Extend gearbox life with new components and methods 2015.04.21

How to Double your Gearbox Life Using New

Materials, Components, and Methods

Presentors

Wesley Thomas

Business Development

Sentient Science

Doug Herr

General Manager

Aerotorque

Jeff Grabowski

Manager of Applications

Development and

Commercialization

QuesTek Innovations

Joe Reisinger

VP Product

Management

Broadwind Energy

How to Double your Gearbox Life Using New Materials, Components, and Methods April 22, 2015

What If?


Business Challenge We’re Trying to Solve

Operators Push

Performance

Failures Increase on

Rotating Components

New Failure Solutions Emerge

There is Limited Time to

Evaluate All Solutions

Different Applications

Have Difference

Value

Expensive and Time

Consuming to Try New Solutions


Why a Trusted Third Party Can Help

Quantify Benefits and Business Case Quickly and Early

Life Modeling Approach

Specific Application

Solution I.P.


Component Risk Failure risk ranking down to the component

level

DigitalClone Life Models


Presenter

Doug Herr

General Manager

Aerotorque

[email protected]


• AeroTorque was spun out of PT Tech Inc. in March of 2013. • PT Tech has spent the last 36 years working to reduce transient

torque loads in many different types of equipment. • Both companies are under EBO Group, an 100% employee

owned company.

April 22, 2015

Rotor inertia

Generator inertia

April 22, 2015

April 22, 2015

Photo courtesy: Aaron Greco/Argonne National Laboratory

April 22, 2015

A control system can only react as fast as the mechanical system that it controls.Can a control system react fast to prevent a torque reversal?

Sense the Wind speed

Initiate blade pitch

Stop pitching

How quickly can it respond to a gust or an emergency stop command?

1.65 MW turbine 750 KW turbine

April 22, 2015

Presenter

Jeff Grabowski

Manager of Applications Development and Product

Commercialization

QuesTek Innovations LLC

[email protected]


p. 26

Contains information protected by SBIR data rights

Agenda

• Background on QuesTek Innovations LLC

• New advanced gear steels:

• properties

• leading applications

• benefits to wind gear boxes

p. 27


QuesTek Innovations LLC - Background

• A global leader in Integrated Computational Materials Engineering (ICME)

• A licensor of four new ultra high performance steels to Carpenter Technology

• QuesTek steels fly as safety-critical landing gear on U.S. Air Force and Navy platforms + key applications in industries where high performance is valued

Ferrium M54 hook shank forging Completed Ferrium M54 steel T-45 hook shank

The U.S. Navy has estimated that using QuesTek’s Ferrium M54 steel for T-45

hook shanks will provide a $3 Million cost savings

NAVAIR Public Release #2014-

712 Distribution Statement A-

"Approved for public release;

distribution is unlimited"

p. 28


Ferrium C61 & C64 high performance carburizing steels:A significant upgrade from incumbent wind turbine gear materials

Commercially Available

C61 (AMS 6517): ~61 HRC case, ultra high-strength & high-toughness core

C64 (AMS 6509): ~63 HRC case, high-strength core For gears, shafts, integrally-geared shafts, pins, ball screws, actuators, etc.

Aerospace-qualified design minima for flight critical components

Longer fatigue life and greater pitting resistance

Greater strength = lighter-weight, or increased power density

High tempering temperature = greater temperature resistance / survivability

p. 29


C61 and C64 steels: Superior fatigue performance

vs. “best-in-class” aerospace gear steels

Single tooth bending fatigue: ~20%

higher performance of C64 steel vs.

Pyrowear 53 (based on 50% failure

criteria)

Greater core strength of C61 steel

leads to ~45 ksi increase in axial

fatigue threshold stress vs. 9310

p. 30


Chinook rotor shafts, Block II upgrade (Boeing):

C61 replaces 9310 to provide ~20% increase in power at same geometry

Crankshaft for aerospace steering actuator:

C61 addresses core strength deficiencies of 9310 (full scale production 2015)

Off-road racing (e.g., BAJA 1000)

