aaah N The times in which the term “wind turbine gearbox” was synonymous with “accident” are fortunately over. Nevertheless, these speed transformers still often demand to be wrapped in cotton wool. But now, metal ceramic coatings are planned to stabilise the tooth profiles. Rewitec plans to rectify defects h profiles by way of ‘special coating "en Protective layer for sensitive profiles profiles is offered a few drops of magic potion and willthen do its job again without complaint ~ that sounds more like a fairytale than an industrial process. However, it has nothing to do with magic, assures Managing Director Stefan Bill from Rewitec (Germany), but rather with high-tech, "We have deve loped a coating which restores worn metal surfaces and subsequently protects them from abrasion,” he says. In this way, he is picking up a core problem of ‘mechanical engineering. This can be illustrated vivid ly by taking the wind turbine gearboxas an example. Normally, the metal friction pairs are separated by way of an cil film, so that “in principle” no problems should occur. l s that possible? A gearbox with damaged tooth But they do occur, as numerous gearbox defects today and in the past have shown. Unconventional load profiles, ie. unexpected dynamic loads which have not been taken into account, result in a failure ‘of the classic lubrication. This, in tur, results in tiny defects of the surface in the first phase ~ so-called micropitting visible asa dullgrey appearence of the formerly bright metal surfaces. Micropitting is not a cosmetic problem but can critically reduce the bear- ing strength ofthe tooth profiles inthe long run. New metal-ceramic layer Now Rewitec claims to be able to undo these defects at least partially, thus improving the contact pattern Sun Wd nee 12010,‘of the tooth profiles permanently. This is apparently attributable toa concentrate of metal silicate which is added to the lubricating oll. That may sound lice the cil additives we know from the automotive branch, butis actualy something completely different. n con- trast to the additives, the metal silicate does not re- main in the oil, ut is deposited on the loaded metal surfaces, where it forms a chemical compound with the molecules of the metal surface. Stefan Bill explains: “The temperatures resuiting from the friction and high partial pressures cause the ‘metal surfaces to react and trigger a chemical inking process.” Inotherwords: the coating particles in the concentrate ceramise the metal surfaces dur Micropitting ‘ates with the gearbox manufacturers Zoller and Hansen Transmission, as well as with the turbine manufacturer Nordex. Scepticism in parts of the branch Nevertheless, there are sceptical voices in the branch, “I see things with mixed emotions,” says FrankcKrull, Design Manager at the gearboxmanufac- turer Elekhoff. “The interaction with the roller bear- ings is not clear. They are dependent on a correct supply of oll. Exaggerating slightly, the concentrate slike dropping. tittle stones into the gearbox. This doesn't fit in with state-ofthe-art oils and This is the way how Rewitec ‘explains the process (from top ing running, The quanti--Micropitting, or greystaining, is@phenome- __thelrsuperfinefilratin.” to bottom): the temperatures tes ofconcetate wed gn ofsutacewearon high loaded meta," alo, Krull isnot resulting from metal ction fe relatively small: ‘ : seein sureoftherealuse ofthe and high partial pressures bout 6 ltresof concen. Amultude of microscopically smlldefectsIM ceramic coating: “The cause the coating particles to trateareaddedto 3001i- the material givethe metaladull-grey appear questioniswhetherthere react on the metal surfaces. ‘ance, Micropitting may result in deeper cracks and can progress to more extensive loss of. material from the surface. If micropitting isnot tres of oll- the common ‘quantity for a 1.5 MW gearbox. The full coating, reallyisa need for action ‘The micropitting is by no means a forever continu Giaphics()-Retar process is completed af- ter about 500 operating hours. The result, Billex: plains, is a new, ex tremely wear-resistant metal-ceramic surface. Inthis way, itis possible to refill “valleys” in the surface up to @ depth of 30 microns, Avaluable side-effect: the metalceramic coating itself provides extraordinary emergency run- ning properties and can thus provide protection in case of a total loss of oil Growing wind-energy market ‘with this technology, the service life of gearbox and bearings can be increased significantly,” he claims, and refers to tests at the University of Bochum and ongoing analyses at Germanischer Lloyd (G1). The lat- ter already confirmed in aletter from the beginning of 2008 that metal silicates reduce the fiction in a die~ ‘sel motor and the wear in a ball bearing. Currently, GL is running test series with the objective oftesting the ‘suitability of metal silicates for use in wind turbine gearboxes. ‘And this growing market is actually the more in- teresting field of business for Bil: "15 % of our sales turnover isin the automotive branch, and 80 % in the field of industrial gearboxes, of which about three {quarters is in wind energy, with an upward tenden- cy.” First experience has already been gained. “For example,” Bill continues, “a clear smoothing of the ‘tooth profile surface showed on the Flender gearbox ofa 1 MWAN Bonus.” Ashe also reports, similar suc- cess was already achieved with several older Tacke ‘machines ofthe output classes 250, 500 and 600 KW in 2007 and 2008. At the moment, Rewitec cooper- ee property treated, the component can eventual ly fal. To rectify the damage, cutting technolo- gies (grinding, lapping, milling) with subse- ‘quent tempering have established themselves ‘as conventional methods. Missing material ‘can be applied by welding. Ing process. Moreover, if the material oss has pro- gressed to a point at which it becomes danger- ous for the gearbox, the concentrate will also no longer achieve that much improvement.” Krull is committed to fighting the ‘actual causes. Much can already be done with lubri- ‘cants featuring higher resistance to micropitting and a careful calculation ofthe critical points in the gear- box. ‘A maintenance specialist who asked not to be named sees things similarly. “I don’t now any appli cations,” he says, “but nevertheless, | am sceptical. For example, there is no guarantee of success. But that, particulary, is what | would expect if Rewitec ‘were convinced by their own product.” Obviously, the high price is also a deterrent, as could be heard be- tween the lines, The price for treatment with the con- centrate is indeed quite high: about € 6,300 for a 41.5 MW gearbox. And the treatment must be repeat ed after two to three years. Klaus Wolters, the Oil Service Manager at Deutsche Windtechnik in Bremen, shares Eickhoff- expert Krull's opinion that there is noimperativeneed for action. “My experience tells methat, in some cas: es, gearboxes run smoothly for a long time despite mictopitting and broken teeth.” The exchange or ‘overhaul ofthe gearbox could be prepared during this time without the need for silicate concentrate. This does not really bother Stefan Bill. After all, he can refertoafirst commendation: in 2009, Rewitec was voted a finalist in the Husum WindEnergy Award for outstanding innovations and was only just beaten inthat final. orate particles ceramise the metal surfaces during running. The final resutis anew, extremely wear-resistant surface, The material properties reference to friction and wear, Rewitec claims, ae improved significantly. 117