R&D Test Systems wins follow-up order from ZF Wind Power: most powerful end-of-line test bench


The check rig conducts remaining assessments earlier than delivery the offshore powertrain, together with the gearbox, generator, and major bearing association; The automated link-arm-coupling idea reduces mounting time by as much as 90 p.c; two items examined per day; The motor can function at 15 MW, making it probably the most highly effective end-of-line wind turbine check bench

Hinnerup, Denmark, 25 April 2023 – R&D Take a look at Techniques, a number one Danish wind turbine check system provider, has acquired a follow-up order from ZF Wind Energy to develop and provide a brand new end- off-line check bench required to confirm system performance of manufactured powertrains, together with gearbox, generator, and major bearing association, previous to cargo to OEMs.

The check rig, which options R&D Take a look at Techniques’ computerized idea based mostly on link-arm coupling, reduces mounting time by as much as 90 p.c, thus permitting each powertrain items to be examined every day.

The tip-of-line check rig shall be delivered to ZF Wind Energy’s manufacturing plant in Lommel, Belgium, within the fall of 2023. R&D Take a look at Techniques has additionally been chosen in early 2022 to produce a 30 MW validation check bench for ZF Wind Energy’s Take a look at & Prototype Heart on the identical web site.

“We’re more than happy to be awarded this extra contract and to collaborate with ZF Wind Energy on two of the strongest check benches. It is a recognition of our abilities within the improvement of check techniques for the testing of high-power offshore wind generators each in manufacturing. and the prototype degree,” mentioned Peter Ulrikkeholm, CEO, R&D Take a look at Techniques.

Performing remaining assessments earlier than the powertrain leaves the manufacturing facility, end-of-line assessments guarantee the standard and efficiency of the ultimate product.

“An end-of-line check cycle will examine system perform below load, testing hydraulics, sensor connections, in addition to contact patterns for gears, along with checking lubrication, temperature, strain and noise and vibration ranges ,” defined Martin Knops, Chief Know-how Officer (CTO) of ZF Wind Energy. A remaining gearbox flush made it able to run from day one.

The gearbox is without doubt one of the most complicated components of a wind turbine as a result of many dynamic interacting sub-systems. So your entire powertrain wants a collection of ultimate, lengthy assessments earlier than going to the sphere. “We imagine as soon as this check rig is up and working, it is going to be probably the most highly effective end-of-line check rig within the wind energy trade,” defined Peter Winther, Key Account Supervisor at R&D Take a look at Techniques.

The check rig for ZF Wind Energy carried out load assessments, powered by a greater than 15 MW motor, which supplied a formidable 18 MNm of torque to check the unit at excessive load ranges. “This remaining check ensures that the powertrain with all its connections works because it ought to, even when uncovered to 5000 instances the torque of Method 1 automobiles,” added Peter Winther.

Able to lifting as much as 300 tons, the crane chosen for the check bench will each raise and exactly place the offshore powertrains on the check bench, which at its highest level is six meters above the land. Three automated hydraulic techniques then clamp the powertrain in place utilizing a link-arm-coupling thus connecting the check motor to the powertrain.

“Mounting a powertrain of this dimension is time-consuming as a result of there are actually lots of of connections that have to be made, each mechanical and excessive and low energy. optimize the powertrain set up course of .

“Dismounting and disconnecting the confirmed unit each profit from the automated course of. This protects handbook work and is a serious benefit for end-of-line testing when the manufacturing stream has a excessive significance. The idea permits us to check two items in sooner or later,” concludes Peter Winther.

The R&D Take a look at System will use its confirmed automated hyperlink arm idea designed to attach the 15 MW motor and the powertrain unit, which have to be robust sufficient to deal with giant masses whereas nonetheless being versatile sufficient to permit the fast change.

An engineering crew consisting of software program, mechanical, low voltage, excessive voltage, civil and hydraulic specialists has began growing the end-of-line check bench at R&D Take a look at Techniques’ Headquarters in Hinnerup close to Aarhus in Denmark. The corporate will apply its check bench experience in high-power drivetrain testing of offshore wind generators.

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About R&D Take a look at Techniques

R&D Take a look at Techniques is a global engineering firm that provides expertise improvement, digital check techniques, and large-scale turnkey check techniques for the aerospace trade.

What makes R&D Take a look at Techniques distinctive is its expertise in all phases of product improvement – from improvement and design to the development of check amenities. R&D Take a look at Techniques makes use of intensive trade information and extremely specialised engineers to method clients’ challenges from a number of angles to develop the precise resolution.

The ambition is to offer particular person, sustainable, and revolutionary options that help the businesses of its clients. That is how R&D Take a look at Techniques creates worth via world-class engineering.

R&D Take a look at Techniques is a division of the American company ITW.



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