Post on 03-Apr-2018
7/29/2019 Energy Brochure Cases a Siemens Business LR
1/24
Partnering with leading companies
Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
2/24
We truly believe that LMS has made a transformational impact on our industry.
Together with our customers and business partners, we have delivered engineering
solutions that have revolutionized how cars, airplanes, satellites, wind turbines
and other high-tech products are developed today.
| 2 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
3/24
Your Leading Partner in
Test & Mechatronic SimulationPride,
is probably the one word that best sums up how we feel about what LMS has achieved during the
past 30 years.
Our passion for innovation is the key driver of our excellence in business and our success in driving
the industry forward.
The industry is facing major challenges inventing, developing and manufacturing the right products
efciently. Designed Right, First Time. Successful products must be attractive, ecological, smart and
distinctive with appealing brand values.
Mastering the complexity of next-generation products and development processes has
become a major challenge for most manufacturers. For LMS, this is the essence of what drives us:
the relentless pursuit of product and process innovation and the transformational solutions required
to achieve this.
With the current drive for smarter and more ecologic products, engineering innovation takes on a new
mission. Simulation and testing are being re-dened to support a novel approach to system-
level engineering. A paradigm shift whereby the mechanics, electronics and software in a new design
will simultaneously be optimized as an integrated mechatronics system.
With the integration of Imagine in 2007 and the 2010 acquisition of Emmeskay, we have expanded
our portfolio for multi-physics system simulation, plant modeling and controls. In 2011 we acquired
Samtech, a leading provider of Computer Aided Engineering and structural analysis software within the
European aviation and aerospace industry. We are well positioned to be the Leading Partner in Test
& Mechatronic Simulation. It is our aim to once again turn this compelling vision of Designed Right,
First Time into reality. Digital design, both testing and simulation, will become so authentic that every
customer expectation will have been exceeded by the time the rst prototype goes into production.
We thank you for your trust and long-term commitment to us and for the opportunity to deliver the
technology, systems and support that are critical for true product innovation for the next 30 years.
Thank you and pleasant reading,
Yours sincerely,
Dr. ir. Jan LeuridanCEO LMS, A Siemens Business
30 years of trust
3
LMS Wind| 3 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
4/24
LMS,
the preferred partner of
Fortune 500 Manufacturers
Through 30 years of engineering innovation and worldwide expansion,
we are servicing more than 100.000 R&D engineers in more than
5.000 manufacturing companies.
LMS has become a trusted partner of the worlds leading automotivemanufacturers, aerospace companies, major energy producers and
manufacturers of other high tech equipment.
| 4 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
5/24
A Scalable Partnering Model
Strategic partner in Product Development & Process Transformation programs
System integrator in Test and Mechatronic Simulation
Partner in attribute engineering for N&V, durability,system dynamics, performance, emissions...
Supplier of Testing Systems, Simulation
software and Engineering Services
LMS,auniqueproviderof
anintegrat
edportfolio
From Troubleshooting to Design-Right-First-TimeVision, Solutions and Best Practices
PartneringLevels
Breakthrough
Innovation
ROI - Protability
LMS Wind| 5 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
6/24
Alstom chooses SAMCEF Wind Turbines (SWT),
SAMTECHs professional product for advanced
dynamic analysis and certication of Wind Turbines
The purchase of SWT is the natural result of the condence of Alstom in SAMTECHs software
solutions and the nal choice for SWT was further consolidated through the outcome of validationcampaigns that proved the accuracy of SWT when comparing numerical results with experimental
measurements. In fact, Alstom evaluated in depth several well-known software systems for aero-
elastic load computations and Multi-Body-System analysis.
| 6 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
7/24
power train was set up. Successful
experimental validation was performed
on that model and triggered a long-term relationship between the two
companies in the domain of advanced
dynamic simulation of wind turbines.
Further collaboration, including intensive
validation campaigns, resulted in the
set up of advanced aero-elastic SWT
models of several Alstom Multi-Mega
Watt class wind turbines. Several key
features for accurate modeling of
wind turbines have been added to the
software over time to match the needs
of todays wind industry and makeSWT the most complete platform on
the wind turbine simulation market.
The collaboration between Alstom
and SAMTECH will continue in several
industrial domains including the simulation
of offshore wind turbines and the
evaluation of innovative Mechatronical
Systems for active damping.
The possibility to include the most
complex mechanical models in one
detailed aero-elastic wind turbinemodel, accurate results and a reduced
learning time were the features which
convinced ALSTOM to select SWT.
