Holistic Condition Monitoring for Wind Turbines - Bosch Rexroth
Holistic Condition Monitoring for Wind Turbines - Bosch Rexroth
Holistic Condition Monitoring for Wind Turbines - Bosch Rexroth
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<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong>Solutions <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Dietmar Tilch<strong>Bosch</strong> <strong>Rexroth</strong>Messekongress 20121D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Content• Introduction• Motivation <strong>for</strong> CMS and current CMS Status• The holistic Approach• Going beyond <strong>Condition</strong> <strong>Monitoring</strong>• Conclusion and outlook2D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Bosch</strong> <strong>Rexroth</strong>Our FocusMobileApplicationsMachineryApplicationsandEngineeringFactoryAutomationRenewableEnergies3D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Bosch</strong> <strong>Rexroth</strong> Renewable EnergiesWhat we stand <strong>for</strong>4D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Main Components of a <strong>Wind</strong> TurbineRotor bladesFocus: Improving the per<strong>for</strong>manceand reliability of wind turbinesPitch systemsFilter-cooler systemHigh speedshaftGeneratorInverterMain bearingGearboxBrake systemYaw drivesAux systemsTrans<strong>for</strong>merControllerTower,foundation<strong>Rexroth</strong> Components5D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
System Solutions <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>CMS is one of <strong>Rexroth</strong>’s System Solutions• Filter-coolerSystems• Hydraulic andelectrical Pitch• Drive trainsimulation• <strong>Condition</strong><strong>Monitoring</strong>6D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Content• Introduction• Motivation <strong>for</strong> CMS and current CMS Status• The holistic Approach• Going beyond <strong>Condition</strong> <strong>Monitoring</strong>• Conclusion and outlook7D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Necessity <strong>for</strong> CMS• Reliability of wind turbines besides the mechanical engineering is alsoinfluenced by the boundary conditions of operation:• Overload caused by high winds• Critical incidents: Emergency stops, lightning strike, insufficientlubrication etc.• Changes over time: Aging, settling• In order to reach the life time and profit expectations the encounteredloads have to be considered• Goal: Estimation of the remaining useful life• Limited accessibility (especially offshore) requires automated supervision• Preventive maintenance requires a continuous surveillance• Service experts can remotely supervise many turbine in many locationout of one service center8D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Failure rates of system componentsHigh failure rates,but little down timeand repair costsFailure rate per year and systemLow failure rates,but long down timesand high repair costsNorthern German lowlandsMedium mountain rangesCoast• Early detecting reduces failures and thus improves the reliabilitySource: Fraunhofer IWES9D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Current Situation CMS <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Rotor• CMS currently only provides specialized partial solutions• Requirement of dealing with numerous different solutions / systems• Overall state of the system is hard to evaluate• High ef<strong>for</strong>ts <strong>for</strong> training due to different system philosophies• High personnel requirements und high system costsDrive trainElectricBearingCMSGearboxCMSadd.CMSDiagnosticsSCADAScreen1Screen2Screen3ScreennScreenn..10D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Particular Challenges of <strong>Condition</strong> <strong>Monitoring</strong>• Indirect assessment of desired data and in<strong>for</strong>mation• Functional chain between measurement and desired in<strong>for</strong>mation is complex• Realization is largely dependent on (empiric) knowledge and experience• Definition of critical states and deduced warning thresholds barely objective• Discrepancy between user expectations (largely subjective) and the technicalcapacities (a lot of expertise is required)• Narrow margin between (perceived) false alarms and late detections• Distorted perception and appreciation of benefits• Differently perceived benefits in different roles: OEM, user / operator• Natural oppositions: Warranty, full-service contracts, insurances• Benefits and added value of CMS is not yet fully accepted in the market11D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Content• Introduction• Motivation <strong>for</strong> CMS and current CMS Status• The holistic Approach• Going beyond <strong>Condition</strong> <strong>Monitoring</strong>• Conclusion and outlook12D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong><strong>Condition</strong> <strong>Monitoring</strong> Approach <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>TorqueIntegrationJoint developmentwith partner DMTDynamic load monitoringvia torsion measurementParticles, H 2 O,TemperatureInternal sensors:vibration, temperat.,dislocationProvide <strong>Condition</strong> <strong>Monitoring</strong> asadded value plus turbine servicesCM • CM System with combined driveSystem train and blade monitoring• <strong>Monitoring</strong> and maintenanceservicesCMenabledCompo-nents• Drive train with integration CMcapabilities higher reliability• Load assessment <strong>for</strong> improvedoperational control and estimation<strong>for</strong> remaining useful life• Integrated sensors <strong>for</strong> higherdetection accuracy13D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong><strong>Holistic</strong> CMSI / OE-PitchDiagnostics, messagesDrive train CMS, vibration monitoringJoint developmentwith partner DMTDMT - <strong>Wind</strong>Safe ®ECUAnalysis andCommunicationWeb ServerControlcenterMainbearingAdd. Features:CM-enabled gearbox withintegrated sensorsSpeedLoad cycles and dynamicsLubrication conditionsMonitored oil cycleTemperatureParticle concentrationWater contentCMS = <strong>Condition</strong> <strong>Monitoring</strong> System, ECU = Evaluation and Communication Unit, I/O = Sensor connection boxGen.Tower