Weitere Kooperationspartner: ACIDA GmbH Centa Antriebe Kirschey GmbH EickHoff Maschinenfabrik GmbH...

Weitere Kooperationspartner:ACIDA GmbH Centa Antriebe Kirschey GmbH EickHoff Maschinenfabrik GmbH ITI Gesellschaft für ingenieurtechnische Informationsverarbeitung mbH

Repower Systems AG SEG Schaltanlagen-Elektronik Geräte GmbH Svendborg Brakes A/S VEM Sachsenwerk GmbH

www.ibh.rwth-aachen.de www.me.tu-dresden.de

SIMU-Wind

Combination of multi body system simulation, electrical simulation and

Condition monitoring a powerful research development

Research Project of “Bundesministeriums für Wirtschaft und Arbeit (BMWA)“

in scope of the support program “InnoNet“

2




Motivation

• increasing risk of damage/defects in combination with increasing performance

• knowledge loss of the actual operating conditions

• increasing performance requirements for all drive train components

• class of insurance claims for determined revision cycle in Germany




Project objective is the …

…development of a combined multi sensor, multi body condition monitoring system for wind turbine drive trains

• optimized dimensioning of drive train elements

• reduction of down times

• integrated consideration of the drive train of wind turbines

• analysis of abnormal drive train operating conditions

• increasing life cycle of drive train elements




Project partners

Research institutes

IMM, TU Dresden IBH, RWTH Aachen

ACIDA GmbH

Centa Antriebe Kirschey GmbHEickhoff Maschinenfabrik GmbH

ITI GmbH

REpower Systems AG

SEG GmbH & Co.KG

Svendborg Brakes A/S

VEM Sachsenwerk

Industrial partners

5




Measurement system (1) 86 sensors at the nacelle

• drive train

• base frame

(data storage on industrial PC)

16 sensors in tower base

• electrical signals of generator and converter

• parallel data storage with signals of drive train

• remote control




64 sensors at the drive train

• torsion and bending at the rotor shaft and generator shaft• movement of the rotor shaft belonging to bearing- and gearbox

housing • movement inside gearbox• gearbox and generator temperature• vibration at gearbox and generator• …

Measurement system (2)




Getriebe (GT) Generator (GEN)Hauptlager (HL)

WSS (Wirbelstromsensoren)

LVDT (Wegmesssystem)

WSS/HL1

WSS/HL2

B/RW1

T/RW1

B/RW2

LVDT/GT5

LVDT/GT4

LVDT/GT1

LVDT/GT2

LVDT/GT3

LVDT/GT6

WSS/GT1

WSS/GT2

WSS/GTi1-3

DMS/GT1DMS/GT2

DMS/GT3DMS/GT4

T/GENW1

PT100/Gen1

PT100/GT1

LVDT/GEN1

LVDT/GEN5

LVDT/GEN3LVDT/GEN6

LVDT/GEN4

LVDT/GEN2

DRZ/GENW1

RW

GenW Generatorwelle

Rotorwelle

KSS/HL1

WSS/RW1,2

HALL/RW1

KSS (Körperschallsensoren, Beschl.)DMSHallsensor (Positionsgeber)

Temperatursensor


8




• 22 strain gauges at the base frame


9




mechanical system consists of rotor and blades, main shaft gear unit coupling, brake disk generator baseframe

controller consists of pitch controller output power

controller speed controller brake controller

electrical system consists of generator converter grid

MBS-Model (modular design)

windaerodyn.

model

mechanical

system

electrical

system

wave

controller

network

Wind TurbineWind Turbine

relevantrelevantonly for offshore only for offshore systemssystems

Field of InterestField of Interest

10




simulation model included rotor model single blade and complete rotor

(bending in flap- and edge-wise direction) drive train torsional vibration model

(with rigid and flexible rotor)MBS model (with rigid and flexible rotor)

nacelle flexible base frame model electrical system asynchronous generator model

with converter and grid model aerodyn. model wind to moment converter model

with cp equation

MBS-Model (components)




P,Q

pitch

rotor

wind

drivetrain

T

rotor

stator

MSC LSC

model of generator and converter IU

grid-model

Electrical simulation model (1)

12




calculation of the electro-mechanical system

Co-Simulation (time domain)

T

rotor

stator

MSC LSC

model of generator and converter

IU

grid-model

13




torsional frequencies

axial mode shape

bending rotor (edgewise)

bending rotor (flapwise)

Tor

sion

al M

odel

Tor

sion

al M

odel

(F

lexi

ble

Rot

or)

Tor

sion

al /

Axi

al M

odel

Tor

sion

al /

Axi

al M

odel

(F

lexi

ble

Rot

or)

natural frequencies

Results (frequency domain)

60 Hz

170 Hz

14




(I) torsional mode shape gearbox [approx. 60 Hz]

(II) axial mode shape low speed shaft LSS [approx. 170 Hz]

(I) torsional mode shape gearbox [approx. 60 Hz]

(II) axial mode shape low speed shaft LSS [approx. 170 Hz]

Results (mode shapes) mode shapes of the rigid drive train model

15




(I) torsional and bending mode shape of base frame and drive train [approx. 2 Hz]

(II) bending mode shape of base frame [approx. 4 Hz]

(I) torsional and bending mode shape of base frame and drive train [approx. 2 Hz]

(II) bending mode shape of base frame [approx. 4 Hz]

Results (mode shapes) mode shapes of the flexible drive train model

16




voltage drop at the net meeting point uPCC

0.4 0.5 0.6 0.7 0.8 0.9

-400

0

400

800

UP

CC

[V

]

[s]

0.4 0.5 0.6 0.7 0.8 0.9

-20000

-10000

0

10000

[s]

Air

gap

mom

ent

[N

m]

Results (electrical signals)

17




- power loss dependent of temperature

23.04.2005 24.04.2005 25.04.2005

0

600

1200

1800

2400

Pow

er [

kW]

0

40

80

120

Tem

p.

Gen

. [°

C]

• non linear property: power dependency of generator temperature

- verification of temperature dependency by measuring data analysis

Results (electrical signals)




Integrated system

Drehzahl

Schwing.

DMS

Weg

A/D

Wa

nd

ler

Em

be

dd

ed

PC

(On

bo

ard

)

Ad m inistra to r PC(Da tenha ltung ,

Ke nnwe rtb ild ung ,Trend üb erwa c hung ,

Ko nfig ura tio n)

TC P/IPM o d e m

ISDN

Zentrale

Condition-Monitoring-System Multi body simulation model

Electrical simulationmodel

Integratedsystem




SIMU-Wind

Combination of multi body simulation, electrical simulation

and Condition monitoring a powerful research development

Thank you for your attention!

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