The SWT solver SAMCEF Mecano was
used for the rst time in a wind turbine
context in Alstoms Wind business 10
years ago. As early as in the year 2000,
the rst non-linear dynamic SAMCEF
Mecano model of a 600 kW wind turbine
LMS Wind| 7 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
8/24
REpower Systems AGs
Advanced Drive Train Simulation
The SWT solver SAMCEF Mecano was used for the rst time in REpowers Wind business
in the year 2006 for the analysis of drive train dynamics of a REpower megawatt class windturbine. The initially applied aero-elastic SAMCEF Mecano model accounted for the most
relevant exible wind turbine components, including a detailed gearbox model and the
turbine control. A strong collaboration was then set-up in the frame of ADTS consortium
to introduce key features in the innovative SWT professional software product.
| 8 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
9/24
REpower Systems AG, a Suzlon
group company, is one of the leading
manufacturers of onshore and offshorewind turbines. The international
mechanical engineering company
develops, produces and markets
wind turbines with rated outputs of 1.8
MW to 6.15 MW and rotor diameters
of 82 meters to 126 meters for almost
any location. The company also offers
a comprehensive portfolio of service
and maintenance packages.
The protable and reliable systems
are designed at the REpower
TechCenter in Osterrnfeld
and manufactured at its plants in
Husum (North Friesland), Trampe
(Brandenburg) and Bremerhavenas well as Portugal and China.
With more than 2,200 employees
worldwide, the company, which has
been listed since March 2002 and is
headquartered in Hamburg, can make
use of the experience gained from
the manufacture and installation of
around 3,000 wind turbines around
the world. REpower is represented by
distribution partners, subsidiaries and
participations in European markets
such as France, Belgium, the UK, Italy,
Portugal, Sweden, Poland and Spainas well as on a global level in the USA,
China, Australia and Canada.
In the year 2007, REpower AG supported
the creation of a consortium of leading
industrial experts for Advanced DriveTrain Simulation/ADTS to improve
further the SWT power train model.
The ADTS consortium was an intensive
technical collaboration in between
REpower Systems AG, Schaefer Group,
Eickhoff Antriebstechnik GmbH and
SAMTECH Iberica. Outcome of that
collaboration where specic extensions
of the SWT solver for advanced power
train modelling in order to match
the needs of todays wind industry.
LMS Wind| 9 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
10/24
U.S. National Renewable Energy Laboratory
Dening the American bounds of wind energy
Engineers at the U.S. Department of Energys National Renewable Energy
Laboratory use LMS technology in performing modal testing on next-generation
wind power systems destined to radically change Americas energy policy.
| 10 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
11/24
The use of wind power in the United
States has expanded quickly over the
last several years. Construction of new
wind power generation capacity in
2011 totaled 6810 megawatts bringing
the cumulative installed capacity to
46,919 MW. This capacity is exceeded
only by China. In 2011 the electricity
produced from wind power in the USamounted to 2.9% of all electric power.
The U.S. wind industry generates
tens of thousands of jobs and billions
of dollars of economic activity.
Wind projects boost local tax bases,
and revitalize the economy of rural
communities by providing a steady
income stream to farmers with
wind turbines on their land.
GE Energy is the largest domestic
wind turbine manufacturer.
Just like GE Energy, NREL
is working with LMS.
LMS Wind| 11 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
12/24
Animated mode shape displays show engineers
how various parts of the wind turbine structurebend, twist and otherwise deform at resonant
frequencies.
The 96-channel LMS SCADAS mobile system
is a lightweight, battery-powered laptop-sizeunit less than a third the size of NRELs former
cumbersome UNIX-based system.
Resonant modes show up as peaks on frequency
response function (FRFs) plots.
Full modal survey
NWTC engineers have already used the
LMS system in performing a full system
model survey of a specially modied
three-bladed 600-kW wind turbine
system, known as the CART-3, which is
used for advanced controls research.
With its rotor xed in a parked position,
accelerometers were placed on the entire
structure, including points on the tower,
rotor blades, gearbox and nacelle. Blades
were excited to vibrate with impact from
an instrumented hammer. For other
parts of the structure, hydraulic shakers
were controlled by signals from the LMS
SCADAS data aquisition system, which
measured amplitude response of the
structure for various input frequencies.
According to NWTC test engineer
Richard Osgood, one of the major
advantages of using the LMS SCADAS
mobile data aquisition system was that
it could be used as a distributed data
acquisition system, with slave units on
the rotor, blades, nacelle, tower, and
even a remote meteorological tower to
measure wind speeds - all daisy-chained
together and connected by ber-optic
cables to a master unit on a truck on
the ground at the base of the tower.
