R&D Test Systems, a Danish wind turbine test system supplier, has received a follow-up order from ZF Wind Power to develop and deliver a new end-of-line test bench needed to verify the system functionality on manufactured powertrains, including the gearbox, generator and main bearing arrangement, prior to shipping to the OEMs. The test rig, which features R&D Test Systems’ automated concept based on link-arm coupling, reduces mounting time by up to 90%, thus allowing two powertrain units to be tested per day.
The end-of-line test rig will be delivered to ZF Wind Power’s production plant at Lommel, Belgium, in autumn 2023. R&D Test Systems was also selected early in 2022 to supply a 30 MW validation test bench for ZF Wind Power’s Test & Prototype Center at the same site.
Wind turbine manufacturers are taking drastic measures to mitigate risks based on strong market fundamentals for achieving sustainable growth. While the wind energy supply chain faces massive challenges, ZF commits to taking important steps in empowering a sustainable future together with its partners. One of these steps is the integration of powertrain assembly at the shop floor level. The team uses an advanced software tool to build a digital twin of the production facility before building the plant and setting up the assembly processes with maximum use of available production knowledge.
“This encompasses all necessary assembly and logistical steps to be virtually predefined, checked in 3D, optimized, and validated,” explains Felix Henseler, CEO of ZF Wind Power. The ZF development of a digital twin for future serial production ensures swift, effective integration in the existing manufacturing facilities. “This involves completely transforming the current set-up for accommodating future product portfolios, including the V236-15.0 MW.”
In the first quarter of 2024, the first serial-produced 15-MW powertrain for the offshore market will leave ZF Wind Power Lommel. Before these powertrains are shipped to the OEM’s destination, the system functionality of the complete powertrain (gearbox, generator, and main bearing assembly) needs to be verified.
“An end-of-line test cycle will check the function of the system under load, testing both hydraulics and sensor connections, as well as contact patterns for the gears, in addition to checking lubrication, temperature, pressure, and noise and vibration levels,” explains Martin Knops, CTO of ZF Wind Power.
The end-of-line test rig for ZF Wind Power will be delivered by R&D in the fall of 2023. It conducts very energy-efficient load tests, powered by the 15-MW generators of the powertrains, providing an impressive 18 MNm of torque to test the unit at high load levels. This final test ensures that the powertrain and all its connections work as they should, even when exposed to all forces of nature.
“The end-of-line test rig reduces mounting time by up to 90% which enables us to test two powertrains a day. This is a win-win situation for us and our partner Vestas,“ summarizes Martin Knops.
“With serial production of the 15-MW powertrain to commence in 2024, we will be able to support our partner in the prompt delivery of offshore wind projects,“ explains Felix Henseler.
Thanks to the close partnership with Vestas, ZF is now able to manufacture innovative powertrain models for offshore turbines that can produce up to 80 GWh/year. This is the equivalent of the annual electricity consumption of 20,000 households.
“These models will accelerate the shift from climate-damaging fuels towards clean, renewable types of energy. We are proud to empower a sustainable future together with our partners,” concludes Felix Henseler.
News item from ZF
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