Mechanical-Drivetrains Kap.1 SS2016 30.03.2016

Mechanical Drivetrains
of Wind Energy Converter
University of Applied Sciences Kiel

Prof. Peter Quell
Summer Semester 2016
Mechanical Drivetrains / SS2015

1
Prof. Peter Quell / University of Applied Sciences Kiel
Inhalt
0. General information
1. Introduction
2. Drivetrain variants
3. Rotor bearings
4. Gearboxes
5. Couplings
6. Rotor breaks and rotor locks
7. Elastomeric bearings
8. Rotor hubs and shafts

2
General Information
0.1
Aims of the module / competencies (1)
In this module you will learn the technical and economical fundamentals of
different drivetrain concepts of wind turbines.
Afterwards we would like you to…

• ..know and understand the general structure and the function of
mechanical drivetrains.
• ..be enabled to perform a technical and economical evaluation of state-of-
art and upcoming solutions of drivetrain concepts.
• ..have a profound knowledge of the specific operational and
environmental conditions and their influences on drivetrains.
• ..know actual standards and norms and to use them.
• ..be able to dimension and design drivetrains and their main components.

3
General Information
0.1
Aims of the module / competencies (2)
Afterwards we would like you to…
• .. be enabled to practical work within teams. In this context you
understand the meaning of team work, motivation and communication.
.. to be even more
interested in drive
trains of wind
turbines!!
Mechanical Drivetrains / SS2015 Source: http://www.conus.kiev.ua/wind/img/turbina_1.jpg (25.03.2014)

Prof. Peter Quell / University of Applied Sciences Kiel 4
General information
0.2
Workload and examination
Student workload
• Credit Points: 5
• Teaching hours per week : 4 h
• Studies by oneself : 90 h
Form of examination
1. Written assignments and Powerpoint-presentations as group during the
semester (30% of final grade)
2. Written test at the end of the semester (70% of final grade)
Mechanical Drivetrains / SS2015 5

General information
0.3
Lecture information and consultation
Consultation
• Please send an email to ‚peter.quell@fh-kiel.de‘ with a
telephone number as possible.
• I will come back to you via email or telephone.
Lecture information
Das Skript und alle ergänzenden Unterlagen finden Sie unter:
T:/Skripte/q/peter.quell/Mechanische Triebstränge
Aktuelle Informationen zur Vorlesung, den Übungen oder Prüfungen
erhalten Sie auf meiner FH Kiel – Homepage unter:
http://www.fh-kiel.de/index.php?id=quell&L=0

6
General information
0.4
Literature
• Schaffarczyk, Alois: Understanding Wind

Power Technology, Wiley, 2014, ISBN: 978-
1118647516
• Hau, Erich: Wind Turbines, Springer, 2013,
ISBN: 978-3642271502
• DNV-GL: Guideline for the Certification of
Wind Turbines, 2010 (Free Download)
• DIN EN 61400: Wind turbines, 2010
• H. Wittel et.All: Roloff / Matek
Maschinenelemente, Verlag Vieweg+Teubner
• Quell, P.: Lecture note ‚Mechanical
drivetrains‘, SS2015

7
Mechanical Drivetrains of
Wind Turbines
Chapter 1
Introduction
University of applied sciences Kiel

Department of mechanical engineering
Prof. Peter Quell

8
Introduction
1.0
Content
1. General assembly of wind turbines

2. Rated power of wind turbines
3. Tasks and functions of the drivetrain
4. Main components
5. Operational and environmental conditions
6. Design requirements
7. Design process

9
1.1 Introduction
General assembly of wind turbines
Differentiators of wind turbines
• Rated power
• Rotor diameter
• Number of rotor blades
• Upwind / downwind
• Hub height
• Power control
• Electrical system
• Drivetrain concept
• Horizontal / vertical axis

10
Prof. Peter Quell / University of Applied Sciences Kiel Source: http://www.repower.de (26.09.2013)
Introduction
1.1
Vertical axis (since 1700 B.C.)
Persia (6th century AD) China

