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E-raamat: Designing Wind Turbines: Engineering and Manufacturing Process in the Industrial Context

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Designing a wind turbine is an interdisciplinary process that requires an understanding of challenges for all parties involved. The authors deliver an effective and economic way to organize such a design by respecting all the challenges involved. The book provides such insight by utilizing specific examples of existing modern designs. Detailed descriptions and explanations are given for those components of the wind turbine that are normally developed by the so-called original equipment manufacturers (OEM) of a particular type. The OEM needs to have full knowledge of the complete system that consists of all parts being rotor blades, nacelle, drive train, tower, and foundation including the dynamic properties and the response to the controller action. This full knowledge is called system competence. For a wind turbine the drive train is the most important system. It consists of many components like shafts, bearings, gearbox, and generator for a wind turbine with a gear box; in systems without a gearbox a large generator has to be integrated into the drive train.

1 Wind Energy Basics
1(12)
1.1 Why Wind Turbines?
1(1)
1.2 Concepts to Utilize Wind Energy
2(6)
1.2.1 Drag-Type Wind Turbines
3(1)
1.2.2 Lift-Type Wind Turbines
4(2)
1.2.3 Power Performance of Different Concepts
6(2)
1.3 The CP(λ) Curve
8(1)
1.4 Electrical Energy from Wind
9(1)
1.5 The Power Curve
9(4)
2 Modern Wind Turbines
13(30)
2.1 Geometry with Upwind Rotor
13(2)
2.2 Components and Systems
15(1)
2.3 Rotor Blades
16(4)
2.4 Towers
20(4)
2.5 Power Generation System
24(3)
2.6 Essential Control Concepts
27(4)
2.6.1 Variable Speed Operation by Torque Control
27(2)
2.6.2 Power Regulation by Blade Pitch
29(2)
2.7 Alternative Power Regulation Concepts
31(1)
2.8 Operational States
31(2)
2.8.1 Safety System
33(1)
2.9 Why All Utility-Scale Wind Turbines Look Similar
33(2)
2.10 Some Recent Wind-Industry Trends
35(2)
2.10.1 Trend to Lower Specific Power
35(1)
2.10.2 Cost of Energy
35(1)
2.10.3 Trend to High Onshore Towers
36(1)
2.10.4 Other Trends
36(1)
2.10.5 Onshore and Offshore
37(1)
2.11 Wind Turbines Used for Illustration in This Book
37(6)
3 Development Process and Requirements
43(14)
3.1 Modern Development Process
43(2)
3.2 Engineering Process
45(1)
3.3 Standards, Guidelines, Certification
46(3)
3.4 Load Cases, Ultimate and Fatigue Loads
49(3)
3.5 Vertical Integration of Manufacturing in Wind Industry
52(2)
3.6 Transport and Logistics
54(2)
3.7 Requirements for Offshore Wind Energy
56(1)
4 Drivetrain
57(24)
4.1 Gearbox or No Gearbox?
57(2)
4.2 Hub Concept
59(1)
4.3 Rotor Bearing
60(1)
4.4 Separated or Integrated Drivetrain
61(2)
4.5 Wind Turbines with Gearbox and High-Speed Generator
63(10)
4.5.1 Low-Speed Side---Machine Frame and Rotor Bearing Concepts
63(6)
4.5.2 Gearbox and Its Interfaces
69(1)
4.5.3 High-Speed Shaft and Connection of Gearbox and Generator
70(1)
4.5.4 High Speed Generator
70(1)
4.5.5 Drivetrain Dynamics for Wind Turbine with Gearbox
71(2)
4.6 Concepts with Medium Speed Generator
73(1)
4.7 Direct Drive Concepts
74(7)
4.7.1 Type of Generator
75(1)
4.7.2 The Air Gap Challenge
76(1)
4.7.3 Position of the Generator and Integration Concept
76(1)
4.7.4 Inner and Outer Rotor
77(1)
4.7.5 Eleon as an Example
78(3)
5 Structural Components
81(32)
5.1 Materials and Manufacturing Process for Main Components
81(4)
5.1.1 Cast Iron and Casting Process
82(1)
5.1.2 Construction Steel and Welding
83(1)
5.1.3 Forged Alloy Steel
84(1)
5.1.4 Glas Fiber Reinforced Plastic
84(1)
5.2 Hub
85(5)
5.2.1 Hub Design Concept
86(2)
5.2.2 2 MW Hub Design and Structural Analysis
88(2)
5.2.3 Hub Stability Analysis
90(1)
5.3 Machine Frame
90(9)
5.3.1 Sizing and Analysis
91(6)
5.3.2 Optimizing the Structure
97(2)
5.4 Generator Frame
99(2)
5.5 Main Shaft
101(4)
5.5.1 Sizing and Analysis
101(4)
5.6 High Speed Shaft
105(1)
5.7 Rotor Lock
106(2)
5.8 Nacelle Cover and Spinner
108(5)
5.8.1 Nacelle Cover
109(2)
5.8.2 Spinner
111(2)
6 Bearings
113(10)
6.1 Main Bearing
113(6)
6.1.1 Bearing Housing
117(2)
6.2 Pitch Bearing
119(2)
6.3 Yaw Bearing
121(2)
7 Gearbox
123(12)
7.1 Gearbox Concepts
123(4)
7.1.1 Alternative Gearbox Concepts
127(1)
7.2 Shrink Disc
127(2)
7.3 Torque Support
129(4)
7.4 Slip Ring and Rotary Union
133(2)
8 Bolt Connections
135(12)
8.1 Basics Concepts
135(5)
8.2 Main Shaft to Hub
140(2)
8.3 Main Bearing Housing
142(2)
8.4 Tower Top
144(3)
9 Yaw and Pitch System
147(10)
9.1 Yaw System
147(5)
9.1.1 Layout
147(1)
9.1.2 Sizing
148(4)
9.2 Pitch System
152(5)
9.2.1 Layout
152(1)
9.2.2 Sizing
153(4)
10 Auxiliary Systems and Secondary Steel
157(16)
10.1 Mechanical Brake
157(2)
10.1.1 Layout
158(1)
10.1.2 Sizing
158(1)
10.2 Meteorological System
159(2)
10.3 Cooling and Heating
161(4)
10.3.1 Basics Heat Exchange
161(1)
10.3.2 Layout
162(1)
10.3.3 HVAC
163(2)
10.4 Hydraulics
165(2)
10.5 Tower Internals
167(6)
References 173
Dr. Uwe Ritschel studied physics and received his Ph.D. in 1989. After several years in fundamental research in 2000, he joined the engineering department of Nordex, a wind turbine manufacturer. In 2002 he established the Windrad Engineering GmbH and worked as managing director. The main business is the development of new wind turbines for international customers from the wind industry. Since 2014 he works as the Chair of Wind Energy Technology at the University of Rostock. In 2019 he co-founded the independent research institute IWEN working more generally on renewable energies and energy transition.





Dr. Michael Beyer received his Ph.D. in physics in 1985. He held several research and teaching positions in different countries including Germany, U.S.A., Switzerland, and several visiting and research grants on basic research. He is affiliated to the University of Rostock since 1994. In 2008 he entered the wind business and from 2014 until 2021 he was managing director of Windrad Engineering GmbH, an independent engineering office and design house for wind turbines. He shares his experience through supervising, consulting, and is presently teaching mechanical aspects of wind energy at the University of Kassel.
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