospheric pressure around the teeth (eg, partial vacuum levels of about 500 mbara or less). The rotational speed of the vacuum pump is controlled based on actual sensor data and can be configured to self-adjust, particularly in connection with feedback control. Similarly, the amount of oil cooling the teeth can be controlled and configured to self-adjust based on actual sensor data. The invention allows for an increase in maintenance intervals, at least for vacuum pumps and also for other associated components, in particular at least five or even ten times. Furthermore, the invention allows for easy implementation of resistance to power outages and microcuts, and in particular includes a restart mode (restart under its own conditions). The present invention may also include a recording and storage facility (particularly in the control unit) for at least the main relevant operating parameters, particularly by automated algorithms provided by the control unit, which facilitates monitoring and control of the gearbox arrangement and related components.

[0015] The invention can be implemented, for example, in the following types of systems, either built-in or stand-alone: ​​Depending in particular on the type of system (built-in or stand-alone), oil dedicated to cooling the teeth or lubricating the entire gearbox can be transported as well. In the built-in type, oil circulation is advantageously realized on the bottom side of the gearbox, so that no refilling for cooling or lubricating the teeth is necessary. After passing through the bottom of the gearbox (where it is mixed with oil from the bearings), the oil is transported by gravity to the main lubrication oil tank.

[0016] In contrast, in the prior art, existing gearbox vacuum systems have a partial vacuum created or controlled by a check valve rather than an automatic valve, a fixed or predefined speed for the vacuum pump (rather than being variably controlled with reference to the vacuum level and air flow rate entering the gearbox), a predefined (rather than controlled) oil flow rate to the teeth, and no provision for maintenance capabilities, the ability to respond to power outages or minor power cuts, or management of the recording and storage of key parameters.

[0017] The present invention provides a general concept for simultaneously achieving high efficiency, high system security, and high process variability, particularly in the context of slim designs (equipment and process). Furthermore, status monitoring is facilitated based on sensor data provided by the sensor unit described herein, in particular with reference to at least the power level and the partial vacuum level of the vacuum pump. In particular, status monitoring is facilitated based on sensor data provided by at least one accelerometer measuring the operating state of the vacuum pump (e.g., in the context of system monitoring and maintenance, extending maintenance intervals by a factor of five or more, or even ten or more).

[0018] The turbo-gearbox arrangement of the gearbox is especially designed for a speed of 5,000 revolutions per minute, in particular 10,000 revolutions per minute, preferably 25,000 revolutions per minute, particularly preferably 50,000 revolutions per minute. In particular, the turbo-gearbox is designed for an output power of up to 0.2 MW, preferably up to 5 MW, in particular up to 50 MW, particularly preferably up to 100 MW. The turbo-gearbox can especially provide an efficiency of at least 98%, preferably at least 99%. A turbo-gearbox with an efficiency of at least 99% is also called a "high-efficiency turbo-gearbox".

[0019] According to this disclosure, the term "vacuum oil tank" refers to a tank that is separate from (or part of) the main (lubrication) oil tank and that is arranged in a siphon arrangement and that buffers the flow of oil from the gearbox to the main (lubrication) oil tank (the main oil supply is supplied from at least one oil tank directly coupled to the gearbox) and through the gearbox to the main lubrication oil tank (particularly in the section from the gearbox to the main lubrication oil tank, oil flow is gravity driven) under at least one of a plurality of operating conditions.

[0020] According to the present disclosure, the "internal volume" (partial vacuum cavity / area) of a gearbox arrangement refers to the area in which the partial vacuum is / will be provided as intended (e.g. 500 mbara). This internal volume may consist of the area surrounding the pinion and wheel, for example, and enclosed / encapsulated by at least one additional seal, especially on the shaft involved in this area.

[0021] According to this disclosure, the term "volume" of a gearbox arrangement generally refers to the volume enclosed by the gearbox housing.

[0022] In the following, some of the devices and components of the present invention will be described in general terms, with some features being explained in more detail. In particular, the device / process according to the present invention may include at least some of the following components: a gearbox, at least one vacuum oil tank (in addition to a main oil tank supplying oil to the gearbox), a pipe connecting the vacuum oil tank and the gearbox, at least one oil pump, at least one vacuum pump (preferably adjustable / controllable in a precise manner in speed / power level), an automatic valve allowing automatic activation of the switchable siphon function, at least one sensing unit, and a control unit. In particular, the device / process of the present invention can be advantageously implemented in combination with the following components: a high-pressure oil system, a shaft seal capable of controlling the flow of air into the internal housing of the gearbox.

[0023] The preferred operating mode is explained in more detail below: A vacuum oil tank is interconnected between the gearbox device and the vacuum pump and can function as a siphon (this function is preferably switched by at least one automatic valve). The vacuum oil tank contains the vacuum only within the gearbox and in the upper part of this tank. An efficient connection between the vacuum pump, the gearbox arrangement and the vacuum oil tank is ensured by a piping system consisting of at least three pipes, at least one pipe connecting the gearbox to the vacuum oil tank and at least two pipes connecting the vacuum oil tank to the lower part of the gearbox or to the piping system connecting the gearbox to the lubrication system of the gearbox arrangement (or plant). These pipes can be reduced in length to a minimum, especially if an integrated type is realized. According to one embodiment, the piping consists of at least seven pipes providing functions related to the partial vacuum, namely a first pipe (suction pipe connecting the internal volume of the gearbox with the oil tank), a second pipe (suction pipe connecting the oil tank with the vacuum pump), a third pipe (connecting oil pipe connecting the oil tank with the oil pump and the gearbox arrangement, which connecting pipe can advantageously be connected to one of the sixth and seventh pipes), a fourth pipe (oil suction / supply pipe connecting the gearbox arrangement with the vacuum pump, supplying cooling and / or lubrication oil), a fifth pipe (oil re-supply pipe connecting the vacuum pump with the gearbox arrangement, which re-supply pipe can advantageously be connected to one of the sixth and seventh pipes), the sixth pipe and the seventh pipe (first and second atmospheric connecting pipes respectively connecting the vacuum oil tank with the atmospheric part of the gearbox arrangement). The oil pump is arranged and configured to pump oil from the vacuum oil tank to a main lubrication system, for example, of a power generation or compression line. The oil pump is preferably driven by a variable speed electric motor, and the speed of the oil pump can be controlled, for example, depending on the level of oil in the vacuum oil tank. The at least one vacuum pump is arranged and configured to reduce atmospheric pressure to a level that reduces the density of gas around the gear, for example, to a minimum of 50% of the surrounding atmospheric pressure. The speed of the vacuum pump (set parameter) is adjustable / adjustable depending on at least one measured or evaluated parameter, in particular depending on the air leakage due to the clearance that actually exists between the input or output shaft of the gearbox device and the shaft seal (this clearance value depends on the actual output level of the gearbox device, and this dependency can optionally be evaluated and processed in connection with the system control). Preferably, the vacuum pump is cooled and lubricated via the gearbox oil inlet system (this feature is believed to provide a significantly enhanced configuration). The vacuum pump arrangement preferably comprises an accelerometer configured to check vibration parameters of the pump's mechanical parts, which also facilitates predictive maintenance. The gearbox arrangement further comprises at least two automatic valves (normally open) which, when closed, act as a siphon for the vacuum oil tank (switchable siphon function). Redundancy of the two automatic valves is also preferred, particularly for safety reasons (this prevents any failed opening). Preferably, the gearbox arrangement further includes an oil high pressure system arranged and configured to close an automatic valve coupled to a vacuum oil tank, the oil high pressure preferably including an oil tank, a high pressure pump, and a check valve to prevent the valve from opening when closed. Preferably, the gearbox arrangement further comprises at least one automatic valve constructed and arranged to regulate the amount of (cooling) oil supplied to the gears / tooths of the gearbox. Preferably, one or two additional automatic valves (normally open) are provided to connect the top of the vacuum oil tank and the top of the gearbox to the atmosphere. These valves are closed during vacuum operation, allowing the gearbox to quickly return to atmospheric pressure when necessary. The gearbox device may include a shaft seal that can control the flow of air into the internal volume of the gearbox, especially under vacuum operating conditions.

