romax: state-of-the-art drivetrain - ewea 2013 by yann rageul
TRANSCRIPT
CONFIDENTIAL@ Copyright 2012
Next generation hybrid drivetrain platform for minimum Cost of Energy
EWEA 2013 Conference:
Romax ButterflyTM Drivetrain
2013
Yann Rageul – Head of European Sales and Strategic Consulting
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Business Facts
Selected clients from the wind industry Selected clients from other industries: Automotive, Off-highway, Marine, Aerospace …
• Established in 1989
• Private Equity Fidelity (1.5Trillion USD)
• Technology-led solutions provider
• Active across a range of sectors:
• Wind energy, Automotive, Off-highway, Marine, Aerospace…
• Head office in Nottingham, UK
• Global offices in the US, Germany, France, Japan, Korea, China and India
• 200 employees globally, with 120 in UK
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax track record for drivetrain & gearbox design:
Beautiful Engineered based on proven track record
2005
• Over 29 drivetrain and gearbox designs• 1.7GW of Romax designed gearboxes shipped as Q3 2012
2007
First Romax drivetrain* integrated solution
*[including main bearing, housing, gearbox and high speed shaft to generator]
2MW
4MW
6MW
2009 2011
8MW
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Conventional High Speed Geared Drivetrain
Medium Speed Geared Drivetrain
Direct Drive
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Onshore vs. offshore: Medium vs. High Speed
• Three most dominant drivetrain technologies in the market:
GamesaVestas
Doosan
Siemens
Vestas
DoosanMinyang
WinWind
Siemens
Siemens
Nordex
Alstom
REpower
SinovelMinyang
Gamesa
REpower
BARD
XEMC Darwind
Areva
Sinovel
GE
Sinovel Sh.Electric
EnerconEnercon
Samsung
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Medium Speed (2 stage)
Offshore Drivetrain
Annual Cost of Energy
Generator
capex
16%
Generator
O&M
37%
Gearbox
capex
14%
Gearbox
O&M
33%
Annual Cost of Energy
Direct Drive Medium Speed
(1 stage)
Medium Speed
(2 stage)
High Speed
Co
stHigh Speed
Offshore Drivetrain
Annual Cost of Energy
Gearbox
O&M
59%
Gearbox
capex
11%
Generator
O&M
24%
Generator
capex
6%
6.xMW Drivetrain CoE Model: OPEX + CAPEX
Off-shore Results (Romax R&D)
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
The Butterfly™ drivetrain platform benefits
Increased reliability
Supply chain flexibility
Reduced time to market
Flexible O&M strategy
The lowest cost of energy drivetrain solution
Offshore applications 5MW-10MW
Onshore applications 3MW-4MW
Rotor assembly module
Gearbox assembly module
Generator assembly module
Patent pending “pure” torque coupling
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: Sensitivity study analysis
Butterfly™ - The effect of the stiffness of the rotor shaft to gearbox connection to the performance of the gearbox bearings & gears is assed in RomaxWindTM software – Only GL certified software for gear calculation which enable parametric studies (Design of Experiment) for optimisation
RomaxWindTM
drivetrain model
Apply worst case system loads
Apply worst case assembly tolerances
Concept optimisation in RomaxWindTM
Select the best design
-400 -200 0 200 400 600
Stage 1 Annulus gear -> Stage 1 Planet gear 1
Stage 1 Annulus gear -> Stage 1 Planet gear 2
Stage 1 Annulus gear -> Stage 1 Planet gear 3
Stage 1 Annulus gear -> Stage 1 Planet gear 4
Stage 1 Annulus gear -> Stage 1 Planet gear 5
Stage 1 Sun gear -> Stage 1 Planet gear 1
Stage 1 Sun gear -> Stage 1 Planet gear 2
Stage 1 Sun gear -> Stage 1 Planet gear 3
Stage 1 Sun gear -> Stage 1 Planet gear 4
Stage 1 Sun gear -> Stage 1 Planet gear 5
Stage 2 Annulus gear -> Stage 2 Planet gear 1
Stage 2 Annulus gear -> Stage 2 Planet gear 2
Stage 2 Annulus gear -> Stage 2 Planet gear 3
Stage 2 Sun gear -> Stage 2 Planet gear 1
Stage 2 Sun gear -> Stage 2 Planet gear 2
Stage 2 Sun gear -> Stage 2 Planet gear 3
um
Gear mesh misalignment - 3mm radial eccentricity
0 1000 2000 3000 4000 5000 6000
Main UW
Main DW
S1 Carrier UW
S1 Carrier DW
S2 Carrier UW
S2 Carrier DW
Brg Force Magnitude (kN)
Brg
s
Bearing force magnitude - 3mm radial eccentricity
Increased Reliability: Our Approach
Reduced time to market
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Removing risks...
