Higher Performance for Gearboxes and Bearings in Wind Turbines.

Transcription

1 Higher Performance for Gearboxes and Bearings in Wind Turbines. Wind Energy Automotive Marine Industry

2 Content Company and Products Technology Scientific testing Examples of applications Sentient Science Conclusion

3 REWITEC COMPANY AND PRODUCTS

4 Establishment in 2003 Developer, manufacturer and distributor of nano and micro particle based surface refinement products for protection and repair of tribologic systems Patents in Europe, China. US in the last decision phase World wide sales network, office in Chicago Founder and Managing Partner: Stefan Bill

5 Tribology, friction, wear Tribology: The science and engineering of interacting surfaces in relative motion. It includes the study and application of the principles of friction, lubrication and wear. Friction: Outer friction, also known as Solid Body Friction, because it appears between contact surfaces of touching solid bodies. It is devided in static friction, sliding friction and rolling friction. Wear: Wear (abrasion) is the mass loss (surface erosion) of a material surface due to grinding, rolling, hitting, scraping, chemical or thermal load. a b

6 Products

7 Target Industries WIND ENERGY - ONSHORE - OFFSHORE INDUSTRY - STEEL - CEMENT - MINING - OIL, GAS SHIPPING - MARINE - INLAND - YACHTS - SUBMARINE AUTOMOTIVE - CONSUMER - OEM - MOTORCYCLES - RACING - OLDTIMER

8 Examples of application Main bearings Main gears Pitch bearings Generator bearings Pitch gears Azimut gears

9 Treated wind turbines Turbine manufactrurer AN Bonus DeWind Gamesa Type of wind turbine kw D4 (600 kw), D6 (1.000 kw), D8 (2.000 kw) G47 (600 kw) More than 2,000 treated wind turbines GE GE 1.5 sl, GE 1.6, GE 2.3, GE3.6 Goldwind 750 kw HSW kw Jacobs 600 kw NEC Micon 600 kw, 800 kw, 1.000kW Nordex N43, N52, N54, N60, N80, N 117/2400, S70, S77 REpower 5M Siemens kw, kw Sinovel 1.5 MW Suzlon Grease applications Tacke TW80, TW600, TW1.500 Vestas V25, V39, V44, V47, V52, V66, V80, V90 CSIC Haizhuang kw VSCF

10 Products

11 Coating process Step 1 Chemical-physical process The product uses the lubricant as carrier to the mixed friction zone Step 2 Chemical reaction The coating particles ceramize the metal surfaces mixed friction zone Step 3 New metal-ceramic surface Original material properties will be improved in terms of friction, temperature and wear siginficantly

12 REWITEC IN ACTION SCIENTIFIC TESTS

13 2-Disc Assembly Rolling Wear Tests with wind turbine oils Stress value: 1 GPa(normal force 2150 N) Rotating speed: 424 rpm / 339 rpm, slip 20 % Test-duration: 39,3 h Temperature: oil inlet temperature 60 C

14 Run 10 Run 11 Run 11 Runingtime hours Runingtime hours Test 10: Agip Blasia 320 without REWITEC Test 11: Agip Blasia 320 with REWITEC

15 SEM images after the 60 hours testing in 1:1 comparison: Without REWITEC With REWITEC REWITEC coating

16 After 60 hours testings of Agip SX320 synthetic oil*: *University Mannheim

17 Castrol Optigear X320 with REWITEC added after 19 hours 39 minutes R z, before = 2,389 µm R z, after = 1,129 µm (-53 %) R a, before = 0,360 µm R a, after = 0,180 µm (-50 %)

18 Castrol Optigear X320 without REWITEC R z, before = 2,389 µm R z, after = 1,663 µm (-30 %) R a, before = 0,360 µm R a, after = 0,285 µm (-21 %)

19 Castrol Optigear X320 with REWITEC R z, before = 2,389 µm R z, after = 1,024 µm (-57 %) R a, before = 0,360 µm R a, after = 0,151 µm (-58 %)

20 Red graph without REWITEC Blue graph with REWITEC added after 20 hours Green graph with REWITEC added at the beginning Reduction of the surface roughness (R a ) due to wear up to 58 % Reduction of the friction force up to 22 %

