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ExecutiveSummary
ThisreportpresentskeyfindingsfromtheDepartmentofEnergysAdvancedDrivetrainWorkshop,held onJune2930,2010inBroomfield,Colorado,toassessdifferentadvanceddrivetraintechnologies,their relativepotentialtoimprovethestateoftheartinwindturbinedrivetrains,andthescopeofresearch anddevelopmentneededfortheircommercializationinwindturbineapplications. TheAdvancedDrivetrainWorkshopevaluatednextgenerationtechnologiestoidentifythosewith potentialtoradicallyimprovethereliability,performance,andcapitalcostofwindturbinedrivetrains beyondtheincrementalimprovementsthatmightbeexpectedforcurrentstateofthearttechnologies. Theworkshopfeaturedfourseparatediscussiontracks,eachfocusedonabroadcategoryofdrivetrain technologies:SuperconductingDrivetrains;AdvancedPermanentMagnetGenerators;Continuously VariableTransmissionsandFluidDriveSystems;andInnovativeandNonTraditionalDrivetrain Concepts. Workshopparticipantsidentifiedmajorresearchtopicswiththepotentialtoimproveonthestateof theartinwindturbinedrivetrainsforeachofthefourbroaddrivetraintechnologycategories.The participantsalsolistedthemajorbarrierstothecommercializationofthesetechnologiesandpotential researchanddevelopmentpathwaysforovercomingthosebarriers.Thoseresultsaresummarizedin Table1below.
Table1.Benefits,Barriers,andDevelopmentPathwaysforAdvancedDrivetrainTechnologies Superconducting Drivetrains Topic Superconducting DirectDrive Generators NextGeneration Superconducting Technologies AdvancedMagnetic Materials Benefits Capitalcosts; reliability;energy capture;supplychain security Energycapture Barriers Technical; perception; scaling;IP Technical Pathways Subcomponentreliabilitytesting; demonstrationprojectdeployment; engageindependentthirdparties Laboratorytesting

Capitalcosts; reliability;energy capture;safetyand serviceability Capitalcosts; reliability;energy capture;safetyand serviceability Capitalcosts; reliability; performance Reliability;

Technical; commercial; perception; certification Technical; commercial; certification; Technical; perception; commercial; Reliability; operator training; certification Technical; scalability;

PermanentMagnetGenerators

SystemDesignand Topology

Materialsscienceresearch;tradeoff analysis;cost/benefitanalysis; InternationalElectrotechnical Commission(IEC)standards development Laboratoryresearch;cost/benefit analysis;IECstandardsdevelopment

PowerElectronics

Diagnosticsand Maintenance

Laboratoryresearch;workforce educationandtrainingcost/benefit analysis; Reliability research;workforce educationandtraining;IECstandards development Costbenefitanalysis;designand modelingtools;demonstration 2|Page

FrictionalContact Drives

Capitalcosts; reliability;energy

Va ria ble Tr

Topic

Benefits capture

Barriers materials Technical; scalability; materials; perception Technical

Pathways projects;componentdevelopment andtesting Costbenefitanalysis;designand modelingtools;component developmentandtesting; demonstrationprojects Feasibilitystudies;equipmentsurvey

FluidDrives

InnovativeConcepts

UptowerDirect Current(DC) Generator GroundLevel Generators RimDriveTurbines TandemGenerators CompleteUpTower GearboxReparability OtherInnovative Drivetrains

Capitalcosts; reliability;energy capture;energy storage Reliability;grid benefits Reliability Reliability Availability; scalability Reliability Capitalcosts; reliability

Technical Technical Commercial Technical Technical; perception

Feasibilitystudies Feasibilitystudies Feasibilitystudies Feasibilitystudies Designstudies

Thetechnologiesoutlinedabovecanbegroupedintothreebroadcategoriesbasedontheirpotential impactonthemarketforcurrentandnextgenerationdrivetrains.Thefirstcategoryincludesconcept stagedesignsfornextgenerationwindturbinesthatofferpotentiallysignificantbutstilluncertain advantagesoverthestateoftheart.Thesecondcategoryincludestechnologiesthatarecurrentlybeing consideredforincorporationintocurrentwindturbinedrivetraindesigns.Thethirdcategoryincludes technologiesthathavepotentiallytransformativeapplicationinnextgenerationturbinedesignswith largenameplatecapacities(5+MW),particularlyinoffshorewindturbines.Theuniquechallengesfacing eachcategorywillrequiredifferentresearchanddevelopmentstrategiesinordertosuccessfully commercializethesetechnologies.

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TableofContents
ExecutiveSummary.......................................................................................................................................2 ListofTables.................................................................................................................................................4 ListofFigures................................................................................................................................................4 1.0 2.0 2.1 2.2 2.3 2.4 3.0 4.0 5.0 Introduction......................................................................................................................................5 WorkshopResults............................................................................................................................. 8 SuperconductingDrivetrains........................................................................................................ 8 PermanentMagnetGenerators.................................................................................................. 12 ContinuouslyVariableTransmissions......................................................................................... 18 InnovativeConcepts................................................................................................................... 22 Summary.........................................................................................................................................26 References......................................................................................................................................27 Appendix:WorkshopAgenda......................................................................................................... 28

ListofTables
Table1.Benefits,Barriers,andDevelopmentPathwaysforAdvancedDrivetrainTechnologies................2 Table2.BenefitsofSuperconductingDirectDriveGenerators..................................................................10 Table3.BarrierstoCommercializingSuperconductingDirectDriveGenerators .......................................11 Table4.BenefitsofPermanentMagnetTechnologyImprovements.........................................................14 Table5.BarrierstoCommercializingPermanentMagnetTechnologyImprovements.............................17 Table6.BenefitsofContinuouslyVariableTransmissions......................................................................... 20 Table7.BarrierstoCommercializingContinuouslyVariableTransmissions..............................................21 Table8.BenefitsofInnovativeDrivetrainConcepts.................................................................................. 22 Table9.BarrierstoCommercializingInnovativeDrivetrainConcepts.......................................................24

ListofFigures
Figure1.Conventionalgearboxdrivetrainconfiguration............................................................................ 5 Figure2.Cutawayofmultistagegearbox.................................................................................................... 7 Figure3.Superconductorcoilsinvacuuminsulatedrotor ........................................................................... 8 Figure4.Benefitsofpermanentmagnettechnologyimprovements........................................................12

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1.0

Introduction

ThisreportpresentskeyfindingsfromtheAdvancedDrivetrainWorkshop,whichwasorganizedbythe U.S.DepartmentofEnergy(DOE)WindandWaterPowerProgramtodiscussthenextgenerationof windturbinedrivetraintechnologies.Theworkshop,heldonJune2930,2010inBroomfield,Colorado, convenedexpertsfromindustry,academia,thefederalgovernment,andnationallaboratories.The purposeoftheworkshopwastoassessdifferentadvanceddrivetraintechnologies,theirrelative potentialtoimprovethestateoftheartinwindturbinedrivetrains,andthescopeofresearchand developmentneededfortheircommercializationinwindturbineapplications.TheWindandWater PowerProgramsponsoredtheworkshopaspartofitslargereffortstoreducethecostofenergy producedbywindturbines.

