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We talked energy efficiency with some major players in the lubricants industryâ€” but with a focus on their productsâ€™ impact regarding energy efficiency of gears and gearboxes in wind turbines.
This article describes some of the most important tests for prototypes conducted at Winergy AG during the product development process. It will demonstrate that the measurement results on the test rig for load distribution are in accordance with the turbine measurements.
The United Statesâ€™ long-held dream of energy independenceâ€”as in cheap, clean, free of overseas extortion and renewable energyâ€”could very well be realized in part by the country-wide development of wind turbines...
Big gears and wind turbines go together like bees and honey, peas and carrots, bread and butter andâ€”well, you get the idea. Wind isnâ€™t just big right now, itâ€™s huge. The wind industry means tremendous things for the energy dependent world we live in and especially big things for gear manufacturers and other beleaguered American industries.
When Belgium-based Hansen Transmissions was under the ownership of Invensys plc in the late 1990s, the parent company was dropping not-so-subtle hints that the industrial gearbox manufacturer was not part of its long-term plans. Yet Hansenâ€™s CEO Ivan Brems never dreamed that, less than a decade later, he would be working for an Indian company.
Faithful Gear Technology readers may recall that our July 2009 issue contained an update of the deliberations provided by Bill Bradley. Now, almost two years later, there is an ISO/IEC wind turbine gearbox standard out for draft international standard ballot (ballot closes 2011-05-17).
Having outlasted the worldwide Great Recession, the Global Wind Energy Council (GWEC) forecasts a constant growth in wind energy, i.e.: "increase in worldwide capacity to 460,000 MW by 2015."
Gear flank breakage can be observed on edge zone-hardened gears. It occurs, for example, on bevel gears for water turbines, on spur gears for wind energy converters and on single- and double-helical gears for other industrial applications.
Although typically considered a late bloomer in the call to wind energy arms, the United States is now the number one wind power producer in the world with over 25,000 MW installed by the end of 2008, according to the Global Wind Energy Council in January 2009.
The wind turbine industry has been plagued with gearbox failures, which cause repair costs, legal expenses, lost energy production and environmental pollution.
The turbines are still spinning. Theyâ€™re spinning on large wind farms in the Great Plains, offshore in the Atlantic and even underwater where strong tidal currents offer new energy solutions. These turbines spin regularly while politicians and policy makersâ€” tied up in discussions on tax incentives, economic recovery and a lot of finger pointingâ€”sit idle. Much like the auto and aerospace industries of years past, renewable energy is coping with its own set of growing pains. Analysts still feel confident that clean energy will play a significant role in the future of manufacturingâ€”itâ€™s just not going to play the role envisioned four to five years ago.
Historically, wind turbine gearbox failures have plagued the industry. Yet an effective oil analysis program will increase the reliability and availability of your machinery, while minimizing maintenance costs associated with oil change-outs, labor, repairs and downtime. Practical action steps are presented here to improve reliability.
Itâ€™s not too often a trade show so far surpasses organizersâ€™ expectations for size that it must be relocated. This was just the dilemma the American Wind Energy Association (AWEA) faced with the Windpower 2009 Conference and Exhibition, which was originally scheduled to take place in Minneapolis, but will now be held at McCormick Place, Chicago.
This article shows the newest developments to reduce overall cycle time in grinding wind power gears, including the use of both profile grinding and threaded wheel grinding.
The global wind energy market has seen average growth rates of 28 percent over the last 10 years, according to the Global Wind Energy Council (GWEC), creating major challenges for the component supply industry. GWEC also forecasts an average growth rate of 22 percent for the next five years, which if realized, will continue to put pressure on suppliers of turbine components.
Recent breakthroughs in profile grinding software are helping Anderson Precision Gears and others meet wind powerâ€™s insatiable appetite for faster production of large, high-quality gears.
Industrial gear standards have been used to support reliability through the specification of requirements for design, manufacturing and verification. The consensus development of an international wind turbine gearbox standard is an example where gear products can be used in reliable mechanical systems today. This has been achieved through progressive changes in gear technology, gear design methods and the continual development and refinement of gearbox standards.
