Highly reliable and highly efficient magnetically geared wind generator technology

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1 Technology Offer Highly reliable and highly efficient magnetically geared wind generator technology Summary An Austrian SME has developed one of the world s most effective magnetic gear boxes. It is based on a very simple and unique engineering concept with highest torque densities, ideal for application in wind turbines. The energy conversion is contactless, resulting in higher system reliability and efficiency. The company is looking for partners for technical cooperation, research-, commercialand/or joint-venture agreements. It is also open to financial- or license agreements. Creation Date 02 July 2015 Last Update 06 July 2015 Expiration Date 05 July 2016 Reference TOAT Details Description Existing problems in wind turbine designs Currently, the mainstream wind turbine system features a mechanically geared generator with a partially rated converter. In this setup, a gearbox is used to step up the input speed of the generator. As shown in several studies, these gear boxes suffer from the extreme torques produced by the rotor blades. Overall, the general perceived operational lifetime of frequently serviced gearboxes is only 7-11 years, versus years design life of wind turbines. Gearbox failures account for the largest amount of downtime, maintenance and loss of power generation while further incurring high repair and replacement expenses. However, loads are expected to increase even further in the future due to ever increasing power demands on wind turbine plants. As a consequence, gearless wind turbine concepts like direct drive (DD) systems have been developed. While these wind turbine systems may present some technological advantages, the economic incentives for a shift from geared systems to direct-drive are still insufficient. The high cost and weight associated with DD-generators are a key deterring factor and have hindered their widespread use up to now. Engineering Solution Magnetic gears have been investigated as an alternative technology, both to mechanical gears and permanent magnet generators of DD-systems. While keeping the setup of a wind turbine with a mechanically geared generator, such an arrangement would replace the mechanical gearbox with a magnetic gear. This requires only minimal changes to the existing drive train while combining both the mass and cost advantages of geared systems and the improved reliability and robustness of direct drive systems. Page 1 of 8

2 The magnetic gearing technology developed by the Austrian company replaces the cogwheels of a mechanical gearbox with elements consisting of magnetic pole-pairs. As opposed to the circular motion of cogwheels, the magnetic elements are rotating around each other at a slightly tilted angle, therefore creating a wobbling motion hence termed Magnetic Wobbling Gearing (MWG). The design completely eliminates the need for additional lubrication and allows for higher torque densities, more precision, more flexible gearing ratios and higher durability. The lack of mechanically interlocking parts in the gearbox further significantly reduces noise pollution by wind turbines. It also allows for operation under extremely harsh environmental conditions, as viscosity and contamination of lubricants is no longer an issue. The technology therefore holds extremely high potential for application in wind turbines. Technical details of the proposed wind generators with MWG: Power output in the range of MW (Mega Watts) Wind Turbine Input Torque in the range of MNm (Mega Newtonmeter) Fixed gearing ratio 1:20 1:200 in a single gear-stage (depending on internal setting and number of magnetic pole pairs) The MWG has already found application in other settings, where contactless and lubrication free torque conversion is an asset (e.g. space technology) high efficiencies are of special interest ( e.g. E-Bikes, battery driven applications) high gearing precision is of special concern (mechanical engineering applications and medical equipment) The aim is to use the existing prototypes, build them to scale and run tests in wind turbines. The company therefore seeks a partner to enter into joint-venture, research- or technical agreement. The company would also be willing to enter into a licence agreement / commercial agreement with technical assistance to make the technology available for other companies for further development or develop the technology in-house with financial support from a project partner. Advantages and Innovations The contactless power transmission of MWG offers distinct economic benefits: Lower investment costs than DD technology, more cost effective On par with mechanically geared wind generator drivetrains, though with higher lifetime Reduced downtime due to lower servicing intervals Lower maintenance and replacement costs Higher margins on invested capital general advantages for wind turbines: Improved reliability and significantly higher lifetime (equal to design lifetime of wind turbine) Inherent overload protection, no permanent damage in case of overload, extremely robust Greatly reduced noise pollution and vibration Lower to no maintenance Highest torque density, resulting in reduced permanent magnet volume High-efficiency power conversion due to contactless gearing technology advantages compared to DD wind turbines: 20-times higher torque density than permanent magnet generator Significantly reduced mass of generator system - lower installation weight of gear box Free choice of generator (brand and type) High flexibility in case of adapting generator power to increased power needs Page 2 of 8

3 advantages compared to geared wind turbines: No mechanical fatigue and operation even under harsh conditions Small mechanical complexity due to high reduction ratio and wobbling kinematics Gear box with only a single gear stage sufficient for all conceivable gearing ratios No lubrication necessary for power transmission Extended operational temperatures Physical isolation between input and output shaft No separate damping elements in drive-train necessary Stage of Development Prototype available for demonstration Comments Regarding Stage of Development Prototypes in small torque range are available; Long-term tests performed on 4 Q-test bench; Collaboration with motor/gear company manufacturing high-class small/medium powered drives; Targeted Collaboration with two European Entities doing Space Business IPR Status Secret Know-how,Patent(s) applied for but not yet granted,patents granted,exclusive Rights Comment Regarding IPR status 3 patent families concerning magnetic wobbling gears; National, international; AT, DE, GB, IT, FR, CH, EU, PCT Different stages, several patents granted, several patents filing Profile Origin National R&D programme Keywords Technology Market NACE Apparatus Engineering Generators, electric engines and power converters Turbines Wind energy Other energy production Power transmission equipment (including generators and motors) C M Manufacture of other special-purpose machinery n.e.c. Other research and experimental development on natural sciences and engineering Page 3 of 8

