Escolar Documentos
Profissional Documentos
Cultura Documentos
Dr John Coultate
R&D and Consultancy Dept. Leader
CONFIDENTIAL
@ Copyright 2011
Contents
1. Introduction
2. Wind turbine trends and segmentation
3. Drivetrain technology and cost drivers
4. Conclusions
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Romax Technology
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
RomaxWIND Wind Turbine Drivetrain Software
RomaxWIND is the best-in-class Virtual Product Development environment for
design and analysis of wind turbine drivetrains
RomaxWIND includes the only gear analysis capability certified by GL
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind turbine trends and drivetrain technology
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets 2010 status
Cumulative MW
MW per year
20,000 100,000
15,000 75,000
10,000 50,000
5,000 25,000
0 0
1983 1990 1995 2000 2005 2010
Year
Source: BTM Consult - A Part of Navigant Consulting - March 2011
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets Forecast
75,000
50,000
25,000
0
1990 2010 2015 2020
Source: BTM Consult - A Part of Navigant Prediction Offshore (Forecast) Forecast Existing capacity
Consulting - March 2011
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
European Market Development
Offshore market today = Onshore market in 1997 (with same growth forecast!)
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets Size trends
Average sizes of wind turbines installed increases each year:
1,400
1,200
1,000
kW
800
600
400
200
0
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets Size trends
Forecasts indicate the largest market share will be for turbines 3 MW
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Wind Turbine Markets Segmentation
Average size trend only tells part of the story
There is natural segmentation of the market for different sites and wind classes:
Onshore
1.5 MW 3 MW
Class I & II wind sites
~3 MW 10 MW+
Offshore Turbines optimised for offshore
Very large rotor (100m+ diameter)
CMS as standard
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Design
Drivetrain design decisions have a huge
impact on future success of a wind turbine
Cost of Energy (CoE) includes many factors for
the drivetrain, e.g.
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
CAPEX and OPEX
Approx. annualised CAPEX and OPEX per MW installed:
OPEX 21 %
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Technology
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Technology Trends
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Conventional
High Speed
Geared
Drivetrain
Medium Speed
Geared
Drivetrain
Direct Drive
with PMG
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Technology Trends
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Conventional
High Speed
Geared
Drivetrain
Medium Speed
Geared
Drivetrain
Direct Drive
with PMG
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Technology Trends
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Conventional
High Speed
Geared
Drivetrain
Medium Speed
Geared
Drivetrain
Direct Drive
with PMG
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Technology Trends
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Conventional
High Speed
Geared
Drivetrain
Medium Speed
Geared
Drivetrain
Direct Drive
with PMG
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011
Drivetrain Design Requirements
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Drivetrain Components and Configurations
1. High speed modular 2-point mounted drivetrain
Rear
Flexible bedplate
(fabricated
Coupling
steel
structure)
Planet carrier
Bedplate
(cast iron)
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Drivetrain Components and Configurations
2. High speed modular 3-point mounted drivetrain
Brake Generator
Gearbox
1x Main Bearings
Flexible
Coupling
High stiffness
(bearing housings)
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Drivetrain Components and Configurations
3. Integrated main bearings; integrated mainframe; modular generator
Brake Generator
Gearbox
Main bearing
integrated into
gearbox housing
Gearbox is flange-
mounted to housing
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Drivetrain Components and Configurations
Medium Speed
Medium speed is an important concept
for next-generation turbines:
o Currently being utilised for large
turbines (3 MW+) by many
manufacturers, e.g. Vestas V164 7
MW, Areva Multibrid M5000, DSME
7 MW, and Gamesa G10X 4.5 MW
o Requires a careful approach to
design and analysis:
high level of integration and
interaction between gearbox
and generator
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Drivetrain Components and Configurations
Medium Speed
4. Example medium speed concept integrated generator (in-line); integrated main
bearings; integrated mainframe
Generator is
Gearbox Generator mounted in-line
onto gearbox
Large diameter
Integrated mainframe/gearbox integrated main Compound Water-cooled PMG
housing bearing planetary gear (integrated into gearbox
stage housing)
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Conclusions
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
Thank you for listening!
john.coultate@romaxtech.com
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX AND DRIVELINE @ Copyright 2011
UK Head Office
Romax Technology is the technology leader in the
T: +44 (0)115 951 8800
precision simulation and analysis of bearing, gearbox
E: sales@romaxtech.com
and driveline systems.
Europe In over 20 years of providing expert engineering
T: +33 6 8091 8280 services to the global vehicle, aerospace, marine, rail
E: sales_fr@romaxtech.com and wind energy industries, Romax created and
refined Romax Designer, the worlds first object
Korea orientated engineering analysis software package.
T: +82 (0) 70 7580 6210
E: sales_kr@romaxtech.com Today Romax Designer has evolved into the worlds
most comprehensive whole-system simulation and
India analysis platform, enabling fast, high precision results
T: +91 (0) 20 67201 800 in one seamless development environment.
E: sales_in@romaxtech.com Romax believes in excellence through collaborative
research and development with leading wind turbine
Japan manufacturers and operators; vehicle manufacturers;
T: +81 (0) 3 5767 9400 gearbox and driveline manufacturers; gear and
E: sales_jp@romaxtech.com bearing manufacturers; and with certification,
research and academic institutions.
China As an innovative specialist Romax adopts a
T: +86 (0) 571 8378 6230 partnership style with customers and industry players
E: romaxchina@romaxtech.com to facilitate knowledge transfer and integrated
solutions. Headquartered in Nottingham, UK, Romax
North America provides an award winning localised service through
T: +1 248 250 7691 an extensive global network, with 12 offices located
E: sales_us@romaxtech.com in the UK, France, USA, Korea, Japan, China and India.
www.romaxtech.com
CONFIDENTIAL
SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE @ Copyright 2011