11
Introduction
1.1
Horizontal axis 1200 – 1950 AD
Central post Wippmühle Dutch wind mill (from 16. century)

mill (from 12. (from 15.
century) century)
12
Introduction
1.1
Horizontal of
Drivetrain axis
the
1200
‚Dutch
– 1950
wind
ADmill‘
• Horizontal rotor shaft

• Angular gear
• Vertical mill stone shafts
• Manual load control:
Step wise mill stones can be
taken into operation

13
Prof. Peter Quell / University of Applied Sciences Kiel Idee: Stiftung Deutsches Technikmuseum Berlin
Introduction
1.1
Horizontal axis for generation of electrical energy
Paul le Cour, Denmark 1891 Honnef, Concept, 5x Balaclava, Krim, 1931,

Ø 160m, 20 MW each, 1st WEC with AC-
Germany 1932 generator, grid connected
14
Introduction
1.1
‚Modern‘ Horizontal axis turbine, 1941: Smith-Putnam/USA, 1250 kW,
Ø 53 m

15
Prof. Peter Quell / University of Applied SciencesSource:
Kiel E. Hau, Wind turbines
1.1 Introduction
Tvind WEA, 2000 kW, GROWIAN WEA, 3000 kW, Monopterus: 380 kW,
Ø 54 m, Dänemark, 1977 Ø 100 m, Deutschland, 1981 Ø 48 m, Deutschland, 1982

16
Introduction
1.1
Vertical axis turbines to generate electrical energy

17
Introduction
1.1
Flowind wind farm with Darrieus rotors 1986,

Pel.= 150 kW, Ø 17m
Source: E. Hau, Wind turbines 18
Introduction
1.1
Vertical axis (Darrieus-Prinzip), Prototype Eóle,

Canada 1987, Pel.=4000 kW, Ø 64m, Height=105m
Source: E. Hau, Wind turbines
19
Introduction
1.1
General assembly of Darrieus-WEC

Source: D. Spera, Wind Turbine Technology, 1994, ASME Press

20
Introduction
1.1
H-Rotor-WEC Heidelberg-Motor, Antarktis, Georg-von-Neumayer research

Pel.=300kW, Ø 35m, 1988 center, H-Rotor-WEC Heidelberg-Motor,
Source: E. Hau, Wind turbines Pel.=20kW, Ø 10m, blade length l=5,6m,
Mechanical Drivetrains / SS2015 vm=9,5m/s, cp=0,31, up to -55°C, 1991-2009 21
Prof. Peter Quell / University of Applied Sciences Kiel Source: http://www.wikipedia.org (19.03.2014)
Introduction
1.1
Vertax WEA, Rotor-Ø 140m, blade length l=110m,

2x 5MW-generators direct drive, each Ø 7m
Quelle: http://www.vertaxwind.com (17.04.2014)

Introduction
1.1
Aerogenerator X by Grimshaw and Arup
Pel.=10 MW, Rotor-Ø 270m
Source: http://www.swamp.de (14.04.2014)

Introduction
1.1
Horizontal axis Vertical axis
+ No active yaw mechanism needed
+ Steady incoming flow to the rotor
due to small wind sheer + No active returning of the power
cables needed
+ Steady incoming flow to the blades
+ Assembly of the drivetrain close to the
during rotor rotations
ground level: simply service works
+ High rotor efficiency(cp up to 0,5)  With the rotor close to ground level
+ Steady loading of the rotor blades just little rotor heights can be realized
-> less energy yield
 High service effort of the drivetrain  Varying inflow resulting in high power
fluctuations (esp. with 2-bladed-
Darrieus or H-Rotor)
 Low rotor efficiency:
Darrieus, H-Rotor: cp up to max. 0,4
 Rotor does not start on ist own
 2-bladed Darrieur with high dynamical
loading
24
Prof. Peter Quell / University of Applied Sciences Kiel  Vertical drivetrain critical for sealing
Introduction
1.1
Renaissance of vertical axis
Darrieus-rotor for urbane WEC
Darrieus-rotor-WEC Quietrevolution QR5, Pel.=6,5kW, Ø 3m

Source: http://www.quietrevolution.com (10.02.2014)

