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Hydrostatic Drive Train in Wind Energy Plants Johannes Schmitz, Nils Vatheuer 14.03.2011 generator 1 generator 2

Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

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Page 1: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

Hydrostatic Drive Train inWind Energy Plants

Johannes Schmitz, Nils Vatheuer14.03.2011

generator 1

generator 2

Page 2: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

2 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outline

Introduction

Configuration of the transmission

Measurement results from the test bench

Outlook and Conclusion

Page 3: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

3 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

IFAS: Institute for Fluid Power Drives and Controls

0 2 4 6 8 10 12-200

0

200

400

F Fr [N

]

0 2 4 6 8 10 12-200

0

200

400

F Fr [N

]

0 2 4 6 8 10 12-200

0

200

400

F Fr [N

]

Page 4: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

4 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Continuously variable transmission ratio Good damping characteristics Save and reliable operation

Basic idea of the hydrostatic transmission

Development and testing of a hydrostatic drive train for wind turbines

Important hydraulic features

Overall efficiency Costs of energy

To be evaluated

Task for IFAS

Problems with reliability ofmechanical gearboxes

Grid stability

Motivation

Axial piston motor

Radial piston pump

Page 5: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

5 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outline

Introduction

Configuration of the transmission

Measurement results from the test bench

Outlook and Conclusion

Page 6: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

6 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Generation of different concepts

Concepts generated in morphological box

Evaluation and optimisation in simulations

Adaption to wide range of power is important Good efficiency at high pressure and full displacement Cascading of pumps and motors is beneficial Combination with mechanical transmission can increase power density Not possible in our time frame

Evaluation

Page 7: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

7 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Two hydraulic circuits Three different modes of operation Components

2 pumps (70 & 280 kNm)

3 variable displacement motors

1 constant motor

2 generators

Chosen configuration for 1 MW

321

Page 8: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

8 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Simulation result: overall efficiency

63 simulation runs Wind speed

2,6 – 15 m/s

1 MW turbine model simulates torque on the drive train Existing efficiency data of components had to be scaled

Boundary conditions

Schmitz, J., Vatheuer, N., Murrenhoff, H.,Development of a Hydrostatic Transmission for Wind Turbines, Proceedings of 7.IFK, Aachen, 2010

Simulated operating points

2 3 4 5 6 7 8 9 10 11 12 13 14 15wind speed [m/s]

0102030405060708090

100ov

era l

l effi

cien

cy [%

]

0

200

400

600

800

1000

pow

er[k

W]

turbine poweroverall efficiency

Page 9: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

9 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Simulation result: dynamic characteristics

70 71 72 73 74 75 76 77 78 79 80time [s]

0

50

100

150

200

250

300

350

torq

u e [k

Nm

]

30.6

30.8

31

31.2

31.4

31.6

31.8

32

rota

tion

s pee

d [rp

m]

torque from windtorque turbine shaftturbine rotation speed

Torque impulses are smoothened

Hydrostatic transmission has a low stiffness Turbine can accept small changes in rotation speed

Page 10: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

10 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outline

Introduction

Configuration of the transmission

Measurement results from the test bench

Outlook and Conclusion

Page 11: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

11 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Integration into the 1 MW test bench

Hydrostatic transmission

generator 1

generator 2

Hydrostatic transmission

motor 1

motor 2

High torque at low speed

Dynamic loads

Limited electrical power

Challenges

Hydrostatic power feed-back

Generators replaced by electrical motors and axial piston pumps

Turbine is simulated by radialpiston motor

Drive is controlled by variable displacement pumps

Test bench layout

Test bench drive Hydrostatic transm.