[0024] In particular, the control unit is capable of controlling at least one parameter related to at least one of the following operating conditions, which can be monitored by suitable sensors: oil level (sensor), vacuum level (sensor), speed / power level (sensor), as well as oil temperature (sensor) and vacuum pump temperature (sensor), valve position (sensor), and in particular the temperature of the electric motor of the associated pump.

[0025] The control unit may also provide a user interface, for example a tactile screen (human-machine interface). The control unit may also control / manage all operations in case of electrical micro-disconnects or power outages, as well as normal start / stop sequences and emergency stop sequences. In particular, based on sensor data provided by the sensor unit, (re)start sequences may be performed more efficiently and safely. The control unit may also communicate with units of other system components (of the arrangement and / or other plants). The control unit may also have the following functions: prediction or predefinition of opening / operation times of automatic valves, predefinition of preventive maintenance of vacuum pump(s) and automatic valves, adjustment of setting parameters, and may provide access to setting parameters and programs (in particular via login and password).

[0026] In particular, the control unit can be pre-configured to control some or all of the following parameters / data: oil level in the oil tank (regulation and alarm), vacuum level in the gearbox and at the top of the oil tank, (minimum) speed of the oil pump and vacuum pump, position of the automatic valve (open / closed), temperature of the vacuum pump, temperature of the electric motor of the oil pump and vacuum pump, position of the automatic valve (open or partly closed) controlling the oil flow rate cooling the gearbox teeth.

[0027] The control unit (or an automated unit with similar functions) also allows: - User interface via touchscreen (human-machine interface) - Manage micro-cuts and power outages in the plant's electrical system safely and efficiently (e.g., if the micro-cut is short, the energy storage unit will initiate an automatic restart sequence without shutting down the control unit; if it is long, the control unit will automatically reset and at least put the vacuum system into a safe configuration). - Communicate with additional automation / control units that control other components of the plant (e.g., using wireless communication modules) Control of normal start-stop and emergency stop sequences, Recording and storing the system's key parameters, Checking the opening time of automatic valves, Preventive maintenance of vacuum pumps and automatic valves, Easy adjustment of configuration parameters, Access to configuration parameters and related computer programs via login and password.

[0028] Therefore, in the present invention, the following functions can also be easily realized. - Reducing power (electricity) consumption, especially based on adjusting the speed / power level of the vacuum pump, especially the real (actual, effective, instantaneous) air flow through the gearbox or its shaft seal system. - reducing to the minimum necessary the actual (actual, effective, instantaneous) air flow rate through the gearbox, especially via its shaft seal system, or the amount of oil applied to the teeth, based on adjustment of the speed / power level of the vacuum pump; and preventing an increase in oil flow rate, especially due to an increase in the overall oil pressure relative to atmospheric pressure, by appropriately operating at least one automatic valve, especially under (partial) vacuum conditions. - Avoiding the need / use of thermal expansion compensators on the pipes connecting the gearbox to the vacuum oil tank and vice versa, especially by shortening the length of the pipes to ensure minimal thermal expansion, thus reducing the forces on the flanges. - Safe operation even in the event of minor power outages or power outages. - Predictive maintenance management, especially based on resetting initial plant parameters and checking the opening times of (main) valves. The extension of maintenance intervals for vacuum pumps, in particular based on the concept of changing the oil in the vacuum pump via the gearbox lubrication system (which also reduces particles that contaminate the oil) and the use of accelerometers to check the degree of damage to the different mechanical parts of the vacuum pump, makes it possible to extend maintenance intervals, for example, from 2,500 hours to more than 32,000 hours. - Event tracking, especially in the context of defining pre-conditions for emergency shutdowns, based in particular on recording and monitoring / analysis of key system parameters, which can reduce the time needed to inspect / survey the system, limit the need to send technicians to the site to locate faults, and limit the requirement to remove components.

[0029] It has been found that in an embedded configuration, the components of the gearbox arrangement consume at least half the power to achieve the same vacuum level compared to a stand-alone configuration. In an embedded configuration, the vacuum within the gearbox is achieved only in the vicinity of the gear meshing, compared to the vacuum throughout the gearbox in a stand-alone configuration. The stand-alone configuration is suitable for any type of gearbox that is not originally designed to operate under vacuum. Thus, the present invention provides a concept that achieves high efficiency in both systems (embedded and stand-alone).

[0030] Unless expressed in a gender-neutral manner, anthropomorphic terms may refer to all genders within the scope of this disclosure. English terms or abbreviations used herein are common terms in the industry and familiar to those skilled in the art who are familiar with the English language.

[0031] Conventional gearbox systems achieve low efficiency levels, and the functionality provided by the invention is only partially realized, requiring relatively high effort. In particular, the teachings of WO 2003 / 074903 A2 highlight the following features: A first buffer oil tank and a second buffer oil tank are provided, with the second tank concentrating the oil flow from the first tank and the oil pump, providing a kind of multi-functionality. A thermal compensator is provided to compensate for the thermal expansion of the connecting pipes between the gearbox and the oil tank and other components of the lubrication system. A bypass allows oil to be transferred from the gearbox to the (external) lubrication system, especially in the event of maintenance work on the first and second oil tanks or other components connected to them. The vacuum pump operates at a fixed speed / power level and is cooled by an external cooling system. An air / oil separator and additional filters are provided upstream of the vacuum pump. The piping supplying air to the vacuum pump and the piping supplying oil back to the lubrication system are equipped with oil drainage devices. The valves on the oil tank are configured to be manually opened (e.g. via a hand wheel (see item G)). To operate / close the aforementioned valves, an oil intermediate pressure system is provided, which includes the oil tank, a pump, and a check valve (a relatively large valve actuator) that prevents the valve from opening when closed. Most valves are actuated by pressurized air.

[0032] In contrast, the present invention provides technical teachings for efficiently and effectively controlling at least the operating state of a vacuum pump and controlling at least one oil flow (particularly depending on the actual vacuum level and / or air leakage). Furthermore, no bypass or thermal compensator is required. Therefore, the concept of the present invention also enables a very slim gearbox design. It should also be noted that the present invention also enables significant power / energy savings, particularly in relation to the control (or feedback control) of the power level of the vacuum pump. In particular, the power level of the vacuum pump is adjusted as low as possible to ensure a preset vacuum level, for example, depending on the actual amount of air leakage into the gearbox. For example, the vacuum pump is a volumetric vacuum pump.

[0033] In one embodiment, the vacuum pump is connected to the internal volume (partial vacuum zone) of the gearbox via a vacuum oil tank, in particular via a suction line (second line) that directly connects the vacuum pump to the oil tank, preferably without intermediate filters or filtration processes (where the oil tank is preferably directly connected to the gearbox via a first suction line, preferably without intermediate filters or filtration processes). This type of connection and link also leads to a slim design and excellent control options.

[0034] According to one embodiment, the plurality of valves comprises at least one automatic valve configured to (directly) couple the oil tank to the gearbox arrangement (in particular to the volume enclosed by the gearbox housing) in an open state and to ensure said siphon function in a closed state, preferably at least two automatic valves in a redundant arrangement, each configured to ensure said siphon function in a closed state, said at least one automatic valve also providing improved controllability and safety.

[0035] It should be mentioned that the concept of the present invention allows for the oil flow to the gearbox device in a highly safe manner. Usually, at least two automatic valves are in a closed state (vacuum operation). Preferably, at least two automatic valves in a redundant arrangement are provided in parallel on two pipes (particularly the sixth and seventh pipes described herein).

[0036] The present invention allows for preventive maintenance and monitoring, and a maintenance procedure can be initiated by, for example, two steps or two conditions: the opening of at least one automatic valve, and the exceeding of a preset level by a value measured by at least one accelerometer connected to the vacuum pump.