25
Introduction
1.1
Assembly of drivetrain components of horizontal axis turbines
Angular gearbox in Gear box with angular Gearbox and gene- Angular gear with Direct driven
nacelle, 2nd gear and gear in nacelle, rator within nacelle generator vertical generator in
generator in tower generator vertical in (standard) in tower head nacelle, no gear
bottom, low or mid tower bottom, high box
speed vertical shaft speed vertical shaft

Introduction
1.1
Advantages?
Disadvantages?
AEOLUS II, Pel.=3 MW, Ø 80m, 1993-2007

Specials: vertical installation of the generator
Mechanical Drivetrains / SS2015 in the tower head 27
Prof. Peter Quell / University of Applied Sciences
Quelle: Kiel
E. Hau, Windkraftanlagen
Introduction
1.1
Angular gear
Voith WEC-520
Special feature:
Generator in the tower bottom
Advantages?
Disadvantages?
2nd gear
Source: E. Hau, Wind turbines
Generator
Introduction
1.1
Selsam Superturbine
Quelle: http://www.selsam.com
(14.04.2014)

Introduction
1.1
Selsam Superturbine
Source: http://www.selsam.com
(08.04.2015)

1.1 Introduction
State-of-art turbines
Today‘s ‚large‘-wind turbines 2-3 rotor blades
generating electrical energy
Rotor blades
come with an (almost)
pitchable along the
horizontal rotor axis. blades axis
It may be assumes that this

Upwind rotor (in
layout will remain the main front of the tower)
drivetrain assembly in the near
an mid future. Horizontal rotor
axis
This lecture will focus on this
Active yaw system
general assembly.
Variable speed
Source: GE

Prof. Peter Quell / University of Applied Sciences Kiel 31
1.1 Introduction
Direct drive Geared drive
Main Low speed ring generator High speed

Differences? generator Gear box
Grid Grid

32
1.2 Introduction
Rated power of wind turbines
Power output boost since 1980
2014
Rated power [kW] 6.000 8000
Rotor diameter [m]
Rotor area [m2] 164
Mechanical
height [m] Drivetrains / SS2015
Hub 33
Prof. Peter
Annual energy Quell / University of Applied
yield [MWh] Sciences Kiel 25.000
Ca. 33.000
1.3 Introduction
Tasks and functions of the drivetrain
The drive train includes all components transferring the power from the
rotor to the generator.
The rotor converts the aerodynamic power of the blades into mechanical
power concentrated in the rotor hub.
The rotor hub is connected to the rotor shaft. The shaft transfers the
mechanical power from the hub to the gearbox or directly to the generator.
The rotor shaft is guided via rotor bearings which are transferring the thrust,
shear forces and bending moments of the rotor into the machine bed.
Senvion 5M-126
Source: Senvion SE

34
1.3 Introduction
The gear box is used to increase the speed of the rotation. By increasing the
speed the torque is decreased which allows smaller dimensioning of the
generator.
Direct drive turbines are working without gearboxes. They compensate the
lower rotational speed by a larger diameter of the generator and more
involved magnetic material (cupper, permanent magnets).
Direct drive turbines are working without gearboxes. They compensate the
lower rotational speed by a larger diameter of the generator and more
involved magnetic material (cupper, permanent magnets).
Additional components in the drive train are couplings (rotor shaft / gearbox
and gearbox / generator) and brakes.

35
1.3 Introduction
1. Power conversion: conversion of the mechanical rotor

power into electrical power
2. Load transfer: transfer of the mechanical rotor loads (thrust,
lateral forces, bending moments) from the rotor into the
machine bed
3. Stopping the rotor: braking the rotor in emergency cases
and locking for servicing
4. Speed conversion: conversion of the variable rotor speed
into the fixed grid frequency (50 Hz / 60 Hz)

36
1.3 Introduction
1. Power conversion
Protor=Mt,rotor∙ωrotor ~/= =/~ Pelectr.
Rotor Rotor Rotor Gearbox Brakes Generator Converter Trans-

Hub Shaft Bearing formator
Ratio i Efficiency η Efficiency η Efficiency η
Efficiency η
Mt2 = Mt,rotor / i
n2 = nrotor ∙i
Example: A wind turbine is running with a mechanical power of Protor = 6000 kW at a rotational
speed of nrotor =11 1/min. The resulting torque moment Mt,rotor is:
Pmech=Mt,rotor∙ωrotor=Mt,rotor∙2∙π∙nrotor
6000 𝑘𝑁𝑚 min 60 𝑠

Mt,rotor = Pmech/ 2∙π∙n = ∙ = 5209 kNm
2∙π∙11 𝑚𝑖𝑛

37
1.3 Introduction
1. Power conversion
Protor=Mt,rotor∙ωrotor ~/= =/~
Pelectr.

