Large Components for Offshore-Wind Turbines. Large Diameter Bearings, Gearboxes, Electric Motors, and Hydraulic Cylindersall from One Source

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1 Large Components for Offshore-Wind Turbines Large Diameter Bearings, Gearboxes, Electric Motors, and Hydraulic Cylindersall from One Source

2 Liebherr a strong partner for the offshore wind industry For more than 60 years Liebherr has provided a range of products and services in many and varied sectors of technology. The company is one of the largest manufacturers of construction machinery in the world, and has earned a fine reputation for the performance and capacity of its products and services. The group can look back over a long history in offshore applications. As early as the late 1950s, they were producing the first harbour, on-board and deck cranes. Since then, the range of equipment and cranes for use along the dockside or actually anchored in the water has been steadily extended. Liebherr places great emphasis on maintaining its own areas of core expertise in order to meet the high demand for quality in these products. As a result, virtually all components used in mechanical, hydraulic and electrical drive and control engineering for maritime equipment are produced on the basis of their own development activity and manufacturing facilities. Examples include large diameter bearings, gearboxes, electric motors and hydraulic cylinders. Liebherr has now been involved in the wind-power industry as a component supplier for more than 15 years and supplies components for rotor blades and yaw adjustment to the world s leading manufacturers of wind turbines. The combination of many years of experience in maritime applications and the wind-power industry makes Liebherr a strong partner for the offshore wind industry. Source: REpower Systems SE/Jan Oelker 2

3 Know-how for large components page 4 Specialist for offshore applications page 6 Engineering competence page 8 Manufacturing depth page 10 Quality-orientated page 12 Product overview page 14 3

4 kw Onshore ,5 MW Onshore ,5 MW Onshore ,5 MW Onshore ,0 MW Onshore ,0 MW Onshore ,0 MW Offshore Installation of the largest Liebherr slewing drives. The DAT 1000s are 2.70 m high, have a dynamic torque of 610,000 Nm and a drive pinion with a module 50 gear. 4

5 Know-how for large components Offshore wind turbines are generally significantly larger than onshore systems and with their present ability to produce up to 6 MW of power, they require considerably larger components. For comparison: in the presently typical 2.5 MW systems, the diameter of a yaw bearing is around 3100 mm, while a similar bearing for a 6 MW system designed for offshore operation requires a large slewing bearing up to 5500 mm in diameter for tracking the wind direction of the nacelle. And the rotor bearings and gearboxes are correspondingly larger. Experience horizon Variety of applications As the graphic on the left demonstrates, Liebherr has been involved in the development towards larger turbines in onshore and offshore applications right from the start. As early as 2001, components were fitted to a 4.5 MW onshore turbine. Components for 5 and 6 MW offshore systems have been supplied as standard products since Liebherr supplies large components not only to the wind-power industry. Many years of manufacturing large diameter bearings and slewing drives for offshore cranes, rope winches for heavy-duty cranes and travel drives and slewing systems for mining excavators mean that Liebherr has gained significant experience in the design of large components for specific applications. This covers a wide range of demands. The heaviest slewing bearing so far manufactured at 25 t and the largest slewing drives with a weight of 6 t and a gear module 50 drive pinion are being installed in an offshore crane. Application Output torque / load torque Weight Special feature DAT 1000 slewing drive ROD slewing bearing KSW 1100 compact rope winch Heavy-duty crane (offshore) Heavy-duty crane (offshore) Heavy-duty crawler crane (offshore) 600,000 Nm 6 t 160,000 Nm 25 t 700,000 Nm* 21 t FAT 1600 drive Mining excavator 2,200,000 Nm 1.5 t Drive pinion with module 50 *in the 10 th rope layer ,0 MW Offshore ,5 MW Onshore Handling a bearing of 6000 mm diameter at the Liebherr plant in Biberach. The internal-gear large diameter bearing in the picture was designed for an offshore crane. Final assembly of the largest KSW 1100 rope winches so far manufactured. These will be installed in a heavyduty crane and weigh 21 t each. 5

