O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential 1

An Overview Of

Orbital2

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/20102

Driven by the high failure rate experienced on current wind turbine

gearboxes,(>40%) and given such failure rates are not sustainable in

capital machinery, certainly for “off shore” turbines

Ray J Hicks MBE - & - Dr Frank Cunliffe who have an association

spanning over 40 years

decided to formed ORBITAL2 in September 2003 to exploit the long

history of the novel Ray Hicks flexible pin epicyclic gear designs and

their application to Renewable Energy Turbines

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/20103

R J Hicks MBE – Inventor of Flexible Pin

• Started working on Aerospace epicyclic gears in 1954

• Invented the “Hicks” flexible pin in 1964.

• Set up Compact Orbital Gears (COG) to design & manufacture

epicyclic gears for a variety of applications

• Applied the “Hicks” design principles to wind turbine gears in the

UK in the 1980’s. (Orkney 3MW torque controlling features 1982)

• Formed ORBITAL2, to carry forward the application of “Hicks”

epicyclic gear designs.

• Co-Founder of Orbital2

• Consultant to Orbital2

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/20104

Dr Frank Cunliffe – Managing Director

• 1st Class Hons Mechanical Engineering / Student Apprentice

Mirlees Blackstone Diesel engines, Fellow Inst Mech, Eng C Eng

• Research PhD Cambridge, epicyclic gear dynamics

• Senior Engineer COG, R J Hicks

• Chief Design Development Engineer, Lucas CAV, Diesel systems

• Technical Director, Cable Belt, long distance conveyers

• Engineering Director, Massey Ferguson Tractors

• Managing Director, Albion Automotive, commercial vehicle axles

• Co-Founder of ORBITAL2, to carry forward the application of “Hicks

flexible pin” epicyclic gear designs.

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/20105

Prof R Parker - none executive member of the ORBITAL2 board.

Professor Parker is a world leading expert on dynamics

Professor and Associate Dean for Education at the University of

Michigan-Shanghai Jiaotong University Joint Institute.

/ / / / /

Antonin Ruzicka – none executive member of the ORBITAL2 board.

Antonin Ruzicka is the CEO of WIKOV INDUSTRY a Czech gearbox

company and manufacturing partner of ORBITAL2.

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

ORBITAL2 UKInnovation,Marketing,

Project managementTechnical CentreDesign Layout

5 engineers

Czech ORBITAL2Prague & Hronov

Design / Manufacturing Drawings,

Supervision of assembly test and development

15 Design engineers

SoftwareSolid Edge ST 3D CAD

KISSsoft

MASTA

ANSYS V11Professional NLS

nCode DESIGNLIFE

Dynamic/Specialist Analysis

Prof. Parker University of

Michigan-Shanghai Jiaotong University Joint

Institute

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/20107

Prof Parker super analysis

• TNF

• Phasing

• Micro Geometry

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

1987 ORKNEY 3 MW Original

flexible pin wind turbine gearbox.

• Flexible pins with load limiting.

• Torque split on input.

• Torque limiting on input.

• Gear case free from deflection.

• Integrated planet wheel taper

bearings.

• Synchronous generator.

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/2010Commercially Confidential

ORBITAL2 Ltd

9

8 planet input train from a 20

year old wind turbine gearbox

with 10+ years of operation

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Why the failures

1. Load distribution across teeth and between planets

2. Rotor loads imposed on gear case

3. Power input not controlled

4. Absolute gear rating

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Carrier

Planet

Hicks - Flexible Pin

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201012

Flexible Pin provides:-

• Multi-planet applications.

• Equal loads between planet wheels (K < 1.1 for eight planets agreed GL)

• Uniform load across face width of teeth sun/planet &

planet / annulus contacts (K < 1.35 agreed GL)

• Uniform loads on planet wheel bearings

• Uniform load under overload and shock load conditions

• Dual rate Flexible pin Over Load Stop Protects from over stress under

dynamic overload conditions.

• Taper bearings with outer races incorporated in the planet wheel bore

provides maximum planet bearing capacity.

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Multiplanet – 4 or greater – flexible pin

Manufacturing error in pin position: 0,1 mm

Incremental force in tooth mesh: 16,9 kNm

Incremental load is 8%

Full load torque:

Deflection of pin: 1,2 mm

Force in pin: 367,2 kNm

Force in tooth mesh: 202,6 kNm

Stage II – MS 3

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

Multi Planet Epicyclics

3 planets statically determinant 3>Statically in determinant

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

W2000spg

8 planet wheel stage

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201016

2MW variable ratio back to back mechanical load test

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201017

Load balance between planets on the four planet train

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201018

Load distribution across the face width, helical gears.

Load sharing between planets with in 3%

Load sharing across the face in the centre

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

MINI-MASS Flexible Pin Gearboxes for wind turbines

•low mass high - reliability wind turbine drive trains with :-.

• Flex pins dual rate stiffness

• uniform tooth / planet load - multi planet

• Torque split - single plane of reaction - gear train.

• Gear case free from rotor loads and deflections.

• Variable ratio drive train for Dynamic control of input torque and

simple high voltage electrics.

PHOTO – 2MW SPG

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Flexible pin-Multi planet-Split torque

single reaction load free gear case

3MW- weight 22 tons

01/07/2010 20

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

ORBITAL2 - Mission Statement

The supply of market leading innovative gearbox designs for

WIND and TIDAL Turbines that offer low weight and high

reliability via ORBITAL2 flexible pin, multi planet epicyclics.

