H

Hansens
Hansen
s DORoTe
DOR T on 13
13.2MW
2MW test
t t rig
ig

PO
PO.
121

D IIr. K
Dr.
Kris
i S
Smolders
ld

Hansen Transmissions International

R1/2 test conditions

Ab t t
Abstract

5 Distribute the test conditions over

5.
th desired
the
d i d number
b off start-stop
t t t p
cycles
6. Add dynamic torque behavior where
appropriate
i t
7 Define appropriate start and stop
7.
profiles
p
fil
10
1.0
08
0.8
0.6
0.4
02
0.2
0

C
Case
carburized
b i d gears
Nitrided gears
Shafts

Ref

33
3.3

ISO281

Pitting
g

6.6

ISO6336

Bending

87
8.7

ISO6336

Pitti
Pitting

57
5.7

ISO6336

Bending

17

ISO6336

Bending

ro
otor s peed
d

Pi i
Pitting

DIN743

Torsion
8
Advantages:
Ad
t g
easy to design for a given set of operational load conditions
tthe
e test program
p og a requires
equ es only
o y constant
co sta t speed and
a d load
oad testing
test g capabilities
capab t es

80

100

120

20

40

60
time [s]

80

100

1.0
0.8
06
0.6
0.4
0.2
0

120

DIN743

1.4
1.2
10
1.0
0.8
0.6
04
0.4
0.2
0

50

100

150

ro
otor torqu
t ue

02
0.2
0

20

10

20
time [s]

02
0.2

04
0.4

250

30

200

0.6
0.4
02
0.2
0

30

10

20

10

20

30

40

50

60

30
40
time [s]

50

60

0.2
01
0.1
0
-0.1
-0.2
02

40

total test time = 2408.6h

hours

3% 6%

tstart up: 67.8h

1.4

100

12
1.2

10

tR2: 723.9h

10
1.0

tshut dow n: 22.8h

0.1

08
0.8
0.6

100
150
time [s]

0.8

40

53%

tR1: 1288.4h

6%

30%

ttorque reversals : 155.1h

0 01
0.01

trare events : 3.5h

0 001
0.001

ttransition cases : 135.9h

0 0001
0.0001

0.2

50

10
1.0

10
1.0

0.4

1.0
08
0.8
0.6
0.4
0.2
0.0
-0.2
-0.4
-0.6
0

08
0.8

S1 + R3 + P1 rotor speed and torque

DORoTe TSDD (2409h)

200

06
0.6
rotor speed

DORoTe is mix of rare events and start-stop cycles

S2 + R3 + R4 + P3 rotor speed and torque

06
0.6
0.4

10

To
orqu
ue

D N (L ) ttest = tops
p

nopdd Lops

ntest Ltest

R ll bbearings
Roller
i

60

0.8

P2 rotor speed and torque

8 Define rare event profile:

8.

roto
or torrque

St t f th
State-of-the-art
t overload
l d ttestt procedures:
p
d

40

1.0
1
0
0.8
0.6
0.4
02
0.2
0

The
e vision
s o be
behind
d DORoTe
O o e
Failure mode

20

rrotor torrque
e

rotorr torq
que

Hansen s DORoTe philosophy:

Hansens
one step beyond state
state-of-the-art
of the art overload test
including
including start-stop
start stop behavior
behavior, torque reversals
reversals, emergency stops
stops, grid losses
losses
a synergy
y gy off customer
t
specifications,
p ifi ti
established
t bli h d calculation
l l ti methods
th d for
f known
k
failure mechanisms and insights from field experience

1.0
1
0
0.8
0.6
04
0.4
02
0.2
0

10
1.0

rrotor spee
ed

Hansen
Hansens
s solution: Design
Design Operational Robustness Test
Test:: DORoTe.
DORoTe

S1 + R4 rotor speed and torque

1.2

rotorr torque

ro
otor sspeed
d

Balancing act before the start of serial production between:

shortening time
time-to-market
to market
achieving
achieving maximum product reliability

ro
otor spe
eed

State-of-the-art
St
t f th
t ffunctional
ti
lp
performance
f
and
d design
d ig robustness
b t
testing:
t ti g
1 year field test: gearbox prototype installed in wind turbine + close monitoring
complete
complete gearbox disassembly and thorough inspection of all components
validated design robustness + maximal reliability before start of serial production

Component

14
1.4

tsetup: 11.3h

1 005
1e-005
0

0.2

0.4

0.6
0.8
Speed

1.0

1.2

250

DORoTe test results

DORoTe validation: 2MW product:
Similar observations compared to 1
year field
Especially
E p i lly for
f bearings
b i g (SKF:
((SKF The
Th
appearance of the bearings,
bearings except the
planet carrier bearing, is similar to what
has been seen in the application after
one year in the field
field, , most
i di ti
indications,
, like
lik smallll indents
i d t and
d
circumferential scratches
scratches, were however
similar after one year in the field and
after the prototype test
test, which makes it
difficult to differentiate
differentiate.))

