The intelligent gearbox more performance and predictable maintenance

Transcription

1 The intelligent gearbox more performance and predictable maintenance Dietmar Tilch, ZF Industrieantriebe Witten GmbH MDA Forum, Hannover Fair LHR IWDR, The Intelligent Gearbox

2 Wind Power Technology In ZF Group MOTION AND MOBILITY Mobility across the board ZF organization is divided into 7 major divisions: Dietmar Tilch LHR Car Powertrain IWDR Car Chassis Technology Technology ZF Friedrichshafen AG Commercial Vehicle Technology Industrial Technology Off-Highway Systems Test Systems E-Mobility ZF Aftermarket Active & Passive Safety Technology Special Driveline Technology Marine Propulsion Systems Aviation Technology Wind Power Technology Industrial Drives

3 ZF Puts Wind Energy In Motion Joining forces for the new generation of wind energy ZF Global Leading Position In the gearbox industry since 1979 Manufacturing capacity on annual basis ~ 18,000 MW Worldwide manufacturing & service coverage Balanced global Manufacturing depth and processes All critical processes in-house Global installed base > 100,000 MW whereof 3 MW segment > 15,000 MW Product portfolio on- and offshore 0.8 MW MW Full Service Offering Dedicated service centers in all major wind market LHR IWDR, The Intelligent Gearbox

4 > 100 GW ZF gearbox capacity installed > Gearboxes Single point of contact for ~25%* of worldwide installed wind capacity *) ~400GW of geared wind turbines installed (end 2016, cumulative); thereof >100GW installed by ZF Wind Power LHR IWDR, The Intelligent Gearbox

5 The Wind Power Gearbox as an Intelligent Mechanical System Essential operation parameters Speed Torque Multiple Sensor Network Dynamic Load Monitor Vibration Oil parameters Cameras etc. DSL, LTE Temperatures Lubrication status On-site data evaluation and communication to turbine controller (real time) Cloud: predictive maintenance Cloud services provide data overview, history and trends as well as: Automated detection of abnormalities Remaining lifetime calculations Remote monitoring information LHR IWDR, The Intelligent Gearbox

6 Dynamic Load Monitoring Torque Measurement Principle Determination of position 1 down to a few µm Possible measurement positions inside a gearbox Contactless robust inductive sensor Determination of position 2 down to a few µm LHR IWDR, The Intelligent Gearbox

7 Potential For Energy Yield Increase Based on individual wind turbine drive train load measurement Today With individual drive train load measurement Higher energy yield without risk High wind turbulences Rated Power Rated Power Rated power Rated Power.... Rated Power Sensor Control Unit t Torque Damping Torque Condition Monitoring System Turbine Controller Feasible Power Feasible Power Feasible Power Design strength.... Feas. Power WTG 1 WTG 2 WTG WTG xx WTG 1 WTG 2 WTG WTG xx Risk for early damage LHR IWDR, The Intelligent Gearbox

8 Optimal Drive Train Load Reduction Based On Closed Loop Control Gearbox as an ideal drive train load measurement position Without damping rpm turbine control torque m1 m 2 m 1 m 2,3,4 m x time 100% Overload Dynamic torque load Average torque load Current state of the art damping (based on generator signals) rpm Damping based on generator signals torque no damping risk for excitation damping no damping time 100% Safety margins reduces feasible power Dynamic torque load Average torque load Closed loop damping based on torque measurement rpm torque measurement turbine control torque LHR IWDR, The Intelligent Gearbox time damping in complete frequency range 100% Potential for torque/power increase Dynamic torque load Average torque load

9 Optimal Drive Train Load Reduction Based On Closed Loop Control Multi-Body-Simulation of a typical multi megawatt wind turbine Without damping rpm Current state of the art rpm turbine control Damping based on generator signals Torque amplitude current state of the art damping without damping closed loop damping 100% 100% Closed loop damping rpm torque measurement turbine control LHR IWDR, The Intelligent Gearbox Reduction of torque amplitudes caused by wind turbulences (especially storms) Frequency [Hz] Excitation with current state of the art damping could result in higher torque amplitudes due to open loop control Reduction of further oscillation with closed loop damping better rotor aerodynamics higher energy yield 100%

10 The Wind Power Gearbox As An Intelligent Mechanical System Cloud services provide data overview, history and trends as well as: Automated detection of abnormalities Remaining lifetime calculations Remote monitoring information OEM and operator benefits: -> ZF enables the reduction of the Cost of Energy sustainably by: Minimizing Operational Expenditures reduced stress and wear demand-oriented maintenance extended oil life cycles Optimizing the turbine performance LHR IWDR, The Intelligent Gearbox

11 Contribution of Intelligent Performance Management to reducing the Cost of Energy LCOE Drivers AEP Reliable & efficient operation Performance increase CAPEX Lifetime extension Value engineering OPEX Maintenance optimization Increase availability LCOE: Levelized Cost of Energy, AEP: Annual Energy Production, CAPEX: Capital Expenditure, OPEX: Operational Expenditure LHR IWDR, The Intelligent Gearbox

12 Cloud-based Performance Management, Park Overview LHR IWDR, The Intelligent Gearbox

13 Drive Train Dynamics Dashboard LHR IWDR, The Intelligent Gearbox

14 Critical Drive Train Dynamics LHR IWDR, The Intelligent Gearbox

15 Load based Lifetime Calculation LHR IWDR, The Intelligent Gearbox

16 The Intelligent Gearbox Making wind power the leading renewable energy source Intelligently designed plus Intelligently operated and maintained SYSTEM BEHAVIOR TORQUE DENSITY INCREASE ADVANCED BEARING TECHNOLOGY INTELLIGENT PERFORMANCE MANAGEMENT LHR IWDR, The Intelligent Gearbox

17 Thank you Meet you on our booth Hall 25, A12 ZF Friedrichshafen AG behält sich sämtliche Rechte an den gezeigten technischen Informationen einschließlich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor LHR IWDR, The Intelligent Gearbox ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.