Figure1.Conventionalgearboxdrivetrainconfiguration

Thedrivetrainofawindturbineconvertsthelowspeed,hightorquerotationoftheturbinesrotor (bladesandhubassembly)intoelectricalenergy.Themostcommondrivetrainconfiguration(Figure1) consistsofalowspeedshaft(alsocalledamainshaft),agearbox,ahighspeedshaft,andagenerator (Hau2006).Thelowspeedshaftconnectstotherotorhubandissupportedbythemainframe(or bedplate)throughoneortwomainbearings.Asaresult,thelowspeedshaftrotatesatarotational speedofroughly1230revolutionsperminute(rpm)forcurrentutilityscalewindturbines.Agearbox connectedtothelowspeedshaftstepsuptherotationalspeedto1,2001,800rpmviaasetofgearsin twoorthreestages,typicallyconsistingofplanetaryandparallelgearconfigurations(Hau2006).Ahigh speedshaftthentransmitsmechanicalpowerfromthegearboxtoagenerator,whichrequireshigh rotationalspeeds(1,2001,800rpm)inordertoeconomicallygenerateelectricity.Generatorsoftenuse powerelectronicstoallowvariablespeedoperationandtoconditiontheelectricalpoweroutputofthe turbinesothatitcanbeintegratedintothepowergrideasilyandefficiently.Somewindturbine configurationsforgoagearboxandinsteadgenerateelectricitybycouplingthelowfrequencyrotation ofthemainshaftdirectlytothegenerator.Suchdirectdriveconfigurationstypicallyrequirelarge
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diametergeneratorsandextensivepowerelectronicstoallowvariablespeedoperationandtocondition theelectricaloutputforthegrid. Drivetrainscontributetothetotalcostofenergyproducedbywindturbinesinmultipleways.First,the drivetrainincludessomeofthemostexpensivecomponentsinawindturbine,namelythegearboxand generator,whichaccountfornearlyonehalfoftheturbinestotalcapitalcost(Fingersh,Handand Laxson2006).Heavierdrivetrainsalsorequiremoresubstantialtowerstosupporttheirweight,further drivinguptheturbinesoverallcapitalequipmentcosts.Second,drivetrainsrepresentasignificant proportionofthetotalenergylosseswithinawindturbine,reducingelectricalpoweroutput,andthus revenue,ofanindividualturbine.Finally,conventionaldrivetrainsarenotmeetingtheirexpected20 yearoperatinglifetimesprimarilyduetoprematuregearboxandbearingsfailuresthatnecessitate turbinedowntimeaswellasexpensiveandtimeconsumingrepairsorreplacements,oftenviathe deploymentofverylargeandexpensiveliftingcranes(Musial,ButterfieldandMcNiff2007).Inaddition tothecostsofreplacementequipment,cranerental,andlostrevenue,widespreadgearboxfailurescan leadfinancierstodemandhigherinterestratesforprojectloansduetoahigherperceivedlevelof technologyrisk. Tohelplowerthecostofwindenergy,theWindandWaterPowerProgramworkstoimprovereliability, increaseperformance,anddecreasecapitalcostsforwindturbinedrivetrains.Theprogramfundsthe GearboxReliabilityCollaborative,apublicprivatepartnershipbetweennationallaboratories, universities,gearboxandcomponentmanufacturers,engineeringconsultants,andwindturbine manufacturers.ThemissionoftheGearboxReliabilityCollaborativeistogather,analyze,andsharedata fromoperationalandexperimentalgearboxes(Figure2).Thegoalofthiseffortistoidentifycritical designparametersandrootcausesthatareresponsibleforgearboxfailuresinthefield.Theprogram alsofundsthedevelopmentoflargedynamometerscapableoftestingnextgenerationwindturbine drivetrainsthisfunctionalityallowsturbinemanufacturerstovalidateandrefinenewdesignsbefore deployingtheminthefield.Insomecases,theprogramhasworkedwithspecificcompaniestodevelop newwindturbinedesignsthatincorporateadvanceddrivetraintechnologies,suchasmultigenerator systems,gearboxcomponentloadmitigation,orpermanentmagnetreplacementsforwound electromagnetsinthegeneratortoreducesystemsize.Finally,theprogramfundslaboratoryresearch anddevelopmentonavarietyoftopicswiththepotentialtoimprovethereliabilityandperformanceof turbinedrivetrains.Twokeytopicsareadvancedmaterialsthatimprovethelubricationandwear resistanceofdrivetrainsanddrivetraincomponents,andtheuseofconditionbasedhealthmonitoring toreduceequipmentfailuresthroughpredictivemaintenance.

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 Figure2.Cutawayofmultistagegearbox TheAdvancedDrivetrainWorkshopevaluatednextgenerationtechnologiestoidentifythosewith potentialtoradicallyimprovethereliability,performance,andcapitalcostofwindturbinedrivetrains beyondtheincrementalimprovementsthatmightbeexpectedforcurrentstateofthearttechnologies. TheworkshopbeganwithintroductoryremarkscoveringDOEsexistingportfolioofdrivetrainresearch anddevelopmentprojects,thecurrentstateoftheartindrivetraindesignconfigurations,andthe purposeandstructureofthemeeting.Theworkshopparticipantsthensplitintofourgroupstodiscuss separatetechnologies:SuperconductingDrivetrains;AdvancedPermanentMagnetGenerators; ContinuouslyVariableTransmissionsandFluidDriveSystems;andInnovativeandNonTraditional DrivetrainConcepts.Overaseriesofthreesessions,theparticipantsprovidedinputonthecurrentstate ofdifferentadvanceddrivetraintechnologies;describedhowthesetechnologiescouldofferan improvementoverthestateoftheart;listedsomeofthecurrentusesofthesetechnologiesandthe barrierstocommercializationinwindturbineapplications;andoutlinedpotentialpathsto commercializationofthesetechnologies,includingestimateddevelopmenttimelinesandkeyareasof researchanddevelopment.TheWorkshopconcludedwithareportoutsessioninwhichthefourgroups presentedtheirkeyfindingstothelargerassembly.

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2.0

WorkshopResults

Thefollowingsectionsdescribethemajortechnologiesdiscussedineachofthefourtechnology breakoutsections,theirpotentialbenefitsoverthestateoftheart,andpossiblepathwaysfortheir commercialization.

2.1 SuperconductingDrivetrains
Thissessiondiscussedthepotentialapplicationofsuperconductingmaterials(materialscapableof conductingelectricitywithnearzerodirectcurrent(DC)electricalresistance)inwindturbine generators.Superconductingmaterialsonlyexhibittheirsuperconductingpropertiesatverylow temperaturesandareclassifiedbythecriticaltemperatureatwhichtheyoperate.Lowtemperature superconductingmaterialstypicallyrequiretemperaturesbelow20Kelvin(253Celsius),whilehigh temperaturesuperconductingmaterialsoperatebetweenapproximately30and40K.Superconducting materialsandcoolingsystemsarecurrentlyusedinmanynonwindapplications,includingMagnetic ResonanceImagingmachines,particleaccelerators,electricaltransmission,andprototypeship propulsionsystems.Superconductinggeneratorsgenerallyfeaturesuperconductingmaterialsinthe rotor(Figure3)andaconventional(nonsuperconducting)stator,althoughalternatetopologiesexist (includinghomopolardesigns,insideoutdesignsinwhichtherotorenclosesthestator,anddesigns combiningpermanentmagnetsandsuperconductingmaterials).Futuresuperconductingtechnologies maymakeitpracticaltoalsousesuperconductingmaterialinthegeneratorstator;however,with currenttechnologies,thealternatingcurrentinherentinthestatorresultsintimevaryingmagnetic fieldsthatincursubstantiallosses.

Figure3.Superconductorcoilsinvacuuminsulatedrotor

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Superconductinggeneratorshavethepotentialtoofferseveralcostandreliabilityimprovementsover conventionalwindturbinedrivetrainswhenscaleduptoveryhighcapacities(5MWandlarger)and whenusedindirectdrivesystems.Directdrivewindturbinesdonotrequireagearbox,thereby eliminatingamajorsourceofreliabilityfailures.Althoughsuperconductinggeneratortechnologycanbe usedwithagearbox,thissessionfocusedontheapplicationofsuperconductinggeneratorsindirect drivewindturbinesduetoperceivedadvantagesincommercialandeconomicviabilityofsuchdesigns. Superconductinggeneratorshavelessmassandrequirelessvolumethancomparablepermanent magnetdirectdrivegenerators,particularlyaswindturbinecapacityratingscontinuetoincrease(power outputtendstoscalewithvolumemorequicklyinsuperconductinggeneratorsthaninconventional directdrivegenerators).Lowergeneratormassandsizereducesthecapitalcostofgeneratorand reducestheloadsonthetower,resultinginanoverallreductioninturbinecapitalcosts.Cost advantagesproducedbysuchweightsavingsaremostlikelytoberealizedinitiallyinlargeturbines (roughly5+MW).Inadditiontoweightsavings,superconductinggeneratorshavethepotentialto increasedrivetrainreliabilitybyallowingamuchlargerairgaptolerancebetweenrotorandstatoras comparedtopermanentmagnetdirectdrivedesigns.Conventionaldirectdrivegeneratorsmust maintainanairgapbetweenrotorandstatorofonlyafewmillimeters,makingcontactbetweenrotor andstatormuchmoredifficulttoavoid,andultimatelyleadingto increased weight due to increased structural support requirements (Mueller and McDonald 2008).Itcanbedifficulttomanufactureand operateconventionaldirectdrivegeneratorswithsuchtighttolerances.Superconductingdirectdrive generators,withairgapsontheorderofseveralcentimeters,canbemoreeasilydesignedtoavoidthis modeoffailure. Superconductingdirectdrivegeneratorsareespeciallysuitedforoffshorewindapplications,because thereisaneconomicincentivetoplaceaslargeofaturbineaspossibleonasinglefoundationto compensateforthehighinstallationcostsforoffshorewind,andbecausethesedesignshavethe potentialtooffergreaterreliabilityandrequirelessmaintenancethanbothgearedandconventional directdrivedesigns.

