Spanning the Spectrum with Brake Expertise

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1 Brake Even Spanning the Spectrum with Brake Expertise

2 Exacting and innovative product development requires qualified employee know-how.

3 Planning Ahead. Safe and Sound Founded in 1898, HANNING & KAHL GmbH & Co. KG is now in the third generation in 100 % family ownership. Around 360 employees design, manufacture and sell safety-related customized solutions for rail-based public transport and industrial applications all over the world. The ideas, products and services provided by our four operating divisions are highly appreciated around the globe. The secret of our worldwide success is a first-class team with vast expertise and intense commitment which is illustrated by the many awards presented to the company, such as the prize for Excellent Knowledge Management and Idea Management, the Innovation Prize, the German Idea Prize, and the TOP Innovation Prize presented to HANNING & KAHL by the BmWi Federal Ministry for Economic Affairs. Worldwide references and certification, such as the International Railway Industry Standard (IRIS), verify HANNING & KAHL s internationality and efficiency. Thanks to in-depth, in-house manufacturing and highly-qualified employees, we can react quickly and competently to customer requirements, and also provide reliable support in the form of service, maintenance and training workshops. Our core competencies are products and systems which we develop and manufacture in-house 80 Years of Brake Competence Developing bespoke brakes is tradition at HANNING & KAHL. The success story started decades ago in 1928 when the company developed and produced track brakes for public transport, followed by hydraulic brake systems. Since then, HANNING & KAHL has played a major role in spearheading brake technology primarily in rail transportation to begin with, and now also in other industrial branches such as wind turbine construction. No other company has such a wealth of experience in the manufacture of electro-mechanical brakes for wind turbines. This competence is reflected in perfected products and reliable service.

4 Thoroughly Thought-Through: the Electro Certified for compliance with the highest standards, we continuously optimise work processes with regard to short turnaround times, adherence to delivery schedules, and quality Creativity and Competence When HANNING & KAHL developed the first electromechanical brake for wind turbines in 2001, this technical appliance was fundamentally new to the industry. Until then, hydraulic brakes were the standard solution in wind turbines. The advantages of electro-mechanics over hydraulics were substantial and quickly proved themselves with impressive results. In 2003, the world s first electromechanical brake for wind turbines went into serial production at HANNING & KAHL. This innovation is meanwhile a standard component in wind turbines. Convincing Technology By installing electro-mechanical brakes, wind turbine manufacturers gain a head start over the competition. Low-maintenance and oil-free braking are just two of the benefits of HANNING & KAHL s trend-setting technology. Such advantages are vital for offshore wind farms, where maintenance is particularly complex and costly. No wonder therefore that electromechanical brakes are also becoming standard features of wind turbines.

5 -Mechanical Brake. Our reliability is demonstrated by our commitment to total quality management and service, and is appreciated by satisfied customers all along the line Innovative and Safe As a specialist for electro-mechanical braking systems, HANNING & KAHL offers you reliable partnership, innovations, sound production capacity and experience with demanding product developments which have successfully proven themselves in operation. At HANNING & KAHL you profit from well-engineered quality from a single source: we develop, design and produce electro-mechanical brakes on our own premises in the Westphalian town of Oerlinghausen. 100 % quality Zero compromise. Guaranteeing you safety from the word go! First Choice Operating wind turbines becomes safer and more economically efficient with the design-engineering advantages of HANNING & KAHL s electro-mechanical brakes: + More economically efficient Electrically-generated braking force. Maintained without energy. Sovereign force. + More reliable No pressurized components. No leakage. + Maintenance-free No need to change oil. No pressure tanks to handle (pressure vessel ordinance). No need to replace hydraulic tubing. No need to bleed the system. + More environmentally-sound No hydraulic oil. No oil disposal. No strain on the environment. + Flexible No mechanical interface problems. With modular product design, extensive proprietary development and intensive in-house production, customer requirements can be met flexibly and economically. On customer request we make prototypes for testing under authentic conditions. We also have sophisticated testing facilities in in-house and external laboratories.

6 Brakes with a System Spanning the Spectrum with Brake Expertise HANNING & KAHL engages in intense knowledge transfer with leading manufacturers of wind turbines and incorporates manufacturers experience into new electro-mechanical brake developments. The result: practical technology and outstanding cost-benefit ratio for operators. Rotor Brakes With electro-mechanical rotor brakes, the rotor can be safely brought to a standstill in all conditions. The brakes are powered by an electric motor, the clamping force is actively built up via a transmission system and maintained without any power. Rotor brakes with braking forces from 5 to 300 kn Yaw brakes with braking forces up to 500 kn Rotor locks Electro-mechanical braking systems with compact direct drive, a wide spectrum of braking forces and dimensions, economically-efficient solutions for every wind turbine, no matter what size. Competence which convinces our customers!