Replacing the previous UNIX-
based system with the portable,
scalable and distributable LMS
SCADAS mobile system connected
with ber optics saves tens of
thousands of dollars for each test
set-up compared to cumbersome,
more-expensive long signal cables
that take lots longer to set up,
said Richard Osgood.
This level of cost and efciency is
important in operations such as ours in
which budgets are extremely tight. Also,
signal loss and background electronic
interference was signicantly reduced
with a distributed system based on
ber optics, so less time is requiredin correcting for these discrepancies,
especially in testing variable-speed
drive trains that tend to generate
considerable radio-frequency noise.
Using multiple-input/multiple-output
acquisition and analysis capabilities
for measured signals, the LMS system
created plots - including animated
mode-shape displays and frequency
response functions (FRFs) - identifying
ten fundamental system modes of
vibration of the structure, including rotorbending and twisting, blade torsion,
and tower fore-aft and side-to-side
bending. The LMS system also accurately
identied vibration modes often difcult
to predict solely through simulation,
such as coupled motion between the
nacelle, tower, and rotor bending.
Test engineers used LMS Virtual.Lab
software to correlate eld test
measurements with predicted results
from a dynamic simulation model
developed by NREL wind researchers.
Initial evaluations were performed using
a Modal Assurance Criteria (MAC) matrix
diagram showing where the experimental
and theoretical types of modal data
aligned and where they diverged.
Tools for advanced R&D testing
Work in addressing these requirements
is spearheaded by the National
Renewable Energy Laboratory
(NREL) - DOEs primary research and
development center for wind power.
A key focus of efforts at NRELs National
Wind Technology Center (NWTC) in
Golden, Colorado, is aimed at testing
proposed new concepts, as well as
improving existing designs, often in
connection with industry partners,
including wind turbine manufacturers
and component suppliers.
In particular, modal testing is performed
to identify resonant frequencies of the
wind machine. As a nationally certied
test facility, the NWTC also performs
modal analysis as part of a suite of
dynamic vibration tests for certifying
wind turbine designs. NREL installed
a LMS Test.Lab data acquisition and
analysis system for performing these
modal and vibration tests, and LMS
Virtual.Lab software for correlating
and updating simulation models.
Measurements are made using a
96-channel LMS SCADAS mobile data
aquisition system in a lightweight,
battery-powered laptop-size unit
that is easy to carry up into a wind
turbine nacelle and between the NWTC
and outdoor wind turbine sites. The
portable units are less than a third the
size and weight of the NWTC former
cumbersome UNIX-based system.
| 12 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
13/24
From this comparison, the test engineers
were able to provide the dynamicist
with information conrming simulation
predictions and updating simulation
modes when discrepancies were found.
In addition, experimental identication
of the turbine drive train frequencieswere used to adjust the wind turbine
controller and resolve vibration problems
occurring during operation of the
variable speed power electronics.
Adjusting simulation models
work together properly, Osgood said.
If a problem arises, there is only one
vendor to contact, and LMS has been
extremely helpful in getting our engineers
up and running on the new system.
The major value of LMS technology
in our testing operations is that we
can operate more efciently and cost-
effectively, providing high-quality data
and greater insight into the vibration
characteristics of next-generation wind
turbines that will serve the nations
energy needs in the coming decades.
For a modal survey, engineer positions accelerometers on the blade of a 600 KW wind turbine
with a 40-meter rotor diameter.
Integration of these functions - plus a
fast processing speed enables NWTC
engineers to see results immediately
after measurements are taken instead of
waiting hours or days for post-processing.
This fast visualization helps engineers
verify the test on the spot, see right away
how the structure behaves, get a good
insight into the root cause of vibration
problems, and easily identify particular
areas that need further investigation.
A fully integrated system ensures that
all tools we need are compatible and
For obtaining accurate predictions
of turbine vibration characteristics,
test-based modal analysis is
critical to adjusting models for awide range of simulation including
nite element analysis, multi-
body dynamics, aerodynamics,
acoustics, and blade pitch
control, said Richard Osgood.
Stiffness attributes and damping
characteristics computed by LMS Test.Lab
from modal data is an essential
structural parameter needed as inputs
to the simulation model to accurately
represent structural members as exiblerather than entirely rigid bodies.