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Table2belowlistsmajorareasofinterestinsuperconductingdirectdrivegeneratorresearchand developmentandthepotentialbenefitsthattheseareasofinterestofferoverthestateoftheartin windturbinedrivetrains.

Table2.BenefitsofSuperconductingDirectDriveGenerators

AreaofInterest LowTemperatureand HighTemperature SuperconductingDirect DriveGenerators

Description
Superconductingdirectdrive generatorseliminateelectrical resistanceinrotorcoilsbysuper coolingthem,allowingforextremely strongmagneticfluxandhightorque densitieswithouttheneedforadding material(largercoilsorpermanent magnets).Asaresult,superconducting generatorstendtobelessmassiveand muchsmallerinsizethanconventional directdrivegenerators,especiallyat generatingcapacitiesof5MWand higher.

Benefits
ReducedCapitalCosts:potentially
significantdrivetrainmassadvantage beginsaround5MWandscales rapidlywithgeneratingcapacity.The lighterconstructionandreduced materialusagecanresultinalower drivetraincost,decreasedtower loading,andeasierinstallation logistics. ImprovedReliability:largerairgap betweenrotorandstatorleadsto reliabilityanddesignbenefits comparedtopermanentmagnet directdrivedesigns.Thismayleadto reductionsinunscheduled maintenance. IncreasedEnergyCapture: superconductingdirectdrivedesigns promotescalabilitytotallerandhigher generatingcapacityturbinesdueto smallerandlighternacelles. SupplyChainSecurity: Superconductingdirectdrive generatordesignsusereadilyavailable materialstogeneratemagneticflux, therebyprovidinganalternativetothe rareearthmagnetmaterials,typically minedoutsidetheU.S.,usedinother directdrivedesigns. IncreasedEnergyCapture:advancesin superconductingtechnologywill increasetheefficiencyof superconductingdirectdrivesystems; increasedefficiencymayresultin highermagneticfluxdensities,lower parasiticlosses(currently<~1%),or furtherdesignoptimization.

NextGeneration Superconducting Technologies

Advancesinsuperconducting technologythatwerediscussed include:superconductingrotorAND stator,linearsuperconducting generators,andsynchronous generatorswithaircoresandcopper stators.

Themajorbarrierstoincorporatingsuperconductinggeneratorsinwindturbinedesignsareinlargepart commercialratherthantechnicalinnature.Theperceptionofsuperconductinggeneratorsasoverly complex,undeveloped,andhighrisktechnologyisexpectedtoincreasethecostoffinancingprojects usingthistechnology.Perceivedsafetyconcernsregardingtheuseofsupercoolednitrogenorhydrogen

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mayalsohindertheadoptionofthistechnology,despiteitswidespreaduseincommoncommercial applicationssuchasMagneticResonanceImaging(MRI).Thelackofascalingreferenceoranoperating prototypeturbineincorporatingsuperconductingdirectdrivetechnologyrenderitdifficulttocompare thecostsandperformanceofthistechnologywithcurrentdrivetraintechnologies,thoughinitialtesting hasbeenperformedonmultimegawattscalesuperconductingmotors.Inadditiontothesecommercial risks,superconductinggeneratorsfacepotentialtechnicalrisksrelatedtoreliabilityanddurabilityof superconductingmaterials,suchaswireperformanceanddurabilitydegradationresultingfrom mechanicalandthermalcycling.Afurtherconcerniscoolingsystemfatigueanddegradationresulting fromthermalcycling. Duetothecommercialbarriersoutlinedabove,aresearchanddevelopmentprogramtocommercialize superconductinggeneratorsinwindturbinesmightfocusheavilyonthedemonstrationofthese technologiestoestablishtheirtechnicalviabilityandcostandperformanceadvantages.The demonstrationofalargescaleprototypeturbinewithasuperconductinggenerator,leveragingexisting, appropriatelysizedturbinecomponentssuchasbladestospeeddeployment,ataprepermittedland basedoroffshoresitecouldaddressmanyoftheperceptionconcerns.ExistingDOEinitiatives,suchas theLargeBladeandLargeDrivetrainTestingFacilitiesandongoingcertificationandstandards development,couldsupportthedevelopmentofthisprototype.Componentandsubcomponent reliabilitytestingwouldbeespeciallyeffectiveinaddressingperceptionsofhightechnologyriskbeforea fullscaleprototypeistestedinaturbine. Table3belowlistsmajorbarrierstothecommercializationofsuperconductingdirectdrivegenerator technologyandpotentialresearchanddevelopmentpathwaysforovercomingthosechallenges.
Table3.BarrierstoCommercializingSuperconductingDirectDriveGenerators

AreaofInterest LowTemperatureand HighTemperature SuperconductingDirect DriveGenerators

CommercializationBarriers

DevelopmentPath

TechnicalRisk:coolingsystem Conductsubcomponentreliability reliability,fatiguecausedbythermal testing:acceleratedreliabilitytesting cycling,andcoolantcontainment couldutilizeshakertablestotest areuntestedinawindturbine operatingcryosystemsandcoil environment. windingsunderrepresentativewind turbineconditions. PerceptionRisk:misperceptions Conductreliabilitytestinganddeploy regardingthenewnessof demonstrationprojects:accelerated superconductingdirectdrive reliabilitytestinganddeploymentof technology,systemcomplexity,and operationaldemonstration safetyuncertaintycauseconcerns superconductingdirectdrivewind aboutitsimplementationinwind turbineswouldhelpalleviate turbinesystems. misperceptionsaboutthistechnology. ScalingRisk:projecteconomicsand Deploydemonstrationprojects: manufacturingrequirementsfor10 successfullydeployedlargewind MWwindturbineshavenotbeen turbinescouldestablishtheirviability. demonstrated.Thereareno10MW scaleprototypetestplatforms

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 IPRisk:superconductingtechnology ownersanddevelopersmaybe hesitanttocollaborateonturbine research,development,andtesting.

NextGeneration Superconducting Technologies

CertificationRisk:windturbine standardshavenotbeendeveloped fordirectdriveorsuperconducting technologies TechnicalRisk:advanced superconductingtechnologiesare stillinthebasicresearchphase.

Engageindependentthirdparties: federalorstategovernments, universities,certificationbodies,or otherindependentorganizationscould assistindataaggregationand benchmarkdevelopment. EstablishIECstandardsfor superconductingdirectdrive:support workinggroupstoestablishstandards language. Conductlaboratorytesting:continued research,development,andtesting willadvancetheTechnologyReadiness Levelofadvancedsuperconducting technologies.

2.2 PermanentMagnetGenerators
Thissessiondiscussedadvancedpermanentmagnetgeneratortopologiesforwindturbineapplications. Thesedesignsusepermanentmagnetscomposedofrareearthmineralalloysinplaceofinduction generatorscomposedofwoundelectromagnetsthatrequireelectricitytooperate.Thissession discusseddirectdrivedesigns(aclassofdrivetrainthatdoesnotrequireagearboxtostepupthe rotationalspeedoftheturbinerotortothehighrotationalspeedsdesiredforelectricitygeneration)as wellastheincorporationofpermanentmagnetgenerators(Figure4)inconventionalgeareddrivetrains. Permanentmagnetgeneratorshavebeencommercializedforwindturbineapplications,bothingeared andindirectdrivetopologies,althoughopportunitiesfortechnologyimprovementsstillexist.

