Drivetrain Simulation and Load Determination using Drivetrain Simulation and Load Determination...

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  • Fakultt Maschinenwesen, Institut fr Maschinenelemente und Maschinenkonstruktion, Lehrstuhl Maschinenelemente

    Drivetrain Simulation and Load Determination using SIMPACK

    SIMPACK Conference Wind and Drivetrain

    Prof. Dr.-Ing. Berthold Schlecht | Dr.-Ing. Thomas Rosenlcher

    Radisson Blu Hotel Hamburg, 7th of October 2015

  • Technische Universitt Dresden Chair of Machine Elements

    Field of research: drive technology, especially gear technology and components

    Technische Universitt DresdenChair of Machine Elements

    07.10.2015 2Drivetrain Simulation and Load Determination using SIMPACK

  • Dynamic analysis of electro-mechanical drive systems Improvement and verification of simulation techniques Investigations in the time and frequency domain using the MBS and FEM Analyses of drive train systems and drive train concepts Verification of simulation models by measurement results

    Technische Universitt DresdenChair of Machine Elements

    07.10.2015 3Drivetrain Simulation and Load Determination using SIMPACK

    2001 2002 2003 2004 2015

    approx. 0.7 MW approx. 1.5 MW approx. 2.0 MW

  • Dynamic analysis of drive systems

    roller mill train drive ladle cranes wind turbines

    07.10.2015 Drivetrain Simulation and Load Determination using SIMPACK 4

    thruster mechanical watches bucket wheel excavator

    compressorssteam turbines

  • Introduction analysis of wind turbines

    07.10.2015 5Drivetrain Simulation and Load Determination using SIMPACK

    global load assumptions (forces/torques at rotor hub, generator)

    measurementof forces and torques at awind turbine

    simulation of wind loads (CFD, Bladed, Flex5, AeroDyn)

    www.purdue.edu

    dimensioning: tower, blades, couplings, shafts,gearings, bearings,generator,

    dimensioning: drive train components

    standards (DIN 743, ISO 6336) software (mdesign, KissSoft, ..)

    finite-element-method (Nastran, Ansys, )

    loads loads

    multibody-system simulation (MBS)

    calculation of design loads for single components by

    recalculation of measured or simulated load cases

    ? simulation component load ?

    determination of design loads for single components by

    transfer/ extrapolation of simulated forces and torques

    ? measurement component load ?

    determination of design loads for single components by

    transfer/ extrapolation of measured forces and torques

  • 07.10.2015 6Drivetrain Simulation and Load Determination using SIMPACK

    Dynamic analysis of drive systems

    Stepped planetary gear (Multibrid)

    Power splitting gear box (MAAG)

    Differential gearbox (Bosch Rexroth)

  • 07.10.2015 7Drivetrain Simulation and Load Determination using SIMPACK

    Dynamic analysis of drive systems

    Student research project: Design and determination of the dynamic behaviour of a multi-staged helical gearbox for wind turbines

  • 07.10.2015 8Drivetrain Simulation and Load Determination using SIMPACK

    Dynamic analysis of drive systems

    Influences of the gear box support concept: three or four point support

    Influences of the main frame design on the dynamic behavior of the drive train

  • Determination of the distribution of the gearing forces

    Over the width of the gearing Over one revolution of the planet carrier Dependent from modelled rotor loads

    11.06.2015 9GET Group 2015 SIMPACK Seminar

    Dynamic analysis of drive systems

    Weight of the rotor neglected

    Analysis for nominal load

    forc

    e [m

    ]

    Weight of hub and rotor blades considered

    Additional modelling of the wind loads

    forc

    e [m

    ]

  • Specification (NREL 5 MW Baseline): Rotor diameter:

    126 m

    Wind speed: 3 m/s to 25 m/s (11.4 m/s)