6 Source: REpower Systems SE/Jan Oelker The picture shows a Form 25 harbour crane in operation in Bremen harbour in The company now supplies not only harbour cranes but also container loading cranes, a wide range of ship, pontoon and barge cranes, and offshore cranes. 6

7 Specialist for offshore applications The rules at sea are different. Extreme environmental conditions and difficult and very expensive logistics place very high demands on the reliability of offshore wind turbines. With decades of experience in supplying components for maritime applications, Liebherr is just as familiar with the resulting demands for quality as with the guidelines of the various standards organisations, e.g. DNV or Germanischer Lloyd. Many years of experience Versatile applications Offshore environment Liebherr has been manufacturing cranes for use in harbours, on ships and on drill platforms since the late 1950s, naturally with drive components developed and manufactured using their own expertise and facilities. Liebherr is continuously extending the company s comprehensive experience and expertise in the field of maritime applications with respect to coatings, material selection and design criteria. External customers are also familiar with Liebherr s offshore experience and install gearboxes and large diameter bearings in equipment such as pipe-laying ships, oil and gas equipment and maritime propulsion systems. Liebherr components have been in use in offshore wind farms for several years. Components designed for offshore applications require reliable corrosion protection against environmental influences such as salt-laden air, spray and seawater. Liebherr uses a range of processes for surface treatment. They include zinc-flame spraying and anticorrosion coatings to protect gear teeth. Cover coatings are applied for C5-M corrosion protection class in accordance with DIN EN ISO Ozone and UV-resistant seals are used for large diameter bearings and sealing surfaces are specially treated. FAT 700 DAT 650 Application Output torque Weight Special feature Pipe-layer ship (tensioner unit) Offshore wind turbine plant 240,000 Nm 2.3 t 120,000 Nm 1.5 t KUD 385VJ Azipod ship drive t Special sealing package The Odin with a jack-up system has a Liebherr BOS D Litronic in operation naturally with large diameter slewing bearings, slewing drives and rope winches developed and manufactured using their own resources. Azipod drives from ABB include large diameter bearings and slewing drives manufactured by Liebherr for adjusting the ship propulsion system in 360 and taking the place of the rudders. The underwater components have been operating successfully for almost 10 years. 7

8 Deformations in the adjacent construction, e.g. in the head of the tower and the rotor hub Bearing deformations at operating and maximum loads Bolt calculations in consideration of the given preload There is close consultation with customers, marketing, design, quality assurance and production at all stages of design and manufacture. This blade bearing test rig is used, amongst other things, for the verification of deformation calculated by FEM and for the examination of friction and breakaway torques under various conditions. 8

9 Engineering competence The correct design and calculation of a component is essential for its reliability and service life. Multi-megawatt wind turbines require design with FEM, because the increasing size of the systems increases their sensitivity to deformation. In addition, strictly defined approval processes for new developments and continuing development ensure optimum product configuration and, as a result, a high level of reliability. Holistic assessment Detailed testing Comprehensive testing and laboratory equipment During product design, the design engineers analyse all influencing variables in close consultation with customers to ensure that the overall system is optimised. The basis for calculation is the modelling of all parts that affect the component for example, components that affect the yaw bearing include the complete machine support and the head of the tower. A FEM analysis comprises a wide range of individual calculations. For large diameter bearings, they include calculations of deformation and stresses in the part itself and in the final assembly. In another step the extent of sealing gap expansion is investigated. In large diameter slewing bearings not only are the forces affecting the roller elements calculated but also the contact angle for every load case. Resistance to the detachment of the hardened coating (core-crushing) is also tested for the raceways. Verification and improvement of calculation models is an essential prerequisite for useful results and therefore a decisive factor in the development of the long-term reliability of components - especially in offshore systems. A wide range of measurement and test stands is available in the Biberach plant for investigating items such as the behaviour of gearboxes under varying loads, or also the service life. Compression in bearing raceways in consideration of the contact angles and raceway edge Gearboxes for wind turbines are subjected to special load tests. In the test runs, the loads of 20 years of operation are simulated. In addition to decades of experience in equipment manufacture, the Liebherr designers rely on measurements using the in-house high-frequency vibrophore and the FZG dynamic test stand during the design and acceptance process of parts. 9