[0037] According to one embodiment, the selectable / switchable siphon arrangement is selectable / switchable by at least one automatic valve arranged on at least one atmosphere communication line of the piping connecting the oil tank and the gearbox device (in particular the volume enclosed by the gearbox housing), preferably by at least two automatic valves arranged redundantly on respective redundant atmosphere communication lines, which also facilitates switching from vacuum operation to atmospheric operation.

[0038] According to this disclosure, the functional term "atmosphere vent" emphasizes the fact that this type of piping is provided for redundancy and increased safety, as well as to allow for a change in oil flow path when a partial vacuum is applied.

[0039] It should be noted that the present invention allows for a bypass, for example, in connection with maintenance requirements. In other words, it is not necessary to provide an auxiliary line bypassing the vacuum oil tank. However, in one embodiment, a bypass can be provided as an option, for example, by arranging at least one first automatic valve in the atmospheric vent line and a second automatic valve in the bypass.

[0040] According to one embodiment, the gearbox arrangement presents an internal volume defined by the gearbox inner housing, a shaft seal preventing air from entering the internal volume, and a vacuum pump communicating with said internal volume via a vacuum oil tank according to at least one operating mode, which allows good oil flow both in the gearbox inner volume (partial vacuum) and in the volume enclosed by the gearbox housing (at least approximately atmospheric pressure), especially in relation to the oil flow driven solely by gravity (returning to the main lubrication oil tank).

[0041] According to one embodiment, the gearbox arrangement is configured to self-adjust the power settings of the vacuum pump depending on the actual sensor data of at least one sensor, in particular depending on both the actual pressure data and the air leakage data, so that a pre-set vacuum level is ensured both in the internal volume (partial vacuum cavity) and in the vacuum oil tank. This concept also allows for a slim design to store oil that can be resupplied to the gearbox. Desirably, the control can be based on (at least) the vacuum level data. The control can preferably be performed via the speed controller of the electric motor.

[0042] It should be mentioned that the actual air leakage data can be (optionally) provided by both a specific sensor arrangement and at least one parameter derived from further sensor data. For example, the actual air leakage data correlates with the actual performance (level) of the gearbox device (e.g., rotational speed or power stage). For example, if the gearbox oil outlet temperature exceeds a predetermined value or if the vacuum pump speed is operating below a predetermined value or threshold (relative to a predetermined vacuum level), the vacuum pump speed can be adjusted by the control unit to, in particular, reduce the oil outlet temperature or increase the vacuum level. In that context, feedback control of the vacuum pump power level can be preferably performed based on the actual pressure data and, optionally, on the air leakage data relating to the actual air leakage.

[0043] According to one embodiment, the gearbox arrangement is configured to ensure a pressure (gas density) within the internal volume (partial vacuum cavity) that is reduced by at least 50% compared to the surrounding atmospheric pressure (e.g., at least 500 mbara reduced compared to 1 bara). This level of partial vacuum should be considered as an example only. Those skilled in the art can implement the invention in connection with individual partial vacuum levels, which may also be selected to be significantly lower.

[0044] According to one embodiment, the gearbox device includes at least one shaft seal that prevents air from entering the gearbox internal housing, and the gearbox arrangement is configured to control the power setting (particularly the speed) of the vacuum pump in response to actual sensor data (air leakage data) related to the actual air flow rate entering the gearbox device, particularly through the at least one shaft seal. This allows for accurate and efficient control or at least monitoring of the vacuum system's functioning. In particular, for individual gearbox arrangements, empirical values ​​correlating a specific vacuum level or a specific speed of the vacuum pump with an air leakage parameter allow for accurate control or at least monitoring of the system's functioning, for example in the context of fault diagnosis.

[0045] The vacuum level parameter is preferably a parameter based on instantaneous measured data, and the vacuum pump power setting (particularly speed) is preferably a control parameter.

[0046] According to one embodiment, the gearbox arrangement further comprises a high-pressure oil system configured to actuate at least some of the valves, in particular at least one automatic valve associated with at least one atmosphere communication line of the piping connecting the oil tank to the gearbox arrangement (in particular the volume enclosed by the gearbox housing). The high-pressure oil system comprises a further oil pump (high-pressure oil pump) and preferably a number of check valves configured to prevent the valves from opening. This configuration also provides a high level of system security, in particular including at least two automatic valves arranged in parallel in two (redundant) atmosphere communication lines.

[0047] According to one embodiment, the oil pump is connected and configured to supply oil from a vacuum oil tank to a lubrication system of the gearbox arrangement (power generation and / or compression lines), the gearbox arrangement being configured to automatically adjust the power setting of the oil pump depending in particular on the actual level of oil in the vacuum oil tank, which configuration also in relation to further components of the gearbox arrangement provides further energy efficiency improvements.

[0048] According to one embodiment, the oil pump is independent of the main lubrication oil tank of the gearbox arrangement. This independence also allows for a high degree of process versatility. In particular, in one of several operating modes of the gearbox arrangement, the oil pump operates to supply oil directly from the vacuum oil tank to the gearbox (particularly the volume enclosed by the gearbox housing or casing).

[0049] According to one embodiment, the oil pump is arranged and configured to supply oil to the oil outlet pipe via the gearbox arrangement for gravity-driven oil flow from the gearbox arrangement back to the main lubrication oil tank, which allows for a preferred implementation in many standard piping arrangements where oil resupply to the main lubrication oil tank is (exclusively) gravity-driven.

[0050] According to one embodiment, the piping connecting the oil tank and the gearbox arrangement comprises at least the following piping: a suction piping (first piping) connecting the gearbox internal volume (partial vacuum region) with the oil tank, an oil piping (third piping) connecting the vacuum oil tank with the oil pump and the gearbox arrangement, and at least one atmosphere communication piping (sixth piping and / or seventh piping) directly connecting the oil tank with the gearbox arrangement. This configuration allows for both a slim design and high safety, while also ensuring versatility.

[0051] According to one embodiment, the plurality of valves comprises at least the following automatic valves: at least one automatic valve (preferably at least two automatic valves in a redundant arrangement, each configured to ensure the siphon function in a closed state) arranged in an atmospheric pressure connecting pipe directly connecting the oil tank and the gearbox unit, and at least one automatic valve connecting the top of the oil tank and the top of the gearbox unit to the atmosphere (vent), respectively, so that the automatic valves can easily control the main operating functions related to both vacuum and atmospheric operation.

[0052] According to one embodiment, the plurality of valves also comprises at least one automatic valve (located on an oil supply pipe connecting the gearbox arrangement with a main oil tank supplying oil to the gears) for regulating the amount of oil supplied to cool the gears / tooths of the gearbox, which should preferably be configured to open fully in the event of an energy shortage.

[0053] According to one embodiment, the plurality of valves comprises at least one automatic valve located in each of the atmosphere communication pipes connecting the oil tank to the gearbox arrangement and one automatic valve located in the pipe connecting the oil tank to the atmosphere, thereby providing controllability related to the performance of the cooling medium.

[0054] According to one embodiment, the vacuum pump is equipped with an acceleration sensor, and the vacuum pump is controlled according to sensor data from the acceleration sensor, thereby specifically improving the monitoring and control of the vacuum pump and contributing to improved maintenance efficiency.

[0055] According to one embodiment, the vacuum pump is cooled, in particular via the gearbox unit's oil circulation (oil intake system), in particular via a separate oil suction / supply pipe (a fourth pipe directly connecting the gearbox unit to the vacuum pump) and a separate oil re-supply pipe (a fifth pipe preferably re-supplying directly from the vacuum pump to the gearbox unit or from the oil tank to the gearbox unit or re-supply pipe). It has been shown that such cooling of the vacuum pump increases the pump's lifespan and maintenance intervals by at least five times, and in some cases by more than ten times. This configuration also improves the inter-process coordination and creates synergistic effects.