21 Castrol Optigear Synthetic X320 Mobilgear SHC XMP 320

22 Klübersynth GEM 4-320N Fuchs Unisyn CLP 320

23 Amsoil PTN 320 Shell Omala S4 GX 320

24 Klüberbio EG 2-150

25 FAG Arcanol Multitop grease Hertzian Stress: Rotational Speed: Slip: 15 % Duration: 40 h 1700 N 212 min -1 and 180 min -1

26 M easured data Oilgrade CastrolOptigear Synthetic X320 M obilgearshc XM P 320 Klübersynth GEM 4-320N Klüberbio EG Fuchs Unisyn CLP 320 Am soilptn 320 ShellOm ala S4 GX 320 R a,before [µm ] 0,22 µm 0,22 µm 0,22 µm 0,22 µm 0,22 µm 0,22 µm 0,22 µm R a,after[µm ] 0,129 µm 0,123 µm µm µm µm µm µm R a,reduction [% ] 41 % 44 % 54 % 40 % 50 % 18 % 25 % R z,before [µm ] 2,00 µm 2,00 µm 2,00 µm 2,00 µm 2,00 µm 2,00 µm 2,00 µm R z,after[µm ] 1,52 µm 1,18 µm 0.91 µm 1,04 µm 1.02 µm 1.51 µm 1.42 µm R z,reduction [% ] 24 % 41 % 55 % 48 % 49 % 25 % 29 % Friction Force,before 62.9 N 63,3 N 73.5 N 120,0 N 69 N 81.8 N 81 N Friction Force,after 42.6 N 41,0 N 44,0 N 54,0 N 44,0 N 44,0 N 47,0 N Reduction Friction Force 33 % 35 % 40 % 55 % 36 % 46 % 42 %

27 Scientific tests 2-Disc assembly rolling wear test black oxide vs. steel disc Left disc: Standard steel disc Right disc: Black oxide disc

28 Black oxide discs without and with REWITEC REWITEC is added Friction force without REWITEC 50.3 N, 20 % lower than a standard steel Friction force with REWITEC 44.0 N, 13 % lower than black oxide Standard steel discs with REWITEC Friction force with REWITEC 42.6 N Reduction of the friction force up to 36 % Note: The reduction of the friction force between a black oxide disc without REWITEC and a standard steel disc with REWITEC is up to 15 % After testing standard and black oxide discs the results show that it not nessary to use black oxide discs when using REWITEC

29 REWITEC on the roller bearing test rig FE-8

30 Magnification: 20x Magnification: 50x Magnification: 200x Microscopy bearing rolling elements, Castrol X320 without REWITEC Magnification: 20x Magnification: 50x Magnification: 200x Microscopy bearing rolling elements, Castrol X320 with REWITEC

31 SEM Microscopy of bearing rolling elements, Castrol X320 without REWITEC SEM Microscopy of bearing rolling elements, Castrol X320 with REWITEC

32 Magnification: 20x Magnification: 50x Magnification: 200x Microscopy bearing ring, Castrol X320 without REWITEC Magnification: 20x Magnification: 50x Magnification: 200x Microscopy bearing ring, Castrol X320 with REWITEC

33 SEM Microscopy bearing ring, Castrol X320 without REWITEC SEM Microscopy bearing ring, Castrol X320 with REWITEC

34 Test 1: Castrol X320 without REWITEC Test 2: Castrol X320 with REWITEC Weight reduction Bearing 1 0,318 g Bearing 2 0,326 g Total 0,644 g Weight reduction Bearing 1 0,269 g Bearing 2 0,266 g Total 0,535 g Evaluation: 17 % less wear with the REWITEC - concentrate Smoother surface

35 Test 1: Castrol X320 without REWITEC Test 2: Castrol X320 with REWITEC

36 WIND ENERGY AUTOMOTIVE MARINE INDUSTRY EXAMPLES OF APPLICATION

37 Examples of application: Wear development on a Bosch Rexroth gear tooth (GE 1.5 SL) over a period of two years Surface roughness R a = 7,606 µm R z = 238,547 µm Surface roughness R a = 3,464 µm R z = 133,443 µm Reduction of the surface roughness (R a ) up to 54 %

38 Wear development on a Bosch Rexroth gear tooth (GE 1.5 SL) over a period of two years Run through marks on the tooth flank Run through marks on the tooth flank after 6 weeks and 2 years: Reduction of the surface roughness and friction force Improved load carrying capacity Less stress for the tooth flank

39 Coating and analysis of a 2 MW Nordex wind turbine planetary bearing before Picture date: after Picture date: Rough bearing surface before the REWITEC treatment Smooth bearing surface after the REWITEC treatment

