051-12 Lohr, 2012-08-02

Husum WindEnergy 2012: Top Performance for Tomorrow’s Wind Turbine

Husum WindEnergy 2012

The competitive pressure as well as the pricing pressure in the wind energy industry is mounting. If the sector wants to continue to expand, reducing the cost of energy (CoE) is a must. When developing new wind turbine generations, manufacturers can contribute a great deal towards that aim by striving to optimise the performance of their turbines without compromising reliability. Simulations across drive trains, intelligent drive train solutions and innovative pitch solutions are the latest examples of their efforts to develop new, efficient turbine types. On top, manufacturers are looking for solutions to improve the availability of wind power plants, which is why Bosch Rexroth came up with condition monitoring and a comprehensive service portfolio, both of which will increase the reliability of wind turbines and reduce the CoE.

Improved development methods increase reliability rates

Wind turbulences and feedbacks from the electric grid are the main cause for dynamics in the drive train. Reducing these vibrations combined with optimum gearbox design achieved by calculating the dynamic loads on the individual gearbox components will increase the service life of a wind turbine and thus help to lower the CoE. Bosch Rexroth conducts a wide range of simulations developed based on the company’s long years of industry knowledge. From the system level and multibody simulation all the way to finished-element models these simulations help manufacturers to further boost wind turbine performance without compromising reliability.

Simulation and design experience is a big asset when it comes to developing new drive generations. The Rexroth differential gearbox, REDULUS GPV-D, offers manufacturers an especially reliable gearbox solution. On request, the gearbox will be factory-fitted with an optimally adjusted Bosch Rexroth cooling filter system, which reduces installation costs and, consequently, manufacturers’ overall costs.

E-Pitch: maximum safety and availability

Safety plays an important role in the development of new wind power plant concepts. The risk analysis to be performed within the scope of the certification of new wind turbines in Europe as set forth in Directive 2006/42/EC on machinery and EN ISO 13849-1 respectively requires safety-relevant functions to fulfil “safety level 2” and “performance level d” standards. In order to meet the new requirements the Rexroth pitch system has been fitted with a patented safety inverter that enables emergency operation with AC motors if a converter fails. Special cables fitted with external shielding capable of carrying lightning current and internal EMC braid additionally protect the turbine against induced voltages caused by indirect lightning strikes.

Furthermore, solutions in place so far caused the wind turbine to shut down immediately if a converter failed as the individual systems are not coupled. Thanks to intelligently interconnected electronics the Rexroth solution provides for an intact converter to take over the control function for the drive of another axis. These options – safety inverter, patented converter operation as well as lightning protection and EMC concept – help manufacturers to sustainably increase safety and the turbine’s availability.

Lifecycle monitoring and service minimise downtimes

Effective manipulative values to enhance the reliability of wind turbines and thus lower the CoE are available not only in development but in running operations, too. The larger the wind turbine the more significant condition monitoring becomes. Rexroth lifecycle monitoring solutions assist wind farm operators in minimising downtimes. As such, the turbine operator can employ Rexroth’s BLADEcontrol system to recognise and follow up on rotor blade damage at an early stage. If the damage occurs suddenly, the turbine can be shut down automatically and promptly. An ice detection device determines the actual ice accretion on rotor blades. The operator may also use the system to automatically restart the turbine. Production downtimes can thus be reduced substantially with BLADEcontrol.

Bosch Rexroth’s extensive service portfolio - ranging from solutions for preventive maintenance and monitoring all the way to field service, OEM spare parts, trainings and a gearbox pool - supports the efforts of manufacturers to increase the efficiency and availability of wind turbines.

Visit Rexroth at the HUSUM WindEnergy fair: hall 3, booth 3D12.

Bosch Rexroth AG is one of the world’s leading specialists in the field of drive and control technologies. Under the Rexroth brand name, the company supplies more than 500,000 customers with tailored solutions for driving, controlling, and moving. Bosch Rexroth is a partner for Mobile Applications, Machinery Applications and Engineering, Factory Automation and Renewable Energies. The company provides customized solutions tailored to the needs and specifications of each individual market. As The Drive & Control Company, Bosch Rexroth develops, produces, and sells components and systems in over 80 countries. As part of the Bosch Group, Bosch Rexroth and its 38,400 associates generated approximately 6.4 billion euros in revenue in 2011.

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The Bosch Group is a leading global supplier of technology and services. According to preliminary figures, more than 300,000 associates generated sales of 51.4 billion euros in the areas of automotive and industrial technology, consumer goods, and building technology in fiscal 2011. The Bosch Group comprises Robert Bosch GmbH and its more than 350 subsidiaries and regional companies in some 60 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent more than 4 billion euros for research and development in 2011, and applied for over 4,100 patents worldwide. With all its products and services, Bosch enhances the quality of life by providing solutions which are both innovative and beneficial.

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Susanne Herzlieb
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