Romax: state-of-the-art drivetrain - EWEA 2013 by Yann Rageul
1. CONFIDENTIAL
@ Copyright 2012
Next generation hybrid drivetrain
platform for minimum Cost of Energy
EWEA 2013 Conference:
Romax ButterflyTM Drivetrain
2013
Yann Rageul – Head of European Sales and Strategic Consulting
2. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
3. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Business Facts
Selected clients from the wind industry Selected clients from other industries:
Automotive, Off-highway, Marine, Aerospace …
• Established in 1989
• Private Equity Fidelity (1.5Trillion USD)
• Technology-led solutions provider
• Active across a range of sectors:
• Wind energy, Automotive, Off-highway, Marine, Aerospace…
• Head office in Nottingham, UK
• Global offices in the US, Germany, France, Japan, Korea, China and India
• 200 employees globally, with 120 in UK
4. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax track record for drivetrain & gearbox design:
Beautiful Engineered based on proven track record
2005
• Over 29 drivetrain and gearbox designs
• 1.7GW of Romax designed gearboxes shipped as Q3 2012
2007
First Romax drivetrain* integrated solution
*[including main bearing, housing, gearbox and high
speed shaft to generator]
2MW
4MW
6MW
2009 2011
8MW
5. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
6. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Conventional High Speed
Geared Drivetrain
Medium Speed Geared
Drivetrain
Direct Drive
1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW
Onshore vs. offshore: Medium vs. High Speed
• Three most dominant drivetrain technologies in the market:
Gamesa
Vestas
Doosan
Siemens
Vestas
Doosan Minyang
WinWind
Siemens
Siemens
Nordex
Alstom
REpower
Sinovel
Minyang
Gamesa
REpower
BARD
XEMC
Darwind
Areva
Sinovel
GE
Sinovel Sh.Electric
Enercon
Enercon
Samsung
7. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Medium Speed (2 stage)
Offshore Drivetrain
Annual Cost of Energy
Generator
capex
16%
Generator
O&M
37%
Gearbox
capex
14%
Gearbox
O&M
33%
Annual Cost of Energy
Direct Drive Medium Speed
(1 stage)
Medium Speed
(2 stage)
High Speed
Cost
High Speed
Offshore Drivetrain
Annual Cost of Energy
Gearbox
O&M
59%
Gearbox
capex
11%
Generator
O&M
24%
Generator
capex
6%
6.xMW Drivetrain CoE Model: OPEX + CAPEX
Off-shore Results (Romax R&D)
8. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
1. Romax brief overview
2. Cost of energy of various drivetrain
configurations
3. Romax Butterfly 6 to 10MW hybrid
medium speed drivetrain
9. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
The Butterfly™ drivetrain platform benefits
Increased reliability
Supply chain flexibility
Reduced time to market
Flexible O&M strategy
The lowest cost of energy drivetrain solution
Offshore applications 5MW-10MW
Onshore applications 3MW-4MW
Rotor assembly
module
Gearbox assembly
module
Generator assembly
module
Patent pending
“pure” torque
coupling
10. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: Sensitivity study
analysis
Butterfly™ - The effect of the stiffness of the rotor shaft to gearbox
connection to the performance of the gearbox bearings & gears is assed in
RomaxWindTM software – Only GL certified software for gear calculation
which enable parametric studies (Design of Experiment) for optimisation
RomaxWindTM
drivetrain
model
Apply
worst case
system
loads
Apply
worst case
assembly
tolerances
Concept
optimisation in
RomaxWindTM
Select the best
design
-400 -200 0 200 400 600
Stage 1 Annulus gear -> Stage 1 Planet gear 1
Stage 1 Annulus gear -> Stage 1 Planet gear 2
Stage 1 Annulus gear -> Stage 1 Planet gear 3
Stage 1 Annulus gear -> Stage 1 Planet gear 4
Stage 1 Annulus gear -> Stage 1 Planet gear 5
Stage 1 Sun gear -> Stage 1 Planet gear 1
Stage 1 Sun gear -> Stage 1 Planet gear 2
Stage 1 Sun gear -> Stage 1 Planet gear 3
Stage 1 Sun gear -> Stage 1 Planet gear 4
Stage 1 Sun gear -> Stage 1 Planet gear 5
Stage 2 Annulus gear -> Stage 2 Planet gear 1
Stage 2 Annulus gear -> Stage 2 Planet gear 2
Stage 2 Annulus gear -> Stage 2 Planet gear 3
Stage 2 Sun gear -> Stage 2 Planet gear 1
Stage 2 Sun gear -> Stage 2 Planet gear 2
Stage 2 Sun gear -> Stage 2 Planet gear 3
um
Gear mesh misalignment- 3mm radial eccentricity
0 1000 2000 3000 4000 5000 6000
Main UW
Main DW
S1 Carrier UW
S1 Carrier DW
S2 Carrier UW
S2 Carrier DW
Brg Force Magnitude (kN)
Brgs
Bearing force magnitude - 3mm radial eccentricity
Increased Reliability: Our Approach
Reduced time to market
11. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Removing risks...