[0056] According to one embodiment, the exhaust line from the vacuum pump is at least indirectly connected to the gearbox via an atmosphere vent, which may further improve functionality from an overall perspective, in particular also taking into account environmental requirements.

[0057] According to one embodiment, the gearbox arrangement is configured to supply oil from a vacuum oil tank for cooling the axial gear teeth of the gearbox arrangement and / or at least the gearbox arrangement itself and also for lubricating the components of the gearbox arrangement, in particular by means of an additional line to the lubrication system. This variability further improves the synergistic implementation of the invention in relation to other components of the gearbox arrangement and provides a broader concept taking into account multiple aspects and conditions for efficient and sustainable operation (control) of the gearbox system.

[0058] The inventive concept also allows for easy retrofitting by simply changing the air flow, particularly by reconnecting the vacuum pump exhaust to the lubrication system, thus preventing emissions into the environment.

[0059] According to one embodiment, the gearbox arrangement is configured to allow for integrated and stand-alone implementation of vacuum and oil pump components. This versatility allows the invention to be implemented in connection with many different types of arrangements.

[0060] According to one embodiment, at least the vacuum component and optionally also the oil pump component are integrated into the gearbox arrangement, which further improves the slim design, compactness and cost efficiency.

[0061] According to one embodiment, at least the vacuum components are provided in a stand-alone configuration with a bypass that allows maintenance, in particular of the oil pump, regardless of the operating state of the gearbox arrangement. This optional configuration may be implemented in certain constellations that require relatively high maintenance efforts. The present invention provides a concept that allows easy adaptation of an integrated design or a stand-alone configuration.

[0062] According to one embodiment, the sensor unit comprises at least one accelerometer, in particular adapted to measure at least one vibration parameter of a mechanical part of the vacuum pump, which allows for further improved monitoring and control, in particular in the context of predictive maintenance.

[0063] According to one embodiment, the control unit is configured to self-regulate the (re)start process of the gearbox arrangement, particularly in connection with maintenance or shutdown of at least one of the components of the gearbox arrangement. The gearbox arrangement preferably comprises an energy storage unit configured to supply energy to the gearbox arrangement, for example in the event of a power outage. This can significantly improve the responsiveness and self-regulation of the system. Such a restart function also makes it possible to save time on reinitializing system parameters. Preferably, the control unit is configured to perform status monitoring of the components of the gearbox arrangement based on incremental storage of important data, particularly regarding performance and maintenance status. The incremental storage is performed over a period of, for example, one week or one month, after which data is stored by overwriting previous (old) data. This enables a safe and streamlined monitoring process, facilitating the checking of parameter accuracy and facilitating maintenance and servicing.

[0064] According to one embodiment, the gearbox arrangement is configured to control at least two types of oil flow to the gearbox arrangement: oil flow to the teeth of the gearbox arrangement and oil flow to at least one bearing of the gearbox arrangement. This allows for more specific control, in particular by linking the oil flow control method with the control method of at least one vacuum pump. The two types of oil flow control can be independent or interdependent.

[0065] One aspect of the present invention relates to a method or process that can readily achieve the above-mentioned advantages. In particular, the above-mentioned object is also solved by a method for providing and maintaining a partial vacuum in at least one gearbox device of a gearbox arrangement, in particular in a high-efficiency turbo gearbox device, in which a vacuum pump communicates with an internal volume (partial vacuum cavity) of the gearbox device via a vacuum oil tank, and an oil pump connected to the vacuum oil tank connects oil flow to the gearbox device and, optionally, to lubrication piping. A control unit controls at least the vacuum pump and the oil pump, respectively, in response to actual sensor data from at least one sensor related to pressure (vacuum level), temperature, and / or oil level. The vacuum oil tank and at least one automatic valve provide a selectable / switchable siphon arrangement so that a predefined / definable vacuum level is ensured in the internal volume (partial vacuum region) via the vacuum pump and the vacuum oil tank. The predefined / definable vacuum level is controlled by controlling the vacuum pump in response to actual sensor data from the at least one sensor. The sensor data includes at least one of the following types of data: pressure sensor data related to the vacuum level in the internal volume (partial vacuum cavity), air leakage sensor data related to the gearbox arrangement, which also ensures improved operating conditions and control functions. In particular, such a method provides the advantages described above in relation to the gearbox arrangement.

[0066] According to one embodiment, at least one automatic valve is actuated to select / switch the siphon arrangement by (directly) connecting the oil tank to the gearbox arrangement in the open state and ensuring said siphon function in the closed state, which, together with the slim design, provides a preferred control option, especially without the need for an additional bypass.

[0067] According to one embodiment, an operating parameter of the at least one automatic valve is monitored, in particular the opening and closing time required to operate the at least one automatic valve. It has been recognized that under certain circumstances the opening and closing time required for the at least one automatic valve may be considered a critical parameter (e.g., during oil pump shutdown, particularly under bull gear conditions). By monitoring and predicting that parameter, the present invention provides a more robust process and system.

[0068] According to one embodiment, the power settings of the vacuum pump, in particular the rotational speed, are automatically adjusted depending on the actual sensor data of at least one sensor to ensure a pre-set vacuum level both in the internal volume (partial vacuum cavity) and in the oil tank, in particular depending on both the actual pressure data and the air leakage data, which may also improve the energy efficiency and extend the lifespan of the associated components.

[0069] According to one embodiment, the pressure (gas density) in the internal volume (partial vacuum cavity) is reduced by at least 50% compared to the ambient atmospheric pressure (e.g. 500 mbara vs. 1 bara). This vacuum level is given by way of example, and those skilled in the art can adjust the desired (predeterminable) vacuum level depending on the individual gearbox arrangement.

[0070] According to one embodiment, at least one of the following parameters is controlled: oil level in the vacuum oil tank, vacuum level in the internal volume (partial vacuum zone) of the gearbox arrangement and in the upper part of the vacuum oil tank, speed / power setting of the vacuum pump, speed / power setting of the oil pump, valve position of the automatic valve controlling how oil flows from the vacuum oil tank through the gearbox arrangement to the main lubrication oil tank, temperature of the vacuum pump, temperature of the oil pump and vacuum pump electric motor, position of the automatic valve controlling the gearbox cooling. These parameters / data provide a large database for further improvements in terms of efficiency, control and maintenance.

[0071] According to an embodiment, particularly in the context of predictive maintenance, at least one vibration parameter of at least the vacuum pump mechanical parts of the gearbox arrangement is measured by at least one accelerometer, which allows for further improved monitoring and control of system parameters and allows for sustained use of the relevant components based on efficient maintenance operations.

[0072] According to one embodiment, depending on the actual vacuum level, the oil flow rate to at least the teeth of the gearbox arrangement and optionally also to at least one further oil flow rate, in particular to at least one bearing of the gearbox arrangement, is controlled, which allows for further efficiency improvements and more specific operating conditions.

[0073] One aspect of the present invention relates to a computer program and a computer-implemented method that provide the above-mentioned advantages, wherein at least the control of the vacuum pump is performed by the computer-implemented method. In other words, at least some of the above-mentioned advantages can be realized by implementing the control functionality described herein, i.e., by using a computer program that provides at least this control functionality in relation to the operation of the vacuum pump, and by operating a siphon arrangement that includes at least one automatic valve.

[0074] [summary] The present invention relates to a gearbox arrangement comprising at least one (turbo) gearbox arrangement, configured to provide a partial vacuum in the gearbox arrangement, the gearbox arrangement comprising a vacuum pump, a vacuum oil tank, an oil pump connected to the vacuum oil tank, and a plurality of valves. The gearbox arrangement also comprises a sensor unit and a control unit configured to control at least the vacuum pump and the oil pump, respectively, in response to actual sensor data, wherein at least one of the vacuum oil tank and the valve ensures a predetermined vacuum level in a pump chamber volume (partial vacuum region) via the vacuum pump and the vacuum oil tank, thereby providing a switchable siphon arrangement by controlling the vacuum pump in response to the actual sensor data. The present invention further relates to a method for providing and maintaining a partial vacuum by means of such a gearbox arrangement.