Ratio i Efficiency η Efficiency η Efficiency η
Efficiency η
Mt2 = Mt,rotor / i
n2 = nrotor ∙i
Example: The rotor torque moment Mt,rotor is transferred through a gearbox with a ratio of i=109
and an effiency of η Gear= 0,978. The torque in the generator shaft Mt,geno will be reduced by:
Mt,geno = Mt,rotor ∙ η Gear / i = 5209 kNm ∙ 0,978 / 110 = 46,3 kNm
In parallel the rotational speed of the generator shaft ngeno will be increased by:
MechanicalnDrivetrains
geno = nrotor ∙ i = 11 1/min ∙ 109 =
/ SS2015 1210 1 /min
38
1.3 Introduction
1. Power conversion
Protor=Mt,rotor∙ωrotor ~/= =/~ Pelectr.

Ratio i
Efficiency η Efficiency η Efficiency η
Efficiency ηGear
Mt2 = Mt,rotor / i
n2 = nrotor ∙i
Within the generator the rotational speed and the torque moment are converted into voltage
and current respectively the electrical power of the generator.
The frequency of the output is depending on the rotational speed of the rotor. Therefore the
power has to be converted from AC to DC followed by a conversion from DC to AC with the
predefined grid frequency.
The transformer increases the voltage of the converter onto grid level.
39
1.3 Introduction
Exercise 1:
A wind turbine (incl. gearbox, generator, converter, transformer) with a rotor
diameter of Ørot.=160m generates at a wind speed of v = 12 m/s its rated rotor
power of Prot.=7000 kW. The rotor rotates with n= 8,5 1/min. The gearbox has a
ration of i=137 and an efficiency of ηGetr.=97,5%. The efficiencies of the additional
components: ηGenerator=98%, ηConverter=98%, ηTransformer=99%.
a. The wind is blowing steadily. How much energy the turbine will produce within 6
hours (measured at the transformer output)?
b. At the given site the turbine works with a capacity factor of k=48%. How much
energy the turbine will produce within one year (annual energy production)?
c. Please calculate the rotational speed of the generator.
d. Please calculate the torque acting on the generator shaft.
e. Please calculate the power output of the converter.

40
1.3 Introduction
2. Load transfer
Forces being transferred from the
rotor into the drive train:
- Thrust FXR
- Lateral forces FYR and FZR
Moments being transferred from
the rotor into the drive train:
- Torque moment MXR = Mt,rotor
- Bending moments MYR and MZR
The center of the displayed

R-coordinate-system is in the
middle of the rotor respectively the
hub.
Standard coordinate system by GL
41
1.3 Introduction
2. Load transfer
Loads to be considered:
1. Operating loads (depending on

wind speed, turbulence,..)
2. Extreme loads (extreme guts,
extreme direction change,..)
3. Extreme environmental conditions
(lcing, earthquake,..)
4. Occurrence of fault (fault in control
system, fault in safety component,
emergency stop,..)
5. Generator short-circuit, grid failure,..

42
Prof. Peter Quell / University of Applied Sciences Kiel Quelle: E. Hau, Windkraftanlagen
1.3 Introduction
3. Stopping the rotor
To stop the rotor in an emergency case
(e.g. fault of the blade pitch system) or
for servicing a rotor brake has to be
applied in the drive train.
Due to the reduced torque moment
normally the disc brake is mounted
windkraftkonstruktion.vogel.de
between gearbox and generator.
The design of the rotor brake is critical due to the high rotational speed
and mass moment of the rotor.
By an additional device the rotor can be locked in a specific azimut

position to enable servicing of the rotor and drive train.

