Design Of Wind Turbine Gearboxes With Respect To Noise
Design of wind turbine gearboxeswith respect to noiseJoris Peeters / Jan HoubenWind Power TechnologyZF Wind PowerZF Wind Power1PresentationTitle,Dategearboxes with respect to noiseDesignof windturbine11/12/2012 ZF Friedrichshafen AG, 2012A brand of ZF
1.ZF Wind Power2.Mechanical noise of wind turbines3.Gearbox design for low noise and vibrations4.Research project ALARM5.ConclusionsZF Wind Power2Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Agenda
Combination of ZF and Hansen CustomersProducts2 MW1,5 MW to 6,15 MWRegionsLommel, BelgiumCoimbatore, IndiaTianjin, ChinaGainesville, USACoimbatore, IndiaLommel, BelgiumTianjin, ChinaSource: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.10ZF Wind Power3Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Gainesville, USAProductionLocations
The Business Unit Wind Power Technology ispart of the Industrial Technology Division of ZFZF Friedrichshafen AGShareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup FoundationDivisionDivisionDivisionDivisionJoint cial VehicleTechnologyIndustrialTechnologySteering Systems50 %TransmissionsChassis SystemsTruck & VanDriveline TechnologyConstructionMachinery SystemsPassenger CarSteering SystemsAxle DrivesChassisComponentsBus DrivelineTechnologyAgriculturalMachinery SystemsCommercial VehicleSteering SystemsCV Axle SystemsMaterial HandlingSystemsPassenger CarSteering ColumnsTest SystemsGlobal Aftermarket4)CEO, MarketFinance,Controlling,IT, Process ManagementPowertrain ModulesRubber & PlasticsHuman ResourcesSuspensionTechnologyCV Chassis ModulesCV DamperTechnologyMaterials ManagementCV PowertrainModulesOperations andTechnologySpecial DrivelineTechnologyElectronic SystemsCompliance 1)Aviation TechnologyDie Casting Technology2)Wind PowerTechnologyZF Services 3)Board of ManagementOrganizational unitIntegration of HansenTransmissionsPartial activitiesin wind powerZF Wind Power41) linked to CEO2) linked to Materials Management domain3) linked to Market domain4) ZF Lenksysteme GmbH is a joint venture betweenZF Friedrichshafen AG and Robert Bosch GmbH.Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Marine PropulsionSystems
1.ZF Wind Power2.Mechanical noise of wind turbines3.Gearbox design for low noise and vibrations4.Research project ALARM5.ConclusionsZF Wind Power5Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Agenda
Mechanical noise of wind turbines1.Aerodynamic noise source blade motion in air primarily broadband - e.g. total SPL 105 dB(A) (turbine at rated wind speed)Ramachandran et al. (2012) [2]ZF Wind Power6Petitjean et al. (2011) [1]Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Frequency spectrum of wind turbine noise sources
Mechanical noise of wind turbinesFrequency spectrum of wind turbine noise sources2.Mechanical noise sources: gearbox, generator, cooling fans, primarily tonal content, not determining WT overall SPLTotal SPL of 3MW gearbox at rated power 92 quency [Hz]ZF Wind Power710000Petitjean et al. (2011) [1]Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Sound power level [dB(A)]110,0
Mechanical noise of wind turbinesTransfer path of mechanical noise (gearbox as example)Gear mesh1Gearbox housing2Wind turbine components43Structure borne transfer path inside / outside gearboxAirborne radiation by gearbox / by other componentsZF Wind Power8Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Source: gear mesh, (bearings, pumps)
Mechanical noise of wind turbinesPotential annoyanceAnnoyance depends on noise level of other sources (a.o. aerodynamic, background)1.tonality:IEC61400-11 [3]2.(overall WT sound power level dominated by mechanical noise)ZF Wind Power9Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012distinguishable tone is audible
Mechanical noise of wind turbinesMeasures / solutions for annoyance of mechanical noiseA.Design “first time right” reduce source level optimise transfer pathX(avoid resonance /add damping)transfer pathreceiverCorrective actions (when needed) shift resonance (e.g. tuned absorber, change speed) add more damping (e.g. nacelle insulation)ZF Wind Power10Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012B.source
1.ZF Wind Power2.Mechanical noise of wind turbines3.Gearbox design for low noise and vibrations4.Research project ALARM5.ConclusionsZF Wind Power11Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Agenda
Gearbox design for low noise and vibrationsChallenges in “first time right” gearbox designGear meshReduce source level reduce gear mesh excitation2.3.1Optimise gearbox housing structure borne airborne radiationGearbox housing1Integration in wind turbine2234Wind turbine components3XsourceZF Wind Power transfer path124receiverDesign of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 20121.