10 Gears are manufactured on machines developed and manufactured by Liebherr in an own plant in Kempten, Germany. Components are manufactured and assembled in economically optimised lot sizes even with large gearboxes such as the DAT 600 shown here. 10

11 Manufacturing depth The design and management of the manufacturing processes is the basic factor for ensuring uncompromising quality and reliability for offshore products. Liebherr meets these requirements with continuous optimisation of product processes, including standardisation measures and comprehensive documentation. Uncompromising management of critical processes Strong vertical integration Comprehensive logistics Decisive factors for the service life of components are not only the best raw materials but also the design and management of critical production processes. The critical factor for large diameter bearings is the hardening process. With state-of-the-art system technology and inductors developed in-house, Liebherr produces a consistently high quality, even with bearings 6000 mm in diameter. The degrees of hardness and the depths of hardness of raceways and teeth are subject to continuous quality testing. Since the group was established, Liebherr s strategy has been to focus on a high degree of vertical integration. Customers profit from consistent processes that assure quality and on-time delivery. Production systems with state-of-the-art technology ensure the consistency of fabricated workpieces and economical production, even with large components. If requested by the customer, Liebherr can take full responsibility for organising the transport of large components to the customer s site. This includes secure packaging of the component, appointment of a suitable transport company, procurement of all required approvals and scheduling, in addition to all other requirements. Because coating a bearing to improve its service life and reliability plays an important role, the associated process stages such as sandblasting, galvanising and coating are all done in the Liebherr plant. The larger the component the more difficult the transport logistics. On request, Liebherr will deliver large diameter slewing bearings and gearboxes on schedule by road, rail or sea transport to the final location. 11

12 Liebherr can comply with all standard certifications in the wind industry. This includes the guidelines issued by Germanischer Lloyd, Det Norske Veritas and, if required, other certification organisations. Worker inputting measurement values into a CAQ terminal, which files the measurement values with the actual order and the workstation so they can be traced at any time. 12

13 Quality-orientated For offshore wind turbines, reliable components of a consistently high quality are particularly important to prevent prolonged production downtimes and logistics costs than is the case for land-based plants. To ensure that the Liebherr quality standards achieved by FEM and FMEA are maintained in subsequent processes, all company processes are designed to maintain quality. This starts with the selection of the supplier and is maintained right through to the after-sales service. Quality management at Liebherr is certified by DIN EN ISO 9001:2000. FMEA processes Consistent quality management Unique measuring equipment Testing critical characteristics Design and process FMEAs (Failure Mode and Effects Analysis) is an integral component of development processes and production planning for new parts to reduce the costs of monitoring and tracing faults. All production and assembly processes are documented in a computer-supported operating data recording system. This is also used as a central quality management system that records production and assembly measurements. This allows comprehensive control, monitoring and traceability. A wide range of evaluations not only quickly detects and corrects process deviations but also contributes to the continuous improvement of processes. In addition to the standardized equipment used during production, Liebherr has a wide range of highly specialised measuring equipment. In recent years, for example, the company has invested in a fully climatecontrolled test chamber for large diameter bearings and in high-precision measuring machines. The 3D measurement process of large diameter slewing bearings up to 6,000 mm in diameter is unique in the world. Uncompromising assurance of delivery quality includes 100% testing of particularly critical dimensions and surface values, e.g. in the area of the hardened raceways and teeth. Gears are not only measured with the modern test instruments but also checked for grinder burn. In addition to ultrasound testing, the individual rings of every single large diameter slewing bearing manufactured by Liebherr are examined in a magnetic testing field for cracks to eliminate the possibility of failures resulting from material faults. 13

