Romax: state-of-the-art drivetrain - EWEA 2013 by Yann Rageul
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State of the art medium drivetrain by Romax Technology Looking at the benefit of medium speed vs direct drive and high speed wind turbine layouts.
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Romax: state-of-the-art drivetrain - EWEA 2013 by Yann Rageul
- 1. 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
- 2. 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
- 3. 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
- 4. 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
- 5. 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
- 6. 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: Gamesa Vestas Doosan Siemens Vestas Doosan Minyang WinWind Siemens Siemens Nordex Alstom REpower Sinovel Minyang Gamesa REpower BARD XEMC Darwind Areva Sinovel GE Sinovel Sh.Electric Enercon Enercon Samsung
- 7. 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 Cost High 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)
- 8. 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
- 9. 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
- 10. 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) Brgs Bearing force magnitude - 3mm radial eccentricity Increased Reliability: Our Approach Reduced time to market
- 11. 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 stage 0.028 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
- 12. 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
- 13. 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 Converter Gearbox Generator mass increases the loads on the gearbox bearings Torque arm high risk stress area Rotor shaft to gearbox connection risk due to additional generator weight Increased Reliability: Structural analysis
- 14. 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
- 15. 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 Romax InSight – 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
- 16. 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: yann.rageul@romaxtech.com