Figure4.Cutawayviewofsinglestagepermanentmagnetdrivetrain 12|Page

Permanentmagnetgeneratorshavethepotentialtoofferseveralcostandreliabilitybenefitsover conventionalinductiongeneratorsusingwoundelectromagnets.First,permanentmagnetgenerators haveincreasedpowerdensitiesoverconventionalinductiongeneratorsusingwoundrotororsquirrel cagedesigns;permanentmagnetgeneratorsthusweighlessandrequirelessspacethancomparable inductiongenerators.Becausepermanentmagnetgeneratorsdonotrequireelectricitytoinducea magneticfieldintherotor,theyofferperformanceimprovements(lowerparasiticenergylosses)over inductiongeneratorsorwoundfieldsynchronousgenerators.Inaddition,permanentmagnet generatorsdonotrequiregeneratorbrushesandrotorwindinginsulation,eliminatingthese componentsaspotentialsourcesofequipmentfailure.Directdrivedesignswithpermanentmagnet generatorsofferadditionalbenefits,mostnotablythecompleteeliminationofthegearboxfromthe drivetrain.Thegearboxisoneofthemostexpensivecomponentsofawindturbine,requiresthemost scheduledmaintenanceandveryexpensiverepairs,andisresponsibleforalargeportionofthe turbinesenergylosses. Althoughdirectdrivepermanentmagnetgeneratordesignsovercomethesegearboxissues,theyfacea separatesetofchallenges.Togeneratepowerfromlowspeed,hightorquerotationalmotion,these topologiesrequirelargediametergenerators,whichincreasethesizeandweightofthedrivetrainand useincreasingamountsofexpensiverareearthmagneticmaterial.Furthermore,thesetopologiesmust maintainaverysmallairgapbetweenrotorandstator(ontheorderofmillimeters)toobtainhigherflux densities.Thisleadstodesign,manufacturing,andoperationalchallengesinhandlingthecomplexloads fromtherotorasthegeneratorsincreaseinsize.Finally,becausedirectdriveturbinesoperateas synchronousgenerators,theyrequireextensivepowerelectronicstoallowvariablespeedoperationand tosynchronizetheiroutputwiththefrequencyofthepowergrid. Table4belowlistsmajorareasofinterestinpermanentmagnetgeneratorresearchanddevelopment andthepotentialbenefitsthattheseareasofinterestofferoverthestateoftheartinwindturbine drivetrains.
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Table4.BenefitsofPermanentMagnetTechnologyImprovements

AreaofInterest AdvancedMagnetic Materials

Description
Improvedmagneticmaterialscould leadtoincreasedenergydensities, whichwouldresultinsmaller generatorsand,consequently,lower weightdrivetrains.Materials improvementsincludebulkmaterial propertyenhancement,nano structuredmagneticmaterials,and flexiblemagnetsthatcanbe magnetizedordemagnetizedpost installation.

Benefits
ReducedCapitalCosts:lowerweight

SystemDesignand Topology

PowerElectronics

Standards

permanentmagnetswouldresultin lowerweightgenerators,reducingup towerweight. ImprovedReliability:relaxedairgap constraintswoulddecreasethe incidenceofrotor/statorimpact, decreasingmaintenancecosts. IncreasedEnergyCapture:lower nacelleweightsmaymakeitcost effectivetodeploytallertowerswith largerrotors. SafetyandServiceability:magnets thataresafertohandleduring installationandmaintenancewould reducethepotentialforaccidents. Possiblesystemdesignandtopology ReducedCapitalCosts:advanced improvementsinclude: topologiescouldresultinsmaller generators,reducinguptowerweight. Radialflux(gearedordirectdrive), transverseflux,Vernierdesigns, ImprovedReliability:betterdesigned magnetgearingandcoreless andtoleranceairgapswoulddecrease armatures; theincidenceofrotor/statorimpact, decreasingmaintenancecosts. Advancedairgapdesignto improvetolerancesandreduce IncreasedEnergyCapture:lower strikes; nacelleweightscouldmakeitcost effectivetodeploytallertowerswith Designsforinsitumaintenance largerrotors. (handling),suchasindividually SafetyandServiceability:systemsthat replaceablecoilsormodularized aredesignedforinstallationand designs. maintenancewouldreducethe potentialformagnetrelatedaccidents. Newconcepts forpowerconverters ReducedCapitalCosts:technology includeadvancedcontrols,better advancesmayleadtolowercost controlledvoltagelevels,improved powerelectronics. switching,andadvancedarchitectures. ImprovedReliability:improvedpower Controlandprotectiontopologiesfor electronicsoperationsandcontrols permanentmagnetgeneratorscould wouldenablewindturbinestoavoid influencedemagnetization, reliabilityproblemscurrentlyseenin overvoltageduetolossofload,short PMgenerators. circuitprevention,andunbalanced ImprovedPerformance:lossesdueto loadprevention) powerelectronicsmaybedecreased. ThereisamarketneedforPMG ImprovedReliability:Standards standardsdevelopment,particularly typicallyleadtomorereliablesystems pertainingtotestingand orcomponents;thiswouldbetruefor measurement. PMGsaswell. ReducedCapitalCosts:Future financingcostswoulddecreaseas 14|Page

Diagnosticsand Maintenance

Signatureanalysis utilizingsmart sensorsallowforadvanceddiagnostics andpredictivemaintenance.

OperatingEnvironment Aswindturbinemoveoffshore(marine
environment)and/orarelocatedin moreextremeoperatingenvironments (extremetemperatures,etc.),new materialsanddesignconsiderations willberequiredtoensuresuccessful longtermoperations.

systemsbecomemorereliableandcan becertifiedtoastandard. ImprovedReliability:Operationsand maintenancecostsdecreaseasaresult ofwellscheduledmaintenancethat minimizesfailuresandturbine downtime. ImprovedReliability:Extreme operatingconditionswillhavea negativeeffectoncomponentand systemlifetime.Technology improvementswiththisinmindmay leadtowindturbinesthatremain reliableregardlessoflocation.

Thesessionidentifiedseveralareasofresearchanddevelopmentthatcouldleadtoimproved permanentmagnetgenerators,includingmagneticmaterialsresearch;developmentofnewgenerator machinedesigns;improvedpowerelectronicscharacteristicsandpowerconverterarchitecture;and developmentofdiagnosticmethods.Thespecificsubtopics,benefits,andchallengesofeachofthese researchareasaredescribedbelow. Magneticmaterialsresearchcouldimprovepermanentmagnetsbyimprovingtheirenergydensity, creatingnanostructuredmagnets,orbycreatingmaterialsthatcanbemagnetizedordemagnetized postinstallationtosimplifyassemblyandmaintenanceprocesses.Theseadvancescouldresultinsize andweightreductionsovercurrentmagnets,particularlyimportantforlargediameterdirectdrive generators.Developmentofsuchmagnetswouldrequirebasicmaterialssciencebreakthroughs,andthe highcostofsuchmaterialsandlackofmarketdemandcouldhindercommercializationinwindturbine applications. Severalopportunitiesexistfornewpermanentmagnetgeneratormachinedesigns.Transverseflux permanentmagnettopologiesandVerniermachinedesignscouldyieldincreasedpermanentmagnet generatorpowerdensities,resultinginsmallersizeandlowerweightdirectdrivegenerators. Commercializationcouldbehinderedbyalackofsufficientmanufacturingcapabilitiesandalackof investorandprojectoperatorexperiencewiththesetechnologies.Mitigatingtheriskofairgapcollapse wouldimproveturbineperformanceandreliabilitybutmaycausecapitalcostincreases;theneedfor andvalueofsuchadesignhavenotbeenquantified.Corelessarmaturewindingdesignscouldimprove reliabilitybyremovingsteelfromthegeneratorcoils(reducingcorrosionrisk),couldreduceoverall generatorweight,andcouldprovidebettervoltageregulation,butthesedesignswouldresultinlarger diametergeneratorsthatincreaseassembly,transportation,andinstallationcomplexity. Permanentmagnetgeneratordesignsthatallowinsitumaintenance(withouttheuseofcranes)could leadtoincreasedreliabilityandavailability,decreasedoperationsandmaintenancecosts,andreduced projectrisk.However,theneedforsuchdesignshasnotbeenquantified,andcommercialusersmaynot recognizethevalueofsuchdesigns.