7 Yaw Brakes HANNING & KAHL s new electro-mechanical yaw brakes ensure safe holding of the nacelle in the wind and yawing with partial braking force or with brake completely released. The brakes are powered by an electric motor, clamping force is built up actively via a gear system. The braking force is maintained without additional power. Rotor Locks Electro-mechanical rotor lock HERW enables swift and safe locking of the rotor without the use of hydraulics. The conical shape of the bolt simplifies pre-positioning of the rotor - the powerful drive of the bolt pulls the rotor into its final position. The brakes are designed for quiet operation (without the screeching or rattling of brake pads).

8 Rotor Brakes Series HEAW The most striking features of HANNING & KAHL s electro-mechanical rotor brakes are compact design, modular assembly and variable control. Compact design is possible by direct electro-mechanical force generation without external moving parts. Combined with modular assembly, this facilitates simple adaptation of the brake geometry to the installation space in the wind turbine. Control Our rotor brakes come with different types of controllers, with simple relay or intelligent control. With the intelligent controller, braking force can be set variably via software. Remote diagnosis is possible; and the brake can be connected to the wind turbine controller via bus systems. Several brakes can be easily networked, realizing redundancies and increasing the availability of the wind turbine. Compact Design The electro-mechnical brakes are designed as floating calipers. By following an innovative design principle and integrating the different gear stages into a housing, construction is compact. Easy to Install Just how convenient electro-mechanical brake systems are, becomes apparent during the mounting stage. Electric lines are required for signal and energy transmission but tubing is no longer necessary. This means there is no need for leakage tests or system bleeding. Different types of brackets can be used for the mechanical interface depending on customer wishes. Functional Highlights If the system is equipped with a micro-controller, complex brake force distribution is possible. The bus interface offers further possibilities, for example continuous status monitoring by upstream controllers or other components. At the same time, complex braking commands can be transmitted, opening up new possibilities for integrating the brake into closed circuits. Functional adaptations (e. g. ramp times, thresholds, communication protocol) can be easily implemented by updating the software.

9 Rotor Brakes One possible application is smooth stopping of the rotor. With this, drive train overshooting and oscillation can be effectively prevented after brake disc standstill, thus minimizing mechanical stress to the gear box and support structures. Wear Adjustment All brake systems can be optionally equipped with automatic pad wear adjustment. Manual Activation As a further option, the braking system can also be equipped with a manual operating unit with which service staff can activate the brake with switches and/ or a potentiometer. Manual activation has turned out to be a major advantage when the rotor has to be stopped in a specific position (e. g. to apply the rotor lock). Fail-Safe Functionality In fail-safe version, the rotor brakes are equipped with a capacitor-based power storage system. The power storage system is designed for 20 years of service, and charging status is continuously monitored. For safety-relevant applications, daily self-diagnosis is possible, i.e. the individual system components of the brake are inspected regularly by minimum stroke movements of the brake in the pad gap range. This way, dormant errors are detected early. F; n Rotor speed Mechanical braking torque Regenerative braking torque, aerodynamic Single-stage initial braking Gentle braking force distribution t Comparison of rotor speed curve for singlestage initial braking and for gentle braking force distribution.

10 Rotor Brakes Mechanical Activation Device The brake can be mechanically moved with a standard tool or a cordless screwdriver, enabling application and release without power supply (e. g. while the wind turbine is being mounted). Electrical Interface The electrical interface consists of the power supply, inputs and outputs of the hardware signals and the bus interface. Friction Linings Various organic and sintered metal linings are available. Selection depends on the conditions the brake is to be deployed in (the amount of energy to be dissipated, expected brake disc temperature, etc.). HEAW 30 Operating principle Nominal clamping force Nominal braking force Nominal power supply Direct driv 400 kn 300 kn AC 400 V Ambient temperature -30 C + Dimensions without bracket ca. 480 x 380 Weight without bracket ca. 175 kg

