Recommandé
Contenu connexe
Similaire à Orbital2 Flexible Pin Gearbox Overview
Similaire à Orbital2 Flexible Pin Gearbox Overview (20)
Dernier
Dernier (20)
Orbital2 Flexible Pin Gearbox Overview
- 1. ORBITAL 2 Flexible Pins – Driving Renewables An Overview Of Orbital2 ORBITAL 2 1 Commercially Confidential
- 2. ORBITAL 2 Flexible Pins – Driving Renewables Driven by the high failure rate experienced on current wind turbine gearboxes,(>40%) and given such failure rates are not sustainable in capital machinery, certainly for “off shore” turbines Ray J Hicks MBE - & - Dr Frank Cunliffe who have an association spanning over 40 years decided to formed ORBITAL2 in September 2003 to exploit the long history of the novel Ray Hicks flexible pin epicyclic gear designs and their application to Renewable Energy Turbines 01/07/2010 2 ORBITAL 2 Commercially Confidential
- 3. ORBITAL 2 Flexible Pins – Driving Renewables R J Hicks MBE – Inventor of Flexible Pin • Started working on Aerospace epicyclic gears in 1954 • Invented the “Hicks” flexible pin in 1964. • Set up Compact Orbital Gears (COG) to design & manufacture epicyclic gears for a variety of applications • Applied the “Hicks” design principles to wind turbine gears in the UK in the 1980’s. (Orkney 3MW torque controlling features 1982) • Formed ORBITAL2, to carry forward the application of “Hicks” epicyclic gear designs. • Co-Founder of Orbital2 • Consultant to Orbital2 01/07/2010 3 ORBITAL 2 Commercially Confidential
- 4. ORBITAL 2 Flexible Pins – Driving Renewables Dr Frank Cunliffe – Managing Director • 1st Class Hons Mechanical Engineering / Student Apprentice Mirlees Blackstone Diesel engines, Fellow Inst Mech, Eng C Eng • Research PhD Cambridge, epicyclic gear dynamics • Senior Engineer COG, R J Hicks • Chief Design Development Engineer, Lucas CAV, Diesel systems • Technical Director, Cable Belt, long distance conveyers • Engineering Director, Massey Ferguson Tractors • Managing Director, Albion Automotive, commercial vehicle axles • Co-Founder of ORBITAL2, to carry forward the application of “Hicks flexible pin” epicyclic gear designs. 01/07/2010 4 ORBITAL 2 Commercially Confidential
- 5. ORBITAL 2 Flexible Pins – Driving Renewables Prof R Parker - none executive member of the ORBITAL2 board. Professor Parker is a world leading expert on dynamics Professor and Associate Dean for Education at the University of Michigan-Shanghai Jiaotong University Joint Institute. / / / / / Antonin Ruzicka – none executive member of the ORBITAL2 board. Antonin Ruzicka is the CEO of WIKOV INDUSTRY a Czech gearbox company and manufacturing partner of ORBITAL2. 01/07/2010 5 ORBITAL 2 Commercially Confidential
- 6. ORBITAL 2 Flexible Pins – Driving Renewables ORBITAL2 UK Innovation, Marketing, Project management Technical Centre Design Layout 5 engineers Software Dynamic/Specialist Czech ORBITAL2 Solid Edge ST 3D CAD Prague & Hronov Analysis KISSsoft Design / Manufacturing Prof. Parker Drawings, MASTA University of Supervision of assembly ANSYS V11 Michigan-Shanghai test and development Professional NLS Jiaotong University Joint 15 Design engineers Institute nCode DESIGNLIFE ORBITAL 2 Commercially Confidential
- 7. ORBITAL 2 Flexible Pins – Driving Renewables Prof Parker super analysis • TNF • Phasing • Micro Geometry 01/07/2010 7 ORBITAL 2 Commercially Confidential
- 8. ORBITAL 2 Flexible Pins – Driving Renewables 1987 ORKNEY 3 MW Original flexible pin wind turbine gearbox. • Flexible pins with load limiting. • Torque split on input. • Torque limiting on input. • Gear case free from deflection. • Integrated planet wheel taper bearings. • Synchronous generator. ORBITAL 2 Commercially Confidential