In this manner, simulations can more
accurately predict the realistic bending
and twisting motion of components that
sometimes can lead to unacceptable
deformations and instabilities.
Value of an integrated system
Osgood noted that having this wide range
of capabilities in a single system was
an important criterion in their selection
process, with LMS Test.Lab providing afully integrated suite of tools - test set-up,
control, measurement, signal conditioning,
result analysis, data management, and
report generation - all in the portable test
unit. The PolyMAX feature, for example,
automatically highlights resonances so
engineers can visually identify natural
frequencies in minutes instead of
spending hours looking through raw data.
With an Active Pictures capability, live test
data in the form of interactive, animated
plots can be cut-and-pasted into Microsoft
Ofce tools like Word and PowerPoint.
LMS Wind| 13 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
14/24
The resulting full-scale acoustic wind
turbine model enabled engineers to
predict far-eld wind turbine acoustics
with adequate accuracy and efciency.
Collaboration, commitment and expertise
helped the team to overcome theprojects extreme modeling and testing
challenges and allowed the wind turbine
manufacturer to establish a robust
virtual path for mastering wind turbine
acoustics. Advanced testing efforts
were deployed to create and validate
the vibro-acoustic simulation model, and
additionally allowed modeling challenges
to be better understood in facilitation
of future wind turbine developments.
Optimizing wind turbineacoustics throughvirtual simulation
The noise wind turbines generate is
inuenced by many factors, includingblade size and design; drivetrain operation
as well as the orientation, force and
turbulence of the wind. Roughly speaking,
a megawatt wind turbine generates a
relatively at 45-55 dBA broadband noise
spectrum at a distance of 130-150 meters.
At average wind speed, wind turbine
noise only drowns out wind turbulence,
vegetation and/or trafc noise that
is present in the background by
approximately 10-15 dBA. Specic tonal
noise components occur as a result of
dynamic forces that come into play insidethe gearbox (teeth meshing), the generator
(electro-mechanical poles interaction),
and system hydraulics equipment.
The large physical size and characteristic
acoustic radiation of wind turbines
make it a real challenge to accurately
simulate wind turbine acoustics early
in development. A leading wind turbine
manufacturer and LMS EngineeringServices joined forces to meticulously
build a hybrid vibro-acoustic simulation
model, and validate the wind turbine
model through operational measurements
executed 100 meters above the ground.
Building a robust path for virtual wind turbine designLeading wind turbine manufacturer partnered with LMS Engineering Services tosharpen capability to master wind turbine acoustics
| 14 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
15/24
These dynamic forces cause local housing
surface vibrations, which distribute the
noise to the surrounding area through
radiation. The noise generated by driveline
rotating machinery also propagates
directly through structural noise paths.
To accelerate efforts to reduce the noise
of its comprehensive range of wind
turbines, the manufacturer contracted
LMS Engineering Services to run a
number of joint hybrid vibro-acoustic
modeling and simulation projects.
Our motivation to engage in these
projects relates to the capability of
acoustic simulation in identifying design
improvements up-front in the development
process, Laurent Bonnet, Leader of
Acoustic & Vibration Engineering at themanufacturer in Germany, stated.
The advanced modeling expertise
acquired through these projects
represents the foundation for
building accurate wind turbine
models, and enables us to predictthe acoustic performance of
multiple design variants. Acoustic
simulation insight is most helpful
in tracing individual noise sources
and adapting the design for
enhanced acoustic performance
early on in the process.
For the initial project, the manufacturer
selected its 1.5 Megawatt wind turbine
platform, which is currently in operation
at a large international install base.
LMS engineering consultants helped
develop a validated vibro-acousticmodel of the full-scale wind turbine,
using a method combining structural FE
(Finite Element), acoustic BE (Boundary
Element) and ATV (Acoustic Transfer
Vector) modeling and simulation.
LMS Wind| 15 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
16/24
Challenging tests to create/validate wind turbine FE model
In the process of building a complete,
accurate and full-scale FE model of
the wind turbine, the engineering team
faced the challenge of characterizing all
principal components that make up
a wind turbine, such as the blades, hub,
rotor, tower, gearbox, brake, bedplate
and nacelle. An exceptional modal
testing experience was undoubtedly thedetailed structural characterization of
a 37- meter rotor blade. Such a blade
almost entirely consists of a complex
laminated composite construction with
various curvature geometrical topology
with relatively low initial structural
damping. Other complex subsystems
that were characterized include the
large oil-cooled gearbox assembly
and the 160-tons and 100-meter tall
carbon-steel wind turbine tower.