40 Examples of application: Coating and analysis of a wind turbine gearbox CSIC 2 MW VSCF before Tooth flank is marked with an oilresistant paint Surface imprints before and after the application

41 Coating and analysis of a wind turbine gearbox CSIC 2 MW VSCF before Significant operational wear visible In the foot area visible micro pitting after Operational wear noticeable reduced Reduction of micro pitting The contact pattern is optimized

42 Coating and analysis of a black oxide bearing from a Nordex wind turbine Picture: 2 months after wind turbine was placed in operation Picture: 12 months after wind turbine was placed in operation Picture: 18 months after wind turbine was placed in operation, with DuraGear

43 ZF test bench for wind power gearbox, 2.5MW: Run through mark development 2 nd analysis 1 st analysis Source:

44 ZF test bench for wind power gearbox, 2.5MW: Run through mark development Imprint was examined under a Keyence VHX-6000 digital microscope Surface after 4 weeks Sa: 0.19 µm Sz: 1.21 µm Surface after 8 weeks Sa: 0.12 µm Sz: 0.68 µm Reduction of the surface roughnesssa up to 36,8 % and Sz up to 43,8 %!

45 ZF test bench for wind power gearbox, 2.5MW: Run through mark development Imprint was examined under a optical microscope Surface after 4 weeks Surface after 8 weeks

46 Goal of application: Wear protection of a Nordex N60 gearbox by REWITEC coating concentrate in May 2014 Protection against further wear and prolongation of lifetime Analysis via SKF Maintenance Services GmbH Results after 2 months: The report shows a significant difference. Stop of the high vibration level, decrease of the damage frequency REWITEC

47 Coating of a wind turbine gearbox Tacke TW600 (Condition Monitoring by CMC GmbH) -20 % Seasonal trend: upper vibration level without REWITEC REWITEC application Downturn of the vibration level over the seasonal trend curve. Further downturn of the vibration level over the following seasonal trend curve. -31 % Downturn of the vibration level (roughness in the area spur gear stage) over the seasonal wave of the vibration trend: I. Reduction of the vibration level up to 20 % II. Reduction of the vibration level up to 31 %

48 REWITEC LIFETIME CALCULATIONS SENTIENT SCIENCE

49 DigitalClone Materials-Based Computional Testing Analysis of REWITEC DuraGear W100 Lifetime Effect on GE 1.5 MW Winergy Gearbox

50 output shaft Calculation of lifetime improvement: Planetary Gear High Speed Pinion Planetary Bearing Intermediate Stage Pinion Bearing interm. shaft 2 main shaft sun shaft interm. shaft 1

51 Intermediate Pinion Gear Gear tooth

52 Mixed-EHL Solution for Life Prediction Left: Surface pressure of two modeled rough surfaces interacting without REWITEC Right: Surface pressure of two modeled smooth surfaces interacting with REWITEC

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54 Sentient Science LIFETIME CALCULATIONS Lifetime improvement by ! Assumptions Failure Rate Life, L50 5,0% Failure Cost Present Value Avoide $ ,00 REWITEC Cost per Turbine $ 6.000,00 Turbines in Fleet 100 Business Value Assessment Total Failure per Year 5 Present Value of Avoiding Failure $ ,00 Total Turbines where REWITEC $ ,00 TOTAL Savings 1st year $ ,00 ROI 108 % Payback 6 Months TOTAL Savings 2nd year $ ,00 TOTAL Savings first 2 years $ ,00 ROI= TOTAL SavingsΤTotal Turbines where REWITEC applied * 100 Payback= Total Turbines where REWITEC applied Τ( Present Value of Avoiding Failure per yearτ12)

55 Recommendations, partners and customers

56 AT A GLANCE CONCLUSION

57 *Research on a 2-Disc Assembly Rolling wear test stand at the Competence Center of Tribolgy Mannheim - Germany DuraGear with convincing arguments: Reduction of friction in gears Reduction of roughness on metal surfaces Improvement of lifetime Prevention of damages Surface conditioning during ongoing operation (no downtime) Reduction of temperatures up to 20 %* in gears and bearings

58 Many thanks FOR YOUR ATTENTION

59 Dr.-Hans-Wilhelmi-Weg Lahnau, Germany Telefon: +49 (0) 6441 / info@rewitec.com Visit us on Facebook or YouTube.