    Rotor speed: 12.1 rpm

    Concept: double-feed

    asynchronous generator

    Operational range: 670 rpm to 1167 rpm

    07.10.2015 10Drivetrain Simulation and Load Determination using SIMPACK

    Design of a 5 MW drivetrain

  • First design of the gear box Scaling of the available 3 MW design without optimisation of ratio split,

    number of planets, number of stages, consideration of power splitting or differential gearboxes

    Second design of the gearbox Optimising of design parameters

    Target: Comparison of gear box designs

    07.10.2015 11Drivetrain Simulation and Load Determination using SIMPACK

    Design of a 5 MW drivetrain

  • Implementation of the gearbox in the NREL 5 MW Baseline Modelling all available degrees of freedom for drive train components Supporting of components in gearbox housing by bearings Three-point support of the drive train

    07.10.2015 12Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline modelling

  • Natural frequencies: 1.01 Hz

    07.10.2015 13Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Natural frequencies: 1.13 Hz

    07.10.2015 14Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Natural frequencies: 1.72 Hz

    07.10.2015 15Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Natural frequencies: 15.90 Hz

    07.10.2015 16Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Natural frequencies: 173.90 Hz

    07.10.2015 17Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Analysis in the frequency domain

    07.10.2015 18Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline frequency domain

  • Analysis in the time domain Simulation of different load cases Example:

    Wind speed: 12 m/s; 18 m/s; 24 m/s Analysis of the check plots Determination of the loads at the hub Validation of the design of the gear stages

    07.10.2015 19

    NREL 5 MW Baseline

  • Design of an optimised gearbox Load optimised design

    Mainframe Gearbox Planet carriers

    Implementation of the mainframe, the gearbox housing and the planet carriers as modal reduced finite element model

    07.10.2015 20Drivetrain Simulation and Load Determination using SIMPACK

    NREL 5 MW Baseline further steps

  • Modelling the gear stages by elastic bodies to analyse:

    Gear twist under torsional load Effects of body irregularities on the meshing

    gear contact Effects of body deformation on load

    distribution and excitation (ring gears, thin gears)

    Effects of flank modifications and pitch error under load

    The tooth loads gets distributes by a referenced MPCs the tooth flanks for each tooth

    07.10.2015 21Drivetrain Simulation and Load Determination using SIMPACK

    Flexible gears SIMPACK 9.8

  • 07.10.2015 22Drivetrain Simulation and Load Determination using SIMPACK

    Simulation model of the pitch drive Combination of the detailed gear box and rotor blade model

    Simulation of the pitching process for different wind conditions, analysis of the bearing and gearing forces

    Determination of the natural frequencies and comparison with excitations

    Analysis of the pitch drive

    + =

  • 07.10.2015 23Drivetrain Simulation and Load Determination using SIMPACK

    Analysis of the pitch drive

    ~ 1.3 HzBending mode shape of the rotor blade

    ~ 15.5 HzTorsional mode shape of the rotor blade

  • 07.10.2015 24Drivetrain Simulation and Load Determination using SIMPACK

    Simulation model of the azimuth drive Consideration of the motor and the gear box, the nacelle and the tower

    Simulation of the wind tracking, evaluation of braking concepts, influence of the acting brake torque on the dynamic behaviour

    Analysis of the mode shapes (superposition: tower, azimuth drive, nacelle)

    Analysis of the pitch drive

  • 07.10.2015 25Drivetrain Simulation and Load Determination using SIMPACK

    Analysis of the pitch drive

    ~ 0.4 HzBending mode shape of the tower and torsional mode shape of the drive train

    ~ 15.5 HzTorsional mode shape of the tower and the drive train

  • SIMPACK enables a detailed analyses of wind turbines to determine critical operational states and component loads for the design, certification and optimisation

    07.10.2015 26Drivetrain Simulation and Load Determination using SIMPACK

    Conclusion

  • Technische Universitt Dresden

    Department of Mechanical Engineering

    Institute of Machine Elements and Machine Design

    Chair of Machine Elements

    Mnchner Platz 3D-01062 Dresden

    www.tu-dresden.de/me

    Thank You for Your Attention

    07.10.2015 27Drivetrain Simulation and Load Determination using SIMPACK