Test & measurement
WORLD’S MOST POWERFUL WIND BEARING TEST FACILITY: SCHAEFFLER COOPERATES WITH LORC AND R&D TEST SYSTEMS
required distance to the target. The composite tape can be anything between 6mm and 13mm wide, so we needed a sensor with a field of view of around 25mm in order to ensure we could capture everything. The cost of the sensor was also within our purchasing budget. During the research, we received excellent technical support from Micro-Epsilon in terms of how to integrate and use the sensor, as well as advice on installation. “It was easy to integrate the scanCONTROL sensor into our machine. The control system for the machine was originally developed using LabVIEW. We used the freely downloadable scanCONTROL Configuration Tools software from Micro-Epsilon to extract the data into other software to create all the defect images. The software also allowed us to easily output the profile data into LabVIEW.” Following the success of the initial proof-of- concept phase, the team at BCI has been awarded a Faculty of Engineering Strategic pump-priming fund to further develop this technology. As Dr. Tretiak concludes: “It’s critical to be able to detect defects during the AFP process. Normally, non-destructive techniques are used to test the parts after they’ve been produced, which makes it very difficult to mitigate any problems, resulting in parts being scrapped that don’t meet the manufacturing specification. Having the ability to automatically detect defects during production means we can react accordingly, save production downtime and reduce material waste. Furthermore, you can avoid manual errors as the machine operator doesn’t need to check for defects.”
Micro-Epsilon
www.micro-epsilon.co.uk Instrumentation Monthly February 2024
an integral part of the drive train, is of elementary importance, as this is where all the forces and torques exerted by the wind on the turbine add up. As a market leader and strategic development partner, Schaeffler is rising to the challenge and will contribute actively to the development of multi-megawatt wind turbines. In Lindø, Denmark, the world’s most powerful test facility for main shaft bearings will be built at LORC (Lindø Offshore Renewables Centre). The investment is in the mid-double-digit millions and includes grants from the Danish GreenLab programme. Concrete test programmes should already be running by the end of 2025. LORC has partnered with R&D Test Systems, which is one of the leading suppliers of test benches for the wind industry, to build the new test facility. Schaeffler played a major part in defining the specifications of the test facility and will be the first customer to test its main shaft bearings for future generations of wind turbines in cooperation with OEMs. Dr. Michael Pausch, CTO Industrial Schaeffler, stresses: “We are a key market and technology leader for bearing technologies in the wind power industry. With LORC, one of the most experienced operators of test facilities for wind turbine drivetrains, we have found a partner to help us further expand our know-how and our product performance. We now have the opportunity to shape the development
T
he expansion of renewable energies is being driven to a great extent by wind turbines. Wind turbines are becoming larger and more powerful. The main shaft bearing system, as
of the next generations of wind turbines with suitable testing technology and method development.” “We have been gaining valuable insights for the development of bearing solutions since 2011 with our large-size bearing test bench 'Astraios,’ the world’s most powerful test bench at the time. With the new test facility, we will now be able to advance into new and future dimensions and contribute to a more rapid development of reliable multi-megawatt turbines,” adds Bernd Endres, vice president Business Unit Wind, Schaeffler Industrial.
“CLOSED LOOP ENGINEERING” FOR WIND TURBINE BEARINGS
Schaeffler has been offering reliable bearing solutions for on- and offshore wind turbines for around 40 years. Rolling bearings from Schaeffler are found in every second to third wind turbine worldwide. Schaeffler takes a “closed loop engineering” approach for its wind turbine bearings. Besides engaging in the pure development of bearing solutions, the Schaeffler experts also support turbine development with system simulations, testing, and field measurement campaigns. The findings gained flow back into the further development of customers’ projects, design tools as well as the development of new bearing solutions. The experts from Schaeffler work closely with developers from OEMs to increase the reliability of wind turbines and make wind power more cost- effective. The new test bench will provide an important building block for the developments of the coming decades.
Schaeffler Group
www.schaeffler.com/en/
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