kenersys. driven by...

KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com

KENERSYS. DRIVEN BY INTELLIGENCE

MANUFACTURER-SUPPLIER CO-DEVELOPMENT: LESSONS LEARNEDHANNOVER, APRIL, 2013

MARKUS BECKER, CTO KENERSYS GMBH


KENERSYS IN SHORT


*Technically feasible

KENERSYS IN SHORT

IEC II IEC III (IEC IV)

LARGER ROTOR-DIAMETERS AND HIGHER HUB HEIGHTS

CAN COMPENSATE LOWER WIND SPEEDS

Low WindMedium Wind

An

nu

al

En

erg

y Y

ield

Mean wind speeds at 100 m hub height (m/s)

WIND

RESOURCE

POTENTIAL:

~ 75%


KENERSYS IN SHORT


DRIVERS FOR MANUFACTURER SUPPLIER

CO-DEVELOPMENT


• From rotor blade down to the foundation - the complex wind

energy turbine reflects all main areas of the engineering:

machine-, electrical-and constructional engineering.

• There are mainly two integration strategies:

VERTICAL INTEGRATION SYSTEM INTEGRATION

• Planning, developing and

building a large amount/ all the

components (total integration)

• Buying the components

• Focus on developing the whole

system (some key components)

• developing components

together with supplier

+ High degree of influence + some influence by co-

development

+ Independence regarding

supplier

+ Insensibility regarding market

fluctuation

+ All rights reserved + flexibility

- High personnel and

development costs and risk

+ lower costs

VERTICAL & SYSTEM INTEGRATION


ADVANTAGES

MANUFACTURER

ADVANTAGES SUPPLIER

Cost benefits Long term partnership

provides planning certainty

Quality benefits More market insight –

chance of increasing the

market share

Time benefits Chance to enter new

markets with new

development

Taking benefit out of

suppliers know-how and

experience

Sharing development cost -

Sell new product to other

customers

ADVANTAGES FOR CO-DEVELOPMENT


SUPPLIER SELECTION


QUALITY GATE PROCESS -

DESIGN AND DEVELOPMENT


QUALITY GATE PROCESS –

TEST PHASE


EXAMPLE – GENERATOR FROM LEROY SOMER

Facts & figures:

• November 2007 start technical discussion between Kenersys

and L+S

• After first layout from Leroy Somer period of development,

exchange of designs, ideas and corrections

• February 2008 finalisation of calculations

• March 2008 handover of technical documentation from L+ S

to KENERSYS

• June 2008 prototype

• Subsequently tests at Leroy Somer test bench

• Design team exists of around 5 engineers

Generator:

• Electrically excited synchronous generator

• The generator was specially developed for KENERSYS

• Just two manufacturers in the wind branch worked with

electrically excited generators before, but as high-speed

version and as direct drive.



KENERSYS design:

• KENERSYS specified the whole generator

including power conversion system

existing of rectifier and converter + all

interfaces details.

LEROY SOMER design:

• Leroy Somer in charge for the detailed

design technical implementation

• Several design review processes between

Kenersys and L+S for fulfillment of

specification

• e.g. the cooling jacket design

• winding allocation for high

redundancy



RESULTS:

• 4 Stator-windings combined with single rotor with

electrical excitation machine

� Split solution allows „full-load-operation“ of single

strings also in partial load for increased efficiency

• Robust curtailment in case of failure of generator

elements

• Advanced water cooling � Higher efficiency, corrosion

protection

• Permanent magnet in exciter � possibility of a black start

• System allows to use quite simple converters

• IMPORTANT FACTORS:

• Some factors hastened the development period essential:

• Engineering tools like 3D-CAD

• 3D-FEM for mechanical design but also magnetic circuit

• Fluid dynamical simulations for the inner aero loop and

the water jacket cooling

• High performance test bay used for system tests with

converter and a complete standard test bay for all

pretests.


EXAMPLE – HYBRID TOWER

Facts and Advantages pf the Hybridtower:

• Consists of 8 segments per ring

• Just two mold forms needed – high modularity

• Fast production set-up in different locations

• Easy transport of segments to site

Facts &Figures:

• ATS design was developed by MECAL 2003 – Today ATS

majority is owned by JUWI

• First ATS prototype with Siemens nacelle in Grevenbroich

• First meeting between Kenersys and ATS end of 2008.

• Project team exists of 2 engineers from KENERSYS and 3-5

engineers from ATS

– Load calculation by Kenersys

– Structural design ATS

– Internal design Kenersys

• First serial towers in with KENERSYS nacelle were erected

in 2010

• 22 more hybrid towers with Kenersys machines installed in

2011 until now


EXAMPLE – HYBRID TOWER

KENERSYS design

• KENERSYS defines

specifications and

requirements (tower internals

e.g. lift, cabling, cellar ) and

cares for the internal design

• Close coordination between

KENERSYS and ATS regarding

the tower interface (steel and

concrete)

ATS design

• ATS cared for the concrete

design

• Execution of construction

ATS with construction

company KENERSYS

accompanies the project

• After every project – review and redesign

• Continuous improvement concerning details

• ATS profits from KENERSYS` turbine know how and

KENERSYS profits form the tower know how of ATS/Mecal

• ATS has the chance to sell the tower to other manufacturers

with some adjustments


• Co-developments were important for KENERSYS to

enter the market in short time

• Co-development of components enables the

development of the whole turbine with a small

team

• Ensures flexibility

• Due to the platform concept the components are

implemented in all turbine types/ OEMS, therefore

highly developed components with already

available track record are crucial

• A large part of the cooperation is strategic due to

the big amount of tailor-made components

SUMMARY: SYSTEM INTEGRATION AT KENERSYS

KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.comwww.kenersys.com

Many Thanks for your Attention!

DIPL.-ING. MARKUS BECKER

CHIEF TECHNOLOGY OFFICER

KENERSYS GMBH

PortAL 10 | Albersloher Weg 10

48155 Münster | Germany

Tel.: +49 251. 210 99 – 0

Fax: +49 251-21099-200

[email protected]

17


Quellen

• http://books.google.de/books?id=KV_B0n507QEC&pg=PA111&lpg=PA111&dq=Fertigungstiefe+Windenergieanlagen&sourc

e=bl&ots=rMbGAfYM0C&sig=ZG9oQTz829iWHhNhn0wmCqREPRo&hl=de&sa=X&ei=PxYeUYrSLs7VsgaK9oCQAQ&ved=0CC4

Q6AEwAA#v=onepage&q=Fertigungstiefe%20Windenergieanlagen&f=false

• http://www.tcw.de/news/systemlieferanten-fuer-oems-im-bereich-erneuerbarer-energien-632

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