Wind Turbine Gear Drive-Trains Based on New Materials and Novel Gear Systems Conference, EWEC 2009 Marseille 18th March 2009 - PowerPoint PPT Presentation

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Wind Turbine Gear Drive-Trains Based on New Materials and Novel Gear Systems Conference, EWEC 2009 Marseille 18th March 2009

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Title: Wind Turbine Gear Drive-Trains Based on New Materials and Novel Gear Systems Conference, EWEC 2009 Marseille 18th March 2009


1
Wind Turbine Gear Drive-Trains Based on New
Materials and Novel Gear SystemsConference,
EWEC 2009Marseille18th March 2009
Alessandro Bozzolo
2
Maintenance problems related to wind turbine
gearboxes
  • Maintenance of wind turbines is characterized by
  • Difficulties related to the remote location where
    wind turbine are frequently installed
  • Difficulties in reaching the nacelle

http//mrgreenbiz.wordpress.com
http//www.tdhvisions.com
3
The need of more efficient gearboxes
  • Gear wear, if not caught in time, can cause
    serious collateral damage affecting the other
    parts of the drive-train and the generator
  • Gearbox failures account for the largest amount
    of downtime, maintenance and lost production
    capacity

http//windtechireland.com
4
X-GEAR Project
  • Within this framework, the aim of the X-GEAR
    Project is the development of novel technologies
    and materials for a new generation of wind
    turbine gearboxes

X-GEAR is a Collective Research Project
(COLL-CT-2006 030433) financed by the European
Commission
5
Partnership
Transnational consortium partners 7 Industrial
Association Groupings (IAGs), 11 Small Medium
Enterprises (SMEs), 4 Research and Technology
Development Performers RTDs
(Co-ordinator)
6
Participants Geographic distribution
7
The enabling technologies
  • Development of novel materials (new air-hardening
    steels, advanced sintered steels and UDDP
    nanopowders)
  • Development of novel coatings and surface
    treatments
  • Design Tool Development (database of materials,
    interactive guidelines, gear design procedures,
    e-learning and e-training module, etc.)
  • Novel Gears for wind turbine applications (novel
    steels / coatings, manufacturing routes, design
    aspects)

8
X-GEAR Project Structures
Material Development
Novel Surface Treatments
Novel Gear Design and Manufacturing
Production of Demonstrators
Testing of Novel Gears
Development of Design Tools
Exploitation and Dissemination Activities
Training Activities
9
Material Development Air-Hardening Steels
  • Air-Hardening Steel steel containing sufficient
    carbon and other alloying elements to fully
    harden to martensite during cooling in air
  • Two steels are being analysed OVATEC 277L
    (case-hardening steel) and OVATEC 677L (through
    hardening steel)

www.ovako.com
10
Material Development Why Air-Hardening Steels?
  • Reduce distortion of heat treated components
    after quenching
  • Minimize the number of production steps
  • Additionally the use of quenching medias such as
    oil and salt can be avoided, which improves both
    safety and environment

http//www.rfglonline.com
Reduce the total cost of production
11
Material Development Experimental tests on new
air-hardening steels
  • Preliminary testing campaign have been performed
    for characterising the novel air-hardening
    steels
  • Rotating Bending Fatigue (RBF) tests
  • Contact Fatigue (CF) tests

12
Material Development Ultra-Dispersed Diamond
Powders (UDDP)
  • Ultra-Dispersed Diamond Powders (UDDP) are
    synthetic diamonds obtained with the use of
    explosion energy (Controlled Detonation Synthesis
    - CDS)
  • Enhanced properties expected by the use of UDDP
    on gears are
  • wear resistance
  • micro - hardness
  • corrosion resistance

13
Novel Surface Treatments
  • Novel surface treatments and coatings have been
    analysed for the improvement of
    friction/lubrication aspects and wear gear
    resistance

Tested Coatings
Ni UDDP (conical explosives)
Ni UDDP (cylindrical explosives)
TiCrC
DLC
TiN
TiC-Cr3C2-Ni-UDDP
TiC-TaC-Ni-UDDP
MoS2
WC/C
CrN WC/C
Ni UDDP
14
Novel Surface TreatmentsThermal Spraying
Processes
  • Two Thermal Spraying Processes have been used for
    testing several coatings (WC Co, Mo, etc.)
  • HVOF (High Velocity Oxygen Fuel)
  • Detonation Spraying Technique

Mo Coating
HVOF Process
15
Novel Surface TreatmentsPVD Processes
  • Two Physical Vapour Deposition (PVD) processes
    have been used for testing several coatings
    (TiCrC, TiN, TiCrN, etc.)
  • Arc Vapour Deposition
  • Magnetron Sputtering

PVD Magnetron Sputtering
16
Novel Surface TreatmentsSurface Finish
Enhancement Process
  • C.A.S.E.sm (Chemically Assisted Surface
    Engineering) process consists of a combination of
    shot peening followed by isotropic finishing
  • The isotropic finishing removes the asperities
    left from shot peening via vibratory polishing
    techniques while maintaining the integrity of the
    residual compressive layer
  • Tests perform on gears made of OVATEC 277 and
    OVATEC 677 in superfinished conditions have shown
    an increase of bending fatigue strength of 48
    and 71 respectively compared to hobbed conditions

17
Novel Gear Design and Manufacturing
  • Design strategies based on conventional
    manufacturing methods do not include any
    operations that are not currently used in wind
    turbine industries
  • Improved efficiency to 99.612 achieved following
    standard gear design practises no additional
    costs associated with manufacture of low loss
    gear designs proposed in X-GEAR Project

80µm tip relief, 10µm crowning (efficiency
99.557)
120µm tip relief, 10µm crowning (efficiency
99.612)
18
Testing of Novel Wind Turbine Gears
Test Rigs (Wind Energy Demonstrators)
Bending Fatigue Test Rig
19
Development of Design Tool
http//www.x-gear.org
  • Home
  • Public Documents
  • Project Documents
  • WP Description
  • X-gear Tools

20
Development of Design ToolX-GEAR Material
Database
21
Development of Design ToolX-GEAR E-Learning Tool
22
Development of Design ToolX-GEAR Design Tool
23
X-Gear Approach
The innovative approach of X-Gear project is to
combine novel materials, novel surface
treatments, novel manufacturing process and
design in order to develop a new generation of
gears for wind turbine applications
New Materials
Novel Surface Treatments Coatings
Design Software Tool
24
Contacts
DAppolonia S.p.A. Via S. Nazaro, 19 16145
Genova Tel. (39) 010 3628148 Fax. (39) 010
3621078 X-Gear website www.x-gear.org E-mail
alessandro.bozzolo_at_dappolonia.it
25
Thank you for your attention
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