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

2 Joris Peeters September 14th, 2009

¬ The Challenge

¬ Functionality of the test facility

¬ Development process and first results

¬ Planned R&D activities

¬ Time schedule

Presentation Overview


48 64 69 82 94

515

5,956 MW339

4,208 MW267

3,795 MW

221

3,480 MW162

2,427 MW

0

100

200

300

400

500

600

FY 2005 FY 2006 FY 2007 FY 2008 FY 2009

(€m)

Industrial Gearboxes Wind Turbine Gearboxes

211

285

336

421

609

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


¬ 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



Vision behind the test rig

It is possible to

transform wind

turbine behaviour

into

test rig conditions



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”


Mechanical design

speed reducer

1:1 or 1:3

• 1000 tons of steel• 1000 tons of

concrete• 10m€+ investment



Picture



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



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)



Dynamic load cases – example

S_1 Start case 1: normal start

Torque control Speed control

0

1000

2000

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6000

1 2 3 40

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1200

1400

1600

1 2 3 4

each load case is parametric


Nm RPM

Time Time


R_4 Run case 4: peak load



Nm RPM

0

5000

10000

15000

20000

25000

0

200

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600

800

1000

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constant speed with variable controller setting


Time Time


P_1 Stop case 1: normal stop



Nm RPM


0

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Time Time


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


Phase D on 13.2 MW test rig

Verify control functionality and robustness & fail-safe operation

planned for end of 2009

Development process


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


First results from phase Cdynamic testing with gearboxes on scale model


¬ 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


First results from phase C – example Start-Run-Stop


Rotational speed

Torque

Time [s]

Time [s]

ist: actual measured value

soll: reference value for controller



Rotational speed

Torque

Time [s]

Time [s]

First results from phase C – dynamics during Run-case


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


¬ 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


Q&A


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.

¬ This presentation and any materials distributed in connection with this presentation may include statements that are “forward-looking statements”. In some cases, these forward-looking statements can be identified by the use of forward-looking terminology, including the terms “believes”, “estimates”, “forecasts”, “plans”, “prepares”, “projects”, “anticipates”, “expects”, “intends”, “may”, “will”, “should” or other similar words. Forward-looking statements may include, without limitation, those regarding the Company’s financial position, business strategy, plans and objectives of management for future operations (including development plans and objectives relating to the Company’s products) and the wind turbine and gearbox markets. Such forward-looking statements involve known and unknown risks, uncertainties and other factors which may cause the actual results, performance or achievements of the Company, or industry results, to be materially different from any future results, performance or achievements expressed or implied by such forward-looking statements. Such forward-looking statements are based on numerous assumptions regarding the Company’s present and future business strategies and the environment in which the Company will operate in the future. These forward-looking statements speak only as of the date of this presentation. The Company expressly disclaims any obligation or undertaking to release publicly any updates or revisions to any forward-looking statement contained herein to reflect any change in the Company's expectations with regard thereto or any change in events, conditions or circumstances on which any such statement is based.

¬ Any information contained in this presentation on the price at which shares or other securities in the Company have been bought or sold in the past, or on the yield on such shares or other securities, should not be relied upon as a guide to future performance.

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first results of hansen’s 13mw test facility for wind turbine gearboxes joris peeters

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