Services include :
- Technology/IP assessment
- Product development
- Programme management
- Design for manufacture
- Product lifecycle cost reduction
- Supply chain
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Dynamic analysis of the entire system is done using Ricardo's dynamic analysis code VALDYN. Finite element models of the housings and tower can be used to support the dynamic model. This itself includes finite element models of the shafts, rolling element bearings and contact models of the gears. As this is a time domain solution, the effect of the dynamic response of the system is coupled with the excitation of the drivetrain forces.
Shaft and bearing analysis is critical in understanding the behaviour of a gearbox.
Wind turbine gearboxes are subjected to very high torques, significantly varying loads, with a large emphasis on reducing weight which has to be supported a the top of the tower.
Quasi-static analysis can be used initially both for concepting and problem solving. Ricardo's shaft and bearing analysis software, SABR, is used to understand the loading conditions within a gearbox.
Critical results for the performance of the gearbox are assessed including:
- Multi-load duty cycle including overload and inertia backdriving
- Bearing damage
- Shaft stress and stress concentrations
- Effect of preload on bearing life
- Effect of relative shaft position on bearing load and size
- Effect of housing deflection on shaft misalignment and bearing life
- Effect of gear misalignment on gear life and stress.
Novel wind turbine
A North American wind energy start-up company used Ricardo as product development partner for their next generation wind turbine energy storage system. The system is based on an innovative high energy density air compressor driven by the turbine shaft in the nacelle, delivering compressed air to a storage reservoir. The stored energy can then be used ‘on demand’ by passing it through an expander plant. Ricardo support covered design optimisation, performance modelling, analysis, design for manufacture, reliability and cost engineering. In particular use was made of Ricardo engineering software tools to develop robust designs in a shorter time period than achievable by conventional approaches.
Gearbox Reliability Collective
Ricardo is part of the gearbox reliability collective (GRC) being co-ordinated by the US National Renewable Energy Laboratory (NREL). The project involves instrumentation and measurement of loads in gearboxes mounted on a drivetrain test rig and in an operating wind turbine, and correlation of these with loads predicted using simulation tools. Ricardo is using its SABR and VALDYN software tools to model the 3-stage gearbox with the objective of developing the most accurate and reliable approach to robust wind turbine gearbox design.
Drivetrain Research
Ricardo is investing its own research funding into wind turbine technology. This includes investigations into the application of magnetic gearbox concepts in the wind industry. A demonstration model has been made to back-up simulations, and a MW scale concept is being developed to confirm cost-benefit performance.
Long-life bearings are another area of research for Ricardo, and a patent has been applied for a novel design to share load around a roller-bearing outer race.
Drivetrain test facility consultancy
Ricardo is a world expert in specifying and operating drivetrain test rigs from kW to multi MW. As a result of this, Ricardo is being used by companies in the wind sector to advise on new wind turbine gearbox, drivetrain and nacelle test facilities. This support covers specifications, measurement systems, operating and test procedures, test planning and integration of testing with the development process. Ricardo is pioneering the application of magnetostrictive materials to wind turbine testrigs to enable fast dynamic loads to be simulated.