14 Rotor blade bearing Yaw drive Pitch control Yaw bearing Pitch drive Spare parts Liebherr parts can be found quickly and locally anywhere in the world if they are required. 14

15 Product overview As the world s only manufacturer of such equipment, Liebherr provides not just individual components but the complete yaw and rotor blade adjustment system for wind turbines. Slewing drives Every gearbox is adapted to the individual requirements of the customer. In meeting these requirements, a distinction is drawn between three primary designs: with short output shaft with long output shaft alternatively as a right-angled drive On request, the gearbox can be supplied with a Liebherr electric motor. minimum maximum Torque Nm 1, ,000 Gear ratio 60 2,200 Weight kg 100 5,500 Single row four point bearing, external gear Double row four point bearing, external gear Blade and yaw bearings The usual designs for blade and yaw bearings are single or double row four point bearings with external and internal gearing. Roller bearings are also available on request. Four point bearing Roller bearing Outside diameter mm 400-6, ,000 Geared module Weight kg 25-7, ,000 Roller bearing, external gear Blade adjustment cylinder As an alternative to electromechanical blade adjustment by means of a gearbox and electric motor, Liebherr can also provide cylinders for hydraulic adjustment. minimum maximum Stroke length mm 5,000 Piston diameter mm Training Liebherr product specialists provide training sessions and welcome the opportunity to pass on their knowledge and experience. Service Liebherr employees are not only there to provide rapid maintenance assistance on site but also to hold training sessions directly at the location of the wind turbine plant. 15

16 Liebherr-Component Technologies Liebherr-Component Technologies AG, with headquarters in Bulle, Switzerland, is responsible for all activities involving the components sector within the Liebherr Group. The companies and corporate units belonging to this sector are specialized in the development, design, manufacture and reconditioning of high performance components in the field of mechanical, hydraulic, and electrical drive as well as control technology. Long Years of Experience Liebherr has decades of experience in the field of top quality components, for use in cranes, construction machinery, in the mining industry, maritime applications, wind turbines, automotive engineering, the aerospace sector, and in transport technology. Synergy effects from the other product sectors of the Liebherr Group of Companies are put to rational use in driving ahead with constant technological further development. The Right Solution for Every Need Thanks to the in-depth manufacturing techniques and the use of the most modern and flexible production resources, Liebherr can provide customers with tailor-made solutions. Every component is developed to meet individual wishes and requirements. Liebherr is your partner for achieving success together, from the product idea to development, manufacture, and taking into service, and right on up to series manufacture. For the mechanical and hydraulic drive train components Liebherr offers reconditioning in different stages from a specialised works. System Solutions from One Source Components from Liebherr are perfectly matched to one another in their functional performance, and in combination they achieve maximum total levels of effect and efficiency. Depending on the requirement, individual components from the broad product selection can be extended up to the complete drive train. This creates system solutions with real conviction, which can be integrated into a whole range of applications. Quality and Cutting Edge Technologies All components meet the highest demands for functional reliability and long service life, even under the toughest conditions. A refined quality management and extensive inspection and testing procedures are applied throughout the entire development and manufacturing process. So they ensure the reliability and long life of the components. Highly qualified staff with a real sense of responsibility plays their part in achieving the fine Liebherr quality standard. Biberach: large diameter bearings, gearboxes, control technology, electrical machines Lindau: electronics Kirchdorf: hydraulic cylinders Bulle: diesel engines, splitter boxes, hydraulics Ettlingen: exchange components Monterrey: large diameter bearings Printed in Germany by Typodruck BK COB _enGB Liebherr-Components Biberach GmbH Sales Components Wind Energy Hans-Liebherr-Straße 45, D Biberach an der Riß , Fax info.cob@liebherr.com Subject to technical modifications.