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Researchonthetransportation,installation,andsupportstructuresofpermanentmagnetgenerators couldleadtoreductionsincapitalequipmentcosts,logisticscosts,andoverallsystemweight,but certaindesigns,suchassegmentationrequiringfieldassembly,mayreducesystemefficiencyandimpact therestofthesystem.Arelatedissueistheongoingcompetitionbetweenmodularizedandintegrated designapproachestopermanentmagnetdirectdriveturbines.Thebenefitsandrisksofdevelopingnew integratedgeneratordesignsthatcouldreducesystemweight,cost,andmaintenanceneedtobe evaluatedincomparisontomodulardesignsthatallowturbinemanufacturerstoretaintheexpertiseof andshareriskswithdedicatedgeneratormanufacturers.Magneticgearinghasthepotentialtoreduce orremovemanyofthereliabilityproblemsassociatedwithconventionalgearboxes,buttheextra permanentmagnetmaterialscosts,lowerpowerdensities,anduncertainefficiencygainsofsuch gearingneedtobeevaluatedinordertodeterminethepotentialforcommercialization.Finally, developmentofruggedizedpermanentmagnetgeneratordesignsforcoldweatherormarineconditions couldincreaseperformance,reliability,andequipmentlifetimeforturbinesoperatinginthese environments,butcommercializationishinderedbythelackofrelevantcodesandstandards,the increasecostsofimplementingsuchupgrades,materialslimitations,anduncertainmarketdemand. Workshopparticipantsidentifiedtwomajorareasofresearchtoimprovepowerelectronicsfor permanentmagnetgenerators:newpowerconverterconcepts,andimprovedcontrolandprotection topology.Newpowerconverterconceptscouldfocusoncontrols,voltagelevels,switching,and converterarchitecture.Advancesintheseareascouldyieldincreasedefficiency,reliability,and availability,butsuccessfulcommercializationwouldhavetofirstovercomethetechnicallimitationsof semiconductors,thelackofexperiencewithhighvoltagesystemsonthepartofwindturbinedesigners andoperators,andtheoveralllackofoperationalexperienceofthesesystems.Controlandprotection topologyresearchcouldfocusondemagnetization,overvoltage,shortcircuitpreventionand management,andunbalancedoperation.Thisresearchcouldyieldimprovedperformanceandenergy captureandwouldrequiresoftware(ratherthanhardware)modification.Themajorbarrierto commercializationisthecostofdevelopingcommercialproductsfromexistingtechnicalpapersand results. Developmentofdiagnosticmethodsforpermanentmagnetgeneratorsmightfeaturesignatureanalysis includingsmartsensorstoimproveturbinereliabilityandavailability.Whiledeploymentofthese sensorswouldincreaseupfrontcapitalcosts,theimprovementstoreliability,scheduledmaintenance, andperformanceshouldoutweighthesecosts.Possibletechnicalbarriersincludeelectromagnetic interferencewithsensorsfromthepermanentmagnets,thepotentialforfaultyinformation,andneed foroperatortraining.Lackofindustrycodesandstandardsrelatedtosensorsanddiagnosticmethods andthehigherupfrontcostscouldlimitcommercialdeployment.
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Table5belowlistsmajorbarrierstothecommercializationofpermanentmagnetgenerator technologiesandpotentialresearchanddevelopmentpathwaysforovercomingthosechallenges.
Table5.BarrierstoCommercializingPermanentMagnetTechnologyImprovements

AreaofInterest AdvancedMagnetic Materials

CommercializationBarriers
TechnicalRisk:basicmaterials sciencebreakthroughsarerequired. CommercialRisk:highcostof permanentmagnetmaterialsmay increasecapitalcosts. PerceptionRisk:currentlackof marketdemand.

DevelopmentPath
Conductmaterialsscienceresearch:
basicresearchintonovel,lowcost magneticmaterialsisneeded. Developtradeoffanalysis:advanced magnetcostsmaybeoffsetbyup towerweightsavings. Developcost/benefitanalysis: definitivestudiesshowcasingcosts andbenefitsofadvancedpermanent magnetmaterials,plusthe developmentofanoffshorewind industry,woulddrivedemand. EstablishIECstandards:develop workinggroupstoestablishstandards languageforpermanentmagnet directdrive. Conductlaboratoryresearch:basic researchintonovelpermanent magnettopologiesmayallowfortheir eventualdeploymentinthefield. Developcost/benefitanalysis: definitivestudiesshowcasingcosts andbenefitsofadvancedpermanent magnettopologieswouldbeginto overcomethisareaofrisk. EstablishIECstandards:develop workinggroupstoestablishstandards language. Conductlaboratoryresearch:basic researchintoadvancedPower Electronicsmayallowfortheir eventualdeploymentinthefield. Increaseeducationandtraining: educationandtrainingprogramswill increasehighvoltageexperience. Developcost/benefitanalysis: definitivestudiesshowcasingcosts andbenefitsofadvancedpower electronicsmayleadtoacompelling businesscaseforfurther development. Increaseeducationandtraining: educationandtrainingprogramswill increaseexperience.

SystemDesignand Topology

CertificationRisk: windturbine standardshavenotbeendeveloped foradvancedpermanentmagnet materials. TechnicalRisks: manufacturing processbreakthroughsarerequired toaffordablyimplementadvanced designsandtopologies. Commercial Risk:theneedforsuch designshasnotbeenquantified; thereforetheeffectonoverallcosts isunknown. CertificationRisk: windturbine standardshavenotbeendeveloped foradvancedPMDDtechnologies.

PowerElectronics

TechnicalRisk: limitationsof existingsemiconductorsneedtobe overcome. PerceptionRisk:lackofwind industryexperiencewithhigh voltageequipment. CommercialRisk:thecostof developingcommercialproducts andlackofoperationalexperience mayhamperfuturepower electronicsdevelopment.

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ImprovedDiagnostics andMaintenance

ReliabilityRisk:electromagnetic interferencemayincreasethe potentialforfaultyinformation. OperatorTrainingRisk:operators withoutpropertrainingmayaddto permanentmagnetrelated operations&maintenancecosts. CertificationRisk: windturbine standardshavenotbeendeveloped foradvancedpermanentmagnet technologies.

Conductresearch:laboratoryandfield researchmayhelpovercome electromagneticinterferenceissues. Increaseeducationandtraining: Educationandtrainingprogramswill increaseoperations&maintenance reliability. EstablishIECstandards:develop workinggroupstoestablishstandards languageforpermanentmagnet diagnosticsandmaintenance.

2.3 ContinuouslyVariableTransmissions
Thissessiondiscussedtheuseofcontinuouslyvariabletransmissions,includingfluiddrivesystems,in windturbineapplications.Continuouslyvariabletransmissionscanshiftsmoothlybetweenaninfinite numberofeffectivegearratioswithinarange,asopposedtoconventionalgearedsystemsthatoffera limitednumberoffixedgearratios(Cotrell2004).Inwindturbineapplications,thesetransmissionscan varytheirgearratioseamlesslytoensurethatthelowspeedrotationoftheturbinesrotor,which changeswiththeincomingwindspeed,isalwayssteppeduptotheexacthighspeedrotationrequired forelectricitygeneration.Thesetransmissionsallowwindturbinestooperateathigheraerodynamic efficienciesoveralargerrangeofwindspeeds.Conventionalwindturbinesmanagevariablespeed operationthroughtheuseofpowerelectronics,whereascontinuouslyvariabletransmissionsmanage variablespeedoperationmechanically.Continuouslyvariabletransmissionscanalsomitigaterotor loadsbyallowingtherotortoaccelerateduringwindgusts;thisloadmitigationreducesrequiredrotor anddrivetrainstructuralstrengthandthereforecost. Thesessionexaminedtwomajorcategoriesofcontinuouslyvariabletransmissions:designsthatuse frictionalcontactbetweencomponentstovarytheeffectivegearratio,andhydraulicdesignsthatusea fluidtovarytheratio.Frictionaldesignsincluderollingtractionsystems;beltorchaindrives;variable diametergears;anddifferentialplanetarydrives.Rollingtractionsystemsvarythedegreeorangleof physicalcontactbetweentransmissioncomponents(usuallyspheres,torroids,discs,orcones)tochange theeffectivegearratio.Beltorchaindrivesystemsfeaturetwovariablediameterpulleysconnectedby abeltorchain;varyingthediameteroftheinputandoutputpulley(s)changesthegearratio.Variable diametergearscanchangetheirdiameterwhileengagedtoalterthegearratio.Differentialepicyclical drives,alsocalleddifferentialplanetarydrives,controltheeffectivegearratiobyrotatingtheannulus (outerring)ofaplanetarygearbox. Hydraulicsystemsincludehydrodynamicdrivesandhydrostaticdrives.Hydrodynamicdrivesusethe inertiaofthefluidtotransmitpower,whilehydrostaticdrivesuseonlystaticpressure.Hydrodynamic drivesfeatureanimpellerontheinputshaftandaturbineontheoutputshaft;theimpellerandturbine arecoupledviaahydraulicfluidsothattorquecanbetransmitted.Thisconceptisalsocalledahydraulic torqueconverter.Hydrostaticdrivesconvertmechanicalrotationintofluidflowusingapumpandthen