monitoring• Combination of drive train and rotor blade monitoring in one system• <strong>Holistic</strong> CMS with a consistent control center architecture• Integration on a unified plat<strong>for</strong>m; open <strong>for</strong> additional functions14D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Key Advantages <strong>Holistic</strong> CMS• Reduced hardware installation ef<strong>for</strong>t due to the combination of 2 CMS• Cost reduction• <strong>Holistic</strong> turbine status representation in one monitoring center• Consistent visualization and operation concept• Increased monitoring efficiency (more turbines per expert )• Improved detection accuracy due to synchronized data acquisition andcorrelation analysis• Hard to be achieved with the current individual CMS in the market• Expandable plat<strong>for</strong>m• Expansions <strong>for</strong> oil cleanliness and drive train load monitoring indevelopment• Close cooperation between CMS and gearbox manufacturer• Exquisite partnership to improve CMS to a new state of the art15D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Prototype installation on a Vestas V80, WP Altenbruch, Germany• Consolidation of data acquisition and communication• Implementation of synchronized measurements• Entire wind turbine represented in the menu tree WEA. Switch-over via single click• Parallel representation of drive train and rotor blade monitoring16D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Plat<strong>for</strong>m structure <strong>Holistic</strong> CMS• Software architecture based on a plat<strong>for</strong>m structure and individual functionmodules• Expansion via additional function modules, also 3 rd partyVisualization,WebserverDrive trainmonitoringRotorblademonitoringFunctional expansionsLoadmonitoring,gearboxConnectivityto 3rd partysystemsPlat<strong>for</strong>m with data base and data analysis17D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Content• Introduction• Motivation <strong>for</strong> CMS and current CMS Status• The holistic Approach• Going beyond <strong>Condition</strong> <strong>Monitoring</strong>• Conclusion and outlook18D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
Beyond <strong>Condition</strong> <strong>Monitoring</strong>Dynamic Load Monitor (DLM)SCUSensorControl UnitTorque / accumul. loadt• Assessment of the actualdrive train loads• Continuous dynamicmeasurement• Capturing of exceptionalload events• Allows <strong>for</strong> operation andper<strong>for</strong>mance optimization• Standard equipment oftorque and load cyclemonitoring:• prolongs the over-alluseful lifetime• secures the turbineoperation• and thus the long-termprofitability19D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
Beyond <strong>Condition</strong> <strong>Monitoring</strong>Active Torque Control (ATC)Active damping ofdynamical loads1Active torque control12Active torquecontrolIndividual pitchcontrol• Dynamic control ofdrive train torque toreduce peak loads andFuture wind turbines:Load-reduced operationtorque oscillations21⇒ higher drive trainlifetime and reliabilityPreventing and reducingloading by means ofinnovative approaches⇒ lower cost of energyLoad reduction <strong>for</strong> torque with active torque control20D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
Torque [kNm]Beyond <strong>Condition</strong> <strong>Monitoring</strong>Drive train torque and speed smoothing with ATC1750150012501000750500250withoutATCDrive train torquewith ATC00 10 20 30 40Time [s]Speed [rpm]1514.914.8Drive train speedwith ATCwithout ATC14.715 16 17 18 19Time [s]Reduction of drive trainspeed oscillations as aresult of less drive traintorque oscillationsHigh reduction of drive train torque and speed oscillations21D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
Beyond <strong>Condition</strong> <strong>Monitoring</strong>Closing the Engineering LoopSimulationClosed loop approach1. Model design 3. Determination of realisticload collectives2. validationUse of simulation <strong>for</strong> developmentprocess• Review and modification of loaddata <strong>for</strong> components in drive train• Design of components to realdynamic loadsLocal controllerTorque,SpeedTemp.SignalsTemp.CoolerFilter cooler circuit<strong>Condition</strong> <strong>Monitoring</strong> (CM)Oil cleanlinessmonitoringOil life timepredictionGearboxload cyclemonitoring•Gearbox withintegrated CMfunctionality•Particle monitoringfrom 4µm on <strong>for</strong> earlywarning•Oil aging monitoringIncreased availabilityby better design and qualitySystem Setup Options FeaturesSpecial options•Use of simulation results<strong>for</strong> improvement ofcondition monitoringmethods•Integration of features andmethods into a superiorCMS or the operationcontroller22D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Content• Introduction• Motivation <strong>for</strong> CMS and current CMS Status• The holistic Approach• Going beyond <strong>Condition</strong> <strong>Monitoring</strong>• Conclusion and outlook23D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
<strong>Holistic</strong> <strong>Condition</strong> <strong>Monitoring</strong> <strong>for</strong> <strong>Wind</strong> <strong>Turbines</strong>Conclusion and Outlook• Components of wind turbines are highly stressed• Operation conditions have a higher influence on wear and damagesthat engineering and manufacturing• The turbine has to be monitored in order to detect and preventcritical operation and component conditions• Future CMS systems have to integrate multiple functions in order toprovide this capability• But CMS alone can only detect conditions and there<strong>for</strong>e only preventdamages exceeding critical stages and thus causing further damage• Using CMS generated in<strong>for</strong>mation to actively improve the operationconditions is the next consequent step <strong>for</strong> reducing stress and preventingdamages‣ The holistic CMS approach combines all these requirements24D. Tilch | 19 Sep 2012 | DC-RE/PAC | | © <strong>Bosch</strong> <strong>Rexroth</strong> AG 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution,as well as in the event of applications <strong>for</strong> industrial property rights.
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