Disadvantages:
tthe
e test program
p og a does not
ot consider
co s de the
t e dynamics
dy a cs of
o the
t e application
app cat o
the test focuses solely on 1 failure mechanism
(local) resonance behavior is not considered
Vision: DORoTe is designed as a test program
1 to validate gearbox design robustness with respect to the actual application
1.
specific
p ifi operational
p ti
l conditions
diti
and
d
2 to reduce time-to-market by accelerating prototype field testing under controlled
2.
indoor test conditions.
Hansen Capability

Industry
y Standard

hours

DORoTe design (1940h)

T que
Torq
e

15
1.5

100
10
1
01
0.1
0.01
0.001
0.0001
1e-005

1.0
0.5
0

0.2

0.4

0.6

0.8

1.0
hours

DORoTe test (1639h)

T que
Torq
e

15
1.5

The DORoTe
O
test methodology
gy

2013h (1011h < Tmin)

14
1.4

1 02
1.02

12
1.2

0 87
0.87

10
1.0

0 73
0.73

08
0.8

0 58
0.58

06
0.6

0 44
0.44

04
0.4

0 29
0.29

02
0.2

0 15
0.15

200

400

bin [#]
[ ]

600

800

1000

roto
or sp
peed

roto
or torrque

accelerated conditions: 8760h

20yr TSRD

> 100revs
1.4

roto
or torque
e

0.2

0.4

0.6
Speed

0.8

1.0

C
Conclusion
l i

100000
10000

The H
Th
Hansen DORoTe
DOR T test
t t algorithm
lg ith Design
D ig Operational
Op ti
lR
Robustness
b t
Test
T t
takes principles of accelerated life testing (HALT) one step further by incorporating
dynamics
y
and transients off wind turbine application.
pp
With its methodology
gy to
reduce test time and facilities to load gearboxes dynamically on its 13
13.2
2 MW test
rig combined in DORoTe,
rig,
DORoTe Hansen is in gear for further increasing gearbox
reliability
li bility and
d reducing
d i g titime-to-market.
t
k t

1000
0.8

100

06
0.6

10
1

0.4

0.1
0.2

0 01
0.01
0

0.2

0.4

0.6
rotor speed

0.8

0 001
0.001

1.0

1.13

0.93

0 75
0.75

0 62
0.62

0.37

0.31

200

400

if (Tops > Tmin ) : Ttest

else :

600
bin [#]

800

1000

1200

ro
otor spe
eed

corresponding PDF

1e+006

10
1.0

0.5

# revs

1.2

rrotorr torrque

1. Gather the customer specification and in

particular the 20 year simulated rotor
speed and torque
2 Generate
2.
G
t aq
quasi-static
i t ti torque-speedt q
p d
revolution-distribution (TSRD) and
corrresponding probability density plot
(PDF)
3 Determine operational time per bin for the
3.
considered
id d operational
p ti
l time
ti
4 Reduce the equivalent test time for the
4.
considered
co
s de ed knwon
o failure
a u e mechanism
ec a s by
increasing the load within allowable

limits:

1.0

Appli ti specific
Application
p ifi conditions
diti
are translated
t
l t d iinto
t DOR
DORoTe
T b
by
y a 8-step
8 t p methodology:
th d l gy

100
10
1
01
0.1
0.01
0.001
0.0001
1e-005

DORoTe applied on 6MW gearbox:

Maximize
M i i reliability
li bility for
f off-shore
ff h
applications
Test finished
Advanced CMS used to monitor
the gearboxes during test
Inspections
I p ti
planned
pl
d for
f O
October
t b
No issues reported thus far

Tops
= min(kTops , Tmax ) & ttest = tops
Ttest
Ttest = Tops & ttest = tops

From successful application of the DORoTe test program on gearbox designs with
k
known
field
fi ld experience,
p i
Hansen
H
concludes
l d th
thatt ffor the
th high
high and
d intermediate
i t
di t
speed stages the test algorithm is representative for operational wind turbine field
conditions.
di i
This
Thi observation
b
i is
i also
l confirmed
fi
db
by
y the
h SKF statement that
h in
i
particular for most of the bearings,
bearings the applied test program delivered comparable
results to 1 year of field operation.
operation

The DORoTe test program currently incorporates the rotor torque and speed but
the methodology is generic in nature and can be adapted to include other degrees
off freedom
f d
whenever
h
necessary.
y

EWEA OFFSHORE 2011,

2011 29 November 1 December 2011
Amsterdam The Netherlands
Amsterdam,