In addition to transfer functions(Frequency Response Functions FRFs)
that were acquired for modal analysis
and general dynamic assessments,
engineers measured and validated FRFs
to characterize the interface between
various wind turbine parts. This testing
approach enabled them to properly
dene appropriate stiffness and contact
area representations. After modeling all
individual components and interfaces, they
grouped a number of related components
into partial system assemblies, such as
the rotor hub in combination with thethree rotor blades. For each subassembly
that was considered, they updated the
overall FRF analysis and junction transfer
functions by specic measurement
blocks. Subsequently, the project team
performed FRF analysis on the complete
wind turbine assembly in order to update
the structural full-system FE model and
to validate all cross transfer functions.
Running operationalmeasurements frominside the nacelle
Besides experimental modal analysis,
testing efforts also included operational
full-turbine measurements to be able to
qualify acoustic sound levels, vibrations
and forces, Laurent Bonnet stated.
The test crew for this extraordinary test
campaign consisted of test personnel
from both the wind turbine manufacturerand LMS. Overall, it deployed 6
LMS SCADAS front-end stations totaling
nearly 400 measurement signals to
acquire deection, vibration and acoustic
responses in, on and around the wind
turbine. Members of the crew used
the LMS Test.Lab software suite to
control synchronous data acquisition,
and to perform any data analysis action
they required. An extra measurement
system, equipped with a wireless LAN,
operated strain gauge measurements
on the rotating rotor blades. In additionto providing lots of data in support
of accurate acoustic simulations,
Operation Deection Shapes (ODS), for
example, immediately provided valuable
insight into the structural operation of
various wind turbine components.
During the time of intensive measurement,
the crew, packed inside the compact
nacelle, faced harsh winter time weather
circumstances. On the coldest days,
nearly-frozen testing professionals relied
on LMS SCADAS front-ends with dripping
icicles to fulll their duties faithfully.
Accurate acoustic simulationand exible design optimization
Based on the structural full-system FEmodel created earlier on, engineers
derived a Boundary Element (BE) model
of the wind turbine through a dedicated
skinning procedure. The acoustic BE
model makes it possible to simulate the
acoustic power generated by the wind
turbine through local surface vibrations
of various system parts. This information
serves as input for the innovative
LMS proprietary ATV method that is
integrated into the LMS Virtual.Lab
software suite, which accurately and
effectively translates the acousticpower into fareld noise emissions.
The ATV method demonstrates the
feasibility of reaching our ultimate goal,
which is reliably determining the noise
radiation of the entire wind turbine
conguration through simulation,
Laurent Bonnet commented.
The satisfactory level of correlation
between the simulated and measured
acoustic radiation proves that the
new vibro-acoustic simulation method
lives up to our high expectations.
One of the major advantages of this
deterministic acoustic simulation
approach is that it supports dif ferent
kinds of analyses that provide detailed
insight into particular noise sources.
Through post-processing, engineers are
able to trace the modal contribution
of specic system parts, or analyze
the effect of individual panels and
loads on overall noise radiation.
It took a lot of energy and
perseverance from the testing
crew to successfully complete this
challenging testing assignment,
which lasted several weeks.
Installing sensor instrumentation
required acrobatic skills rather
than any other specialty.
To equip strain gauge sensors inside
the blades, the operator needed to
exit through the nacelle roof, climb
inside the rotor and enter the interior
of the blade, which for the occasion,
was positioned horizontally.
| 16 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
17/24
The engineering information resulting from
these investigations is vital for driving
development improvements and new
wind turbine development. Deterministic
acoustic simulations were performed
up to a frequency of 200 Hertz, which
allowed signicant structure-borne noise
phenomena to be traced and tackled with
sufcient reliability. To keep the massive
processing workload that is involved in
vibro-acoustic simulation within
acceptable levels, multiple processing
stations were used to crunchdata simultaneously.
In parallel with this hybrid vibro-acoustic
simulation approach, the wind turbine
manufacturer additionally performed
hybrid SEA (Statistic Energy Analysis)
and far-eld acoustic holography.
Their engineers used hybrid SEA to
model the wind turbine and investigate
non-deterministic noise and vibration
sources. Far-eld acoustic holography,
a second high-frequency modeling
method, was deployed to qualify
noise emissions in the far eld andto extract statistically signicant
acoustic phenomena.
Developing wind turbines withsuperior acoustic performance
The deployment of the hybrid
vibro-acoustic simulation in future
wind turbine development processes
will help the company in cascading
structural and acoustic targets for
the complete wind turbine down to
subassembly and component level.
