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Technological Advances in Hydraulic Drivetrains for Wind Turbines

Technological Advances in Hydraulic Drivetrains for Wind Turbines. CTO Knud Erik Thomsen EWEA 2012 Annual Event, Copenhagen Conference session: Technology for drivetrains Track: Hardware technology Tuesday, 17 April 2012, 16:00 - 17:30. Contents. Company introduction

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Technological Advances in Hydraulic Drivetrains for Wind Turbines

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  1. Technological Advances in Hydraulic Drivetrains for Wind Turbines CTO Knud Erik Thomsen EWEA 2012 Annual Event, Copenhagen Conference session: Technology for drivetrains Track: Hardware technology Tuesday, 17 April 2012, 16:00 - 17:30

  2. Contents • Company introduction • Technology trends as basis for developing hydraulic transmission • ChapDrive compact and integrated variable hydraulic drivetrain • How can ChapDrive avoid using frequency converters? • Concept and functionality • Measurements and model verification • Technical benefits impact financial performance • Question and answer ChapDrive AS - proprietary

  3. Company introduction • 20 employees in Norway, Denmark, UK and China supported by the investors: - NorthZoneVentures, Statoil Venture, Hafslund Venture, Viking Venture and Investinor From left: Headquarter in Trondheim, subsiduary in Denmark, workshop and test site in Trondheim 3+ MW integrated drive train 225 kW test turbine 50 kW test bench 300 kW test bench 900 kW test turbine 5+ MW conceptual design 2005 2007 2009 2011 – 2013 ChapDrive AS - proprietary

  4. Management with broad experience within hydraulics and wind power Jens Anders Jensen CEO Background CSO in Vestas Chairman of the Danish Wind Industry 10 years experience in the wind industry Knud Erik Thomsen CTO Background 15 years in R&D at Vestas Head of mechanical and electrical engineering ÅsmundFuruseth VP & Co-founder Background Former CEO Project manager Technology Transfer Office NTNU Paul Chang Marketing Director Background MD in Hägglunds Drives China and R&D Asia Pacific Center. 25 years experience in the hydraulic industry Peter Chapple Senior Scientist & Co-founder Background Professor in hydraulics, Technical director Staffa Products, Industry consultant Thor Schjetne Project Director Background Offshore Oil and gas engineering at Reinertsen Board of directors with industrial and business development expertise Pål Engebretsen – Chairman (Former CEO Bergen Group and Chairman of Scanwind) Ståle Myhre (Statoil Venture) Joachim Cock (Hafslund Venture) Torben Bjerre Madsen (Former deputy-CEO in Vestas) Tellef Thorleifsson (NorthZone Ventures) • Jostein Vik • (Viking Venture) • Steinar Fossen • (Investinor) ChapDrive AS - proprietary

  5. Technology trends as basis for developing hydraulic transmission Market development for wind power • Market trends: • Turbine sizes are increasing • Reliability must be improved • Cost of energy must come down • Challenges facing the wind industry: • Top weight reduction is increasingly critical • Mechanical gearbox and frequency converter are statistically unreliable • Sourcing and cost of permanent magnets • Hydraulic transmissions are generally robust and will reduce top weight for wind turbines • High efficiency hydraulic technology enables competitive efficiency • New technology is driven by the industry for mobile hydraulic systems TWh annual wind power production Turbine size development 160 112 Rotor diameter (m) 15 Year ‘85 ‘89 ‘93 ‘97 ‘01 ‘05 ? MW 0.5 8/10 0.3 4.5 0.05 1.6 ChapDrive AS - proprietary

  6. ChapDrive compact and integrated variable hydraulic drivetrain Pump Motor Electrically Excited Synchronous Generator, EESG Control System Perfection via Simplicity ChapDrive AS - proprietary

  7. ChapDrive compact and integrated variable hydraulic drivetrain Fewer critical components: • No mechanical gearbox - causing high maintenance costs on today’s wind turbines • No need for permanent magnets (PM) - high cost rare earth materials • No frequency converter - causing the highest failure rates and most down time on today’s wind turbines • No transformer ChapDrive AS - proprietary

  8. How can ChapDrive avoid using frequency converters? Grid Grid 10 kV 10 kV Double fed induction generator Gearbox Frequency converter Transformer EE synchronous generator Hydraulic transmission ChapDrive AS - proprietary

  9. How can ChapDrive avoid using frequency converters? Grid Grid 10 kV 10 kV Double fed induction generator Gearbox Frequency converter Transformer Speed control EE synchronous generator Hydraulic transmission Speed control ChapDrive AS - proprietary

  10. How can ChapDrive avoid using frequency converters? Gearbox Double fed induction generator Gearbox (Fixed, e.g. 1 : 100 @ 3 MW) Transformer Frequency converter Grid Grid 10 kV 10 kV Direct drive Direct drive PM generator (Fixed 1 : 1) Frequency converter Transformer Speed control Grid 10 kV ChapDrive EE synchronous generator Hydraulic transmission (1 : variable) Speed control ChapDrive AS - proprietary

  11. Concept and functionality Result: • High energy yield from the wind • Low loads on the turbine structure and the turbine components Transmission ratio: Variable 1:100 – 1:300 for a 3 MW wind turbine 11 ChapDrive AS - proprietary

  12. Concept and functionality ChapDrive Direct Drive Gearbox 12 ChapDrive AS - proprietary

  13. Concept and functionality • ChapDrive core technology • Control system for hydraulic motor, pitch system and generator (patents grated) • Hydraulic transmission for wind turbines (patents granted) • Design and integration of hydraulic drive train solutions in wind turbines(patent pending) • Products • The ChapDrive control system is essential for control of the vital features of a wind turbine with a hydraulic drive train solution (patents granted) • Prototype has been verified in the ChapDrive wind turbines • The ChapDrive Integrated Hydraulic Transmission is essential for low top weight and robustness (patent pending) • Design under development ChapDrive control system Pitchcontrol (blades) Excitationcontrol (generator) Displacementcontrol (hydraulic motor with digital valves) ChapDrive integrated hydraulic transmission ChapDrive AS - proprietary

  14. Measurements and model verification ChapDrive Control Software Dynamic models Model verification Comparison Simulation results Model tuning Measurements ChapDrive Control System Wind turbine ChapDrive AS - proprietary

  15. Measurements and model verification • 10 minutes mean values are shown from the test wind turbine (ChapDrive 1 - 225 kW) for a period of 5 month • Optimal rotor speed at all time ensuring maximum energy yield from the wind • Generator speed is always constant ChapDrive AS - proprietary

  16. Measurements and model verification • Method • Combined and optimised control of: • Pitch • Displacement (transmission ratio) • Excitation • Results • Constant power above rated wind speed • Power and torque fluctuations eliminated due to fast displacement control • Full control over reactive power ChapDrive AS - proprietary

  17. Technical benefits impact financial performance Top weight scaling with different drive trains Electromagnetic DD Traditional gearbox Permanent magnet DD ChapDrive hydraulic Drive Top head mass (ton) Nominal power (MW) • Robust light-weight variable hydraulic drivetrain with an electrically excited synchronous generator directly connected to the grid • This means: • No mechanical gearbox • No need for permanent magnets • No frequency converter • No transformer CAPEX reduced with up to 20% OPEX reduced with up to 15% Cost of Energy reduced with up to 20% AEP is up to 2% lower than other technologies ChapDrive AS - proprietary

  18. Q&AThank you for your attention! Professor Brochs gt 2 Trondheim 7030 Norway www.chapdrive.com

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