• Failure data indicates 64% of gearbox failures are typically due to high speed shaft gear & bearing failures
1st stage0.028
18%2nd stage
0.028
18%
3rd stage
0.103
64%
Failure rate of 3MW PL-PL-PA gearbox
(failures/turbine/year)
Improved assembly alignment
• Butterfly™ drivetrain
3 modules aligned using housing connections
No adjustment required in nacelle
Potential for high misalignment• Conventional modular layout
o Mounting and bedplate flexibility can cause high misalignment between the gearbox & generator
o Generator can be incorrectly positioned or sink over time as the rubber mounts degrade it also moves due to dynamic loading
� Can lead to gearbox & generator bearing failures
High speed gear stage eliminated
Increased Reliability: Reducing potential risks
Source: Romax data from failure investigation
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Butterfly™ - Rotor bending moments transferred through main bearing housing, directly into the main frame
Off axis rotor bending loads can results in early failure of gearbox gears & bearings (even in 2 point mount rotor shafts!)
Romax ButterflyTM: Gearbox & generator
protected from rotor bending loads
Butterfly™ - Unique Romax designed rotor shaft to gearbox connection to minimise the bending load transferred from the rotor shaft into the gearbox (patent pending)
Increased Reliability: “Pure torque”
Deflections of the structure under extreme load investigation in RomaxWindTM
System modelled in RomaxWindTM
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: Generator weight not
supported by gearbox bearings
Butterfly™ - Generator mass is supported through the gearbox housing by the mainframe – not by the gearbox bearings
Butterfly™ - Layout is insensitive to generator mass
Gearbox & generator mass supported by rotor shaft
Gearbox & generator mass supported by mainframe
Torque arm Generator
ConverterGearbox
Generator mass increases the loads on the gearbox bearingsTorque arm high risk stress areaRotor shaft to gearbox connection risk due to additional generator weight
Increased Reliability: Structural analysis
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Main bearing concept 2 tapered roller bearings (TRB) rotor bearings
Double Row TRB ‘moment’ rotor bearing
Support structure mass(rotor shaft, rotor bearing housing, main frame)
Similar Similar
Total cost (support structure + bearings) Baseline +9%
Scalability to 10MW Yes, study complete Very limited manufacturing & availability >6MW
Drivetrain length (6MW) 8.3m 7.3m
Maintenance/inspection access (rotor bearings, gearbox/rotor shaft connection, gearbox stage 1)
Better Worse
Ease of setting bearing preload Worse Better
Sufficient bearing structural support Easier More difficult
Romax ButterflyTM: Multiple drivetrain configuration options
Supply chain flexibility
Flexible O&M Strategy
CONFIDENTIAL@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: platform key features
Innovative lubrication system
Analysis of drivetrain dynamics and system-level behaviour
Designed for RomaxInSight – integrated health management system
Advanced Romax gearbox design with patented technology
Simple drivetrain assembly & alignment
Design scalable to 10MW
Multiple suppliers available for all components & sub systems
Fast replacement of all serviceable items
3 self contained ‘modules’ for ease of assembly & replacement
Complete drivetrain ‘tube’ can be lifted into position as one assembly
Supply chain flexibility
Reduced time to market
Increased Reliability
Flexible O&M Strategy
CONFIDENTIAL@ Copyright 2012
ButterflyTM drivetrain platform
beautifully engineered
Contact details:
Yann Rageul – Head of European Sales & Strategic Consulting
Mobile: +44 (0) 7581 194679
E-mail: [email protected]