Long before oil, climate change and energy demand were making headlines in Washington, Minnesota State Auditor Rebecca Otto and her husband installed a wind energy system on their property in Minnesota.
It seems that nothing can hold back the power of the wind—unless, of course, it's the availability of rugged, reliable, specially designed gearboxes. How Gleason is Keeping up with Demand.
Lamentations continueâ€”legitimately soâ€”over the second-citizen status of manufacturing in the United States. The need undoubtedly continues for renewed support by government and educators for making things here once again...
Onshore and offshore wind turbines boast some of the most critical assets in order to run effectively.
Gear manufacturers are moving into an era that will see changes in both engineering practices and industry standards as new end-products evolve. Within the traditional automotive industry, carbon emission reduction legislation will drive the need for higher levels of efficiency and growth in electric and hybrid vehicles. Meanwhile, the fast growing market of wind turbines is already opening up a whole new area of potential for gearbox manufacturers, but this industry is one that will demand reliability, high levels of engineering excellence and precision manufacturing.
Vibration and noise from wind turbines can be significantly influenced - and therefore reduced - by selecting suitable gearing modifications. New options provided by manufacturers of machine tools and grinding machines, and especially state-of-the-art machines and controls, provide combined gearing modifications - or topological gearing corrections - that can now be reliably machined. Theoretical investigations of topological modifications are discussed here with the actual machining and their possible use.
There exists an ongoing, urgent need for a rating method to assess micropitting risk, as AGMA considers it a "a very significant failure mode for rolling element bearings and gear teeth - especially in gearbox applications such as wind turbines."
In the wide, wide world of moving parts, the gears required for the big jobsâ€”the really big jobsâ€”often experience big problems. Proper lubrication of these gears is paramount in industrial applications such as wind turbines, kilns, sugar mills, crushers, heavy construction, offshore drilling rigs, mining and quarrying.
"An industrial business with a very important growth potential for the next decade." That's the wind energy as described by Ivan Brems of gear manufacturer Hansen Transmissions International.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
Let's talk about large gears. Not the size or scope or inspection process, but the forecast and market potential in areas that utilize these massive components. We'll examine key industry segments like energy and mining and tap IHS Economics for a forecast for 2016 and 2017 (spoiler alert: it's not great). Additionally, we'll discuss some of the critical factors influencing global big gear manufacturers Ferry-Capitain and Hofmann Engineering.
A high number of wind turbine gearboxes do not meet their expected design life, despite meeting the design criteria of current bearing, gear and wind turbine industry standards and certifications.
The complete Industry News section from the July 2014 issue of Gear Technology.
Amidst the energy industry's uncertain future, gearbox manufacturers are focusing on supplying the aftermarket.
Capitalizing on a burgeoning new technology where gears are of great import, the gear community gathered en masse at the American Wind Energy Associationâ€™s Windpower Expo 2010.
The Fabyan Windmill in Geneva, IL
A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses. Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss.
Natural resourcesâ€”minerals, coal, oil, agricultural products, etc.â€”are the blessings that Mother Earth confers upon the nations of the world. But it takes unnaturally large gears to extract them.
This article reviews mathematical models for individual components associated with power losses, such as windage, churning, sliding and rolling friction losses.
A series of short reports on global manufacturing growth and the gear industry's role.
When a customer needed gears delivered in three weeks, hereâ€™s how Brevini Wind got it done.
Industry battles it out for World's Largest Gear title.
Over the past few months we've talked with a lot of gear manufacturers. Many of them tell us business is strong, while others are struggling with reduced demand. The difference between them isn't so much in the quality of their manufacturing operations, but rather trends in the end markets they serve.
News Items About wind turbines
1 GE to Supply Canada with 660 New Wind Turbines (January 22, 2004)
GE Energy has been selected to supply up to 660 wind turbines, totaling 990 megawatts of wind-generated electricity for eight projects to... Read News
2 IQwind and Guascor Partner to Commercialize Variable IQGear Technology for Wind Turbines (September 10, 2009)
IQwind and Guascor announced that they will partner to commercialize and bring to market the IQGear, a high efficiency variable gearbox f... Read News