Driveline and Chassis Technology

ZF Friedrichshafen AGDivision Industrial TechnologyBusiness Unit Test Systems94030 PassauGermanyPhone +49 851 494-5529Fax +49 851 494-905529sales.it@zf.comwww.zf.com

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ZF Test Systems, the independent system supplier for test systems, is offering test rigs for wind power gearboxes as turnkey whole facilities with CE- mark-ing, thus obviating any safety risks and customer’s need for expensive interfaces.

Decades of experience and know-how gained in the production of development and series test rigs for vehicle and industrial transmissions in the high power range provided an excellent basis for getting quickly and successfully established in the wind power market.

The modular structure of the new ZF nacelle test rig provides a construction kit which leaves nothing to be desired:

■ nacelle mounting on adjustable apron■ nacelle mounting with transport frame■ test rig with or without wind power simulation■ wind power simulation in six axes with

standard components■ fast change of test unit ■ patented shaft coupling

ZF wind power gearbox test rigs are employed in the development, production and service sectors. In use round the clock, they reliably fulfil a wide range of test functions:

■ fatigue strength■ overload behaviour■ efficiency■ temperature properties■ structure-borne/airborne noise■ running-in program■ cleaning■ gear-meshing quality

As with all ZF test systems, the nacelle test rigs are also planned and supplied as turnkey test facilities from one source. They fulfil the highest demands of availability, safety, efficiency and economy.

Wind power gearbox test rig

Nacelle test rig

left: 6.4 MW Gearbox test rig with damping foundation

Wind power simulation in six axes

Nacelle mounting

with modular construction

Well-developed driveline with

patented coupling

Following a long tradition in test rig design, ZF has expanded its range of test systems. Systems for testing wind power gearboxes have been included for years in the standard range of products. The range of ser-vices on offer extends through to large off-shore systems.

The new nacelle test rig comes with up to 18 MW of drive pow-er and wind power simulation. The innovation from ZF Test Sys-tems comprises the combination of low-maintenance standard components.

Nacelle test rig10 MW drive power, network fault simulation, wind power simulation in six axes, patented coupling

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Power input

Thanks to the electric twist principle, power input is only required for losses and dynamic procedures.Flexibility

Highly fl exible adaptation of motor andgenerator unit to test unit geometries.Output

A back-to-back arrangement and a quick inserting of the test units lead to short test cycles.Tooling times

The automatic clamping concept reduces tooling times to a minimum.

Fixtures

Individual combination of test units with a minimum of fi xtures required.Test results

Special test unit fi xture as a basis for reliable test results close to reality.Acoustics

Acoustic measurements during speed run-ups with extensive evaluations, for example order analyses, produce comprehensive “acoustic fi nger prints“.Automatic mode

ZF-MODAS reliably and quickly automatizes test sequences, measurements and data management.

Advantages of the ZF wind power gearbox test rigs

Use of standard and proven technologies

and components

Depending on the test unit power, drive systems are designed in the low and medium voltage range. The connection of the inverters on motor side via voltage intermediate circuit makes energy exchange of motor and generator possible, as a consequence allowing low power input.Thanks to an active power supply unit a nearly sine-shaped current is taken from the mains and genera-tor energy is supplied back into the mains.

On the network side fault conditions can be simu-lated on customer request to ensure dependability in realistic field operation. ZF driveline technology is dimensioned for overload and continuous run-ning capabilities. The latest controls technology safeguards critical test cycles, such as changes of torque directions.

Drive technology: great movements with little energy

The applied testing methods meet the high quality standards applicable in the automotive sector.Besides conventional measuring technology, oil pureness is measured, and acoustic measurements are made with extensive evaluations like FFT- and order analysis.High-resolution, dynamic and modularly scalable signal condi-tioning permits versatile real-time analyses, from standardized

Measuring technology: visible quality

tasks right through to highly complex ones, even for automatic test operation.A consistent collection and archiving of all testing and test unit data ensures traceability of the test results for later analyses.System supported calibrations and evidences of measuring capability ensure a return to the international normal.

FFT-evaluation of a body sound measurement Order analysis of a body sound measurement

For nacelle and gearbox test rigs, ZF combines the latest measurement, control and driveline technology with a module concept. This produ-ces advantages in availability, effi ciency, reliability and through less complexity.

ZF driveline technology is characterised by high performance capability and availability in the harsh every-day routine of testing. In this respect overload test runs are reliably handled just as perfectly as shorter cycles for quality inspection.

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Modularity:unlimited scope

Noise protection cabin with sliding doors

With ZF wind power test systems the modular con-cept leads to corresponding solutions in various areas. Some examples illustrate the advantages: Test systems can be expanded with X/Y adjustment of the motor units, even if not initially ordered. In addition, Z adjustment of the motor-generator set can be retrofitted. ZF offers various modular solu-tions for mounting the test unit to be able to eco-nomically adapt to customers’ various unit sizes. Control, measurement and automation systems are implemented in subsystems in a modular design to facilitate perfect adaptability to the customer’s inter-

faces. With wind power simulation on six axes ZF depends on reliable, high performance standard components.

ZF wind turbine test rigs are controlled, configured or maintained by the standardized self-explanatory visualization and operating system ZF-ATOS. Various control modes are available for these pur-poses.

Modular generation and flexible configuration of automatic test sequences is possible with the auto-mation tool ZF-MODAS.A safe and reliable future is achieved due to the use of mainstream and standardized components.

Data management■ Test rig configuration■ Test unit data■ Flexibly configurable test sequence■ Evaluation and test reports■ SQL data base■ Data exchange with customer network

Test rig control■ Control modes Service, Setting-up, Manual, Automatic■ Intuitive operation■ Real time system■ State-of-the-art control technology■ Main adjustments via servo axes

Automation technology:complete control

User interface ZF-ATOS Test run parameterization ZF-MODAS

Lifting unit with bearing

X-Y-Z-adjustment of motor-genera-

tor units

FEM-analysis on damping foundation

In electrical driveline technology and software solutions modularity is long established. Modular solutions are also consistently implemen-ted in the machine construction and in media technology of ZF test systems and offer the economic and technical optimum with the highest reliability.

ZF-MODAS automates what customers need. Together with the ZF-ATOS operating panel, it represents a complete and reliably opera-ting automated solution – not only for wind power test systems.

ZF automation solutionsZF-ATOS displays operating states and also facilitates manual operation. ZF-MODAS conveniently automates all test sequences.