First results of Hansen’s 13MW test facility for wind turbine gearboxes Joris Peeters

1. 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. Presentation Overview • The Challenge • Functionality of the test facility • Development process and first results • Planned R&D activities • Time schedule

3. The Challenge – cope with dynamics Demand for proven technology in booming wind turbine business 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 Turnover Hansen CAGR: +18% CAGR: +33%

4. 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 The Challenge – cope with dynamics

5. Vision behind the test rig The Challenge – cope with dynamics It is possible to transform wind turbine behaviour into test rig conditions

6. Vision behind the test rig Functionality of the test facility “Test the gearbox under realistic wind turbine conditions” back-to-back gearbox test rig

7. Mechanical design Functionality of the test facility speed reducer 1:1 or 1:3 • 1000 tons of steel • 1000 tons of concrete • 10m€+ investment

8. Picture Functionality of the test facility

9. Specifications Nominal power of 13.2 MWat nominal speed of 1500 rpm Peak power of16.8 MWat nominal speed of 1500 rpm Functionality of the test facility

10. Identification of dynamic loads from wind turbines and translation into test rig load cases Start cases (3) Run cases (4) Stop cases (3) Specials (1) Functionality of the test facility

11. Dynamic load cases – example Functionality of the test facility S_1 Start case 1: normal start Torque control Speed control Nm RPM Time Time • each load case is parametric

12. Dynamic load cases – example Functionality of the test facility R_4 Run case 4: peak load Torque control Speed control Nm RPM Time Time

13. Dynamic load cases – example Functionality of the test facility P_1 Stop case 1: normal stop Torque control Speed control Nm RPM Time Time

14. 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

15. Development process 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 Phase C – static testing • Taking into operation for standard tests Successfully solved Successfully solved Phase A Demonstrate control functionality & accuracy on scaled set-up Phase C – dynamic testing Demonstrate control functionality and robustness & fail-safe operation on scaled set-up Phase B Verify control functionality & accuracy + validation of electrical components

16. 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 Development process and first results

17. First results from phase C – example Start-Run-Stop Development process and first results Rotational speed Time [s] Torque ist: actual measured value soll: reference value for controller Time [s]

18. First results from phase C – dynamics during Run-case Development process and first results Rotational speed Time [s] Torque Time [s]

19. 13.2MW test rig is an R&D facility for testing gearboxes under defined dynamic conditions 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 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

20. 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 13.2MW test rig Time schedule

21. Q&A

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