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Tecnologias de controle de conversores diretos e híbridos em turbinas eólicas modernas.
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Transcript of Tecnologias de controle de conversores diretos e híbridos em turbinas eólicas modernas.
© Fraunhofer IWES
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Fraunhofer IWESInstitute for Wind Energy and Energy System Technology
Hybrid & direct drive technology in modern wind turbines
Hans Kyling, Dr. Jan Wenske, Hans-Georg Moll, Louis Quesnel
Jaraguá do Sul, 28.06.2012
© Fraunhofer IWES
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General Map
� About the Fraunhofer IWES
� Some wind turbine basics
� Overview of different drive train topologies
� Current drive train trends
© Fraunhofer IWES© Fraunhofer IWES
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Research spectrum:
� Wind energy from material development to grid optimization
� Energy system technology for all renewable energies
Foundation: 2009
Formerly:
� Fraunhofer Center for Wind Energy and Maritime Technology (CWMT) in Bremerhaven
� Institute for Solar Energy Supply Technology ISET in Kassel
� Directors: Prof. Dr. Andreas Reuter
Prof. Dr. Jürgen Schmid
Annual budget: € 31 million (2011)
Employees: 376
Fraunhofer IWES in figures
IWES in figures
Some basics
Drive train topologies
Current trends
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Sorted by test level according to V-model (VDI 2206)
� Material
• Climate chambers
• Offshore test field
� Component
• Rotor blade (full scaled, down scaled)
• Composite part testing and development
� Sub-system and integration
• Dynamic Nacelle Laboratory
(DyNaLab) -in development-
Portfolio example: test facilities at Fraunhofer IWES
IWES in figures
Some basics
Drive train topologies
Current trends
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Introduction: some history on wind turbines
� There was no comparable application in engineering, so that the design needed to be developed from scratch
� The first big industrial wind turbines were designed with components sourced from other industries (no wind turbine specific components available by that time)
� The different drivetrain components didn’t match perfectly with each other.
� With a growing market for wind turbines specialized components and designs were developed.
IWES in figures
Some basics
Drive train topologies
Current trends
Wind turbine
boundaryconditions
extreme highnumber ofload cycles
(N > 108)
very hightorques and
parasiteloads
slowrotational
speed
Permanently changing
service loads
flexible structure
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Some basic physics:
The kinetic energy/power of the wind is
The power extracted by a wind turbine
The theoretically extractable power grows with
the square of the rotor radius!
>>>Higher energy yield<<<
Positive influence of the rotor diameter
tcoefficienpowerswtcvRρcP
vRρvmΕP
vmΕ
pairp
air
':2
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⋅⋅⋅⋅⋅=
⋅⋅⋅⋅=⋅⋅==
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π
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v
R
IWES in figures
Some basics
Drive train topologies
Current trends
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Source: Alstom
Negative influence of the rotor diameter
mBlade ~ lBlade3
IWES in figures
Some basics
Drive train topologies
Current trends
increased blade length
higher mass/
aerodynamical loads
strengthened drivetrain/support structure
higher turbine weight/cost
energy yield
weight/cost
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Why are there so many different drivetrain concepts?
The shown ambivalent problem regarding the blade length is a good example for explaining the variety of concepts:
� Depending on the drivetrain design the rotor loads may “flow” in a different way through the turbine structure and effect thus the component design
There are a couple of parameters that have to be considered in order to find the best suited drivetrain concept, like:
• Global/local market situation (e.g. rare earth availability)
• Site assessment (high turbulences, )
• Availability of turbine (e.g. offshore very important)
• Service & maintenance costs
• Etc.
Which drive train concept is the best?
� Answer is project-specific
IWES in figures
Some basics
Drive train topologies
Current trends
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How to classify drivetrains?