[0075] These and other aspects will be apparent from and elucidated with reference to the embodiments described hereinafter. Individual features disclosed in the embodiments may, alone or in combination, constitute aspects of the invention. Features of different embodiments may be carried over from one embodiment to another. [Brief explanation of the drawings]

[0076] [Figure 1] 1A, 1B and 1C show perspective views of a gearbox arrangement according to one embodiment (built-in implementation). [Figure 2] FIG. 2 shows a perspective view of a gearbox arrangement according to one embodiment (embedded implementation). [Figure 3] FIG. 3 shows a perspective view of a gearbox arrangement according to one embodiment (standalone implementation). [Figure 4] 4A and 4B show a perspective view of a prior art gearbox (single implementation). [Figure 5] FIG. 5 shows the steps of the process according to the embodiment. [Figure 6] FIG. 6 shows a schematic diagram of a gearbox arrangement according to an embodiment. [Figure 7] FIG. 7 shows a schematic diagram of a transmission according to the prior art. [Figure 8] Figures 8A, 8B and 8C each show a schematic representation of a further gearbox according to the prior art. [Figure 9] 9A, 9B and 9C each show a schematic diagram of a gearbox arrangement according to an embodiment.

[0077] [Detailed explanation of the figure] First, reference numerals will be described in general terms and specific reference will be made to the respective figures.

[0078] A gearbox 4 is usually located between the driver 2 and the driven machine 6. These components are connected to a main oil tank 1 by a main oil inlet pipe 1b, and a main lubrication oil pump 1a supplies the oil flow. Recirculation to the main oil tank 1 can be achieved via an oil outlet pipe 1c (driven machine), an oil outlet pipe 1d (gearbox), and an oil outlet pipe 1e (driver). The main oil tank 1 is usually equipped with an oil vapor fan extractor 1f and a vapor filter 1g.

[0079] The gearbox 4 is composed of at least one pinion 4a and at least one wheel (gear) 4b, and a shaft 4.1 connecting the driving machine and the gearbox and a shaft 4.2 connecting the gearbox and the driven machine are sealed by seals 4c and 4d.

[0080] The fixed-speed vacuum pump 5 allows partial vacuum to be supplied to the gearbox via the oil tank 7. Here, an isolation (maintenance) valve 7a and at least one thermal expansion joint 7b are arranged in the inlet pipe 7.1, which allows bypassing of this (first) oil tank 7 and further vacuum components. The oil tank 7 is equipped with an air intake 7c (breathing air) with an automatic valve. A bypass line 9e allows oil flow recirculation to the main lubrication oil tank 1 by gravity (particularly, gravity alone) and is equipped with an automatic valve 7d. The main oil pump 8 is arranged downstream of the (first) oil tank 7. This arrangement further includes an intermediate oil tank 9 and at least one thermal expansion joint 9a. An automatic valve 7e arranged between the two tanks 7, 9 allows vacuum to be supplied only to the tank and the gearbox. This arrangement further includes an isolation (maintenance) valve 9b arranged downstream of the intermediate oil tank 9. An air / oil filter 9c is arranged upstream of the vacuum pump 5 and connected to the intermediate oil tank 9. The arrangement further includes a pipe 9d connecting both the intermediate oil tank 9 and the bypass line 9e to the main lubrication system, i.e. the main lubrication oil tank 1. The interaction, i.e. cooperation, of these components can be managed by at least one electrical and instrumentation device 3.

[0081] Based on this, the present invention provides a gearbox arrangement 10, which shows a gearbox device 11 having a gearbox housing 11.1 and an inner gearbox housing 11.1a that houses gears / tooths 11.5. The gearbox housing 11.1 is sealed by a shaft end seal 11.3, and the inner gearbox housing 11.1a is sealed by an additional shaft seal 11.4. The gearbox housing 11.1 encloses a volume C11.1, and the inner gearbox housing 11.1a encloses an inner volume that represents a partial vacuum region under vacuum operating conditions. The siphon arrangement 20 (including the pump, tank, piping, and valves) enables preferred operating modes under atmospheric pressure and partial vacuum conditions, respectively. The siphon arrangement 20 enables preferred switching between these operating modes and also enables preferred maintenance procedures. In particular, the siphon arrangement 20 includes an (auxiliary) vacuum oil tank 12 (separate from the main lubrication oil tank), an oil pump 13 having an oil pump motor 13.1 (particularly a variable speed electric motor) and an oil pump inlet 13.3 and an oil pump outlet 13.5, and a vacuum pump 14 having a vacuum pump motor 14.1 (variable speed electric motor) and a vacuum pump foot 14.3 and an air intake 14.5. The siphon arrangement 20 further comprises at least one of the following piping components 15: a first pipe 15.1 (suction pipe connecting the gearbox internal volume with the oil tank), a second pipe 15.2 (suction pipe connecting the oil tank with the vacuum pump), a third pipe 15.3 (oil pipe connecting the oil tank with the oil pump and gearbox arrangement), a fourth pipe 15.4 (oil suction / supply pipe connecting the gearbox arrangement with the vacuum pump), a fifth pipe 15.5 (oil re-supply pipe connecting the vacuum pump with the gearbox arrangement), a sixth pipe 15.6 (first open-to-air connection between the oil tank and the gearbox arrangement), a seventh pipe 15.7 (second atmospheric communication between the oil tank and the gearbox arrangement), an eighth pipe 15.8 (exhaust pipe from the vacuum pump, e.g. connected to the sixth or seventh pipe), and a ninth pipe 15.9 (connecting the main lubrication oil tank with the gearbox housing).The siphon arrangement 20 preferably includes redundant automatic valves 16, i.e., first and second automatic valves 16a arranged on the first and second atmospheric communication lines, at least one automatic valve 16b arranged and configured to connect the top of the oil tank and the top of the gearbox arrangement to the atmosphere (vent), and at least one automatic valve 16c arranged and configured to regulate the amount of oil supplied to cool the gears / tooths. The control unit 17 provides at least one control function based on data provided by a sensor unit 18 consisting of at least one of the following sensors: a pressure sensor 18a (vacuum sensor), an acceleration sensor 18b (an accelerometer, in particular, for checking vibration parameters in the vacuum pump), an oil level sensor / indicator 18c (in particular, referring to the oil level in the vacuum oil tank), an air leak sensor 18d, a vacuum cooling system level sensor or indicator 18e (in particular for the vacuum pump), an oil level sensor / indicator 18f (in particular, referring to the oil level in the vacuum oil tank), and an oil level indicator 18g, which correlates with an alarm function.

[0082] The lubricating oil facility 19 provided / maintained by the plant operator includes a main lubricating oil tank 1, the connection to the gearbox arrangement 11 can be achieved for example by an oil outlet flange 19d.

[0083] The gearbox arrangement 11 may further comprise a swivel motor 11.7. Advantageously, the siphon arrangement 20 is provided in a frame 21 which can be handled, for example, via a number of suspension points 23 (force application points).

[0084] The gearbox arrangement 10 may further include an oil high-pressure system 30 with an additional oil pump 33 (high-pressure oil pump) and at least one check valve 36 configured to actuate the high-pressure line 31 .

[0085] The intermediate electrical connection device 40 may also provide accommodation for the control unit 17. The gearbox arrangement 10 may further include a switch 50 (coupled to the control unit) for measuring the pressure level at the top of the tank (pressure probe) or for controlling at least one of the operating modes described herein.