11 Technical Attributes Compact design Straightforward installation Simple mechanical auxiliary activation Brake pads can be easily replaced Suitable for offshore applications Suitable for extreme climatic conditions Different supply voltages and network frequencies Options Bus connection Braking force can be set as required via software Back-up power storage for fail-safe function Automatic pad wear adjustment Automatic gap centring 0 EVO HEAW 100 EVO HEAW 63 HEAW 40 HEAW 15 e Direct drive Linear drive Linear drive Linear drive 130 kn 100 kn 50 kn 22 kn 100 kn 63 kn 40 kn 15 kn AC 110 V AC 240 V or DC 24 V AC 110 V AC 240 V or DC 24 V AC 110 V AC 240 V or DC 24 V AC 110 V A240 V or DC 24 V 60 C -25 C +60 C -25 C +60 C -25 C +60 C -30 C +60 C x 590 mm 480 x 310 x 450 mm 480 x 310 x 750 mm 430 x 290 x 710 mm 330 x 180 x 440 mm 155 kg 135 kg 75 kg 40 kg

12 Yaw Brakes Series HEAW On HANNING & KAHL s new yaw brake system, the logical continuation of our development strategy becomes clear: compact design, robust construction and the absence of external moving parts form the basis for a product that rounds off HANNING & KAHL s portfolio. The complete system consisting of rotor brake, rotor lock and yaw brake can be implemented without the use of hydraulics. On the yaw brake, clamping force is generated by an electric motor and a gear system as on the rotor brakes. Braking force is maintained without energy. If the power supply fails, braking status does not change. This means that the brake can remain activated without external power for an indefinite period. Control The yaw brakes can be activated in different ways: Variant A: The upstream wind turbine controller activates the components and evaluates the position indicators. Variant B: Each brake is equipped with a simple controller, the wind turbine controller only transmits a brake / release command. Variant C: Each brake is equipped with an intelligent controller which performs extensive self-diagnosis and exchanges status data with the wind turbine controller via a bus system. All brakes can be activated individually and independently of each other and are thus redundant components which increase the availability of the braking system. Mechanical Activation Device The brake can be mechanically moved with a standard tool or a cordless screwdriver, enabling brake application and release without power supply (e. g. while the wind turbine is being mounted). Brake Pads When selecting brake pads, we extensively tested different makes of friction materials on the H&K test station to find a pad quality which meets the requirements with regard to friction (static and dynamic) and noise (avoidance of stick-slip effects)

13 Yaw Brakes Brake Pad Replacement Experience shows that the most frequent reason for brake pad replacement on yaw brakes is contamination of the pads following leakage of hydraulic oil. Pads are practically not worn in operation. As HANNING & KAHL s electro-mechanical brakes function without hydraulic oil, it is highly unlikely that brake pads would have to be replaced. Should replacement be necessary, however, the pads are easily accessed by pivoting the brake. Mechanical Connection The mechanical interface is based on the 12 M36-screw interface found in wind turbines. Operating principle Nominal clamping force Nominal braking force Nominal power supply Active 500 kn 400 kn AC 400 V Ambient temperature -30 C +60 C Dimensions ca. Weight ca. 475 x 380 x 860 mm 395 kg

14 Rotor Locks Electro-mechanical rotor lock HERW enables swift and safe locking of the rotor without the use of hydraulics. The conical shape of the pin simplifies pre-positioning of the rotor and the powerful drive of the rotor lock pulls the rotor into its final position. The rotor lock can only be actively moved out of its final position. Self-locking drive ensures that external loads cannot cause unintended movement of the rotor lock. In contrast to conventional hydraulic rotor locks whose actuating force is substantially greater in locking than in unlocking direction, the travel force of HANNING & KAHL s electro-mechanical rotor locks is equal in both directions. This prevents the pin from jamming when locked. Position Monitoring Standard: 2 potential-free contacts (locked/unlocked) Optional: Up to 4 further potential-free contacts for any position (also intermediate positions). HERW 120 HERW 200 HERW 240 Pin diameter 120 mm 200 mm 240 mm Permissible shear force 500 kn 2000 kn 4000 kn Operating principle Spindle drive Spindle drive Spindle drive Travel force 50 kn 160 kn 170 kn Nominal power supply AC 400 V AC 400 V AC 400 V Ambient temperature -30 C +60 C -30 C +60 C -30 C +60 C Dimensions ca. 310 x 205 x 600 mm 340 x 280 x 780 mm 390 x 320 x 870 mm Weight ca. 37 kg 120 kg 182 kg

15 Globally, we are a powerful partner for safety-relevant system solutions in rail transportation.

16 Spanning the Spectrum with Brake Expertise GmbH & Co KG Rudolf-Diesel-Straße Oerlinghausen Germany Phone Fax info@hanning-kahl.com 09/2014

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