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Technological Advances in Hydraulic Drivetrains for Wind Turbines. CTO Knud Erik Thomsen EWEA 2012 Annual Event, Copenhagen Conference session: Technology for drivetrains Track: Hardware technology Tuesday, 17 April 2012, 16:00 - 17:30. Contents. Company introduction - PowerPoint PPT Presentation
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Technological Advances in Hydraulic Drivetrains for Wind Turbines
CTO Knud Erik Thomsen
EWEA 2012 Annual Event, Copenhagen
Conference session: Technology for drivetrains
Track: Hardware technology
Tuesday, 17 April 2012, 16:00 - 17:30
Contents
2
Company introduction
Technology trends as basis for developing hydraulic transmission
ChapDrive compact and integrated variable hydraulic drivetrain
How can ChapDrive avoid using frequency converters?
Concept and functionality
Measurements and model verification
Technical benefits impact financial performance
Question and answer
ChapDrive AS - proprietary
20 employees in Norway, Denmark, UK and China supported by the investors:
- NorthZone Ventures, Statoil Venture, Hafslund Venture, Viking Venture and Investinor
Company introduction
3ChapDrive AS - proprietary
3+ MW integrated drive train
5+ MW conceptual design
225 kW test turbine
50 kW test bench
900 kW test turbine
300 kW test bench
2005 2007 2009 2011 – 2013
From left: Headquarter in Trondheim, subsiduary in Denmark, workshop and test site in Trondheim
Jens Anders Jensen CEO
Background CSO in Vestas Chairman of the Danish Wind Industry 10 years experience in the wind industry
Knud Erik ThomsenCTO
Background15 years in R&Dat Vestas Head of mechanicaland electricalengineering
Åsmund FurusethVP & Co-founder
BackgroundFormer CEOProject managerTechnologyTransfer Office NTNU
Peter ChappleSenior Scientist &Co-founder
BackgroundProfessor in hydraulics, Technical director Staffa Products, Industry consultant
Thor SchjetneProject Director
BackgroundOffshore Oil and gas engineering atReinertsen
Paul ChangMarketing Director
BackgroundMD in Hägglunds Drives China and R&D Asia Pacific Center. 25 years experience in the hydraulic industry
Pål Engebretsen – Chairman(Former CEO Bergen Group and Chairman of Scanwind)
Board of directors with industrial and business development expertise
Torben Bjerre Madsen (Former deputy-CEO in Vestas)
Tellef Thorleifsson(NorthZone Ventures)
Ståle Myhre(Statoil Venture)
Joachim Cock(Hafslund Venture)
Jostein Vik(Viking Venture)
Steinar Fossen (Investinor)
Management with broad experience within hydraulics and wind power
ChapDrive AS - proprietary4
Technology trends as basis for developing hydraulic transmission
Market trends: Turbine sizes are increasing Reliability must be improved Cost of energy must come down
Challenges facing the wind industry: Top weight reduction is increasingly critical Mechanical gearbox and frequency
converter are statistically unreliable Sourcing and cost of permanent magnets
Hydraulic transmissions are generally robust and will reduce top weight for wind turbines
High efficiency hydraulic technology enables competitive efficiency
New technology is driven by the industry for mobile hydraulic systems
TWh annual wind power production
40
500
1000
1500
2000
2500
3000
1990 2008 2015 2025 2035
‘85
Rot
or d
iam
eter
(m
)
‘89 ‘93 ‘97 ‘01 ‘05 ?
0.05
YearMW 0.3 0.5 1.6 4.5 8/10
15
160
112
Turbine size development
Market development for wind power
5ChapDrive AS - proprietary
ChapDrive compact and integrated variable hydraulic drivetrain
6
Pump
Motor
Electrically Excited Synchronous Generator, EESG
Control System
Perfectionvia
Simplicity
ChapDrive AS - proprietary
ChapDrive compact and integrated variable hydraulic drivetrain
7
Fewer critical components:
No mechanical gearbox
- causing high maintenance costs on today’s wind turbines
No need for permanent magnets (PM)
- high cost rare earth materials
No frequency converter
- causing the highest failure rates and most down time on today’s wind turbines
No transformer
ChapDrive AS - proprietary
GearboxDouble fed
induction generator Frequency converter Transformer
Grid
10 kV
Grid
10 kV
Hydraulic transmission
EE synchronous generator
How can ChapDrive avoid using frequency converters?
8ChapDrive AS - proprietary
GearboxDouble fed
induction generator Frequency converter Transformer
Grid
10 kV
Grid
10 kV
EE synchronous generator
Speed control
Speed control
Hydraulic transmission
How can ChapDrive avoid using frequency converters?