[0086] In the following, the features of the invention will be explained in more detail with reference to individual figures or example embodiments. 1A, 1B, 1C and 2 each illustrate a gearbox arrangement 10 that provides a siphon arrangement 20 in an embedded implementation. With reference to Figure 1A, an additional air intake 14.5 is provided for the vacuum pump 14, and the following piping arrangement can be specified in more detail: an oil pipe 15.4 for lubricating and cooling the vacuum pump connected to the outlet pipe of the oil tank; an oil pipe return 15.3 from the main oil pump connected to the tank oil return; a vacuum pipe inlet resp. oil pipe inlet 15.1 (from the gearbox) of the oil tank; Oil pipe outlets 15.6, 15.7 from the oil tank (from the main tank to the gearbox arrangement); and first and second atmospheric communication between the oil tank and the gearbox arrangement. Figure 1A further shows an oil level sensor / indicator 18f (referring in particular to the oil level in the gearbox) and an oil level indicator 18g which correlates with the alarm function. According to Fig. 1B, a vacuum cooling system level indicator 18e is provided for the vacuum pump. A vacuum pump foot 14.3 ensures the positioning of the pump. Figure 1C further shows the oil pump inlet 13.3 and the oil pump outlet 13.5. An intermediate electrical connection device 40 is arranged laterally in the tank 12. According to Figure 1C, a switch 50 (pressure probe) makes it possible to measure the pressure level at the top of the tank. As shown in Figure 2, the electric motor 11.7 of the swivel of the gearbox arrangement 11 can rotate the gear. The oil outlet flange 19d can connect the gearbox arrangement to a specific lubrication facility (especially provided by the plant operator).

[0087] Figure 3 shows a stand-alone configuration in which the siphon arrangement is provided separately from the gearbox arrangement 11. To increase efficiency, the siphon arrangement 20 can be provided on a separate frame 21. A suspension point (force point) 23 allows the siphon arrangement 20 to be handled separately.

[0088] In the arrangement shown in Figures 4A and 4B (prior art), the vacuum pump components are separate from the gearbox unit, and bypass line 9e allows bypass of the vacuum pump arrangement. The inlet pipe 7.1 of the main oil vacuum tank 7 allows connection to the gearbox. The arrangement shown in Figure 4 allows bypass of the entire unit, which is provided for efficiency, but especially for different operating modes. However, this design has several drawbacks (especially evident in daily practice). These include the need for a temperature compensator to accommodate thermal expansion of the pipes, a frame to support the oil tank and other components, manual valves to isolate the unit, an intermediate outlet tank upstream of the customer's main oil tank, and an oil / air separator upstream of the vacuum pump. This design also requires numerous automatic valves. Furthermore, special piping is required to drain oil condensate before feeding the vacuum pump, and the vacuum pump must be cooled with very specialized equipment. Thermal insulation of the oil tank is also required to ensure the safety of technicians working on the tank while it is in operation. Furthermore, air cooling is required to cool the main electrical equipment.

[0089] FIG. 5 illustrates steps in a process according to an embodiment of the present invention. Step S1: Supplying a partial vacuum (for example 500 mbara) to the internal volume of the gearbox device, in particular via a vacuum pump communicating via an intermediate vacuum oil tank. Step S1 may include step S1.1. Step S1.1 Cooling and / or lubricating the vacuum pump via the gearbox oil inlet system. Step S2: Controlling at least the vacuum pump and the oil pump according to the actual sensor data. Step S2 may include steps S2.1 and S2.2. Step S2.1 Supplying oil to the gearbox unit and optionally to the lubrication lines. Step S2.2: Controlling oil supply from main oil tank for gear cooling / lubrication. Step S3: Selecting / switching the vacuum oil tank in siphon configuration. Step S4 Automatically adjustable output settings for vacuum pump and / or oil pump. Step S5 Control at least one of the following parameters: oil level, vacuum level, pump power setting, valve position, temperature of the pump or associated motor. Step S6: Activate at least one valve (vent) on the gearbox and / or oil tank to return to atmospheric pressure / conditions.

[0090] 6 shows a schematic diagram of a gearbox arrangement 10 illustrating a gearbox arrangement 11 comprising a gearbox housing 11.1 and an inner housing 11.1a that separates the toothing (gear / toothing 11.5) from the bearing and provides a partial vacuum area C11 (which is different from the total area C11.1 enclosed by the housing 11.1). Shaft end seals 11.3 are configured to seal the gearbox housing 11.1, and shaft seal 11.4 is configured specifically to isolate the inner gearbox housing 11.1a from atmospheric pressure, thereby controlling / preventing the inflow of air into the inner housing 11.1a.

[0091] The main oil tank (lubricating oil) 1 is connected to the gearbox via a valve 16c to control the oil inflow. The auxiliary (vacuum oil tank) 12, oil pump 13, vacuum pump 14, and piping 15 provide a siphoning arrangement, which is connected to the oil pump motor 13. In particular, the first pipe 15.1 is configured as a suction pipe connecting the gearbox internal volume with the oil tank, the second pipe 15.2 is configured as a suction pipe connecting the oil tank with the vacuum pump, the third pipe 15.3 is for connecting / coupling the oil tank with the oil pump and gearbox device, the fourth pipe 15.4 is configured as an oil suction / supply pipe connecting the gearbox device with the vacuum pump, and the fifth pipe 15.5 is configured as an oil re-supply pipe connecting the vacuum pump with the gearbox device (or at least the sixth or seventh pipe). The sixth pipe 15.6 is configured as a first atmosphere vent between the oil tank 12 and the gearbox arrangement 11, the seventh pipe 15.7 is configured as a (redundant) second atmosphere vent between the oil tank 12 and the gearbox arrangement 11, and the eighth pipe 15.8 is configured as an exhaust pipe from a vacuum pump and is connected, for example, to the sixth or seventh pipe. Each oil pipe (especially pipes 15.1, 15.2) is configured so that it is not completely filled with oil, thereby allowing a vacuum to pass / expand in the upper region of the respective pipe.

[0092] In particular, the arrangement shown in Figure 6 is preferable in relation to maintenance requirements, such as maintenance of the vacuum oil tank and pumps, even while the gearbox is in operation. Any of the previous components (which allow maintenance work to be carried out while the gearbox is in operation) can be eliminated or abandoned.

[0093] FIG. 7 shows a first configuration according to the prior art, which includes in particular the following components: a main lubrication oil tank 1, a main lubrication oil pump 1a, a main oil inlet pipe(s) 1b, an oil outlet pipe 1c of the driven machine 6, an oil outlet pipe 1d of the gearbox, an oil outlet pipe 1e of the driving machine 2, an oil vapor fan extractor 1f, a vapor filter 1g, a shaft 4.1 connecting the driving machine and the gearbox, a gearbox 4, a pinion 4a and a wheel 4b (gear), at least one seal 4c on the high speed shaft section, at least one seal 4d on the low speed shaft section, and a shaft 4.2 connecting the gearbox and the driven machine.

[0094] It should be noted that the pipes 1c, 1d, 1e are designed to supply oil to the main lubricating oil tank 1 based on gravity (without additional technical driving forces, without technical flow driving parameters), which may also be a requirement or at least a requirement on the part of the plant operator in the context related to the present invention.

[0095] Figures 8A, 8B, and 8C show a second prior art arrangement. In this arrangement, two oil tanks 7 and 9 are connected between the gearbox 4 and the main lubrication oil tank 1. That is, the oil tank 7 is located downstream of the gearbox, and the intermediate oil tank 9 is located downstream of the oil tank 7. A vacuum pump 5 and a main oil pump 8 are located between these tanks 7 and 9. The vacuum pump 5 is driven at a constant speed. An air / oil filter 9c containing an oil condenser tube is located upstream of the vacuum pump 9.

[0096] The piping between the oil tank 7 and the intermediate oil tank 9 is equipped with a main oil pump 8 and an automatic valve 7e, which allows vacuum pressure to be supplied only to the oil tank and the gearbox. The piping between the gearbox and the main lubricating oil tank 1 is equipped with thermal expansion joints 7b and 9a, which are connected via isolation (maintenance) valves 7a and 9b. The oil tank 7 has an air intake with an automatic valve 7c, which supplies breathing air (including a filter to prevent dust that may contaminate the oil).