As such, the engineering consultancy
project provides us a head start in
tackling the root causes of wind turbine
noise and in designing countermeasures
that further reduce radiated noise
levels. Advanced testing efforts provide
detailed insight into mechanical wind
turbine operation, help create/validate
vibro-acoustic simulation models
and allow modeling challenges to be better
understood in facilitation of future wind
turbine development. For a large part, the
success of this innovative engineering
project was founded on the specialized
skills and experience of LMS engineering
consultants and our own engineers,
which really made the difference.
This new innovative approach
strengthens the capability
of our engineering teams in
efciently identifying the most
promising design concepts
and in developing the most
effective component variants,
Laurent Bonnet concluded.
LMS Wind| 17 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
18/24
Harnessing Wind Power:
Natures Inexhaustible Energy Resource
| 18 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
19/24
Speeding up development is a daunting
task, however, given the increasing
complexity of the designs and the need for
machines to operate reliably for decadesin adverse weather conditions. These
issues all come down to considerably
more tests to be performed on each of
the custom-designed units. Jari Toikkanen,
Manager of the Research and Test Group
at Moventas has seen the number of noise
and vibration tests quadruple in the last
ve years, with many projects requiring
same-day turnaround.
In addition to greater product
development efforts for these units,
wind turbine OEMs are demanding more
vibration tests that measure behaviorin greater detail than ever before, says
Toikkanen. Tests are done primarily to
meet strict demands from regulatory
agencies such as the AGMA (American
Gear Manufacturers Association) and
European ISO standards.
Studying gearbox resonances
He notes that particular attention is
focused on studying vibrations of the wind
turbines massive gearbox, which uses
a combination of planetary and helical
gearing to step up rotor speed 100-fold for
driving the electrical generator. Another
major component of interest is the torque
arm connecting the gearbox to the turbine
framework. For large three-megawatt
rated models made by Moventas,
the gearbox weighs 30 tons and measures
two meters in diameter and two-and-a-half
meters in length.
The torque arm is four meters wide from
bushing to bushing, a half meter thick and
weighs another ve tons.
Engineers perform extensive modal
impact testing to ensure that resonances
of these components do not match the
natural frequencies of the surrounding
structure, thus exciting potentially
damaging vibrations in the framework,
rotor blades, drive shafts and the huge
tower the tallest of which is over 200
meters. Generally, the goal is to avoid the
modal frequency range of 80 to 150 Hz for
the torque arm and 400 to 800 Hz. When
resonances are identied within or near
these ranges, engineers shift the modalfrequencies by modifying the geometry of
the gearbox components and torque arm
typically increasing wall thicknesses or
adding ribs to stiffen parts. The stiffness
of torque arm bushings may also adjusted
if necessary.
Toikkanen notes that the process is
complicated by the variable gearing
frequencies that excite gearbox and torque
arm vibration modes at different rotor
blade speeds from an input rotation of
ve rpm for a light breeze to a maximum
of 60 rpm for gale-force winds. Further,
Moventas is sometimes required to
perform additional tests and studies of
fatigue life or torsional vibration beyond
the scope of their resources.We can easily carry the unit
between test rigs at our facility,
and if necessary our engineers can
go at a customer or end-user site
very quickly to provide support or
troubleshooting, says Toikkanen.
LMS helps Moventas increase testing efciency and shorten customer turnaround
time in developing wind turbine gearboxes
Boosting test productivity
Unfortunately, limitations of the former
test solution hampered Moventas in
always meeting these challenges in a
timely manner. Test equipment was
awkward to move between test rigs, test
setups were typically lengthy ordeals, and
engineers had to spend time on multiple
test runs because only two channels
were available for modal analysis. Also,
measurement data had to be post-
processed before results could be viewed,
thus requiring tests to be completely
re-run if sensors were not properly
connected, for example, or if more
detailed study was needed to troubleshoot
unexpected problems.
These limitations were overcome when
Moventas implemented the LMS Test.
Lab software with an LMS SCADAS
Mobile data acquisition system that has
eight channels, enough to take all modal
analysis measurements in a single run.
The system contains an integrated suite
of tools Moventas engineers need for
modal analysis test set-up, control ,
measurement, signal conditioning, result
analysis, data management and report
generation all in a lightweight, portable
laptop-size unit.