There are various drivetrain topologies, and different ways to classify them. A practical way to classify wind turbines is the generator speed/number of gear box stages:
• High speed generator (HSG) (approx. 500 – 2000 rpm)
These drivetrains make use of a 3-4 stage gearbox (planetary/spur)
• Medium speed generator (MSG) (approx. 40 – 200 rpm)
These drivetrains make use of a 1-2 stage planetary gearbox
• Slow speed generator (SSG) (approx. 4 – 35 rpm)
These drivetrains are called direct driven, because the rotor torque is transmitted directly (without a gearbox) to the generator.
IWES in figures
Some basics
Drive train topologies
Current trends
© Fraunhofer IWES
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Drivetrains with 3-4 stage gearbox (HSG)
Characteristics:
positive
• The generator torque is low thanks to the gearbox.
• Classical drivetrainsolution (a lot of experience available)
• High availability on the supplier’s market (resulting in lower prices)
neutral negative
• High number of rotating parts (within gearbox)
• High maintenance effort
• High drivetraintotal length
• Reduced torsionalstiffness
• Low efficiency
IWES in figures
Somebasics
Drive train topologies
Current trends
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3-4 stage gearbox – moment bearing
Example: Vestas V90-3.0
Tower head mass: approx.: 114 t
No main shaft 2 planetary, 1 spur stages
Doubly fed induction generator (DFIG)Moment bearing integrated into gearbox housing
(bending moments transmitted through gearbox)
Source: Vestas
IWES in figures
Somebasics
Drive train topologies
Current trends
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3-4 stage gearbox – double suspension
Example: GE 2.75-103
Tower head mass: approx.: XXX t
Double suspension
(in stiff housing)
Permanent magnet synchron generator (PMSG)
2 planetary, 1 spur stage
IWES in figures
Somebasics
Drive train topologies
Current trends
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3-4 stage gearbox – 3-point suspension
Example: Vestas V112-3.0
Tower head mass: approx.: 120 – 130 t
4-stage gearbox
Main bearing
Shrink disc
Support bearing integrated into first gearbox stage
PMSG generator
Source: Vestas
IWES in figures
Somebasics
Drive train topologies
Current trends
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Drivetrains with 1-2 stage gearbox (MSG)
Characteristics:
positive neutral
• Moderate generator torque
• Moderate generator size, weight and cost
• Moderate number of rotating parts (within gearbox)
• Moderate maintenance effort
• Moderate drivetraintotal length
• Moderate torsionalstiffness
• Moderate efficiency
negative
• Smallest global market share (little experience available)
• Limited generator availability on the supplier market
IWES in figures
Somebasics
Drive train topologies
Current trends
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1-2 stage gearbox, moment bearing
Example: Fuhrländer FL 3000
Tower head mass: approx.: 165 t
Source: Fuhrländer
PMSG
Winergy HybridDrive (flexible bolted to bedplate)
2 stage planetary gearbox (1:43)
Moment bearing (3 row cylindrical roller bearing)
Flexible coupling (elastic bolts)
IWES in figures
Somebasics
Drive train topologies
Current trends
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1-2 stage gearbox, double suspension
Example: Gamesa G10X-4.5
Tower head mass: approx.: 250 t
2 stage planetary gearbox (1:38, flanged to bearing case)
PMSG (housing flanged to gearbox)Double bearing in common stiff case,
Planet carrier is supported by main shaft’s rear bearing
IWES in figures
Somebasics
Drive train topologies
Current trends
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1-2 stage gearbox, double suspension
Example: DSME 7 MW Offshore
• Integrated power unit “FusionDrive”
• (approx. 90 t, from Moventas/TheSwitch)
� 2 stage planetary gearbox
� PMSG
• Prototype installation scheduled for Q1-2013
IWES in figures
Somebasics
Drive train topologies
Current trends
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Drivetrains without a gearbox (direct drive) (SSG)
Characteristics:
positive
• Simple drivetrain design (no gearbox, coupling and main shaft necessary)
• Less dynamic loads due to higher torsional stiffness (lower safety factor, lighter design, better controllability)
• Modularization and Standardization applicable (mass production)
• higher efficiency, especially for under rated conditions (no gearbox losses)
• Mechanically little maintenance needed
• Short design
• Small number of rotating parts (within gearbox)
neutral
• Moderate experience on the market
negative
• High generator torques lead to a bigger and thus heavier generator
• Generator relatively expensive (higher material demand)
• Wind turbine’s purchase cost relatively high compared to geared solutions
IWES in figures
Somebasics
Drive train topologies
Current trends
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Direct drive, moment bearing
Example: Siemens SWT-2.3-113, SWT-3.0-101
Tower head mass: approx.: 140 t
Moment bearing
(3 row cylindrical bearing)
PMSG
IWES in figures
Somebasics
Drive train topologies
Current trends
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Direct drive, double suspension
Example: Enercon E-101
Tower head mass: approx.: 250 t
IWES in figures
Somebasics
Drive train topologies
Current trends
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Direct drive, double suspension
Example: GE 4.0-110, Alstom PureTorque 6 MW
IWES in figures
Somebasics
Drive train topologies
Current trends
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Which company uses which drivetrain concept?
