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Research Project of “Bundesministeriums für Wirtschaft und Arbeit (BMWA)“

SIMU-Wind Combination of multi body system simulation, electrical simulation and Condition monitoring a powerful research development. Research Project of “Bundesministeriums für Wirtschaft und Arbeit (BMWA)“ in scope of the support program “InnoNet“. Motivation.

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Research Project of “Bundesministeriums für Wirtschaft und Arbeit (BMWA)“

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  1. SIMU-WindCombination of multi body system simulation, electrical simulation and Condition monitoring a powerful research development Research Project of “Bundesministeriums für Wirtschaft und Arbeit (BMWA)“ in scope of the support program “InnoNet“

  2. Motivation • increasing risk of damage/defects in combination with increasing performance • knowledge loss of the actual operating conditions • increasing performance requirements for all drive train components • class of insurance claims for determined revision cycle in Germany

  3. …development of a combined multi sensor, multi body condition monitoring system for wind turbine drive trains Project objective is the … • reduction of down times • analysis of abnormal drive train operating conditions • increasing life cycle of drive train elements • integrated consideration of the drive train of wind turbines • optimized dimensioning of drive train elements

  4. Research institutes Project partners IMM, TU Dresden IBH, RWTH Aachen Industrial partners ACIDA GmbH ITI GmbH SEG GmbH & Co.KG VEM Sachsenwerk Svendborg Brakes A/S REpower Systems AG Eickhoff Maschinenfabrik GmbH Centa Antriebe Kirschey GmbH

  5. Measurement system (1) • sensors at the nacelle • drive train • base frame • (data storage on industrial PC) • 16 sensors in tower base • electrical signals of generator and converter • parallel data storage with signals of drive train • remote control

  6. Measurement system (2) 64 sensors at the drive train • torsion and bending at the rotor shaft and generator shaft • movement of the rotor shaft belonging to bearing- and gearbox housing • movement inside gearbox • gearbox and generator temperature • vibration at gearbox and generator • …

  7. Measurement system (3)

  8. Measurement system (4) • 22 strain gauges at the base frame

  9. mechanical system consists of rotor and blades, main shaft gear unit coupling, brake disk generator baseframe controller consists of pitch controller output power controller speed controller brake controller electrical system consists of generator converter grid Wind Turbine controller wind aerodyn. model mechanical system electrical system network Field of Interest wave relevant only for offshore systems MBS-Model (modular design)

  10. simulation model included rotor model single blade and complete rotor (bending in flap- and edge-wise direction) drive train torsional vibration model (with rigid and flexible rotor) MBS model (with rigid and flexible rotor) nacelle flexible base frame model electrical system asynchronous generator model with converter and grid model aerodyn. model wind to moment converter model with cp equation MBS-Model (components)

  11. I model of generator and converter U w T rotor drive train rotor LSC MSC wind P,Q stator pitch grid- model Electrical simulation model (1)

  12. calculation of the electro-mechanical system model of generator and converter I U w T rotor LSC MSC stator grid- model Co-Simulation (time domain)

  13. natural frequencies Torsional Model Torsional Model (Flexible Rotor) Torsional / Axial Model Torsional / Axial Model (Flexible Rotor) 60 Hz 170 Hz Results (frequency domain) bending rotor (flapwise) bending rotor (edgewise) torsional frequencies axial mode shape

  14. mode shapes of the rigid drive train model • torsional mode shape gearbox [approx. 60 Hz] • axial mode shape low speed shaft LSS [approx. 170 Hz] • torsional mode shape gearbox [approx. 60 Hz] • axial mode shape low speed shaft LSS[approx. 170 Hz] Results (mode shapes)

  15. mode shapes of the flexible drive train model • torsional and bending mode shape of base frame and drive train [approx. 2 Hz] • bending mode shape of base frame [approx. 4 Hz] • torsional and bending mode shape of base frame and drive train [approx. 2 Hz] • bending mode shape of base frame [approx. 4 Hz] Results (mode shapes)

  16. 800 400 UPCC [V] 0 -400 [s] 0.4 0.5 0.6 0.7 0.8 0.9 Results (electrical signals) voltage drop at the net meeting point uPCC 10000 0 Air gap moment [Nm] -10000 -20000 [s] 0.4 0.5 0.6 0.7 0.8 0.9

  17. Results (electrical signals) • non linear property: power dependency of generator temperature • power loss dependent of temperature 2400 1800 Power [kW] 1200 600 0 120 80 Temp. Gen. [°C] 40 0 23.04.2005 24.04.2005 25.04.2005 • verification of temperature dependency by measuring data analysis

  18. Integrated system Condition-Monitoring-System Multi body simulation model Integrated system Electrical simulation model

  19. SIMU-WindCombination of multi body simulation, electrical simulation and Condition monitoring a powerful research development Thank you for your attention!

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