[0097] The arrangement depicted in Figure 8 includes a bypass (bypass line 9e; Figures 4B, 8C) that allows bypassing the oil tank arrangement 7, 9, including the automatic valve 7d. This bypass line leads to a pipe 9d that redirects to the main lubrication system (lubrication oil tank 1). The electrical and instrumentation device 3 is configured to control the function and interaction of the components shown in Figure 8 insofar as control is required.

[0098] It should be noted that, especially in relation to oil flow under "normal" or maintenance conditions, the oil level does not (should not) exceed half the diameter of the pipe, so that a vacuum can flow or spread on the upper side of the pipe or tank (see also the relative positions of the in and out flanges of tanks 7 and 9 in Figure 8).

[0099] Figure 8A shows the normal oil flow condition, i.e., standard operating mode (dashed line), where oil is recirculated via gearbox 4, oil tank 7, oil pump 8, intermediate oil tank 9, and back to main tank 1.

[0100] Figure 8B shows the vacuum operating mode (dotted line indicates the cross section through which the partial vacuum is provided), where the partial vacuum is generated by the vacuum pump 5 and extends into the gearbox volume enclosed by the gearbox housing 11.1.

[0101] 8C shows the oil flow conditions in relation to the maintenance procedure (dotted lines). The oil flow passes through the bypass line 9e, avoiding or bypassing the complete arrangement or piping provided by the oil tank 7, the intermediate oil tank 9 and the vacuum pump 5.

[0102] Referring to Figure 8, it should be noted that a partial vacuum is provided from the shaft end seal 11.3 via the oil tank 7 to the point of the vacuum pump 5 (shown only in dotted lines in Figure 8B). Oil flow in the maintenance state is bypassed via line 9e. Oil flow in the normal state is shown in dashed lines, while oil flow in the maintenance state is shown in chain lines.

[0103] 9A, 9B and 9C illustrate a gearbox arrangement 10 according to a further embodiment, with reference to the main components of the siphon arrangement 20.

[0104] In particular, the vacuum oil tank 12 is connected to the inner gearbox housing 11.1a, which separates the bearing section (and its respective oil flow) from the toothing section (and its respective tooth oil flow). This allows for isolating the bearing from the vacuum, regrouping the bearing oil flow, and even using the oil flow from the main oil pump before resupplying it to the main lubrication oil tank 1. It should be noted that this inner housing 11.1a provides a housing specifically surrounding the pinion and wheel (respectively, the gear / tooth section), i.e., a kind of double housing, in addition to the standard housing 11. The vacuum oil tank volume 12 provides a siphon arrangement 20 that can be dedicated (according to one advantageous implementation) to handle only the tooth oil flow. An air intake with an automatic valve 7c is connected to the vacuum oil tank 12. Both the main oil pump 13 and the vacuum pump 14 are speed-controlled (each with a controllable power level). A redundant automatic valve 16a ensures vacuum only in the vacuum oil tank 12 and the gearbox 11 (specifically, only in the toothing section, separate from the bearing section). Furthermore, automatic valve 16c controls the oil inlet of the gearbox, particularly depending on whether the gearbox is operating under vacuum and / or the expected performance level. A control unit 17 including instrumentation is configured to control at least the vacuum pump depending on actual sensor data of at least one sensor, the sensor data including at least one of the following types of data: pressure sensor data related to the vacuum level in the internal volume, air leak sensor data related to the gearbox device. These sensors may be provided in each component, for example in the gearbox, or may be provided in conjunction with control unit 17. Control unit 17 is further configured to predict maintenance requirements and record main vacuum process parameters, particularly on an incremental basis.

[0105] It should also be mentioned that the redundancy of the valve 16a and the respective piping ensures high system security either in atmospheric or partial vacuum conditions. According to the embodiment described with reference to Figure 9, the valve 16a is arranged between the vacuum oil tank 12 and the partial vacuum zone defined by the inner housing 11.1a of the gearbox arrangement 11. This arrangement is particularly preferred from a cost-effective point of view.

[0106] Figure 9A shows the normal oil flow condition, i.e., standard operating mode (dashed line). Oil flow passes through the gearbox inner housing 11.1a, pipe 15.1, vacuum oil tank 12, one of the redundant automatic valves 16a, pipes 15.6 and 15.7 (redundant atmospheric connection between oil tank 12 and gearbox unit 11), vacuum oil tank 12, one of the redundant automatic valves 16a, and pipes 15.6 and 15.7 (redundant atmospheric connection between oil tank 12 and gearbox unit 11), outlet pipe 1d, and recirculation to the main tank 1 by gravity. Additionally, oil flow also flows from the main lubrication oil tank 1 via line 15.9 to the gearbox housing 11.1 (passing nearby, rather than through, internal volume 11.1a) and outlet pipe 1d, thereby recirculating to the main lubrication oil tank 1 (by gravity). Therefore, oil flow under atmospheric pressure conditions can involve two possible paths:

[0107] Referring to Figure 9B, it should be noted that a partial vacuum is provided on a section starting from shaft end seal 11.3 and shaft seal 11.4, through inner gearbox housing 11.1a and line 15.1, vacuum oil tank 12, to the point / location of vacuum pump 14 (the dotted section indicates the section where partial vacuum is provided).

[0108] Figure 9C shows the oil flow situation (dashed lines) when a partial vacuum is applied to the arrangement, with the oil flow going from the main lubricating oil tank 1 through the gearbox inner housing 11.1a and pipe 15.1 and the vacuum oil tank 12 to the oil pump 13 and then recirculated (recirculated) to the gearbox 11. Furthermore, the oil flow also goes from the main lubricating oil tank 1 through line 15.9 to the gearbox housing 11.1 (passing close to it, but not through the inner volume 11.1a) and outlet pipe 1d, where it is recirculated (by gravity) to the main lubricating oil tank 1. Thus, even in this operating mode, the oil flow can involve two possible paths:

[0109] It should be noted that in the arrangement described here, it is also possible for the oil pump to use the gearbox casing / housing as an intermediate oil tank, recirculating the oil before returning it by gravity to the (customer's) main lubrication oil tank.

[0110] Referring to FIG. 9, the oil flow under standard / normal conditions (respectively standard operating mode) is shown by the respective dashed lines, the section to which partial vacuum is applied is shown by the dotted lines (separately in FIG. 9B only), and the oil flow in partial vacuum mode is shown by the respective chain lines.

[0111] 7, 8 and 9, the symbol "<" indicates a gravity-driven oil outlet. An oil outlet or oil recirculation to the main lubricating oil tank 1 by gravity can be a customer requirement (a requirement of the plant operator) and can be realized in a preferred manner, particularly in connection with the present invention.

