1 2006 wind program peer review drivetrain development and reliability sandy butterfield 5/10/2006...
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12006 Wind Program Peer Review
Drivetrain Development and Reliability
Sandy Butterfield
5/10/2006
•Need pictures
22006 Wind Program Peer Review
Design Evolution (Jason)
History of designs. Why do they look like they do.
Variable speed – enabler for control of torque loads
High speed brakes gone
Noise (much reduced)
Integration ???
Design tools much improved
Margins much lower
Standards (assisted development of design practice now used for rest of the industry)
Size, lubrication, condition monitoring,
32006 Wind Program Peer Review
Drivetrain Evolution
1980 1985 1990 1995 2000 2005 2010
Drivetrain rating increasing
Lubrication additives and filtration
High failure rates & noise
Variable speed introduced
High speed brakeseliminated
Wind turbine standards development
40,000 hr. rebuilds required
Condition monitoring
42006 Wind Program Peer Review
State of the art in drivetrain design
Vestas, 4.5 MW
Enercon, 6 MW Multibrid, 5 MW Clipper, 2.5 MW
52006 Wind Program Peer Review
Design Problems Plaguing Industry Gearbox failures have plagued the wind industry since early
80s.
Current life much less than 20 years, even using best practice
Reliability remains an issue throughout the drivetrain– Mainshaft and gearbox bearings—especially planetary spherical
roller bearings– Housing deflections?– Power electronics IGBT failures– Others
Planetary Bearing Inner Race and Roller Failure •A. Toms - Gastops
62006 Wind Program Peer Review
Sample Wind Turbine Data
Critical Mass Loss
Critical Mass Rate
Related to AFRL Prognostics
72006 Wind Program Peer Review
Program contributions (Walt)
Dyno history of contributions (industry partnerships)
understanding field problems
qualifying production prototypes
qualifying new braking controls, lubricants, gear tooth lead
testing new concepts
multi gen (clipper)
NPS (DDG) (WindPact)
GEC (mediuim speed gen) (WindPact)
Standards support
role in AGMA / IEC 61400-4
gearbox guideline by errichello
WindPact drive train study
Prototypes
NPS DDG
GEC hybrid
82006 Wind Program Peer Review
What should the DOE program be doing to foster High-Reliability Systems?
High-ReliabilitySystems
Appropriate Environmental
Conditions
Accurate Loads &Design Requirements
Desig
ned-in
Reliabilit
y
Condition M
onitorin
g
Reduced Failure Rates Improved O&M
System
Reliab
ility A
nalysis
Cap
ability
O&M Data Base
Designed-in
Maintainability
Fu
ll-Scale
Te stin
g
92006 Wind Program Peer Review
Current Programs (Full Scale Dyno Tests)
NPS WindPact Direct Drive Gen prototype test
GEC WindPact medium speed drive prototype test
NPS
GEC
102006 Wind Program Peer Review
Current Program (Improved O&M)
Drive train R&D needs workshop (NREL 4/05) – Identified near term needs (failure data, industry collaborative root
cause analysis, condition monitoring)
– Loads validation
– Greater integration between loads codes and internal stress codes
– DDG appear to be heavier/more costly but hold promise for greater reliability and lower cost with R&D, especially for offshore
Predictive Maintenance Management workshop (NREL 4/20/06)– CM technology for gearing & bearings available but challenge to
apply it economically to wind.
– Other areas unique to wind turbines unexploited. (blades, automated fault diagnosis, model assisted load monitoring, poor performance diagnosis.
– Need for integrated SCADA systems, O&M management systems and automated data interpretation tools.
112006 Wind Program Peer Review
Opportunities: (Reducing Failure Rates)
Reliability tools
Second generation WindPact drive train study under SeaCon and prototypes.
Loads Code/Gearbox internal stress code integration
122006 Wind Program Peer Review
Integrated Codes are Needed
Component Level
– Determine design integrity of individual components based on specified loads
– Single-physics model– Not industry-specific– Commercial products available
(ANSYS, etc.)
Full System Level
– Determine loads throughout full system for component level analysis
– Multi-physics model
– Wind industry-specific
– Simple modeling of components
Component Level
– Single-physics model
– Uncoupled loads do not capture housing flexure
– Commercial products available (ANSYS, ADAMS, SimPack)?
•L. Mumper - SKF
132006 Wind Program Peer Review
Opportunities: Industry Collaboration
O&M database – Develop automated diagnostics– Identify R&D needs– Fuel reliability models
Predictive Maintenance Management (PdM)– Sandy will finish this.
152006 Wind Program Peer Review
Opportunities: Exploring new concepts
SEACON extension of WindPACT drivetrain study1. Survey existing concepts2. Cost estimates3. Reliability estimates4. Better understand the direct drive / geared system reliability and cost tradeoff
162006 Wind Program Peer Review
Future Plans (Sandy)
More workshops planned – O&M Practices (SNL Sept 06)– Predictive Maintenance Management II (NREL March 07)
SeaCon Drivetrain concept studies
Attempt to organize industry collaboratives– Gearbox failure investigation– O&M data base– Condition monitoring opportunities
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