Gearbox design for low noise and vibrations1. Excitation reduction through gear optimisationRequirements on capacity and noiseRequirements on capacity and noise(ZFWP and Customer specification)BasicBasic designdesign macromacro geometrygeometry(ZFWP Gear Design ncy(Rikor2Dyn)NOKOKDesign ofof toothtooth flankflank modificationsmodificationsDesign(3D-Load distribution analysis, i.e. RIKOR)Calculation of gear excitationOKCertified gears(Safety, load distribution, NVH)ZF Wind Power13Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012NOK
Gearbox design for low noise and vibrations2. Transfer path optimisation: structure borne and airborneOptimisation by virtual design assessmentGear mesh1Gearbox housingSimulation requirements: Gear mesh model Transfer path structural model Radiation structure borne at interfaces airborne at housingChosen solution:Acoustic FE simulation for airborne radiationZF Wind Power14Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Multibody simulation for vibrations
Gearbox design for low noise and vibrations2. Transfer path optimisation: structure borne and airborneStructural multibody simulation model in SIMPACK Gear excitation forcesSIMPACK FE-225 Bearing forces6x6 stiffness matrix Flexible components via CMSreduction:- planet carriers- housing: mesh size 5cm,1st eigenmode 100Hz, 1006 DOFsZF Wind Power15Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012- shafts
Gearbox design for low noise and vibrations2. Transfer path optimisation: structure borne and airborneZF Wind Power16Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Example of a housing design optimisation to avoid resonance
1.ZF Wind Power2.Mechanical noise of wind turbines3.Gearbox design for low noise and vibrations4.Research project ALARM5.ConclusionsZF Wind Power17Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Agenda
Research project ALARM“First time right” wind turbine design requires cooperation between stakeholdersCooperation between 3 stakeholders insource and transfer path:WT manufacturerHamburgWT gearboxmanufacturerAntwerpBushing manufacturerRimbach 2 engineering companiesHamburgSoftware & Hardware /Simulation & TestLeuvenX 2 universitiesZF Wind PowerChair of Eng. DesignErlangenDept. Mechanical Eng.Leuven18source transfer pathDesign of wind turbine gearboxes with respect to noisereceiver11/12/2012 ZF Friedrichshafen AG, 2012Software / Simulation
Research project ALARM„Assistenzsystem zur LärmreduziertenAuslegung Rotierender Maschinen”Goal: Save money and time in the development of wind turbines, gearboxesand elastomer bushings by avoiding tonal noise issues in the fieldTotal budget:DetailGerman partners: 2.0 M Belgian partners: 1.8 M ValidationTroubleshootingwith governmental support high level of innovationDuration: 3 years (01.03.2012 – 28.02.2015)ZF Wind Power19Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Concept
Research project ALARMALARM research activitiesExpert system developmentImplementationSimulations & MeasurementsData acquisitionGearbox development process Correlation with test rigsTest rig measurements Gear mesh excitationWT development process structure and airborne radiationWT measurement (a.o. TPA) structure and airborne radiationElastomer development process Uncoupling structure borne transferMeasurements: WT, high freq shaker uncoupling structure borne transferSimulation test rig Gear mesh excitationMeasurements test rig, WT Gear modelling, TPAZF Wind Power20Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Knowledge acquisitionKnowledge storageKnowledge disseminationSimulation WT structure and airborne radiation
Research project ALARMRepower 3.2M114 wind turbineStatusZF gearbox-gearbox simulation models ready-1st proto gearbox test rig measurements done-gearbox assembly in wind turbine planned-additional test rig measurements-elaborate field measurement campaign-correlation of simulations with experimental resultsZF Wind Power21Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Outlook (planned for 2013)
1.ZF Wind Power2.Mechanical noise of wind turbines3.Gearbox design for low noise and vibrations4.Research project ALARM5.ConclusionsZF Wind Power22Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012Agenda
Conclusions1. Mechanical noise of wind turbines lower in overall sound power level compared to aerodynamic noise typically tonal and mainly structure borne noise avoid annoyance ( tonality) by reducing source level and optimising transfer path2. Gearbox design for low noise and vibrations excitation reduction by optimising macro and microgeometry transfer path optimisation by using MBS and acoustic FE to predict the response additional analysis at wind turbine level enhances optimisation potential at gearbox level3. Research project ALARM simulation of noise sources, transfer paths and radiation experimental analyses on test rigs and in the field to build up know how and verify modelsZF Wind Power23Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012 7 industrial partners cooperating on ‘expert design system’ to avoid tonality issues in the field focus on Repower 3.2M114 wind turbine development:
ZF Wind Power24PresentationTitle,Dategearboxes with respect to noiseDesignof windturbine11/12/2012 ZF Friedrichshafen AG, 2012Thank you very much for your attention!