LMS Wind| 19 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
20/24
Also, the system is extremely convenientto set up. Built-in workbooks and prompts
show us step-by-step where to enter
parameters and how to proceed through
the process. Templates even ll in values
weve used in the past that arent likely
to change. Geometry models showing
the placement of accelerometers on the
gearbox housing are especially useful
and easy to congure. From start-to-
nish, set-ups with LMS Test.Lab are
very fast and easy, so were ready to take
measurements in a few minutes rather
than several hours.
Another capability of LMS Test.Lab that
greatly improves testing productivity is
on-line monitoring. We can see results
immediately as measurements are being
taken instead of waiting hours for post-
processing, says Toikkanen.
With its mobility, test set-up, on-linemonitoring, visualization and report-
generation capabilities LMS Test.Lab
boosts our test productivity immensely,
he notes.
Using a combination of planetary and helical gearing, wind turbine
gearboxes step up rotor speed 100-fold for driving electrical
generators. Moventas uses LMS Test.Lab for modal analysis in
studying resonances created by gear-tooth meshing in these units.
With real-time visualization, we can
verify the test on the spot, see rst-
hand how the structure deforms
with every hammer impact, and
readily identify the root cause of any
unexpected resonances.
Visualization is particularly helpful toMoventas engineers with the animated
mode shapes displayed together on the
same screen with plots such as frequency
response functions (FRFs) showing
vibration amplitude versus frequency at
key locations on the gearbox.
This enables engineers to see immediately
how the gearbox housing bends and twists
at various frequencies so they can readily
identify which bearings are transmitting
vibrations and determine critical gear-
mesh harmonics.
When testing is done, report generation
features allow Moventas engineers
to efciently create the necessary
documentation, complete with LMS
Active Pictures that show live test data
including mode shape animations in
Microsoft Word documents as well as
PowerPoint presentations. LMS Test.Lab
report generation with Active Pictures lets
us quickly create reports that clearly show
our designers, customers and regulatory
agencies the modal behavior of the
gearbox. says Toikkanen.
Now we can complete routine tests
in a few days instead of weeks.
When faster turnaround is needed,
our team can run an entire battery
of modal tests in the morning
and have results analyzed and
documented that afternoon.
Fast-response engineeringprojects
In addition to implementing LMS Test.Lab,
the company has worked closely with LMS
Engineering Services on projects beyond
the scope of Moventas resources
projects where fast response was needed
to meet requirements for key wind-turbine
manufacturer customers.
In one such project, LMS Engineering
Services was called upon to provide
critical fatigue life data needed by
Moventas customer REPower in Germany
for certifying a wind turbine.
| 20 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
21/24
The study was to verify that two critical
wind-turbine gearbox cylindrical
components a torque arm and gear
carrier would withstand expected loadsover a 20-year operational lifetime. LMS
engineers created nite element models
of the components and applied unit load
cases to determine the stress-time series
on each part. This stress-time series
together with the complete load time
histories for the components were then
used with LMS Virtual.Lab Durability
simulation software to determine fatigue
life prediction for the base material.
Results were provided within two weeks
from the start of the project, thus enabling
Moventas to give a fast response inverifying that cumulative damage values
were well within the safety factor of the
designs.
In another project, Moventas contracted
LMS Engineering Services to measure
the rotational vibration on the low-speed
input and high-speed output shafts ona gearbox developed for Spanish wind
turbine manufacturer Acciona. Signals
from accelerometers mounted directly on
the low-speed shaft were fed into LMS
Test.Lab for analysis. Signals for the high-
speed shaft were obtained from a laser
vibrometer system measuring rotational
velocity. A series of operating response
color maps accurately identied rotational
vibration and related resonances for both
shafts. In less than one week, Moventas
was provided valuable data needed by the
wind turbine manufacturer in simulatingthe dynamic performance of the entire
drivetrain.
The collaboration with LMS
Engineering Services demonstrates
that LMS goes far beyond sellinghardware and software, says
Toikkanen. Their industry-wide
expertise in performing this work and
fast response in providing exactly
the right data made us look good
in the eyes of our customers and
made a lasting impression that has
immeasurable business value for us.
LMS SCADAS Mobile data aquisition system has an integrated suite of vibration analysis all in a lightweight, portable laptop-size unit that Moventas
engineers can easily carry between test rigs.
LMS Wind| 21 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
22/24
A Unique Portfolio of Software
Platforms and Engineering Services
Much of the potential gains individual tools offer are lost in developing unique interfaces and error-prone
data translations. Each major application family has been built with a consistent user interface paradigm
and data model resulting in a consistent platform for numerous application modules. Each modular family is
packaged in such a way that users are assured maximum flexibility at the most economical price point.