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backintomechanicalmotionusingahydraulicmotor;thevariablespeedmanagementisachievedby changingthedisplacementofthepumpormotor. Continuouslyvariabletransmissionsmayofferanimprovementovercurrentwindturbinedesignsthat useconstantratiotransmissions.Thesetransmissionscouldallowturbinestooperateatahigher aerodynamicefficiencyoveralargerrangeofwindspeedsthandoconventionaldesigns.This performanceimprovementwouldincreasetheamountofenergyproducedbytheturbine,ultimately decreasingthecostofenergy.Thesesystemsalsohavetheabilitytoabsorbrotortorquefromsudden windgusts,thusalleviatingfatigueloadingandimprovingoverallturbinereliability.Finally,continuously variabletransmissionsreducetheneedforpowerelectronicsforpowerconditioningandvariablespeed operationspurposes(seeCammetal.foradetaileddescriptionofdoublyfedinductiongeneratorsin variablespeedwindturbines).Areducedroleforpowerelectronicscouldloweroverallturbinecapital cost,reducepowerlossesduetopowerelectronicsinefficiencies,andimprovereliabilitybyeliminating theneedformaintenancepronesliprings(Cotrell2004).Finally,somehydrostaticdriveconfigurations offerthepossibilityofenergystoragethroughhydraulicfluidaccumulators,potentiallysmoothingthe integrationofwindturbineenergyoutputintotheelectricalgrid.
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Table6belowlistsmajorareasofinterestincontinuallyvariabletransmissionresearchand developmentandthepotentialbenefitsthattheseareasofinterestofferoverthestateoftheartin windturbinedrivetrains.

Table6.BenefitsofContinuouslyVariableTransmissions

AreaofInterest FrictionalContact Drives

Description
Thesedesignschangethephysical contactbetweencomponentstovary theeffectivegearratio.Physical contactdesignsincluderollingtraction systems;beltorchaindrives;variable diametergears;anddifferential planetarydrives.

Benefits
ReducedCapitalCosts:thesesystems
reducetheneedforpowerelectronics.

ImprovedReliability:thesesystems
canabsorbrotortorquefromsudden gusts,therebyalleviatingfatigue loading.Thesedesignscouldalso improvereliabilitybyeliminating generatorsliprings. IncreasedEnergyCapture:these designsincreaseturbineenergy productionbyallowingturbinesto operateatahigheraerodynamic efficiencyoveralargerrangeofwind speeds.

FluidDrives

Thesedesignsusepressurizedhydraulic ReducedCapitalCosts:thesesystems fluidtovarytheeffectivegearratio. reducetheneedforpowerelectronics. Designsincludehydrostaticand ImprovedReliability:thesesystems hydrodynamic(orhydraulictorque canabsorbrotortorquefromsudden converter)designs. gusts,therebyalleviatingfatigue loading.Thesedesignscouldalso improvereliabilitybyeliminating generatorsliprings. IncreasedEnergyCapture:these designsincreaseturbineenergy productionbyallowingturbinesto operateatahigheraerodynamic efficiencyoveralargerrangeofwind speeds. EnergyStorage:hydrostaticdrives offerthepossibilityofenergystorage bymeansofhydraulicfluid accumulators.

Thesessionidentifiedanumberoftechnicalandcommercialchallengestothecommercializationof continuouslyvariabletransmissionsforwindturbineapplications.First,thesetechnologiesmay introducenewcostandreliabilitychallengesbecausetheirapplicationinwindturbinesiscurrently untested.Incorporatingnewcomponentsandsystemsintotheturbinecouldincreaseoperationsand maintenancecostsandintroducenewavenuesofreliabilityfailure.Second,thescalabilityofthese componentsandmaterialshasnotbeenestablished.Certaindesignapproaches,suchasrollingcontact designsandbeltdrives,maynotscaletothehightorqueproducedbymegawattscalewindturbine rotors.Third,materialsconstraintsmaylimitthecommercializationofthesetechnologies;hydraulic

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drivesystemsmayneedresearchanddevelopmentofenvironmentallybenignfluids,whilecertain frictionalcontactdrivedesignscouldrequirenewhighfrictionmaterialsinordertoeffectivelytransfer powerbetweencomponents.Finally,theperceptionofcontinuouslyvariabletransmissionsascomplex andundevelopedtechnologiesmaylimitthecommercialadoptionofthesetechnologies. Aresearchanddevelopmentefforttofacilitatethecommercializationofcontinuouslyvariable transmissionswouldfocusonanalyzing,proving,anddemonstratingthebenefitsoftherespective designsandtechnologieswithinthislargercategory.Theoverallgainsinturbineperformance, reliability,andcostneedtobemodeledandanalyzedfordifferentcontinuouslyvariabletransmission designsandincomparisontoconventionalvariablespeedturbinedesigns.Partofthiseffortcould includethedevelopmentofspecializeddesign,modeling,andanalysistools.Engineeringworktoprove andimprovethereliabilityofcontinuouslyvariabletransmissioncomponentsandmaterialsinwind turbineapplicationsisalsoneeded.Finally,thedemonstrationofdifferentcontinuouslyvariable transmissiondesignsinturbinetestplatformscouldhelpestablishthecosts,benefits,andreliability impactsofthesetechnologies. Table7belowlistsmajorbarrierstothecommercializationofcontinuouslyvariabletransmission technologiesandpotentialresearchanddevelopmentpathwaysforovercomingthosechallenges.
Table7.BarrierstoCommercializingContinuouslyVariableTransmissions

AreaofInterest FrictionalContact Drives

CommercializationBarriers
TechnicalRisk:thesetechnologies mayintroducenewcostand reliabilitychallengesorincrease operationsandmaintenancecosts.

DevelopmentPath
Undertakecostbenefitanalysis: modelandanalyzethegainsinturbine performance,reliability,andcostover conventionaldesigns. Designandmodelingtools:develop toolsfordesigning,modeling,and analyzingcontinuouslyvariable transmissionturbineconcepts. Demonstration:deploycontinuously variabletransmissionsinturbinetest platformstoestablishbenefits. Componentdevelopmentandtesting: optimizecomponents,materials,and designsthroughtesting. Undertakecostbenefitanalysis: modelandanalyzethegainsinturbine performance,reliability,andcostover conventionaldesigns. Designandmodelingtools:develop toolsfordesigning,modeling,and analyzingcontinuouslyvariable transmissionturbineconcepts. Demonstration:deploycontinuously variabletransmissionsinturbinetest

FluidDrives

ScalabilityRisk:scalabilityofthese componentsandmaterialshasnot beenestablishedforhightorque applications. MaterialsRisk:couldrequirenew highfrictionmaterialsinorderto effectivelytransferpowerbetween components. TechnicalRisk:mayintroducenew costandreliabilitychallengesor increaseoperationsand maintenance;fluidcleanliness requirements.

ScalabilityRisk:scalabilityofthese componentsandmaterialshasnot Page|21

beenestablishedforhightorque applications. MaterialsRisk:mayneedresearch anddevelopmentofenvironmental fluids. PerceptionRisk:thesetechnologies couldbeperceivedascomplexand undeveloped,limitingcommercial adoption.

platformstoestablishbenefits. Componentdevelopmentandtesting: optimizecomponents,materials,and designsthroughtesting. Demonstration:deploycontinuously variabletransmissionsinturbinetest platformstoestablishbenefits.