Measuring wind turbine gearboxesSuggestion for an efficient measurement strategy for WT gearboxes1. Wind turbine should comply with (local)acoustic regulationsGear mesh1Measurements in prototype phaseCorrelation between test rig and in-the-fieldGearbox housing2Wind turbine components34Test rig measurements in serial productionIdentify quality deviationsZF Wind Power25Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 20122. Gearbox should meet general qualityrequirements
References[1] Dr. Benoit Petitjean, Dr. Roger Drobietz, Dr. Kevin Kinzie, Wind Turbine Blade NoiseMitigation Technologies, in Fourth International Meeting on Wind Turbine Noise,RomeItaly 12-14 April 2011[2] Rakesh C. Ramachandran, Hirenkumar Patel and Ganesh Raman, Localization of windturbine noise sources using a compact microphone array with advancedbeamforming algorithms, in Berlin Beamforming Conference 2012ZF Wind Power26Design of wind turbine gearboxes with respect to noise11/12/2012 ZF Friedrichshafen AG, 2012[3] IEC61400-11 Ed.3: Wind turbines - Part 11: Acoustic noise measurement techniques
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ZF Wind Power 26 Design of wind turbine gearboxes with respect to noise 11/12/2012 [1] Dr. Benoit Petitjean, Dr. Roger Drobietz, Dr. Kevin Kinzie, Wind Turbine Blade Noise Mitigation Technologies, in Fourth International Meeting on Wind Turbine Noise,Rome
2. Brief Wind Turbine Description The wind turbine under study belongs to an onshore wind park located in Poland. It has a power of 2300 kW and a diameter of 101 m. Figure 1 shows its major components. A summary of the wind turbine technical specifications is Fig. 1. Main components of the wind turbine [16]. given in Table I. The wind farm .
red wind/red wind xlr h50 t-15m l 35 mm red wind/red wind xlr h80 t-16m l 65 mm red wind/red wind xlr h105 t-17m l 90 mm racing speed xlr h80 t-19m l 74 mm profile rim female valve adapter (option) red wind/red wind xlr h50 t-15f l 37 mm red wind/red wind xlr h80 t-16f l 67 mm red wind/red wind xlr h105 t-17f l 92 mm racing speed .
Jan 31, 2013 · blades. Horizontal-axis wind turbine was developed a high wind speed location. A hybrid composite structure using glass and carbon fiber was created a light-weight design Structural analysis for wind turbine blades is investigated with the aim of improving their design, minimizing weight. The wind turbine blade was modelled by using Catia.
Advances in Wind Turbine Aerodynamics . Blank 2 Outline Introduction Wind turbine design process Wind turbine aerodynamics Airfoil and blade design . Propeller Helicopter wind turbines Each annular ring is independent Does not account for wake expansion Applicable only to straight blades .
Wind energy is generated by a wind turbine which converts the kinetic energy of wind into electrical energy. The system mainly depends on speed of the wind to enhance the performance the turbine in mounted on a tall tower. Wind energy conversion system has a wind turbine, permanent magnet synchronous generator and AC-AC converter. As wind .
the valve position in a control room. The valve position can be read from a position indicator on the device. Part-turn Gearboxes Worm gearboxes GS 40.3 – GS 250.3 GS 160 – GS 500 Torques up to 265,000 ft lb Reduction ratios from 39:1 to 3328:1 The worm gearboxes can also be supplied with-out end stops for multi-turn applications. Valve .
in Wind Turbine Main Shafts and Gearboxes TDI Design and Predictive Modeling Bearing design criteria includes a 20-year or more fatigue life prediction, dynamic stress limits of 1650 MPa, extreme stress limits of 4000 MPa, and capability to handle a high degree of static and operating misalignment.
ACCOUNTING 0452/22 Paper 2 October/November 2018 1 hour 45 minutes Candidates answer on the Question Paper. No Additional Materials are required. READ THESE INSTRUCTIONS FIRST Write your Centre number, candidate number and name on all the work you hand in. Write in dark blue or black pen. You may use an HB pencil for any diagrams or graphs. Do not use staples, paper clips, glue or correction .