1.3 Introduction
3. Locking the rotor
To perform service on the rotor or other
rotating parts of the drive train, the rotor has
to be stopped and locked safely.
Therefor a rotor lock has to be applied, which
locks the rotor in a fix position in order to
avoid unlocking by accident.
Normally the rotor lock is mounted between
Electrical-mechanical rotor lock
rotor hub and rotor shaft in case of geared www.hanning-kahl.de
drives. Or between rotor hub and generator
in case of direct drives.

Introduction
1.4
Main components
‘Classical’ drive train with high ratio gearbox
Rotor hub Floating bearing Fixed bearing Brake, Coupling Generator
Rotor flange Rotor shaft Coupling Gearbox Elastomeric bearings

Source: Schaffarczyk, Einführung in die Windenergietechnik

45
Introduction
1.4
Main components
Example: ‘Classical’ drive train with high ratio gearbox
1. Rotor blade
18 12 19 13 8 7 5 6 1 2 4 2. Rotor hub
3. Blade pitch mechanism
4. Spinner
5. Rotor shaft
6. Rotor lock
7. Rotor bearing system
8. Gearbox
9. Torque support arm
10. Rotor brake
11. Coupling
12. Generator
13. Switch box
14. Hydraulics
11 17 20 10 16 9 14 15 3 15. Machine bed
16. Yaw bearing
Vestas V-52 850 kW 17. Yaw drive
Source: Vestas AS 18. Nacelle cover
19. Cooling system
Mechanical Drivetrains / SS2015 20. Tower 46
Introduction
1.4
Main components
Direct drive
Axle pin Generator-rotor
Airgap
Rotor hub Generator-stator
Rotor brake
Fixed bearing
Machine bed
Floating bearing
47
Introduction
1.4
Main components
Example: Direct drive
8
1. Rotor blade
1 3 5 4 11 12
2. Rotor hub
3. Blade pitch mechanism
4. Rotor lock
5. Rotor bearing
6. Generator
7. Converter
8. Machine bed
9. Yaw bearing
10. Yaw drive
2 6 13 9, 10
11. Nacelle cover
Enercon E-82 Source: Enercon 7 (at tower bottom)
12. Cooling system
48
Prof. Peter Quell / University of Applied Sciences Kiel 13. Tower
Introduction
1.5
Operational- and environmental conditions
Operational conditions
- Significant load variations (P ~ v3)
- High dynamics (e.g. tower deflection)
- Low stiffness of drive train foundation (machine bed)
- Long service intervals (6 to 12 months):
• Capacity of oil filter
• Life time of carbon brushes
• Greasing of bearings -> automatic lubrication systems
• Leakage control
- Extreme critical to acoustic noise emission. Steel tower transforms structure-
borne-noise into airborne noise
- Converter generates electromagnetic radiation
- Induced voltage peaks e.g. in bearings (most critical: DFIG)
- Loads from ‚both sides ‘:
• Aerodynamically and inertia induced loads from the rotor
• Torque shocks by circuits or grid failures from the generator
49
Introduction
1.5
Operational- and environmental conditions
Environmental conditions
- Extreme temperatures (-30° up to +45°C):
• Materials (steel, castings)
• Oils and grease (rotor bearing, gearbox, hydraulics)
• Heating of components (e.g. gearbox)
- High humidity
• Coating (offshore-standards)
• Electrical protection classes
• Gearbox air filter
• Dehumidifier
- Snow and icing
- Sand and Dust (deserts)
- High number of lightning strikes -> proven lightning protection
- Earthquakes
- Remote sites and high hub heights:
• Long response times in case of turbine break down
• High costs for change of components

50
1.6 Introduction
Design requirements
Expected life Low costs

time 20 years+
High efficiency
Low weight
High reliability
Low structure-
borne-noise ………………
Low
maintenance
Service and
effort
maintenance
Mechanical Drivetrains / SS2015 friendly
51
Introduction
1.6
Design requirements
Criteria for choosing a drive train concept
1. Customer perspective
• Operator: LCC-oriented (long term considerations)
LCC (Life-cycle-costs): including all project costs from initial planning, purchasing the
turbines, installation, operation, servicing to dismantling after taking out of operation
• Wind park or fund developer: CAPEX-oriented (short-term considerations)
CAPEX (Capital expenditures): including all investment costs to plan a wind park, purchase
and install the turbines to be ready for operation
2. Bank’s and assurance company’s perspective

