NATIONAL RENEWABLE ENERGY CENTER
Independent Test Facilities
for Large Gearboxes
EWEA OFFSHORE – 11th of March, 2015 Copenhagen
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CENER Contribution to WTGS Development
Blade Testing
Systems Testing
Development V-Cycle
Design-Testing Feedback
Effective Testing of Large Gearboxes
CENER CONTRIBUTION TO WTGS DEVELOPMENT
Wind Turbine Test Laboratory
BLADE TESTING
BLADE TESTING
IEC TS-61400-23 standard
Up to 75 m blade lengths / Sections of up to 100m blades
Static Tests
• Mass, COG, moments of inertia
• Stiffness bending/torsion
• Ultimate strength
Fatigue Tests
• Modal analysis
• Biaxial + Multipoint
• Hydraulic actuators UREX & GREX
SYSTEMS TESTING
SYSTEMS TESTING
Power Train test bench
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Test of WTG power train up to 8MW
Functional tests on mechanical parts
- Load test of brake/coupling at high speed haft HSS
Compressed life test
bearings in the main shaft (LSS)
gears and bearings in the gearbox
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Generator test bench
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Functional/accelerated test of generator and power electronics
Electrical transient simulation (LVRT Grid Code requirements)
Functional tests, vibration, acoustic noise, heating, etc.
Overspeed tests and transients surges
SYSTEMS TESTING
Nacelle test bench
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functional, emergency stop, overspeed, environmental, etc.
electrical transient simulation “Voltage dips”
EMC and accoustic test
Reactive power measuring
Nacelle assembly
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WTG erecting and nacelle setup procedures
Use of auxiliary assembly cranes
Simulation of maintenance exercises, including major corrections
Staff training in the assembly and maintenance of WTG
Training in evacuation and security operations in WTG
NEW
INDEPENDENT
LARGE GEARBOX
MARKET TEST BENCHES
DEVELOPMENT “V-CYCLE”
DESIGN-TESTING FEEDBACK
DETAILED DRIVE TRAIN LOAD ANALYSIS
– Multibody approach
– Flexible bodies (housings, shafts, etc.)
– Integration in overall WT model
(including detailed aerodynamics)
COMPONENT STRUCTURAL ANALYSIS
– Gears, bearings, mainframe, hub, etc.
– Static / fatigue
DESIGN OF EXPERIMENTS
– Synthetic Test Cycles
– Robustness & Fatigue Tests
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EFFECTIVE TESTING OF LARGE GEARBOXES
Javier San Miguel Armendáriz
Strategy & Business Development
Manager
[email protected]
Tel: +34 648272625
www.cener.com