- 9. 8 planet input train from a 20 ORBITAL 2 year old wind turbine gearbox with 10+ years of operation Flexible Pins – Driving Renewables 01/07/2010 9 Commercially Confidential ORBITAL 2 ORBITAL2 Ltd Commercially Confidential
- 10. ORBITAL 2 Flexible Pins – Driving Renewables Why the failures 1. Load distribution across teeth and between planets 2. Rotor loads imposed on gear case 3. Power input not controlled 4. Absolute gear rating ORBITAL 2 Commercially Confidential
- 11. ORBITAL 2 Flexible Pins – Driving Renewables Hicks - Flexible Pin Planet Carrier ORBITAL 2 Commercially Confidential
- 12. ORBITAL 2 Flexible Pins – Driving Renewables Flexible Pin provides:- • Multi-planet applications. • Equal loads between planet wheels (K < 1.1 for eight planets agreed GL) • Uniform load across face width of teeth sun/planet & planet / annulus contacts (K < 1.35 agreed GL) • Uniform loads on planet wheel bearings • Uniform load under overload and shock load conditions • Dual rate Flexible pin Over Load Stop Protects from over stress under dynamic overload conditions. • Taper bearings with outer races incorporated in the planet wheel bore provides maximum planet bearing capacity. 01/07/2010 12 ORBITAL 2 Commercially Confidential
- 13. ORBITAL 2 Flexible Pins – Driving Renewables Multiplanet – 4 or greater – flexible pin Full load torque: Deflection of pin: 1,2 mm Force in pin: 367,2 kNm Force in tooth mesh: 202,6 kNm Stage II – MS 3 Manufacturing error in pin position: 0,1 mm Incremental force in tooth mesh: 16,9 kNm Incremental load is 8% ORBITAL 2 Commercially Confidential
- 14. ORBITAL 2 Flexible Pins – Driving Renewables Multi Planet Epicyclics 3 planets statically determinant 3>Statically in determinant ORBITAL 2 Commercially Confidential
- 15. ORBITAL 2 Flexible Pins – Driving Renewables W2000spg 8 planet wheel stage ORBITAL 2 Commercially Confidential
- 16. ORBITAL 2 Flexible Pins – Driving Renewables 2MW variable ratio back to back mechanical load test 01/07/2010 16 ORBITAL 2 Commercially Confidential
- 17. ORBITAL 2 Flexible Pins – Driving Renewables Load balance between planets on the four planet train 01/07/2010 17 ORBITAL 2 Commercially Confidential
- 18. ORBITAL 2 Flexible Pins – Driving Renewables Load distribution across the face width, helical gears. Load sharing between planets with in 3% Load sharing across the face in the centre 01/07/2010 18 ORBITAL 2 Commercially Confidential
- 19. ORBITAL 2 Flexible Pins – Driving Renewables MINI-MASS Flexible Pin Gearboxes for wind turbines •low mass high - reliability wind turbine drive trains with :-. • Flex pins dual rate stiffness • uniform tooth / planet load - multi planet • Torque split - single plane of reaction - gear train. • Gear case free from rotor loads and deflections. • Variable ratio drive train for Dynamic control of input torque and simple high voltage electrics. ORBITAL 2 Commercially Confidential PHOTO – 2MW SPG
- 20. ORBITAL 2 Flexible Pins – Driving Renewables Flexible pin-Multi planet-Split torque single reaction load free gear case 3MW- weight 22 tons 01/07/2010 ORBITAL 2 20 Commercially Confidential
- 21. ORBITAL 2 Flexible Pins – Driving Renewables ORBITAL2 - Mission Statement The supply of market leading innovative gearbox designs for WIND and TIDAL Turbines that offer low weight and high reliability via ORBITAL2 flexible pin, multi planet epicyclics. ORBITAL2 – Deliverables • INOVATIVE Licensed Design gearbox solution with a full set of manufacturing drawings • Prototype build and test supervision • GL or others approval documentation • Supervision and Training of gearbox manufacturer in the production of the licensed design • Ongoing audit of gearbox build quality by licensee • In service improvements of the gearbox via updates of the manufacturing drawings A Full design and engineering service from concept to end of life ORBITAL 2 Commercially Confidential