2.4 InnovativeConcepts
Thissessiondiscussedavarietyofnovelconcepts,designapproaches,components,andtechnologies thatcouldbedeployedinwindturbinedrivetrains.Themajorconceptsdiscussedwereuptowerdirect currentgenerators;innovativedrivetraintopologies;groundlevelgenerators;tractionorrimdrive turbinedesigns;tandemgenerators;andcompleteuptowergearboxreparability.Thesetechnologies areatdifferentstagesofreadiness,fromconceptstudiestofielddeploymentinwindturbines,andeach offersitsownbenefitsoverthestateoftheartaswellascommercializationchallenges.Session participantsalsodiscussedbeltdrives,variablediametergears,hydrodynamictorqueconverters, magneticgears,magneticbearings,hydrostaticbearings,fluiddrives,andtheuseofadvancedmaterials indrivetrains.Toavoidduplication,thefindingsoftheInnovativeConceptssessionwithrespecttothese technologieshavebeenincorporatedintheprecedingsections2.1through2.3.Finally,althoughnot strictlyaninnovativeconcept,sessionparticipantsidentifiedresearchanddevelopmenttoovercome thegearboxfailuresafflictingcurrentturbinedesignsasacrucialeffort. Table8belowlistsmajorareasofinterestininnovativedrivetrainconceptresearchanddevelopment andthepotentialbenefitsthattheseareasofinterestofferoverthestateoftheartinwindturbine drivetrains.
Table8.BenefitsofInnovativeDrivetrainConcepts

AreaofInterest
UptowerDirectCurrent (DC)Generator

Description
ThisconceptwouldincorporateDC generatorsintoturbinenacelles, feedingintoaplantwideDCcollection system.

Benefits
ImprovedReliability:reducedneed
fortransistorsforACDCAC conversion. GridBenefits:energystorage potential;improvedfaultridethrough capabilities. ImprovedReliability:generatorat groundlevelmaybeeasiertoservice andreplace. ImprovedReliability:potentially eliminatestheneedforagearbox. ImprovedAvailability:turbinecan 22|Page

GroundLevelGenerators

RimDriveTurbines TandemGenerators

Thisdesignwouldplacethegenerator atthebaseofthetower;themain shaftinthenacellewouldconnecttoa verticaldriveshaftwithabevelgear. Anouterrimwouldenclosethe turbinesrotor;generatorsembedded alongthatrimwouldproducepower. Thesedesignswouldstackmultiple

permanentmagnetdirectdrive generatorsintandemalongthesame horizontalaxisdriveshaft.

CompleteUptower GearboxReparability OtherPotential InnovativeDrivetrain Topologies

Developmentofgearboxesand drivetrainsthatcanberepairedinsitu withoutrequiringexternalcranes Thisconceptreferstothewholesale reevaluationofturbinedrivetrain layouts.

continuetoproducepowerifone generatoristakenoutofservice. Scalability:conceptmayscalewellto largergeneratingcapacities. ImprovedReliability:repairscanbe completedmorequicklywithout requiringcranesorwholesalegearbox replacement. ReducedCapitalCosts:potentialfor improvement,butneedstobe demonstrated. ImprovedReliability:potentialfor improvement,butneedstobe demonstrated.

Uptowerdirectcurrent(DC)generatorswouldenableawindpowerplantwideDCcollectionsystem, designedaroundtheDCbus.Suchasystemcouldincreasereliabilitybyreducingthenumberof transistorsforACtoDCtoACconversion.Thesystemcouldalsoimprovefaultridethroughcapabilities, increasetransmissionefficiency,especiallyforoffshorewindsystems,andprovideopportunitiesfor energystoragethroughcapacitorsandbatteries.Themajortechnicalbarrierstosuchasystemarethe designofthecollectionsystemandtheneedforextensivedesignworkoncontrolsystemsandpower electronics.Apotentialresearchanddevelopmentapproachmightincludesystemdesignandcost studiestodeterminethepotentialbenefitsandcostsofaplantwideDCcollectionsystemandtoreview theavailablehighvoltageDChardwareneededtobuildsuchassystem. Groundlevelgeneratorconfigurationswouldreduceweightintheturbinenacellebyplacingthe generatoratthebaseoftheturbine,potentiallywithgearboxstagestostepupthedriveshafts rotationalspeed.Thesedesignswouldincorporateabevelgearinthenacelletoconnectthehorizontal lowspeedshafttoaverticaldriveshaftrunningthelengthofthetower.Thislayoutwouldreduce nacelleweight,therebyreducingthestructuralrequirementsofthetower,andwouldallowforeasier maintenanceandreplacementofthegenerator.However,suchalayoutwouldbemechanically complex;specifictechnicalchallengesincludemaintainingalignmentintheverticaldriveshaft, transferringhightorquerotationthroughrightanglegearing,anddevelopingsuitablecomponentssuch asalightweightverticalshaft.Initialresearcheffortscouldfocusonanalyzingthefeasibility,costs,and benefitsofsuchassystem. Tractionorrimdriveturbinedesignsrepresentaradicaldeparturefromcurrentcommondrivetrain configurations.Asthenameimplies,thesedesignsenclosetheturbinesrotorwithinanouterrim; generatorsembeddedalongthatrimwouldproducepowerastherotormoves.Similardesignshave beendevelopedbythemarineandhydrokineticenergyindustrytoproducepowerfromtidesandocean currents.Whilesuchdesignswouldreduceoreliminatetheneedforagearbox,theywouldbe technicallychallengingtodesignandconstruct.Researchisneededtodeterminethetechnicalfeasibility oftheconceptandanypotentialbenefitsoverexistingtechnology. Stackingmultiplepermanentmagnetdirectdrivegeneratorsintandemalongthesamehorizontalaxis driveshaftcouldimproveoverallturbinereliabilityandavailabilitybycreatingredundancy.Ifoneofthe
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generatorsweretofail,theturbinecouldcontinuetoproducepower(albeitataloweroutput)while thatunitwasrepaired.Scalabilityofthisconceptisanothermajorbenefit,especiallyforoffshorewind applications.However,addingcomponents,weight,andexpensivepermanentmagnetmaterialstothe turbinecoulddriveupcapitalcosts.Feasibilitystudieswouldbeneededtoevaluatethetradeoffs betweenaddedcapitalcostsandimprovedreliabilityandreparability. Innovativedrivetraintopologyconceptsrefertothewholesalereevaluationofturbinedrivetrainlayouts toseeifentirelynewcomponentconfigurationsmayimproveonthecurrentstateoftheartby reducingweightandcostsandimprovingreliability.Suchworkinvolvessubstantialtechnologyrisk,since thesenewconfigurationshavenotbeentestedandcouldcreatenewproblems.Researchand developmentoftheseconceptswouldlikelytaketheformofextensiveconceptstudiestodevelopnew designconfigurations.Shouldnewconfigurationsappeartoofferimprovementstothestateoftheart, researcheffortsmightexpandtoincludedesignvalidation,optimization,andtesting. Completeuptowergearboxreparabilityreferstothedevelopmentofgearboxesanddrivetrainsthatcan bemaintainedandrepairedinsituwithoutrequiringexternalcranestohoistequipment.Suchagearbox wouldimproveturbineavailabilityandreducemaintenanceandreplacementcostsbyeliminatingthe needforexpensivecranerentals.Suchdesignswouldlikelyrequireadditionalfacilitiesuptowertolay outparts,builtinhandlingfixturesandtools,andextensiveconditionmonitoringsystemstodetermine whichparticularpartorcomponenthasfailed.Feasibilitystudieswouldbeneededtodemonstratethe costcompetitivenessofsuchconceptswithcostsofreplacingorrebuildingconventionalgearboxes. Table9belowlistsmajorbarrierstothecommercializationofinnovativedrivetrainconceptsand potentialresearchanddevelopmentpathwaysforovercomingthosechallenges.
Table9.BarrierstoCommercializingInnovativeDrivetrainConcepts

AreaofInterest
UptowerDirectCurrent (DC)Generator

CommercializationBarriers
TechnicalRisk:designoftheDC collectionsystem;needtomaintain variablespeedcontrolonaDC generator.

DevelopmentPath
Feasibility Studies:systemdesignand coststudieswoulddeterminethe potentialbenefitsandcostsofaplant wideDCcollectionsystem. EquipmentSurvey:reviewthe availablehighvoltageDChardware neededtobuildsystem. Feasibility Studies:analyzethe feasibility,costs,andbenefitsofsuch assystem.

