Tecnologias de controle de conversores diretos e híbridos em turbinas eólicas modernas.

Fraunhofer IWES
Institute for Wind Energy and Energy System Technology

Hybrid & direct drive technology in modern wind turbines

Hans Kyling, Dr. Jan Wenske, Hans-Georg Moll, Louis Quesnel
Jaraguá do Sul, 28.06.2012

1
© Fraunhofer IWES

General Map

About the Fraunhofer IWES

Some wind turbine basics

Overview of different drive train topologies

Current drive train trends

2
© Fraunhofer IWES

Fraunhofer IWES in figures

Research spectrum:
Wind energy from material development to grid
optimization
Energy system technology for all renewable
energies
Foundation: 2009
Formerly:
Fraunhofer Center for Wind Energy and
Maritime Technology (CWMT) in Bremerhaven
Institute for Solar Energy Supply Technology
ISET in Kassel
Directors: Prof. Dr. Andreas Reuter
Prof. Dr. Jürgen Schmid
Annual budget: € 31 million (2011)
Employees: 376

IWES in Some Drive train Current
3 figures basics topologies trends
© Fraunhofer IWES

Portfolio example: test facilities at Fraunhofer IWES

Sorted by test level according to V-model (VDI 2206)
Material
• Climate chambers
• Offshore test field
Component
• Rotor blade (full scaled, down scaled)
• Composite part testing and development
Sub-system and integration
• Dynamic Nacelle Laboratory
(DyNaLab) -in development-

© Fraunhofer IWES

Introduction: some history on wind turbines
extreme high
number of
load cycles
(N > 108)

very high
flexible
structure Wind torques and
parasite

turbine loads

boundary
conditions
Permanently slow
changing rotational
service loads speed

There was no comparable application in engineering, so that the design needed to be
developed from scratch
The first big industrial wind turbines were designed with components sourced from
other industries (no wind turbine specific components available by that time)
The different drivetrain components didn’t match perfectly with each other.
With a growing market for wind turbines specialized components and designs were
developed.

© Fraunhofer IWES

Positive influence of the rotor diameter

Some basic physics:
The kinetic energy/power of the wind is
1
Ε= ⋅ m ⋅ v2 v
2

& 1 & 1
P = Ε = ⋅ m ⋅ v 2 = ⋅ ρair ⋅ π ⋅ R 2 ⋅ v 3 R
2 2

The power extracted by a wind turbine
1
P = c p ⋅ ⋅ ρair ⋅ π ⋅ R 2 ⋅ v 3 c p : wt ' s power coefficient
2
The theoretically extractable power grows with
the square of the rotor radius!

>>>Higher energy yield<<<

© Fraunhofer IWES

Negative influence of the rotor diameter

increased blade length
mBlade ~ lBlade 3

higher mass/
aerodynamical loads

strengthened
drivetrain/support structure

higher turbine weight/cost
Source: Alstom

energy
weight/cost
yield

© Fraunhofer IWES

Why are there so many different drivetrain concepts?

The shown ambivalent problem regarding the blade length is a good example
for explaining the variety of concepts:
Depending on the drivetrain design the rotor loads may “flow” in a different
way through the turbine structure and effect thus the component design

There are a couple of parameters that have to be considered in order to find
the best suited drivetrain concept, like:
• Global/local market situation (e.g. rare earth availability)
• Site assessment (high turbulences, )
• Availability of turbine (e.g. offshore very important)
• Service & maintenance costs
• Etc.

Which drive train concept is the best?
Answer is project-specific

© Fraunhofer IWES

How to classify drivetrains?

There are various drivetrain topologies, and different ways to classify them. A
practical way to classify wind turbines is the generator speed/number of gear
box stages:

• High speed generator (HSG) (approx. 500 – 2000 rpm)
These drivetrains make use of a 3-4 stage gearbox (planetary/spur)

• Medium speed generator (MSG) (approx. 40 – 200 rpm)
These drivetrains make use of a 1-2 stage planetary gearbox

• Slow speed generator (SSG) (approx. 4 – 35 rpm)
These drivetrains are called direct driven, because the rotor torque is
transmitted directly (without a gearbox) to the generator.

© Fraunhofer IWES

Drivetrains with 3-4 stage gearbox (HSG)

Characteristics:

positive neutral negative

• The generator • High number of
torque is low rotating parts
thanks to the (within gearbox)
gearbox. • High maintenance
• Classical drivetrain effort
solution (a lot of • High drivetrain
experience total length
available) • Reduced torsional
• High availability on stiffness
the supplier’s • Low efficiency
market (resulting
in lower prices)

© Fraunhofer IWES

3-4 stage gearbox – moment bearing
Example: Vestas V90-3.0
Tower head mass: approx.: 114 t Source: Vestas

No main shaft 2 planetary, 1 spur stages

Moment bearing integrated into gearbox housing Doubly fed induction generator (DFIG)
(bending moments transmitted through gearbox)

© Fraunhofer IWES

3-4 stage gearbox – double suspension

Example: GE 2.75-103
Tower head mass: approx.: XXX t
Double suspension 2 planetary, 1 spur stage
(in stiff housing)