• Failure data indicates 64% of gearbox
failures are typically due to high speed
shaft gear & bearing failures
1st stage
0.028
18%
2nd stage
0.028
18%
3rd stage
0.103
64%
Failure rate of 3MW PL-PL-PA gearbox
(failures/turbine/year)
Improved assembly alignment
• Butterfly™ drivetrain
3 modules aligned using housing connections
No adjustment required in nacelle
Potential for high misalignment
• Conventional modular layout
o Mounting and bedplate flexibility can cause high
misalignment between the gearbox & generator
o Generator can be incorrectly positioned or sink over
time as the rubber mounts degrade it also moves due
to dynamic loading
Can lead to gearbox & generator bearing failures
High speed gear stage eliminated
Increased Reliability: Reducing potential risks
Source: Romax data from failure investigation
12. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Butterfly™ - Rotor bending
moments transferred through
main bearing housing, directly
into the main frame
Off axis rotor bending loads can
results in early failure of gearbox
gears & bearings (even in 2 point
mount rotor shafts!)
Romax ButterflyTM: Gearbox & generator
protected from rotor bending loads
Butterfly™ - Unique Romax designed rotor shaft to gearbox
connection to minimise the bending load transferred from
the rotor shaft into the gearbox (patent pending)
Increased Reliability: “Pure torque”
Deflections of the structure under extreme
load investigation in RomaxWindTM
System modelled in RomaxWindTM
13. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: Generator weight not
supported by gearbox bearings
Butterfly™ - Generator mass is
supported through the gearbox
housing by the mainframe – not
by the gearbox bearings
Butterfly™ - Layout is
insensitive to
generator mass
Gearbox &
generator mass
supported by
rotor shaft
Gearbox &
generator mass
supported by
mainframe
Torque arm Generator
Converter
Gearbox
Generator mass increases
the loads on the gearbox
bearings
Torque arm high risk stress
area
Rotor shaft to gearbox
connection risk due to
additional generator weight
Increased Reliability: Structural analysis
14. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Main bearing concept 2 tapered roller bearings
(TRB) rotor bearings
Double Row TRB ‘moment’
rotor bearing
Support structure mass
(rotor shaft, rotor bearing housing, main frame)
Similar Similar
Total cost (support structure + bearings) Baseline +9%
Scalability to 10MW Yes, study complete Very limited manufacturing
& availability >6MW
Drivetrain length (6MW) 8.3m 7.3m
Maintenance/inspection access (rotor
bearings, gearbox/rotor shaft connection, gearbox
stage 1)
Better Worse
Ease of setting bearing preload Worse Better
Sufficient bearing structural support Easier More difficult
Romax ButterflyTM: Multiple
drivetrain configuration options
Supply chain flexibility
Flexible O&M Strategy
15. CONFIDENTIAL
@ Copyright 2012SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE
Romax ButterflyTM: platform key features
Innovative lubrication
system
Analysis of drivetrain
dynamics and system-
level behaviour
Designed for Romax
InSight – integrated
health management
system
Advanced Romax gearbox
design with patented
technology
Simple drivetrain
assembly & alignment
Design scalable to 10MW
Multiple suppliers
available for all
components & sub
systems
Fast replacement of all
serviceable items
3 self contained ‘modules’
for ease of assembly &
replacement
Complete drivetrain ‘tube’ can be lifted
into position as one assembly
Supply chain flexibility
Reduced time to market
Increased Reliability
Flexible O&M Strategy
16. CONFIDENTIAL
@ Copyright 2012
ButterflyTM drivetrain platform
beautifully engineered
Contact details:
Yann Rageul – Head of European Sales & Strategic Consulting
Mobile: +44 (0) 7581 194679
E-mail: yann.rageul@romaxtech.com