Claims

1. A gearbox arrangement (10) comprising at least one turbo gearbox device (11), The gearbox arrangement (10) is configured to provide a partial vacuum within the gearbox device (11), the gearbox arrangement (10) comprising: a vacuum pump (14) in communication with an internal volume (C11) of the gearbox device (11); a vacuum oil tank (12); an oil pump (13) coupled to the vacuum oil tank (12); a plurality of valves (16); and piping connecting the vacuum oil tank (12), the gearbox device (11), and the vacuum pump (14); at least one of the vacuum oil tank (12) and the valve provides a selectable / switchable siphon arrangement (20) so that a pre-determinable vacuum level is ensured in the internal volume (C11) via the vacuum oil tank (12) by the vacuum pump (14); the gearbox arrangement (10) further comprises a sensor unit (18) comprising at least one sensor (18a, 18b, 18c, 18d, 18e, 18f, 18g), the gearbox arrangement (10) further comprises a control unit (17) configured to control at least the vacuum pump (14) and the oil pump (13), respectively, depending on actual sensor data of the at least one sensor, the pre-settable vacuum level being controlled / controllable by controlling the vacuum pump (14) depending on actual sensor data of the at least one sensor, the sensor data comprising at least one of the following types of data: pressure sensor data related to the vacuum level in the internal volume (C11), air leakage sensor data related to the gearbox arrangement (11), A gearbox arrangement (10) characterized in that:

2. The vacuum pump (14) is in communication with the internal volume (C11) of the gearbox device (11) via the vacuum oil tank (12); and / or said plurality of valves comprises at least one automatic valve (16; 16a, 16b) configured to connect said vacuum oil tank to said gearbox device (11) in an open state and to act as a siphon for said vacuum oil tank in a closed state; and / or the selectable / switchable siphon arrangement (20) is selectable / switchable by at least one automatic valve (16) arranged in at least one atmospheric connection pipe of the piping connecting the vacuum oil tank and the gearbox device (11); and / or the gearbox arrangement (10) comprises an internal volume (C11) defined by an internal gearbox housing (11.1a), a shaft seal preventing air from entering the internal volume (C11), and the vacuum pump (14) is in communication with the internal volume (C11) via the vacuum oil tank (12) depending on at least one operating mode; Gearbox arrangement (10) according to claim 1 .

3. the gearbox arrangement (10) is configured to self-adjust the power setting of the vacuum pump (14) depending on actual sensor data of the at least one sensor, so that the predetermined vacuum level is ensured both in the internal volume (C11) and in the vacuum oil tank (12); and / or the gearbox arrangement (10) is configured to ensure a pressure in the internal volume (C11) that is reduced by at least 50% compared to the ambient atmospheric pressure, and / or the gearbox device (11) has an internal gearbox housing or at least one shaft seal for preventing air from entering the internal gearbox housing, and the gearbox device (10) is configured to control the power setting of the vacuum pump (14) in response to actual sensor data related to the actual air flow rate entering the gearbox device (11). A gearbox arrangement (10) according to claim 1, characterized in that

4. The gearbox arrangement (10) further comprises an oil high-pressure system configured to actuate at least some of the valves; The oil high pressure system further includes an oil pump (33). A gearbox arrangement (10) according to claim 1, characterized in that

5. the oil pump (13) is connected to a lubrication system of the gearbox arrangement and is configured to supply oil from the vacuum oil tank (12); the gearbox arrangement (10) is configured to automatically adjust the power setting of the oil pump (13) in response to actual oil sensor data; and / or the oil pump (13) is separate from the main lubrication oil tank of the gearbox arrangement (11); and / or the oil pump (13) is constructed and arranged to supply oil via the gearbox arrangement (11) to an oil outlet pipe for gravity driven oil flow from the gearbox arrangement (11) back to the main lubrication oil tank. A gearbox arrangement (10) according to claim 1, characterized in that

6. The piping connecting the vacuum oil tank and the gearbox device (11) includes at least the following piping: an intake pipe connecting the internal volume (C11) and the vacuum oil tank; an oil pipe connecting the vacuum oil tank (12), the oil pump (13), and the gearbox device (11); and at least one atmosphere communication pipe directly connecting the vacuum oil tank and the gearbox device (11), and / or said plurality of valves comprises at least the following automated valves: At least one automatic valve is arranged on an atmosphere communication pipe that directly connects the vacuum oil tank and the gearbox device (11), and at least one automatic valve that connects an upper portion of the vacuum oil tank and an upper portion of the gearbox device (11) to the atmosphere, and / or the plurality of valves also includes at least one automatic valve for regulating the amount of oil supplied to cool the gears / tooths of the gearbox arrangement; and / or the plurality of valves includes at least one automatic valve arranged in an atmosphere communication pipe connecting the vacuum oil tank and the gearbox device (11), and one automatic valve arranged in a pipe connecting the vacuum oil tank to the atmosphere; A gearbox arrangement (10) according to claim 1.

7. the vacuum pump (14) is cooled and / or lubricated via oil circulation in the gearbox arrangement; and / or an exhaust pipe from the vacuum pump (14) is at least indirectly connected to the gearbox device via an atmosphere communication pipe. A gearbox arrangement (10) according to claim 1.

8. the gearbox arrangement (10) is also configured to provide oil from the vacuum oil tank (12) and to cool the gears / tooths of the gearbox device (11) and / or to lubricate at least the gearbox device (11) and / or further to lubricate components of the gearbox arrangement, and / or the gearbox arrangement (10) is configured for both integrated and stand-alone implementation of vacuum and oil pump components. A gearbox arrangement (10) according to claim 1.

9. At least the vacuum components, and optionally also the oil pump components, It is incorporated into the gearbox device (11), Or at least the vacuum component provides a bypass to allow maintenance regardless of the operating state of the gearbox arrangement (11). It is provided in a standalone configuration, and / or the sensor unit includes at least one accelerometer and is configured to measure at least one vibration parameter; and / or the control unit is configured to self-regulate the (re)starting process of the gearbox arrangement (10), A gearbox arrangement (10) according to claim 1.

10. The gearbox arrangement (10) is configured to control at least two types of oil flows into the gearbox device (11): oil flow to the teeth and oil flow to at least one bearing of the gearbox device (11). A gearbox arrangement (10) according to claim 1.

11. 1. A method of providing and maintaining a partial vacuum in at least one turbo gearbox device (11) in a gearbox arrangement, comprising: A vacuum pump (14) communicates with the internal volume (C11) of the gearbox device (11) via a vacuum oil tank (12); an oil pump (13) connected to the vacuum oil tank (12) provides oil flow connection to the gearbox arrangement (11) and, optionally, also to lubrication lines; the vacuum oil tank (12) and at least one automatic valve (16) provide a selectable / switchable siphon arrangement (20) so that a pre-determinable vacuum level is ensured in the internal volume (C11) by the vacuum pump (14) and via the vacuum oil tank (12); a control unit controlling at least the vacuum pump (14) and the oil pump (13) respectively in response to actual sensor data of a sensor unit having at least one sensor related to pressure, temperature or oil quantity, and a pre-determinable vacuum level is controlled by controlling the vacuum pump (14) in response to actual sensor data of at least one of the sensors; The sensor data comprises at least one of the following types of data: pressure sensor data relating to the vacuum level in the internal volume (C11) or related to said vacuum level, air leakage sensor data relating to the gearbox arrangement (11); method.

12. at least one automatic valve (16) is actuated to connect the vacuum oil tank back to the gearbox arrangement (11) in an open state and to cause the vacuum oil tank to act as a siphon in a closed state, thereby selecting / switching the siphon arrangement (20); and / or the operating parameters of said at least one automated valve (16) are monitored; and / or the power setting of the vacuum pump (14) is automatically adjusted depending on the actual sensor data of the at least one sensor, so that the pre-determinable vacuum level is ensured both in the internal volume (C11) and in the vacuum oil tank (12), and / or the pressure in the internal volume (C11) is reduced by at least 50% compared to the ambient atmospheric pressure, The method of claim 11.

13. At least one of the following parameters is controlled: the oil level in the vacuum oil tank (12), the vacuum level in the internal volume (C11) of the gearbox unit (11) and in the upper part of the vacuum oil tank (12), the speed / power setting of the vacuum pump (14), the speed / power setting of the oil pump (13), the valve position of the automatic valve (16) that controls the oil flow connection from the vacuum oil tank (12) through the gearbox unit (11) to the main lubrication oil tank, the temperature of the vacuum pump (14), the temperature of the electric motors of the oil pump (13) and the vacuum pump (14), and the position of the automatic valve (16) that controls the oil flow for cooling the gears / tooths. The method of claim 11.

14. The method of claim 11, wherein at least one vibration parameter is measured by at least one accelerometer.

15. at least the oil flow to the teeth of the gearbox device (11) is controlled in response to the actual vacuum level, and optionally at least one further oil flow is also controlled; and / or said control of at least said vacuum pump (14) is performed by a computer-implemented method. The method of claim 11.

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