Permanent magnet synchron generator (PMSG)

© Fraunhofer IWES

3-4 stage gearbox – 3-point suspension

Example: Vestas V112-3.0 Source: Vestas
Tower head mass: approx.: 120 – 130 t
4-stage gearbox
Shrink disc
Main bearing

PMSG generator

Support bearing integrated into first gearbox stage

© Fraunhofer IWES

Drivetrains with 1-2 stage gearbox (MSG)

Characteristics:


• Moderate generator • Smallest global
torque market share (little
• Moderate generator experience available)
size, weight and cost • Limited generator
• Moderate number of availability on the
rotating parts (within supplier market
gearbox)
• Moderate
maintenance effort
• Moderate drivetrain
total length
• Moderate torsional
stiffness
• Moderate efficiency

© Fraunhofer IWES

1-2 stage gearbox, moment bearing

Example: Fuhrländer FL 3000
Tower head mass: approx.: 165 t

2 stage planetary gearbox (1:43)

PMSG

Flexible coupling (elastic bolts)

Moment bearing (3 row cylindrical roller bearing)

Winergy HybridDrive (flexible bolted to bedplate) Source: Fuhrländer

© Fraunhofer IWES

1-2 stage gearbox, double suspension

Example: Gamesa G10X-4.5

2 stage planetary gearbox (1:38, flanged to bearing case)

Double bearing in common stiff case,
Planet carrier is supported by main shaft’s rear bearing PMSG (housing flanged to gearbox)

© Fraunhofer IWES

1-2 stage gearbox, double suspension

Example: DSME 7 MW Offshore

• Integrated power unit “FusionDrive”
• (approx. 90 t, from Moventas/TheSwitch)
2 stage planetary gearbox
PMSG
• Prototype installation scheduled for Q1-2013

© Fraunhofer IWES

Drivetrains without a gearbox (direct drive) (SSG)

Characteristics:


• Simple drivetrain design (no • Moderate experience on the • High generator torques lead
gearbox, coupling and main market to a bigger and thus heavier
shaft necessary) generator
• Less dynamic loads due to • Generator relatively
higher torsional stiffness expensive (higher material
(lower safety factor, lighter demand)
design, better controllability) • Wind turbine’s purchase cost
• Modularization and relatively high compared to
Standardization applicable geared solutions
(mass production)
• higher efficiency, especially
for under rated conditions (no
gearbox losses)
• Mechanically little
maintenance needed
• Short design
• Small number of rotating
parts (within gearbox)

© Fraunhofer IWES

Direct drive, moment bearing

Example: Siemens SWT-2.3-113, SWT-3.0-101

PMSG

Moment bearing
(3 row cylindrical bearing)

© Fraunhofer IWES

Direct drive, double suspension

Example: Enercon E-101

© Fraunhofer IWES

Direct drive, double suspension

Example: GE 4.0-110, Alstom PureTorque 6 MW

© Fraunhofer IWES

Which company uses which drivetrain concept?

Geared
3-4 Stages 1-2 Stages

DFIG Vestas (old),
Sinovel, Vestas
Areva Wind,
Gamesa PMSG
Double-Fed REpower (new), Offshore,
Samsung, Vestas V164, Permanent
EESG Kenersys GE Fuhrländer Magnet
Synchronous
Generator
Electrical Excited Siemens (new),
Enercon,
Synchronous Gen. Goldwind,
MTorres
GE Offshore,
Alstom

Direct Drive
© Fraunhofer IWES

Efficiency of different drivetrain/generator systems

© Fraunhofer IWES

PMSG Volume and weight vs. gear ratio

vδ1
pel Rotor volume per power:
(related to „direct drive“)
D ~ 6m
P = 3,8MW
16rpm D ~ 1,8m
total D ~ 0,7m
81.000kg D ~ 0,8m
0,1

P = 1,7MW P = 2,7MW
150 rpm 1650 rpm
total P = 1,0MW total 7750 kg
vδ
(i ) ≈
1 17.000kg 1200 rpm
pel i total
π
M Magnets _ mass =
4
[(D + 2 h ) − D ]α
M
2 2
P L ρM 3.400kg
0,01
0 10 20 30 40 50 60 70 80 90 100
Transmission gear ratio i

© Fraunhofer IWES

Drivetrain concepts of the global TOP15 OEMs

Commercialized
through 2010
1900n1900r00l

1900n1900r00l

1900n1900r00l

1900n1900r00l

1900n1900r00l

1900n1900r00l

1900n1900r00l

© Fraunhofer IWES

Newly installed power capacities in South America

global growth rate
1900n1900r00l +23%
+19%
1900n1900r00l +5%
1900n1900r00l

+9%
1900n1900r00l
+6%
+4% +4%
1900n1900r00l

1900n1900r00l

-5%

Source: Make Consulting

© Fraunhofer IWES

Tecnologias de controle de conversores diretos e híbridos em turbinas eólicas modernas.

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Tecnologias de controle de conversores diretos e híbridos em turbinas eólicas modernas.