4 Client Type and Size of Organisation Behind the Profile Industry SME Year Established 1965 Already Engaged in Trans-National Cooperation No. Languages Spoken English German Client Country Austria Partner Sought Type and Role of Partner Sought Integration partners: Manufacturer and supplier of wind power plants; Integrators of gears in wind generator drive-trains; Supplier of components of wind generators drive-trains; Development partners: Design and development of geared wind turbine drive-trains Design and development of components of wind turbine drive-trains Universities/Institutions with know-how in component design/simulation of drivetrains for energy conversion Tasks to be performes: Adaptation and integration of the magnetically gearing system into a customer s product or plant; Assembly of wind power plants; Support in system integration by developer engineers; Joint research and development; Marketing and distribution of the product; Type and Size of Partner Sought SME 11-50,University,R&D Institution,>500 MNE, ,SME ,>500 Type of Partnership Considered License agreement Financial agreement Commercial agreement with technical assistance Page 4 of 8

5 Technical cooperation agreement Joint venture agreement Research cooperation agreement Page 5 of 8

6 Technology Request Improving gasoline burning efficiency in transport vehicles and hybrid-motor efficiency in electric vehicles Summary Indian company, engaged in the area of automotive research, aims to to improve the efficiency of internal combustion engines.it is seeking collaboration mainly in the areas of: (a) Hydrogen supplementation in commercial vehicles to improve gasoline burning efficiency and reduce emissions, (b) Use of innovative and more efficient hybrid motor in electric vehicles. Creation Date 28 April 2015 Last Update 16 June 2015 Expiration Date 05 July 2016 Reference TRIN Details Description Indian company, engaged in the area of automotive research, aims to to improve the efficiency of internal combustion engines. According to the company, the efficiency of the engines in terms of fuel consumed to mechanical output happens to be approximately 40%, and about 60% of energy is wasted. Hydroxy-oxygen generated by splitting of water up on passing direct current between two electric plates in presence of electrolytes is one of the methods to improve the IC engine efficiency. Adding Hydroxyoxygen with primary fuels like gasoline (petrol, diesel, LPG, CNG and fuel obtained from renewable sources) could improve their burning efficiency by more than 20%. Once the burning efficiency of fuel is improved, automatically, the performance of the engine in terms of mileage and torque will be improved. The complete burning of fuel results in lesser pollutants in engine exhausts. The company has key technology competencies and expertise is in the following areas: - Hydrogen and gasoline dual fuel systems - Hydrogen gasoline supplementation system - Electric vehicles:traction motor development The main products/services offered by it include: - Performance Booster for 2 wheeler, 3 wheeler and cars, - Traction Motor for electric vehicles Page 6 of 8

7 According to the company, its main R&D activities during the last about 5 years are oriented towards design and development of: - Low tension alternator for wind electricity generation - Multi-input UPS system for micro wind-solar hybrids. - Efficient hydrogen generation system for running single cylinder four stroke petrol engine (100cc and 125cc) in duel fuel mode (Hydrogen-Petrol) - Efficient hydrogen generation system for four stroke multi-cylinder LPG (800cc) engine Technical Specification or Expertise Sought The company is seeking collaboration in the following two areas: 1. Hydrogen supplementation in commercial vehicles to improve gasoline burning efficiency and reduce emissions. It is intended to use of "on board" hydrogen generation for the improving gasoline burning efficiency 2. Use of innovative and more efficient hybrid motor in electric vehicles Stage of Development Under development/lab tested IPR Status Patent(s) applied for but not yet granted Comment Regarding IPR status The company has filed 2 patents for performance booster technology in 2014 and 2 patents for alternator & motor technology in Keywords Technology Automotive engineering Air pollution control for cars and transport Market Other Industrial Products (not elsewhere classified) NACE C H Manufacture of other special-purpose machinery n.e.c. Urban and suburban passenger land transport Page 7 of 8

8 Client Type and Size of Organisation Behind the Profile Industry SME Year Established 2012 Turnover <1M Already Engaged in Trans-National Cooperation No. Languages Spoken English Client Country India, Republic of Partner Sought Type and Role of Partner Sought The partner should be able to provide assistance/expertise to the company in the following areas: - Hydrogen supplementation in commercial vehicles to improve gasoline burning efficiency and reduce emissions - Use of innovative and more efficient hybrid motor in electric vehicles Type of Partnership Considered Technical cooperation agreement Joint venture agreement Page 8 of 8

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