First results of Hansen’s 13MW test facility for wind turbine gearboxes Joris Peeters
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Transcript of First results of Hansen’s 13MW test facility for wind turbine gearboxes Joris Peeters
First results of Hansen’s 13MW test facility for wind turbine gearboxes
Joris Peeters
BUWE Technology Development
co-authors: Dirk Leimann, Rob Huijskens, Filip De Coninck
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¬ The Challenge
¬ Functionality of the test facility
¬ Development process and first results
¬ Planned R&D activities
¬ Time schedule
Presentation Overview
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48 64 69 82 94
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5,956 MW339
4,208 MW267
3,795 MW
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3,480 MW162
2,427 MW
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FY 2005 FY 2006 FY 2007 FY 2008 FY 2009
(€m)
Industrial Gearboxes Wind Turbine Gearboxes
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Demand for proven technology in booming wind turbine business
CAGR: +18% CAGR: +33%
The Challenge – cope with dynamics
Turnover Hansen
In 2004, Hansen has anticipated on this demand by taking up the Challenge and committing a
large investment to:
build a highly dynamic test facility for
the new generation of wind turbines
in order to prove and improve future concepts of Hansen gearboxes for wind turbines
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¬ Continuously increasing wind turbine power in the market test facility should anticipate on increasing gearbox size
¬ Wind turbine is a highly dynamic application gearboxes should be tested in controlled environment under
realistic dynamic conditions => how do we cope with dynamics?
¬ Test facility is a combination of a mechanical design and a complex electrical controller system no straightforward solution standard available
This Challenge has been translated into: description of functionality development process in various phases
The Challenge – cope with dynamics
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Vision behind the test rig
It is possible to
transform wind
turbine behaviour
into
test rig conditions
The Challenge – cope with dynamics
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Vision behind the test rig
wind rotor drive train generatorelectricity
grid
tow
er
sea waves
Controlsystem
Functionality of the test facility
Motor 1 Gearbox 1 Motor 2Gearbox 2(*) (*)
Control systemspeed torqueback-to-back gearbox test rig
“Test the gearbox under realistic wind turbine conditions”
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Mechanical design
speed reducer
1:1 or 1:3
• 1000 tons of steel• 1000 tons of
concrete• 10m€+ investment
Functionality of the test facility
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Picture
Functionality of the test facility
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Specifications
Nominal power of 13.2 MW at nominal speed of 1500 rpm
Peak power of 16.8 MW at nominal speed of 1500 rpm
Functionality of the test facility
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Identification of dynamic loads from wind turbines and translation into test rig load cases
1. Start cases (3)
2. Run cases (4)
3. Stop cases (3)
4. Specials (1)
Functionality of the test facility
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Dynamic load cases – example
S_1 Start case 1: normal start
Torque control Speed control
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each load case is parametric
Functionality of the test facility
Nm RPM
Time Time
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R_4 Run case 4: peak load
Torque control Speed control
Functionality of the test facility
Nm RPM
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constant speed with variable controller setting
Dynamic load cases – example
Time Time
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P_1 Stop case 1: normal stop
Torque control Speed control
Functionality of the test facility
Nm RPM
Dynamic load cases – example
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Development process
Prove functionality of dynamic testing
on scale model and apply consequently
on 13MW facility
● phase A:scale model – motor & generator directly coupled
● phase B:13MW – motor & generator directly coupled
● phase C:scale model – motor & generator with gear units
13MW – static testing with gear units
● phase D:13MW – motor & generator with gear units
Development process and first results
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Phase D on 13.2 MW test rig
Verify control functionality and robustness & fail-safe operation
planned for end of 2009
Development process
Development process and first results
Phase B
Verify control functionality & accuracy
+ validation of electrical components
Phase C – dynamic testing
Demonstrate control functionality and
robustness & fail-safe operation
on scaled set-up
Phase A
Demonstrate control functionality
& accuracy on scaled set-up
Phase C – static testingTaking into operation for standard tests
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First results from phase Cdynamic testing with gearboxes on scale model
Development process and first results
¬ Challenge is to cope with:● backlash during torque reversals
● gearboxes with different stiffness values
● various gearbox ratios
● gearboxes with different direction of rotation
● …
¬ Development process● fully analysed using dedicated
simulation software
● comparison of simulations and
experiments is used to optimise
performance
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First results from phase C – example Start-Run-Stop
Development process and first results
Rotational speed
Torque
Time [s]
Time [s]
ist: actual measured value
soll: reference value for controller
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Development process and first results
Rotational speed
Torque
Time [s]
Time [s]
First results from phase C – dynamics during Run-case
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13.2MW test rig is an R&D facility for testing gearboxes under defined dynamic conditions
1. Experimental validation of dynamic load simulation models from actual prototype gearboxes for future use in wind turbine models
● multibody simulations with software SIMPACK
● via extensive measurement campaigns on highly instrumented gearboxes
2. Extend limits of standard prototype validation tests by functional testing during dynamic load conditions
¬ cooperation with Catholic University Leuven, Dept. Mechanical Engineering
¬ supported by the Flemish Government via the Institute for the Promotion of Innovation by Science and Technology in Flanders (IWT Vlaanderen)
Planned R&D activities
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¬ 2nd half 2008:● completion of phase A and B for dynamic testing
● completion of phase C static testing on 13MW test rig-succesfull taking into operation for standard tests
-succesfull overload and robustness tests on prototypes
¬ 1st half 2009:● completion of phase C dynamic testing on scale model
¬ 2nd half 2009:● phase D: final acceptance tests of dynamic load cases
¬ 2010:● fully booked for R&D activities
Time schedule
13.2MW test rig
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Q&A
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IMPORTANT NOTICE
¬ The information, statements and opinions contained in this presentation do not constitute or form part of, and should not be construed as, an offer, solicitation or invitation to subscribe for, underwrite or otherwise acquire, any securities of Hansen Transmissions International NV (the “Hansen” or “the Company”) or any member of its group nor should it or any part of it form the basis of, or be relied on in connection with, any contract to purchase or subscribe for any securities of the Company or any member of its group, nor shall it or any part of it form the basis of or be relied on in connection with any contract or commitment whatsoever.
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