Netzwerk WindRegion Mnsterland

Rheine
Jannuar 2017

Center for Wind Power Drives

Competence in System design and Testing of Wind Power Drives

Ralf Schelenz
Overview Presentation

Wer ist das CWD RWTH Aachen University

Prfstnde fr Windenergiegondeln
Netzkonformitts Prfung
BMWi Proposal Cert Bench

Multi Body Simulation am CWD

Turbine Design & Development: Themen

Weitere Themen aus der Perspektive eines Operators

Center for Wind Power Drives | Competence in System design and

Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Center for Wind Power Drives Concept and Integration
I3-Institute: Integrated Interdisciplinary Institute:
aerodynamics, control technology, electrical
and mechanical engineering under one umbrella

slide 3 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
CWD - Wind Power Drivetrain Research
1995 ...

2010

2014
continuing

300 kW 7,5 MW Bilateral research and industrial projects

RWTH Networking

91b proposal: CWD 4 MW CWD: Operation 4 MW Nacelle test rig

MBS @ IME in 1998

Demonstrator 1 MW Nacelle test rig

Lecture: Wind turbines

IEA Task: Full Size Ground

Testing
MultiDuoRed: Nacelle configuration

slide 4 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Field Testing

costly real loads

time consuming (waiting for wind)
limited to site specific conditions
wind is unpredictable, turbulent and in general unknown

slide 5 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
System test WTG Drive Train
Approach: Same Input & Output Loads as on Tower
6 DOF:
Rotor blade + All degrees of freedom
Rotor speed + Defined loads
Pitch angle 3D + Good observability
Tower shadow wind field + Time scaling
wind loads - Effort
T, F
Research topics:
Reliability
Availability
Efficiency
Costs
Certification
U, f
Grid
Gridloads
Smart-Grid
voltage FRT
drop EU-Grid
US-Grid

slide 6 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
4MW WTG System Test Bench

slide 7 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Grid Emulation with 22 MVA power
Full FRT capabilities
public network Point of common coupling: PCC @ 20 kV
Variation of voltage: LVRT & OVRT
10 kV Variation of frequency: 48-52 Hz / 5862 Hz
Variation of phase:
Controllable via HIL-model
GE MV7306 _ Smart-grids
Wind parks
DC - link
_ _ _ _
motor pulser grid emulation
RTDS
GE MV7306 3 x GE MV7308
7,5 MVA 21,5 MVA
Low Voltage Ride Through:
LVRT Grid Codes

20 kV 4 winding

V / Vrated
trafo

slide 8 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
4 MW demonstrator WTG nacelle test bench
Investigation & proofing WTG MHIL testing techniques

slide 9 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Modern Wind Turbine Design
by means of Multi-Body-Simulation

Aerodynamic system Mechanical system Electrical system

[Quelle: VEM]

[Source: VEM]

WT Controller

slide 10 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Running research projects: focused on wind turbine development
Conversion Roller Bearings to Hydro Dynamic Plain Bearings (HPB)
Main Gear Box & Main Bearing: Full repair of the main bearing on Tower

Roller Bearing Assessment: White Etching Phaenomena (WEC)

BMWi Project Pronowis: WEC Sensors & Reverse Data Analysing
Wlzlagerzentrum

Endurance Blade Bearings

Testing & Simulation

Endurance Pitch Drive Systems

Individual Pitch Control IPC CPC
SPPP
Condition Monitoring
Failure Models, Observer Based Technics

NVH: Prediction of MGB & Generator tonalities

New Concepts: Rapid Wind: Redundancy & Repairable

slide 11 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Site Assessment Offshore
Alpha Ventus & Fino 1

WT 1

WT 2

Turbulence
Umean [m/s] intensity [-]

WT 4,5,6

WT 8

WT 7
After Alpha Ventus
Before Alpha Ventus

Folie 12 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Comparison of various turbulence intensities
IEC 61400 DLC 1.1: cut in cut out, NTM
Thrust force on Nacelle over 20 years
TI = 4% TI = 21%

slide 13 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
New Low Cost Sensor System
Small autonomous sensor to determine
Mechanical input load (torque & bending)
and rotating vibration

In cooperation with:

Center for Wind Power Drives | Competence in System design and

Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
Applications of the sensor system

Load Monitoring Condition Monitoring

Strain based measurements of torque, Rotating vibration measurements on
yaw- and tilt-bending moments on main main shaft
shaft
Analysis in dependence of rotation
Inspired by IEC 61400-13
angle
Rotor loads as time-series or load
collectives

WT lifetime extension > 20 years Misalignments

Performance-Information Unbalances
Performance-Optimization Rotor blade vibrations
(Yaw-errors, wind farm effects etc.) Detection of failures in main bearing
Calculation of remaining component and first planetary gear stages
lifetime

Center for Wind Power Drives | Competence in System design and

Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg
 Thank You for your Attention

slide 16 Center for Wind Power Drives | Competence in System design and
Testing of Wind Power Drives | Dr. Ralf Schelenz
November 2016 | Hamburg