• Low risk profile
• Technical evolution instead of big innovations (track record oriented)

52
Introduction
1.6
Design requirements
Criteria for choosing a drive train concept
WEC-manufacturer’s perspective
• Known and manageable risk portfolio. Often manufacturer have to full-fill service
(and warranty) contracts up to 15 years
• Consistent product portfolio (sticking with one concept):
- Efficient purchase, production, assembly, service
- Optimized spare parts management
• Highest profit (sales prize less costs)
 Higher drive train efficiency -> higher sales prize possible
 Low service effort -> lower service costs -> higher sales prize possible
 High reputation –> higher sales prize possible
• Interest in stability of material costs (f.e. rare earth: € 100,- -> € 400,- -> € 100,-)
• Supply guarantee / possibility to negotiate:
 Single-sourcing / in house manufacturing (esp. direct drive generators)
 Multi-sourcing (gearboxes, generators,..)
53
Introduction
1.6
Design requirements
Pros and cons of multi-sourcing for the turbine manufacturer
Pros:
- Independent of market fluctuation cause the risks are transferred to the supplier
- Due to multiple supplier the risks of serial failures is minimized
- Prices are negotiable
- Security of supply in case of unscheduled production downtimes
- Low investment costs in case of internationalization (local content) cause the
investment has to be done by the supplier

Introduction
1.6
Design requirements
Pros and cons of multi-sourcing for the turbine manufacturer
Cons:
• Loss of know-how cause it has to be transferred to the supplier (supplier ->
competition)
• No detailed knowledge about the cost structure of the components
• Complex interface management cause the same component will be produced by
several supplier with slight differences. Attention to:
- Mounting dimensions, weights, stiffness
• High demands to the service organization:
- Failure analysis and know-How
- Diversity of spare parts

Introduction
1.7
Design process
Phase-oriented design process:
Requirements Project Definition of Validation &
analysis planning Design Prototype
concept serial release
• Market • Objectives • Draft / • Development & • Production and • Measurement

analysis of Design assembly of the campaign
• Competition • Milestones
various prototype
• Operational and • Certification
• Strategic • Costs concepts
objectives of the safety concept • Transportation • Documentation
• Resources • Design-to- and installation
company • Loads • Serial release
• Responsibi- spec
• Commissioning
lities (Pflichtenheft) • Controller • Lessons Learned
Requirements Project Design-to-spec Specifications Prototype Certification

specification order
Definition of Drawings Commissioning Final report
concept protocol

Introduction
1.7
Design process
Phase 1: Requirements analysis
Market analysis Internal requirements
• Customer survey • Production
• Market potential • Service
• Laws, standards, guidelines (EEG, • Purchase
Local content,..) • Board / Management
• Raw materials trends Intellectual property research
• Market trends (‚Game changer‘) (patents)
Competition analysis Literature research
• Brochures • Google
• Fairs • Books
• Customer • Newsletter
• Supplier • Conference proceedings
• Assurance companies / Banks (national und international)
• Own service department
Introduction
1.7
Design process
Phase 2: Project planning
Project
planning
Not part of this

• Objectives
• Milestones
• Costs
lecture but very

• Resources
• Responsibi-
lities
important for your

professional career!
Project
order

Introduction
1.7
Design process
Phase 3: Definition of concept
Systematic comparison of different concepts:
Concepts Concept A Concept B Concept C
Criteria Weighting Rating R W*R Rating W*R Rating W*R
W [%]
Costs
Efficiency
Technical risk
Economical risk
Service effort
Weight
Noise emission
Patents
Market access
Health & safety
Environment
……
Sum: 100%
Introduction
1.7 Dimensions, masses,
Design process stiffness,..
WEC Concept
Rotor Drive train Tower/Foundation Electrical system Controller
Simulation model (Bladed, Flex5, Simpack, Fast,..)