3-4x life improvement vs incumbent 9310 steel

NASCAR pinions

Eliminated in-race failure issues of incumbent steel

Oil and gas pinions

Solved core failure of 9310

F-1 components

Under evaluation for longer fatigue life

Ferrium C61

Leading application examples

C61 steel forward rotor shaft

undergoing rough machining,

successful rig testing in 2014

p. 31


Ferrium C64

Leading applications examples

Next Generation Helicopter Gear

Steel

“C64….allows gears to run at high load levels

without failure and carry more loads through

the gearbox,” March/April 2015 issue of Army

Technology Magazine

• Multi-year programs with Bell

Helicopter and Sikorsky

And…

• Currently under evaluation by several

major global aerospace companies for

next generation engines and gearsBell Helicopter’s tiltrotor V-280 Valor, with

Ferrium C64 as main gear material,

scheduled to fly in 2017 (Artist’s rendering

courtesy of Bell Helicopter)

p. 32


Ferrium C61 and C64

The Benefits for Wind Turbine Gear Boxes

• Increased gear box durability and life

extension

• Reduced maintenance costs and turbine

downtime

p. 33


Resources

• Ferrium C61 and C64 are commercially available from

Carpenter Technology, stocked in a range of sizes from

1” to 14” bar diameter

• Processing documents with forging, machining, heat

treating guidelines available

• QuesTek technical support for component prototype

development and testing

• Gear Solutions Magazine, January 2015, page 31-38,

summary of C61 and C64 steels “Application of ICME to

Optimize Metallurgy and Improve Performance of

Carburizable Steels” link on upper right hand corner of

QuesTek web site.

Presenter

Joe Reisinger

Vice President – Product Management

Broadwind Energy

[email protected]


© 2013 Broadwind Energy, Inc. All Rights Reserved

Reduce crane costs

Limit turbine down time

Reduce shipping costs

Eliminate gearbox CapEx

Proactive approach = reduced downtime

and lower gearbox repair cost

© 2015 Broadwind Energy, Inc. All rights reserved.


Shop Remanufacturing

On-site engineering, machine shop

Inventory management system (MRP)

Adequate crane capacity

Clean environment

On-site test stand



Complete Uptower Rebuild

Our unique, self-contained mobile

drivetrain service units were designed

to reduce cost and downtime.



Deep Precision Gear and Gearbox Expertise

In-house gear hobbing & grinding

Carburizing, induction hardening, heat treat

Re-grind & requalification services

Magnetic particle inspection & Nital etch standard

RCA failure analysis services

On-site full metallurgical & NDT laboratory services

>Produced more than 3,000 gear sets for wind.



Gearbox Upgrades

Gearing

Geometry

Heat treat

Material

Bearings

Partnering with OEMs on

RCAs and upgrades

Lubrication

Work closely with several oil

manufacturers on additives,

cleanliness, changing &

flushing procedures

Heat exchangers

Seal upgrades



• Goal: Compare and quantify

Broad Wind ring gear design with

OEM and another gear alternative

to quantify the life extension

changes between the three

• How: Develop DigitalClone model

for wind turbine Ring Gear #C2

and run simulations to predict

dominant damage mode and

fatigue life

Ring Gear Life

Extension Assessment



Sentient PredictionsL50 (Years of Operation)

4340Ring Gear

43B17 Ring Gear

DriveMax4340 Ring

Gear

4.72 14.93 37.84

- 3.2x 8x

LEGEND

4340Ring Gear

43B17 Ring Gear

DriveMax4340 Ring

Gear

Ring Gear Fatigue

Comparison Results

Fatigue Life Predictions – Load Case 1 – Max. Contact Stress: 1371.2MPa



Our proven process, tools

& fixtures enable a custom

turnkey gearbox repair plan

…from simple bearing replacements

to complete gearbox rebuilds.


DigitalClone Live – Site Level

Asset Ranking Default Most-at-Risk, Sortable, Filterable …

Asset Map View Risk Level,

Interactive, Navigable


Trade-Off Studies Asset/Customer specific trade-off option to confidently

predict impact on life/ROI

DigitalClone Live – Trade-Off Study


DigitalClone Live – ROI Optimization

ROI Optimization All trade-offs based on ROI at the

individual asset level/group, maximizing ROI for the fleet.Grouping Asset type,

sub-site, region, etc.


Extend gearbox life with new components and methods 2015.04.21

Engineering

Transcript of Extend gearbox life with new components and methods 2015.04.21