SAMCEF Wind Turbines & LMS Virtual.Lab platform
for 3D Performance Simulation
SAMCEF Wind Turbines is the worlds most advanced computation platform dedicated towind turbine design. From the early stages in the design process, thanks to the integrated
parametrized model, down to component vibration analysis, SAMCEF Wind Turbines approach
exceeds todays certication requirements. SAMCEF Wind Turbines brings coherence to your
design process by providing a common interface to various engineering disciplines, hence
improving team work.
LMS Imagine.Lab platform
for Mechatronic System Simulation... is a complete 1D system simulation platform to model and analyze multi-domain,
intelligent systems and predict multi-disciplinary performance. Model components
are described using validated analytical models that represent the systems actualhydraulic, electric or mechanical behavior. LMS Imagine.Lab frontloads mechatronic
system simulation for multi-physics modeling and full system analysis.
LMS Test.Lab platform
for Test-Based Engineering... an integrated platform offering a complete software and hardware portfolio for
noise and vibration testing including solutions for acoustic, rotating machinery,
and structural testing, reporting and data management. With its unied interface
and seamless data-sharing capability between different applications, LMS
Test.Lab offers users tremendous efciency gains and ease-of-use.
LMS Engineering Services
LMS engineers work with customers to solve their most critical problems and often make the
difference between successful product launches and costly repairs or even failures. Experienced
in critical performance attributes the teams unique balance of skills, engineering experience
and process know-how turns attribute engineering into a strategic competitive advantage.
| 22 |LMS Wind
7/29/2019 Energy Brochure Cases a Siemens Business LR
23/24
Design - CAD Controls
Structural integrity
System dynamics
Vehicle dynamics
Comfort
Noise and vibration
Sound quality
Durability
Safety
Performance
Power management
LMS Customer Services
LMS supports its customers with engineers who not only understand the hardware and
software, but also master the related engineering applications. Extensive training, seminars,
and on-site services help our clients technical staff gain and maintain their software and
system know-how. LMS offers a complete portfolio of professional services, including
full installation management, on-site training and support, and continuous knowledge transfer.
LMS Virtual.Lab LMS Samtech suite
LMS Imagine.Lab
LMS Test.Lab
System Synthesis System Data Management Multi-physics Modeling
Laboratory TestingLMS SCADAS
Data Acquisition SystemsMobile Testing
Fuel economy and emissions
Fluids
Electromechanical systems
Thermal management
...
LMS Wind| 23 |
7/29/2019 Energy Brochure Cases a Siemens Business LR
24/24
LMS INTERNATIONAL
Researchpark Z1, Interleuvenlaan 68
B-3001 Leuven [Belgium]
T +32 16 384 200 | F +32 16 384 350
info@lmsintl.com | www.lmsintl.com
Worldwide For the address of your local representative,
please visit www.lmsintl.com/lmsworldwide
L
MS2013.
Allrightsreserved.
Thematerialspresentedherearesummaryinnature,subjecttochange,andintendedforgeneral
info
rmationonly.
Additionaldetailsandtechnicalspecificationsareavailable
atwww.lmsintl.com.
LMSINTERNATIONAL,
LMSTest.Lab,
LMSVirtual.Lab,
LMSVirtual.LabDesigner,LMSImagine.LabAMESim,
LMS
SCADAS,
LMSSoundBrush,
LMSTest.Xpress,
LMSTec.Manager,LMSCADA-X,
LMSDADS,
LMSFALANCS,
LMSPolyMAX,
LMSTecWare,
LMSTWRandLMSCDTire,
SAMCEF,
are
registeredtrademarksofLMSINTERNATIONALNV.
Allothertrademarks
acknowledged.
LMS, A Siemens Business, is a trusted
partner of the worlds leading automotive
manufacturers and their suppliers, leading
aerospace companies, major energy
producers and innovative manufacturers of
other high tech equipment. As a business
segment within Siemens PLM, LMS
offers a unique combination of best-in-class mechatronic simulation and testing
solutions, and engineering services. We help
to get better products faster to the market
and turn superior process efficiency into key
competitive advantages. Through 30 years
of engineering innovation, 1,200 people
and 40 offices worldwide, we are servicing
more than 100,000 R&D engineers in more
than 5,000 manufacturing companies. LMS
partners with all of the Fortune 500 top
auto- and aero manufacturers.
Leading partner in
Test & Mechatronic Simulation