Wind (wave) Rotor aerodynamic Flexible structure Controller
Load simulation (load cases)

Wind regime Environmental conditions Guidelines Operational concept
Design loads
Phase 4: Design
Extreme loads Fatigue loads Time series
Stress capacity Structure stress

- Material parameter
- Guidelines
not o.k.
Stress analysis Redesign
Safety factors - Failure stress
Mechanical Drivetrains / SS2015 - Fatigue strength o.k.
60
Introduction
1.7
Design process
Standards and Guidelines
IEC-Standards
The international electro-technical Commission (IEC) published 11 standards about
the different technical fields of wind energy. These standards have the number 61400.
The most important ones for the design of drivetrains are:
- IEC 61400-1 Design requirements
- IEC 61400-3 Design requirements for offshore wind turbines
Guidelines of certification companies

In parallel some certification companies published their own guidelines which are
Phase 4: Design
closely based on the IEC-standards, e.g.:

- DNV-GL, ‚ Guideline for the Certification of Wind Turbines, 2010 ‘
ISO, EN, DIN-standards for the design of components

For the design of the specific components additional national and international
standards are relevant (ISO, EN, DIN).

61
Introduction
1.7
Design process
Phase 5: Phase 6:
Validation &
Prototype
serial release
• Production and • Measurement

assembly of the campaign
prototype • Certification
• Transportation • Documentation
and installation
• Serial release
• Commissioning
• Lessons Learned
Prototype Certification
Commissioning Final report
protocol


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Mechanical Drivetrains

of Wind Energy Converter

University of Applied Sciences Kiel

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

Afterwards we would like you to…

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015 Source: http://www.conus.kiev.ua/wind/img/turbina_1.jpg (25.03.2014)

Mechanical Drivetrains / SS2015 5

Mechanical Drivetrains / SS2015

• Schaffarczyk, Alois: Understanding Wind

Mechanical Drivetrains / SS2015

University of applied sciences Kiel

Mechanical Drivetrains / SS2015

1. General assembly of wind turbines

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

Persia (6th century AD) China

Mechanical Drivetrains / SS2015

Central post Wippmühle Dutch wind mill (from 16. century)

• Horizontal rotor shaft

Mechanical Drivetrains / SS2015

Paul le Cour, Denmark 1891 Honnef, Concept, 5x Balaclava, Krim, 1931,

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

Flowind wind farm with Darrieus rotors 1986,

Vertical axis (Darrieus-Prinzip), Prototype Eóle,

General assembly of Darrieus-WEC

Mechanical Drivetrains / SS2015

H-Rotor-WEC Heidelberg-Motor, Antarktis, Georg-von-Neumayer research

Vertax WEA, Rotor-Ø 140m, blade length l=110m,

Mechanical Drivetrains / SS2015 22

Mechanical Drivetrains / SS2015 23

Darrieus-rotor-WEC Quietrevolution QR5, Pel.=6,5kW, Ø 3m

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015 26

AEOLUS II, Pel.=3 MW, Ø 80m, 1993-2007

Mechanical Drivetrains / SS2015 29

Mechanical Drivetrains / SS2015 30

It may be assumes that this

Mechanical Drivetrains / SS2015

Main Low speed ring generator High speed

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

Mechanical Drivetrains / SS2015

1. Power conversion: conversion of the mechanical rotor

Mechanical Drivetrains / SS2015

Rotor Rotor Rotor Gearbox Brakes Generator Converter Trans-

6000 𝑘𝑁𝑚 min 60 𝑠

Mechanical Drivetrains / SS2015

Rotor Rotor Rotor Gearbox Brakes Generator Converter Trans-

Mt,geno = Mt,rotor ∙ η Gear / i = 5209 kNm ∙ 0,978 / 110 = 46,3 kNm

Rotor Rotor Rotor Gearbox Brakes Generator Converter Trans-

Mechanical Drivetrains / SS2015

The center of the displayed

1. Operating loads (depending on

Mechanical Drivetrains / SS2015

By an additional device the rotor can be locked in a specific azimut

Mechanical Drivetrains / SS2015 43

Mechanical Drivetrains / SS2015 44

Rotor hub Floating bearing Fixed bearing Brake, Coupling Generator

Rotor flange Rotor shaft Coupling Gearbox Elastomeric bearings