the intelligent gearbox - deutsche messe...

© ZF Friedrichshafen AG, 20171 2017-04-25 LHR IWDR, The Intelligent Gearbox

The intelligent gearbox –more performance and predictable maintenance

Dietmar Tilch, ZF Industrieantriebe Witten GmbH

MDA Forum, Hannover Fair 2017

ZF Friedrichshafen AG

LHR IWDRDietmar Tilch

MOTION AND MOBILITYWind Power Technology In ZF Group

Car PowertrainTechnology

Car ChassisTechnology

Commercial VehicleTechnology

IndustrialTechnology

E-Mobility ZF Aftermarket

Off-Highway Systems

Test Systems

Special Driveline Technology

Marine Propulsion Systems

Aviation Technology

Wind Power Technology

Industrial Drives

Active & Passive Safety Technology

Mobility across the boardZF organization is divided into 7 major divisions:


ZF Puts Wind Energy In Motion

Joining forces for the new generation of wind energy

In the gearbox industry since1979Manufacturing capacity on annual basis~ 18,000 MWWorldwide manufacturing & service coverageBalanced globalManufacturing depth and processesAll critical processes in-houseGlobal installed base> 100,000 MW whereof 3 MW segment > 15,000 MWProduct portfolio – on- and offshore0.8 MW - 8.0 MWFull Service OfferingDedicated service centers in all major wind market

ZF Global Leading Position

© ZF Friedrichshafen AG, 20174 2017-04-25 LHR IWDR, The Intelligent Gearbox*) ~400GW of geared wind turbines installed (end 2016, cumulative); thereof >100GW installed by ZF Wind Power

Single point of contact for ~25%* of worldwide installed wind capacity

> 100 GWZF gearbox capacity installed

> 55.000Gearboxes


The Wind Power Gearbox as anIntelligent Mechanical System

On-site data evaluation and communication to

� turbine controller (real time)

� Cloud: predictive maintenance

Essential operation parameters

� Speed

� Torque

� Temperatures

� Lubrication status

DSL, LTE

Cloud services provide data overview, history and trends as well as:

� Automated detection of abnormalities

� Remaining lifetime calculations

� Remote monitoring information

Multiple Sensor Network

� Dynamic Load Monitor

� Vibration

� Oil parameters

� Cameras

� etc.


Dynamic Load MonitoringTorque Measurement Principle

Determination of position 1 down to a few µm

Determination of position 2 down to a few µm

Possible measurement positions inside a gearbox

Contactless robust inductive sensor


Potential For Energy Yield Increase Based on individual wind turbine drive train load measurement

Rat

ed P

ow

er

Str

ess

WTG 1

Str

ess

WTG 2

Today

Str

ess

WTG xx

Str

ess

WTG 3 . . . .

. . . .

Rat

ed P

ow

er

Rat

ed P

ow

er

Rat

ed P

ow

er

Risk for early damage

High wind turbulences

Rated power

With individual drive train load measurement

Fea

sib

le P

ow

er

Str

ess

WTG 1

Design strength

Str

ess

WTG 2

Str

ess

WTG xx

Str

ess

WTG 3 . . . .

. . . .

Fea

sib

le P

ow

er

Fea

sib

le P

ow

er

Fea

s. P

ow

er

Higher energy yield without risk

SensorControl Unit

t

ConditionMonitoring

System

TurbineController

Torque Stress

DampingTorque


Optimal Drive Train Load Reduction Based On Closed Loop Control Gearbox as an ideal drive train load measurement position

turbine control

rpm

torque measurement

Closed loop damping based on torque measurement

damping in complete frequency range

timetorq

ue

Potential for torque/power increase

Average torque loadStr

ess Dynamic torque load

100%

turbine control

rpm

Without damping

torq

ue

time

m1mx

m2,3,4m1m2

Str


100%

Average torque load

Overload

Damping based on generator

signals

rpm

Current state of the art damping (based on generator signals)

timetorq

ue

no dampingdamping Str


100%

Average torque load

Safety margins reduces feasible power

no dampingrisk for excitation


Optimal Drive Train Load Reduction Based On Closed Loop ControlMulti-Body-Simulation of a typical multi megawatt wind turbine

Damping based on generator

signals

rpm

Current state of the art

Str

ess

100%

turbine control

rpm

Without damping

Str

ess

100%

turbine control

rpm

torque measurement

Closed loop damping

Str

ess

100%0 1 2 3 4

0

0.5

1

1.5

2

Torq

ue

amp

litu

de

Frequency [Hz]

without dampingcurrent state

of the art damping

closed loopdamping

Reduction of further oscillation with closed loop damping � better rotor aerodynamics� higher energy yield

Excitation with current state of the art damping

could result in higher torque amplitudes due to open loop control

Reduction of torque amplitudes caused by wind turbulences (especially storms)


The Wind Power Gearbox As An Intelligent Mechanical System

Cloud services provide data overview, history and trends as well as:

� Automated detection of abnormalities

� Remaining lifetime calculations

� Remote monitoring information

OEM and operator benefits:-> ZF enables the reduction of the Cost of Energy sustainably by:

� Minimizing Operational Expenditures� reduced stress and wear� demand-oriented maintenance� extended oil life cycles

� Optimizing the turbine performance


Contribution of Intelligent Performance Management to reducing the Cost of Energy

LCOE: Levelized Cost of Energy, AEP: Annual Energy Production, CAPEX: Capital Expenditure, OPEX: Operational Expenditure

LCOE Drivers

CAPEXLifetime extension

Value engineering

AEPReliable & efficient operation

Performance increase

OPEXMaintenance optimization

Increase availability


Cloud-based Performance Management, Park Overview


Drive Train Dynamics Dashboard


Critical Drive Train Dynamics


Load based Lifetime Calculation


The Intelligent Gearbox

INTELLIGENT PERFORMANCE MANAGEMENT

TORQUE DENSITY INCREASE

SYSTEM BEHAVIOR

ADVANCED BEARING TECHNOLOGY

Making wind power the leading renewable energy source

Intelligently designed plusIntelligently operated and

maintained

Intelligently designed plusIntelligently operated and

maintained

© ZF Friedrichshafen AG, 201717 2017-04-25 LHR IWDR, The Intelligent GearboxZF Friedrichshafen AG behält sich sämtliche Rechte an den gezeigten technischen Informationen einschließlich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.

ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.

Thank you

Meet you on our booth

Hall 25, A12

the intelligent gearbox - deutsche messe...

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