Load Assumptions for the Design of electro mechanic Pitch Systems Andreas Manjock Germanischer Lloyd...
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Transcript of Load Assumptions for the Design of electro mechanic Pitch Systems Andreas Manjock Germanischer Lloyd...
Load Assumptions for the Design of electro mechanic Pitch Systems
Andreas ManjockGermanischer Lloyd Industrial Services GmbH, Business Segment Wind Energy
[email protected], www.gl-group.com/glwind
EWEC 2007 No. 2
Load Assumptions for the Design of electro mechanic Pitch Systems
1. Design of electro mechanic Pitch System
2. Simulation Model
3. Design Load Cases (DLCs)
4. Data Postprocessing
5. Conclusion and Outlook
Source: ENERCON
EWEC 2007 No. 3
Blade Bearing
1.1 Pitch System Components
Control Unit
Rotor Blade
Symbol Definition
JPD Moment of Inertia, Pitch Motor
JRB Moment of Inertia, Rotor Blade
iPD Ratio of Pitch Drive Gearbox
iPB Ratio of Pitch Bearing Mesh
iP Ratio of entire Pitch System
PitchController
Drive MotorGear Box
iP
JPD
JRB
iPB
iPD
EWEC 2007 No. 4
Source: ENERCON
1. Design of electro mechanic Pitch System
2. Simulation Model2.1 Load Components2.2 System Model2.3 Local Model for Mesh Moment2.4 Drive Motor Characteristics2.5 Drive Motor Limitations2.6 Drive Control Scheme
3. Design Load Cases (DLCs)
4. Data Postprocessing
5. Conclusion and Outlook
Load Assumptions for the Design of electro mechanic Pitch Systems
EWEC 2007 No. 5
2.1 Load Components
Symbol Definition
αP Pitch Angle
MPDA Pitch Drive Actuator Torque
MZB Pitch Torque Rotor Blade
MR Friction Torque Blade Bearing
αP
Blade Root Coordinate System
MZB
MPDA
MR
Source: GL „Guideline for the Certification of Wind Turbines“, 2003
MR = M0 + µbend∙ Mres+ µaxial∙ Faxial+ µradial∙ Fradial
EWEC 2007 No. 6
2.2 System Model
Structural Model Global Simulation Model
Source: GH Bladed 3.67
iP2•JPD+JRB
α P
iP•M PDA
M R
M ZB
JPD•i P2•α P** JRB•α P**
EWEC 2007 No. 7
2.3 Local Model for Mesh Moment
Local MM - Assumption“
Mass System Pitch Drive
iP2•JPD
α P
iP•M PDA M M
JPD•i P2•α P**
Mass System Rotor Blade
+JRB
•M M
M R
M ZB
JRB •α P**
Split of Mass System provides Loads for Drive Train Components
α P
MM = MZB+ JRB ∙ αP** - MR
EWEC 2007 No. 8
2.4 Drive Motor Characteristics
MPDAiP P
PitchController
Control Unit
Drive Motor
Source: OAT Osterholz Antriebstechnik GmbH
EWEC 2007 No. 9
Source: OAT Osterholz Antriebstechnik GmbH
2.5 Drive Motor Limitations
EWEC 2007 No. 10
2.6 Drive Motor Control Scheme
PitchController
EWEC 2007 No. 11
1. Design of electro mechanic Pitch System
2. Simulation Model
3. Design Load Cases (DLCs)3.1 Identified Load Cases 3.2 Fatigue DLCs3.3 Extreme DLCs
4. Data Postprocessing
5. Conclusion and Outlook
Load Assumptions for the Design of electro mechanic Pitch Systems
Source: ENERCON
EWEC 2007 No. 12
3.2 Identified Load Cases
DLC1.2 Turbulence State
1 2 m/s 57.0% idling
2 5 m/s 30.0% power production
3 7 m/s 24.9% power production
4 9 m/s 22.0% power production
5 11 m/s 20.2% power production
6 13 m/s 18.9% power production
7 15 m/s 18.0% power production
8 17 m/s 17.3% power production
9 19 m/s 16.7% power production
10 21 m/s 16.3% power production
11 23 m/s 15.9% power production
12 25 m/s 15.6% power production
13 28 m/s 15.2% idling
Load Case Wind Gust Type Event
DLC1.5 12 m/s EOG1 Grid Loss
DLC1.6 25 m/s EOG50 Active Safety Syst.
DLC2.2 25 m/s constant Pitch Runaway
Fatigue Load Cases Extreme Load Cases
Wind
EWEC 2007 No. 13
3.3 Fatigue DLCsControl Variables Load Variables
EWEC 2007 No. 14
3.4 Extreme DLCsControl Variables Load Variables
EWEC 2007 No. 15
1. Design of electro mechanic Pitch System
2. Simulation Model
3. Design Load Cases (DLCs)
4. Data Postprocessing4.1 Design Driver4.2 Loads for Drive Motor4.3 Loads for Gearbox4.4 Loads for Blade Bearing Mesh
5. Conclusion and Outlook
Load Assumptions for the Design of electro mechanic Pitch Systems
Source: ENERCON
EWEC 2007 No. 16
4.1 Design Driver
Pitch System Component Type of Load
Drive Motor MPDA - Pitch Actuator Torque
αP* - Speed of Pitch Actuator
RMS(MPDA ) - Thermal Loading
Gearbox LDD of MM - Mesh Torque
(Load Duration Distribution)
Mesh of BladeBearing
LDD of MM - Mesh Torque
Distribution of MM vs. αP
(Pitch Angle Duration Distribution)
EWEC 2007 No. 17
4.2.1 Loads for Drive Motor• Operation States of Drive Motor, Confirmation of global Wind Turbine Simulation
EWEC 2007 No. 18
4.2.2 Thermal Loads for Drive Motor
Thermische Belastung des Pitchantrieb
MP
DA
rms [
Nm
]
normales Lagerreibmoment erhöhtes Lagerreibmoment
Normal bearing friction Increased bearing friction (+50%)
• Standard Deviation (RMS) of pitch actuator torque for thermal impact
• Efficiency of gear box and has to be considered
EWEC 2007 No. 19
4.3 Loads for Gearbox
Load Duration Distribution of Mesh Torque M_M, Variation of Blade Bearing Friction Level
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Load Level Mesh Torque M_M
Dur
atio
n
No Friction
Low Friction
Medium Friction
High Friction
M_M > 0 M_M < 0
• Load Duration Distribution counting for Mesh Torque M_M
• Influence of Blade Bearing Friction Level comparatively low
EWEC 2007 No. 20
4.4 Loads for Blade Bearing Mesh• Load Duration Distribution counting for Mesh Torque M_M
• Pitch Angle Duration Distribution counting
EWEC 2007 No. 21
1. Design of electro mechanic Pitch System
2. Simulation Model
3. Design Load Cases (DLCs)
4. Data Postprocessing
5. Conclusion and Outlook
Load Assumptions for the Design of electro mechanic Pitch Systems
Source: ENERCON
EWEC 2007 No. 22
5 Conclusion and Outlook• Aerodynamic pitch Moment MZB is not sufficient for the
design of pitch systems drive train Pitch Actuator Torque is inevitable
• Blade bearing friction model included in the global simulation model
• Integration of drive control unit into the global simulation model, e.g. limitations in speed and torque of pitch drive actuator
• 80% damage within first 20°- 25° of blade bearing mesh
• Measurements on drive trains of pitch systems to validate MM-assumption
EWEC 2007 No. 23
Keep in Contact
Andreas ManjockGermanischer Lloyd Industrial Services
[email protected], www.gl-group.com/glwind