ORBITAL2 – Deliverables

• INOVATIVE Licensed Design gearbox solution with a full set

of manufacturing drawings

• Prototype build and test supervision

• GL or others approval documentation

• Supervision and Training of gearbox manufacturer

in the production of the licensed design

• Ongoing audit of gearbox build quality by licensee

• In service improvements of the gearbox via updates

of the manufacturing drawings

A Full design and engineering service from concept to end of life

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Documentation Control

ORBITAL2 gearboxes can be offered either as

Licensed designs for third party manufacture

or completely finished gearboxes from our

manufacturing partner, WIKOV CZ.

ORBITAL2 main design office is adjacent to

the WIKOV factory to facilitate control and

supervision of prototype gearbox build and test

by WIKOV.

Engineers fully integrated to support the

product from the spec, through production, to

ongoing maintenance support.

2MW SPG IN ACTION

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Examples of Orbital2>>>>>>

MS3 – Stage I

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

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ORBITAL2 – gearbox history / projects

1986 – First European 3MW wind turbine and the first flexible pin wind turbine gearbox. UK

1990’s – 350 kW production wind turbine gearboxes. (100 plus), UK

2002 – World’s first production (100 Turbines) variable ratio wind turbine 650kW. NZ

2004 – 3.4 MW variable ratio prototype wind turbine. Norway

2006 – 1.3 MW the world’s first production tidal turbine. UK

2007 – 2 MW variable ratio prototype wind turbine. CZ

2008 – 500 kW tidal turbine prototype. UK

2008 – 3 MW off shore wind turbine production gearboxes. Korea DOOSAN

2009 – 3 MW off shore wind turbine production gearboxes. China SINOVEL (160 )

2010 – 1.6 MW wind turbine production gearboxes.

2010 – 3.6 MW Wind Turbine China SEWIND (20)

2010 – 1.5 MW Wind Turbine China

2010 – 2 MW Rotor Turbine licence to China

2010 – 2 MW Rotor Turbine – India

2011 – 5 MW Rotor Turbine – China

PHOTO- 2MW SPG IN ACTION

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Wind Flow (NZ) 2002

650 KW Wind turbine for high wind

states (16m/s )

Gearbox designed by Hicks and

manufactured in NZ.

With flexible pins, torque limiting and

synchronous generation,

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/201026

3.4 MW SCANWIND turbine converted to a VR gear drive - 2004

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201027

3.4 MW variable ratio gearbox on part load test.

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/201028

TIDAL TURBINES – new applicationsMCT Production Turbine

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201029

MCT tidal gearbox on load test

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/201030

Marine Current Turbines installation April 2008

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/2010 31

MCT Tidal - Installed

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential 01/07/2010 32

MCT Tidal – Installed

Orbital2 – unrivalled experience

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

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MCT Tidal – Installed

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/201034

Tidal Generation

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/2010 35

Tidal Generation

Pre-series turbine

during test

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Prototype 2MW SPG turbines now operating

in Czech Republic

Power train assembly of W2000spg

Wind Turbine in Wikov’s assembly

hall in Hradec Králové, Czech

Republic

01/07/2010 36

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

W2000SPG Drivetrain

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

20.10.200938

• Allows ratio of the gearbox to be continuously

varied throughout the whole range of the wind

turbine rotor operating speed; making it

possible to maintain constant speed of the

synchronous generator

• 6.3 kV nominal voltage is generated by the

wind turbine => lower costs of connection to

the grid

• High voltage synchronous or fixed speed

induction generators can be used without full

power converters.

• Allows all of the main power electrics and

transformers to be placed on shore in a

central point further reducing the weight in the

nacelle and improving reliability.

• Provides torque protection of the gear train

and rotating elements against wind gusts

resulting in high reliability.

Gearbox with variable gear ratio

patented SPG (super position gear)

system

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/2010 39

2MW – Installed

W2000SPG Drivetrain in Operation in Czech Republic

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

• 3MW gearbox - China

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

01/07/201041

• 1.25MW IWP Type

• Optimised for balance between cost of energy,

logistics and service life-time cost.

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

• 1,5MW China

• Areodyn Type

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/2010 43

W1650

WindTec Type

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

01/07/2010 44

Main Frame Layout – W2000 Fixed Ratio

WindTec Type

O R B I T A L 2Flexible Pins – Driving Renewables

20.10.2009ORBITAL 2

• 3MW main drive gearbox

• Offshore version

3 MW

O R B I T A L 2Flexible Pins – Driving Renewables

20.10.2009ORBITAL 2

Commercially Confidential

ORBITAL 246

• Normal or Cold Climate version

• For 90/100/112m rotor diameter

• Torque reaction linkage (not shown)

• 3MW main drive gearbox

• Offshore/Onshore version

• 50 Hz or 60 Hz option available

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

3,6 MW

• 3.6MW ORBITAL2 Flexible Pin, Multi-Planet,

• Offshore China

• Torque 2806 kNm

• Ratio 1:84

• Weight 37 ton

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential 01/07/2010 48

Doosan 3MW – Test Rig

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

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Doosan 3MW – Test Rig

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Sinovel 3MW – Test Rig

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Building in Korea

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential

Building In China

O R B I T A L 2Flexible Pins – Driving Renewables

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Commercially Confidential

Opportunities ……………

O R B I T A L 2Flexible Pins – Driving Renewables

ORBITAL 2

Commercially Confidential PHOTO – 2MW SPG

DRIVING RENEWABLE ENERGY VIA

HIGH RELIABILITY, LOW WEIGHT,

MULTI PLANET, FLEXIBLE PIN,

EPICYCLIC GEARBOXES.

O R B I T A L 2