romax: state-of-the-art drivetrain - ewea 2013 by yann rageul

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


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


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




configurations




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


Medium Speed (2 stage)

Offshore Drivetrain

Annual Cost of Energy

Generator

capex

16%

Generator

O&M

37%

Gearbox

capex

14%

Gearbox

O&M

33%


Direct Drive Medium Speed

(1 stage)

Medium Speed

(2 stage)

High Speed

Co

stHigh Speed

Offshore Drivetrain


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)




configurations




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


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 Sun gear -> Stage 1 Planet gear 1











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



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


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


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


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


Flexible O&M Strategy


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



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]

romax: state-of-the-art drivetrain - ewea 2013 by yann rageul

Technology

romax drivetrain

gearbox driveline medium

drivetrain gearbox design

romax butterflytm drivetrain

sharing innovation

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