Page 12: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

12 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Measurement result 1/2

Test bench drive applies torque Transmission controller adjusts the

rotation speed

Procedure of the measurement

Page 13: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

13 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32rotation speed [rpm]

0102030405060708090

100

over

all e

ffic i

enc y

[%]

Measurement result 2/2

generator 1

generator 2

generator 1

generator 2

generator 1

generator 2

Torque is applied dependent on rotation speed (turbine characteristics)

Transmission controller controls the rotation speed

Procedure of the measurement

Page 14: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

14 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outline

Introduction

Configuration of the transmission

Measurement results from the test bench

Outlook and Conclusion

Page 15: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

15 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outlook: simulation of wind turbine environment

Hardware-in-the-Loop Dynamic wind loads Drive train controller

Hydrostatic transmission

motor 1

motor 2

Measurements under realistic conditions

Adaptation of standard components Switching strategy

Transmission optimisation

Transplant the transmission into a pilot wind energy plant

Page 16: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

16 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Outlook: proposal for multi-megawatt turbine

Doubling the power four times more pump displacement

Hydraulic pumps are not available yet Approach: Upstream mechanical

transmission

Challenge with multi-megawatt transmissions

Mechanical ratio: 4.5 Four independent hydraulic modules 1.25 MW per module

5-MW-Concept

Combining the benefits of mechanical and hydraulic drive trains

Page 17: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

17 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Evaluation so far Resistance against pulsing torque loads, protection against overload Variable transmission ratio allows the usage of a synchronous generator

without a frequency converter Components and operating strategy open up a wide area for improvements

Conclusion

Hydrostatic drive train can be adapted to WEP power-curve Simulation and measurement results match at high power 85 % overall efficiency throughout a wide power range Switching off individual units can improve efficiency at partial load

Page 18: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

Thank you for your attention.Questions, Suggestions?

J. Schmitz, N. Vatheuer14.03.2011

generator 1

generator 2

Page 19: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

19 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Page 20: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

20 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Test bench

Test bench drive Hydrostatic transmission

Page 21: Hydrostatic Drive Train in Wind Energy Plants · Hydrostatic Drive Train in Wind Energy Plants ... Conclusion Hydrostatic drive train can be adapted to WEP power-curve ... Hydrostatic

21 of 18Hydrostatic Drive Train in WEPJ. Schmitz, N. Vatheuer

Englisch

Q_P2

V5

Q_P2zuP1

Q_P1zuP2

Ventil_P1zuP2

RSV_P2zuP1

Q_DBV_P2

DBV_P2

HD_M1

Schlauch_P2

Schlauch_P1

Q_P1

p_HD

M3

M2

M1

M4

Leckage_M1

Leckage_M3

Leckage_M4

Leckage_M2

H2SpQ

Stellzeit_M4

Stellzeit_M3

Stellzeit_M2

Stellzeit_M1

S5123

Antriebsleistung_P2Antriebsleistung_P1

Motor3

HD

ND T

Motor4

HD

ND T

Wirkungsgrad_M4

Wirkungsgrad_M3

Wirkungsgrad_M2

Leistungsverlust_M4

Leistungsverlust_M3

Leistungsverlust_M2

Antriebsleistung_M4

Antriebsleistung_M3

Antriebsleistung_M2

Motor2

HD

ND T

Motor1

HD

ND T

Wirkungsgrad_P2

Leistungsverlust_P2

Wirkungsgrad_P1

Leistungsverlust_P1

Leckage_P2

M_Verlust_P2M_Verlust_P1

Leckage_P1

Pumpe2

PPumpe1

P

RSV M4

RSV M3

V_M4

V_M3

Ventil_M4

Ventil_M3

RSV M2

V_M2

Ventil_M2

RSV M1

V_M1

Ventil_M1

schw_M3

schw_M2

schw_M4

Q_Ventil_P1Q_Ventil_P2

HD_P2V_P1

RSV_P1

Ventil_P2Ventil_P1

P2_ausP1_aus

Blasenspeicher2

Q_DBV_ND

Q_ND

ND1RohrND

HD_M234

schw_M1

Leistungsverlust_M1Antriebsleistung_M1

Wirkungsgrad_M1

Q_DBV_P1

ND2

Speisepumpe

DBVstatisch2

HD_P1

DBV_P1

Rotorwelle

Resonant frequency

1 2

Bode-plot

34.11570.0 rpmHz

Hzf

JCV

HH

RH

PH

570.02

22

Analyses

Theoretical

Simplified model

Without leakage

Including Leakage

Complete transmission model

Pumpe

P

pump

RSV

DBV

ND

HD

DM

1 2

frequency [Hz]