DFIG
Direct Drive
Geared
EESG
PMSGDouble-Fed
Electrical Excited Synchronous Gen.
Vestas (old),
Sinovel,
REpower
Siemens (new),
Goldwind,
GE Offshore,
Alstom
Vestas
(new),
Samsung,
GEKenersys
Enercon,
MTorres
3-4 Stages 1-2 Stages
Areva Wind,
Gamesa
Offshore,
Vestas V164,
Fuhrländer
Permanent Magnet Synchronous Generator
IWES in figures
Somebasics
Drive train topologies
Current trends
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Efficiency of different drivetrain/generator systems
IWES in figures
Somebasics
Drive train topologies
Current trends
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PMSG Volume and weight vs. gear ratio
0,01
0,1
1
0 10 20 30 40 50 60 70 80 90 100
D ~ 6m
P = 3,8MW
16rpm
total
81.000kg D ~ 0,8m
P = 2,7MW
1650 rpm
total 7750 kg
D ~ 1,8m
D ~ 0,7m
P = 1,7MW
150 rpm
total
17.000kgP = 1,0MW
1200 rpm
total
3.400kg
Rotor volume per power:
(related to „direct drive“)elp
vδ
iTransmission gear ratio
( )[ ]MPMmassMagnets
el
LDhDM
ii
p
v
ραπ
δ
22
_2
4
1)(
−+=
≈
IWES in figures
Somebasics
Drive train topologies
Current trends
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Drivetrain concepts of the global TOP15 OEMs
IWES in figures
Somebasics
Drive train topologies
Current trends
1900n1900r00l
1900n1900r00l
1900n1900r00l
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1900n1900r00l
1900n1900r00l
1900n1900r00l
Commercialized
through 2010
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Global gearbox/generator segmentation
IWES in figures
Somebasics
Drive train topologies
Current trends
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Nacelle weight trend
IWES in figures
Somebasics
Drive train topologies
Current trends
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Drivetrain mass contribution for key concepts
IWES in figures
Somebasics
Drive train topologies
Current trends
data derived from 3 MW turbines
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Generator weight trend
IWES in figures
Somebasics
Drive train topologies
Current trends
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Rare earth material price development in 2011
IWES in figures
Somebasics
Drive train topologies
Current trends
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Cost structure for onshore wind turbine
no logistics cost included
IWES in figures
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Newly installed power capacities in South America
+4%
+19%
+23%
-5%
+9%
+6%+4%
1900n1900r00l
1900n1900r00l
1900n1900r00l
1900n1900r00l
1900n1900r00l
1900n1900r00l
global growth rate
+5%
Source: Make Consulting
IWES in figures
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Estimated compound annual growth rate (2012 – 2016)
IWES in figures
Somebasics
Drive train topologies
Current trends
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Some impressions from Asian fabrication sites
IWES in figures
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End of presentation
IWES in figures
Somebasics
Drive train topologies
Current trends