- 22. ORBITAL 2 Flexible Pins – Driving Renewables 2MW SPG IN ACTION Documentation Control ORBITAL2 gearboxes can be offered either as Licensed designs for third party manufacture or completely finished gearboxes from our manufacturing partner, WIKOV CZ. ORBITAL2 main design office is adjacent to the WIKOV factory to facilitate control and supervision of prototype gearbox build and test by WIKOV. Engineers fully integrated to support the product from the spec, through production, to ORBITAL 2 ongoing maintenance support. Commercially Confidential
- 23. ORBITAL 2 Flexible Pins – Driving Renewables Examples of Orbital2>>>>>> MS3 – Stage I ORBITAL 2 Commercially Confidential
- 24. ORBITAL 2 Flexible Pins – Driving Renewables ORBITAL2 – gearbox history / projects 1986 – First European 3MW wind turbine and the first flexible pin wind turbine gearbox. UK 1990’s – 350 kW production wind turbine gearboxes. (100 plus), UK 2002 – World’s first production (100 Turbines) variable ratio wind turbine 650kW. NZ 2004 – 3.4 MW variable ratio prototype wind turbine. Norway 2006 – 1.3 MW the world’s first production tidal turbine. UK 2007 – 2 MW variable ratio prototype wind turbine. CZ 2008 – 500 kW tidal turbine prototype. UK 2008 – 3 MW off shore wind turbine production gearboxes. Korea DOOSAN 2009 – 3 MW off shore wind turbine production gearboxes. China SINOVEL (160 ) 2010 – 1.6 MW wind turbine production gearboxes. 2010 – 3.6 MW Wind Turbine China SEWIND (20) 2010 – 1.5 MW Wind Turbine China 2010 – 2 MW Rotor Turbine licence to China 2010 – 2 MW Rotor Turbine – India 2011 – 5 MW Rotor Turbine – China ORBITAL 2 24 Commercially Confidential PHOTO- 2MW SPG IN ACTION
- 25. ORBITAL 2 Flexible Pins – Driving Renewables Wind Flow (NZ) 2002 650 KW Wind turbine for high wind states (16m/s ) Gearbox designed by Hicks and manufactured in NZ. With flexible pins, torque limiting and synchronous generation, ORBITAL 2 Commercially Confidential
- 26. ORBITAL 2 3.4 MW SCANWIND turbine converted to a VR gear drive - 2004 Flexible Pins – Driving Renewables 01/07/2010 26 ORBITAL 2 Commercially Confidential
- 27. ORBITAL 2 Flexible Pins – Driving Renewables 3.4 MW variable ratio gearbox on part load test. 01/07/2010 27 ORBITAL 2 Commercially Confidential
- 28. ORBITAL 2 Flexible Pins – Driving Renewables TIDAL TURBINES – new applications MCT Production Turbine 01/07/2010 28 ORBITAL 2 Commercially Confidential
- 29. ORBITAL 2 Flexible Pins – Driving Renewables MCT tidal gearbox on load test 01/07/2010 29 ORBITAL 2 Commercially Confidential
- 30. ORBITAL 2 Marine Current Turbines installation April 2008 Flexible Pins – Driving Renewables 01/07/2010 30 ORBITAL 2 Commercially Confidential
- 31. ORBITAL 2 Flexible Pins – Driving Renewables MCT Tidal - Installed 01/07/2010 31 ORBITAL 2 Commercially Confidential
- 32. ORBITAL 2 Flexible Pins – Driving Renewables MCT Tidal – Installed Orbital2 – unrivalled experience ORBITAL 2 Commercially Confidential
- 33. ORBITAL 2 FlexibleTidal – Installed MCT Pins – Driving Renewables ORBITAL 2 Commercially Confidential
- 34. ORBITAL 2 Flexible Pins – Driving Renewables Tidal Generation 01/07/2010 34 ORBITAL 2 Commercially Confidential
- 35. ORBITAL 2 Flexible Pins – Driving Renewables Tidal Generation Pre-series turbine during test 01/07/2010 35 ORBITAL 2 Commercially Confidential