9ChapDrive AS - proprietary
Grid
10 kV
Gearbox(Fixed, e.g. 1 : 100 @ 3 MW)
Double fed induction generator Frequency converter Transformer
Grid
10 kV
Frequency converter Transformer
Grid
10 kV
Direct drive PM generator(Fixed 1 : 1)
Gearbox
Direct drive
ChapDrive
Hydraulic transmission(1 : variable)
Speed control
Speed control
How can ChapDrive avoid using frequency converters?
ChapDrive AS - proprietary10
EE synchronous generator
Concept and functionality
Transmission ratio: Variable 1:100 – 1:300for a 3 MW wind turbine
Result: High energy yield from the wind Low loads on the turbine structure and the
turbine components
ChapDrive AS - proprietary11
Concept and functionality
Component At rated power
Pump 96%
Hydraulic motor with digital valves
95-96%
EE Generator 98%
Summary 89-90%
Component At rated power
PM Generator 94-95%
Power electronics + Transformer
97%
Summary 91 – 92%
Component At rated power
Gearbox 96-97%
Generator 98%
Power electronics + Transformer
97%
Summary 91-92%
Gearbox Direct Drive ChapDrive
ChapDrive AS - proprietary12
ChapDrive control system
Pitch control (blades)
Excitation control (generator)
Displacement control (hydraulic motor with digital valves)
ChapDrive core technology
Control system for hydraulic motor, pitch system and generator (patents grated)
Hydraulic transmission for wind turbines (patents granted)
Design and integration of hydraulic drive train solutions in wind turbines(patent pending)
Products
The ChapDrive control system is essential for control of the vital features of a wind turbine with a hydraulic drive train solution (patents granted)
Prototype has been verified in the ChapDrive wind turbines
The ChapDrive Integrated Hydraulic Transmission is essential for low top weight and robustness (patent pending)
Design under development
ChapDrive integrated hydraulic transmission
Concept and functionality
13ChapDrive AS - proprietary
Model verification
Dynamic models
ChapDrive Control
Software
Wind turbine
ChapDrive Control System
1
2
3
4x 10
4
T p [
Nm
]
System inputs
4
4.5
5
5.5
6x 10
-5
Dm
[m
3/r
ad]
30
35
40
45
50
p [
rpm
]
System outputs
50
100
150
200
p m,in
[ba
r]
0 100 200 300 400 500 600 700 800 9000
50
100
150
Pg [
kW]
(Measurement start time: 2011-12-07 11:24:00) t [s]
20
40
60
80
p [
rpm
]
System outputs
50
100
150
200
p m,in
[ba
r]
0 100 200 300 400 500 600 700 800 9000
50
100
150
Pg [
kW]
(Measurement start time: 2011-12-07 11:24:00) t [s]
Comparison
Model tuning
Simulation results
Measurements
Measurements and model verification
ChapDrive AS - proprietary14
10 minutes mean values are shown from the test wind turbine (ChapDrive 1 - 225 kW) for a period of 5 month
Optimal rotor speed at all time ensuring maximum energy yield from the wind
Generator speed is always constant
Measurements and model verification
ChapDrive AS - proprietary15
Method Combined and optimised control of:
• Pitch• Displacement
(transmission ratio)• Excitation
Results Constant power above rated wind
speed Power and torque fluctuations
eliminated due to fast displacement control
Full control over reactive power
Measurements and model verification
ChapDrive AS - proprietary16
Technical benefits impact financial performance
Robust light-weight variable hydraulic drivetrain with an electrically excited synchronous generator directly connected to the grid
This means: No mechanical gearbox No need for permanent magnets No frequency converter No transformer
CAPEX reduced with up to 20%
OPEX reduced with up to 15%
Cost of Energy reduced with up to 20%
AEP is up to 2% lower than other technologies
0
200
400
600
800
1000
1200
1400
0 2 4 6 8 10 12
Siemens 6 MW
Enercon 4.5 MW
Enercon 6 MW
Enercon 2 MW
Vestas3 MW
Siemens 3 MWSiemens 2.3 MW
Vestas7 MW
RePower 5 MW
Siemens 3.6 MW
Top weight scaling with different drive trains
Top
head
mas
s (t
on)
Nominal power (MW)
Trad
itiona
l gea
rbox
Permanent m
agnet DD
ChapDrive hydraulic Drive
Elect
rom
agne
tic D
D
ChapDrive AS - proprietary17
Q&A
Thank you for your attention!
Professor Brochs gt 2Trondheim7030 Norway
www.chapdrive.com