The validation of MBS multi-megawatt gearbox models on a 13.2 MW test rig

Transcription

1 The validation of MBS multi-megawatt gearbox models on a 13.2 MW test rig Ben Marrant Wind Power Technology A brand of ZF ZFWP R&D department 1 The Presentation validation of Title, MBS Date multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

2 Overview 1. Introduction 2. Research project 3. ZFWP gearbox model 4. Validation of flexible structural components 5. Validation of MBS model of test set-up 6. Conclusions ZFWP R&D department 2 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

3 Introduction + Customers Products 2 MW 1,5 MW to 6,15 MW Regions Production Locations Gainesville, USA Coimbatore, India Lommel, Belgium Tianjin, China Gainesville, USA Coimbatore, India Lommel, Belgium Tianjin, China Source: ZF; Hansen Transmission Annual Report 2011, and Annual Report 2010, ZFWP R&D department 3 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

4 Research project è Drive train modeled with limited DOF in wind turbine simulation models when using FLEX and BLADED: u Loads on gearbox need to be derived from loads at rotor hub u Drive train model is representative for small frequency range < 6 Hz è Robust and reliable gearbox designs for multi-megawatt wind turbines require in-depth insight in gearbox dynamics: u Resonances u Transient loads è MBS can give insight in gearbox dynamics provided that models are trustworthy ZFWP invested in large validation campaign for wind turbine gearboxes on 13.2 MW test rig ZFWP R&D department 4 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

5 Research project è Validation of gearbox models using measurement campaign on 13.2 MW test rig, NOT in wind turbine è Two gearbox types tested: u 2 MW gearbox set-up: 1 planetary stage & 2 parallel stages u 3 MW gearbox set-up: 2 planetary stages & 1 parallel stages ZFWP R&D department 5 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

6 Research project è Extensive measurement campaign: u > 200 sensors Ø Accelerometers Ø Strain gauges Ø Rotational speed encoders Ø Distance measuring equipment Ø Torque sensors u Measurements Ø Quasi-static events Ø Dynamic events representative for wind turbine operation è MBS model of the gearboxes on the test rig: u 600 DOF u 150 bodies (13 flexible bodies) ZFWP R&D department 6 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

7 ZFWP gearbox model ZFWP R&D department 7 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

8 Validation of flexible structural component models è Major influence of structural components on overall gearbox dynamics validation of FE models of structural components is important è Validation of complex structural components: u Planet carriers u Empty housings è Validation of structural components by comparison of FE models with EMA MAC criterion è 1 st eigenfrequency of empty housing for 2MW and 3 MW gearbox in frequency range of Hz within reach of internal gearbox excitation ZFWP R&D department 8 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

9 Validation of flexible structural component models ZFWP R&D department 9 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

10 Validation of MBS model of test set-up è Validate MBS gearbox models in frequency domain is important: u Variable speed wind turbines have broad RPM operating range => broad excitation range u Necessity to predict resonances in drive train of the wind turbine => resonance avoidance è Challenges: u Classic EMA techniques cannot be used on gearbox in operation u Several types of sensors are used in measurement campaign ZFWP R&D department 10 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

11 Validation of MBS model of test set-up è Therefore development of composite modal analysis technique: u Semi-quantitative: eigenfrequencies u Semi-qualitative: qualitative description of eigenmodes u Procedure: Ø Speed run-up measurements Ø Campbell diagrams Ø Eigenfrequencies Ø Mode Maps Ø Risk estimation ZFWP R&D department 11 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

12 Validation of MBS model of test set-up è Correlation of eigenmodes from simulations and measurements based on comparison of: u Mode Maps u Orders u Frequency Response Functions (FRF s) u Animations in SIMPACK u Measured Operational Deflection Shapes (ODS) è Good correlation for most important resonances: u Frequency range of Hz: torsional drive train modes u Frequency range of Hz: local gearbox mode determined by housing flexibility ZFWP R&D department 12 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

13 Validation of MBS model of test set-up ZFWP R&D department 13 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

14 Conclusions è Insight in importance of housings on dynamics of multi-megawatt gearboxes è Experience gained in techniques for measurement and analysis of vibrations è Due to extensive validation ZFWP is able to confidently use MBS models for resonance analysis of wind turbine gearboxes: u Retro-active: troubleshooting u Pro-active: design decisions è ZFWP vision: MBS will become part of virtual prototyping strategy complex gearbox MBS models in virtual wind turbine: => Reduced time-to-market for robust and qualitative gearbox designs ZFWP R&D department 14 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

15 Acknowledgement The research project was done in collaboration with the Katholieke Universiteit Leuven and supported by the Institute for the Promotion of Innovation by Science and Technology in Flanders. ZFWP R&D department 15 The validation of MBS multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012

16 Thank you very much for your attention! ZFWP R&D department 16 The Presentation validation of Title, MBS Date multimegawatt gearbox models on a 13.2 MW test rig, 26/09/2012