- 36. ORBITAL 2 Flexible Pins – Driving Renewables Prototype 2MW SPG turbines now operating in Czech Republic Power train assembly of W2000spg Wind Turbine in Wikov’s assembly hall in Hradec Králové, Czech Republic 01/07/2010 ORBITAL 2 36 Commercially Confidential
- 37. ORBITAL 2 Flexible Pins – Driving Renewables W2000SPG Drivetrain ORBITAL 2 Commercially Confidential
- 38. ORBITAL 2 Flexible Pins – Driving Renewables • Allows ratio of the gearbox to be continuously varied throughout the whole range of the wind turbine rotor operating speed; making it possible to maintain constant speed of the synchronous generator • 6.3 kV nominal voltage is generated by the wind turbine => lower costs of connection to the grid • High voltage synchronous or fixed speed Gearbox with variable gear ratio induction generators can be used without full patented SPG (super position gear) power converters. system • Allows all of the main power electrics and transformers to be placed on shore in a central point further reducing the weight in the nacelle and improving reliability. • Provides torque protection of the gear train and rotating elements against wind gusts resulting in high reliability. 20.10.2009 ORBITAL 2 38 Commercially Confidential
- 39. ORBITAL 2 Flexible Pins – Driving Renewables W2000SPG Drivetrain in Operation in Czech Republic 2MW – Installed 01/07/2010 39 ORBITAL 2 Commercially Confidential
- 40. ORBITAL 2 Flexible Pins – Driving Renewables • 3MW gearbox - China ORBITAL 2 Commercially Confidential
- 41. ORBITAL 2 Flexible Pins – Driving Renewables • 1.25MW IWP Type • Optimised for balance between cost of energy, logistics and service life-time cost. 01/07/2010 41 ORBITAL 2 Commercially Confidential
- 42. ORBITAL 2 Flexible Pins – Driving Renewables • 1,5MW China • Areodyn Type ORBITAL 2 Commercially Confidential
- 43. ORBITAL 2 Flexible Pins – Driving Renewables W1650 WindTec Type 01/07/2010 43 ORBITAL 2 Commercially Confidential
- 44. ORBITAL 2 Flexible Pins – Driving Renewables Main Frame Layout – W2000 Fixed Ratio WindTec Type 01/07/2010 44 ORBITAL 2 Commercially Confidential
- 45. ORBITAL 2 Flexible Pins – Driving Renewables 3 MW • 3MW main drive gearbox • Offshore version 20.10.2009 ORBITAL 2
- 46. ORBITAL 2 Flexible Pins – Driving Renewables • 3MW main drive gearbox • Normal or Cold Climate version • Offshore/Onshore version • For 90/100/112m rotor diameter • 50 Hz or 60 Hz option available • Torque reaction linkage (not shown) 20.10.2009 ORBITAL 2 46 Commercially Confidential
- 47. ORBITAL 2 Flexible Pins – Driving Renewables 3,6 MW • 3.6MW ORBITAL2 Flexible Pin, Multi-Planet, • Torque 2806 kNm • Offshore China • Ratio 1:84 • Weight 37 ton ORBITAL 2 Commercially Confidential
- 48. ORBITAL 2 Flexible Pins – Driving Renewables Doosan 3MW – Test Rig ORBITAL 2 01/07/2010 Commercially Confidential 48
- 49. ORBITAL 2 Flexible Pins – Driving Renewables 01/07/2010 49 ORBITAL 2 Doosan 3MW – Test Rig Commercially Confidential
- 50. ORBITAL 2 Flexible Pins – Driving Renewables 50 ORBITAL 2 Sinovel 3MW – Test Rig Commercially Confidential
- 51. ORBITAL 2 Flexible Pins – Driving Renewables Building in Korea ORBITAL 2 Commercially Confidential
- 52. ORBITAL 2 Flexible Pins – Driving Renewables Building In China ORBITAL 2 Commercially Confidential
- 53. ORBITAL 2 Flexible Pins – Driving Renewables Opportunities …………… ORBITAL 2 Commercially Confidential
- 54. ORBITAL 2 Flexible Pins – Driving Renewables DRIVING RENEWABLE ENERGY VIA HIGH RELIABILITY, LOW WEIGHT, MULTI PLANET, FLEXIBLE PIN, EPICYCLIC GEARBOXES. ORBITAL 2 ORBITAL 2 Commercially Confidential PHOTO – 2MW SPG