GroundLevelGenerators

RimDriveTurbines TandemGenerators

TechnicalRisk: maintainingvertical driveshaft;transferringhightorque rotationthroughrightangle gearing;componentdevelopment. TechnicalRisk:extremely FeasibilityStudies:analyzethe technicallychallengingtodesignand feasibility,costs,andbenefitsofsuch construct. assystem. CommercialRisk:adding FeasibilityStudies:evaluatethetrade components,weight,and offsbetweenaddedcapitalcostsand permanentmagnetscoulddriveup improvedreparability. capitalcosts.

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CompleteUptower GearboxReparability

OtherPotential InnovativeDrivetrain Topologies

TechnicalRisk:mayintroducenew reliabilitychallenges;wouldrequire additionaluptowerfacilities; requiresextensiveconditionbased healthmonitoringsystems. TechnicalRisk:newconfigurations havenotbeentestedandcould createnewcost&reliability challenges. PerceptionRisk:designshavenot beentested,developed,or deployed.

FeasibilityStudies:analyzecost competitivenessofconceptsversus costsofreplacingconventional gearboxes. DesignStudies:extensiveconcept studiestodevelopnewdesign configurations.

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3.0 Summary
ParticipantsattheAdvancedDrivetrainsWorkshopdiscussedawiderangeoftechnologies,system designconcepts,components,andstrategiesthatofferthepotentialtoimprovethestateoftheartin windturbinedrivetrains.Theseareasofinterestcanbegroupedintothreebroadcategoriesbasedon theirpotentialimpactonthemarketforcurrentandnextgenerationdrivetrains. Thefirstareaofinterestincludesconceptstagedesignsfornextgenerationwindturbines;these conceptsofferpotentiallysignificantbutstilluncertainadvantagesoverthestateoftheart.These technologiesrequireanalysistoevaluateandquantifythebenefitstheyofferoverconventional drivetrains,aswellasfeasibilitystudiestodeterminetheiroveralltechnicalviability.Inmanycases, thesetechnologieswerealreadystudiedextensivelyinthe1970sand1980sandweredeterminedtobe notascommerciallyviableasthedrivetrainsthatendedupintodaysmodernwindturbinedesigns, whichessentiallywonoutduringthe1990sastheoptimumconfiguration.However,givenadvances overthepastthirtyyearsinfieldssuchasmaterialsscience,fluiddynamics,andcomputationaldesign tools,theremaybeopportunitiesthatpresentthemselvesuponreexamininginnovativedrivetrain conceptsfromthepast,aswellasmorerecentdesignsandideas. Thesecondareaofinterestincludestechnologiesthatarecurrentlybeingexploredbywindturbine manufacturersandthirdpartiesforthecurrentgenerationofwindturbinedrivetraindesigns.These technologies,someofwhichhavebeensuccessfullycommercializedinaerospace,automotive,marine propulsion,andindustrialmachineryapplications,requireappliedresearchanddevelopmentto optimizedesigns,testcomponentsinwindturbineapplications,andaddresspotentialreliabilityand scalabilityissues.Noveldesignsinthiscategorymayleadtoincrementalimprovementsinwindturbine reliability,performance,orcapitalcosts. Thethirdareaofinterestincludestechnologiesthathavepotentiallytransformativeapplicationinnext generationturbinedesignswithlargenameplatecapacities(5+MW),particularlyinoffshorewind turbines.Manyofthesetechnologieshavebeensuccessfullycommercializedinotherindustriesandin differentapplications,suchasmagneticresonanceimaging(MRI),navalvessels,andciviltransportation. Thesetechnologiesrequireappliedresearch,development,anddemonstrationprogramstofacilitate theiroperationaldeployment,andresearchprogramsinthisareashouldhaveamultiyearperspective ontherequirementsoffuturewindturbines.

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4.0 References
Cotrell,J.MotionTechnologiesCRADACRD03130:AssessingthePotentialofaMechanicalContinuously VariableTransmission.TechnicalReport,Golden:NationalRenewableEnergyLaboratory,2004. E.H.Camm,M.R.Behnke,O.Bolado,M.Bollen,M.Bradt,C.Brooks,W.Dilling,M.Edds,W.J.Hejdak,D. Houseman,S.Klein,F.Li,J.Li,P.Maibach,T.Nicolai,J.Patio,S.V.Pasupulati,N.Samaan,S.Saylors,T. Siebert,T.Smith,M.Starke,R.Walli."CharacteristicsofWindTurbineGeneratorsforWindPower Plants."IEEEPower&EnergySocietyGeneralMeeting.Calgary:IEEE,2009.5. Fingersh,L.,M.Hand,andA.Laxson.WindTurbineDesignCostandScalingModel.Technicalreport, Golden:NationalRenewableEnergyLaboratory,2006. Hau,E.WindTurbines:Fundamentals,Technologies,Application,Economics.2ndEdition.NewYork: Springer,2006. Mueller,M.,andA.McDonald."Alightweightlowspeedpermanentmagnetelectricalgeneratorfor directdrivewindturbines."Proceedingsofthe2008EuropeanWindEnergyConference&Exhibition. Brussels:EuropeanWindEnergyConference,2008.19. Musial,W.,S.Butterfield,andB.McNiff.ImprovingWindTurbineGearboxReliability.Conferencepaper, Golden:NationalRenewableEnergyLaboratory,2007. Poore,R.,andT.Lettenmaier.AlternativeDesignStudyReport:WindPACTAdvancedWindTurbineDrive TrainDesigns.Golden:NationalRenewableEnergyLaboratory,2003. Ragheb,A.,andM.Ragheb."WindTurbineGearboxTechnologies."Proceedingsofthe1stInternational NuclearandRenewableEnergyConference(INREC10).Amman,Jordan,2010.8.

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5.0 Appendix:WorkshopAgenda DAYONE:June29,2010

11:00am 12:00pm 12:10pm 12:20pm 12:35pm 12:55pm 1:00pm Registrationandlunch OpeningremarksandoverviewofDOEWindProgram JacquesBeaudryLosique,ProgramManagerforDOEWindandWaterPowerProgram DOEsdrivetrainresearchanddevelopmentactivities MarkHiggins,TurbineR&DTeamLeaderforDOEWindandWaterPowerProgram ARPAEsperspectiveoninnovativedrivetraindevelopment MarkHartney,ProgramDirector,ARPAE Windturbinedrivetrainstateoftheart Dr.FortFelker,Director,NationalWindTechnologyCenter Breakoutsessioninstructions MarkHiggins Breakoutsessionstechnologystatus&benefits Fourworkinggroups:SuperconductingDrivetrains,AdvancedPermanentMagnet Topologies,ContinuouslyVariableTransmissions,andInnovativeandNonTraditional DrivetrainConcepts. 1. Whatisthecurrentstateofthistechnology? 2. Howdoesthistechnologyofferanimprovementoverthestateoftheart? BREAK Breakoutsessionsbarrierstocommercialization (Sameworkinggroupsasbefore) 1. Whatarethebarrierstothecommercializationofthistechnologyinwindturbine applications? ADJOURN

3:00pm 3:30pm 5:00pm

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 DAYTWO:June30,2010
8:00am 8:30am 8:45am Breakfast DayOnerecapandinstructions MarkHiggins Breakoutsessionspathtocommercialization (Sameworkinggroupsasbefore) 1. Whatisthebestwaytocommercializethistechnologyforwindturbine applications? 2. HowwouldanR&Deffortaddressthebarrierstocommercialization? 3. Whatkeytechnicalmilestonesorbreakthroughswouldbeneeded? 4. Describearealistictimelineforcommercialization. 5. HowmuchwouldasuccessfulR&Deffortcost? 6. Whatmightconstituteappropriatelevelsofgovernment,industry,andacademic involvement? 7. HowcanwemeasurethesuccessofanyDOEsponsoredprojectsinthisarea? BREAK Breakoutsessionsconsolidatingresults Eachworkinggroupwillreadthroughtheirnoteswiththefacilitatortoensureaccuracy, andwillpreparetheirkeyfindingtopresenttothelargerworkshopaudience. LUNCH Presentationofbreakoutsessionfindings Eachgrouphas20minutestopresenttheirmajorfindings,includingQ&A. Conclusionandwrapup MarkHiggins ADJOURN

11:15am 11:30am 12:30pm 1:00pm 2:40pm 3:00pm

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