aaah N
The times in which
the term “wind
turbine gearbox”
was synonymous
with “accident” are
fortunately over.
Nevertheless, these
speed transformers
still often demand to
be wrapped in cotton
wool. But now, metal
ceramic coatings are
planned to stabilise
the tooth profiles.
Rewitec plans to rectify defects
h profiles by way of
‘special coating "en
Protective layer for
sensitive profiles
profiles is offered a few drops of magic potion
and willthen do its job again without complaint ~
that sounds more like a fairytale than an industrial
process. However, it has nothing to do with magic,
assures Managing Director Stefan Bill from Rewitec
(Germany), but rather with high-tech, "We have deve
loped a coating which restores worn metal surfaces
and subsequently protects them from abrasion,” he
says. In this way, he is picking up a core problem of
‘mechanical engineering. This can be illustrated vivid
ly by taking the wind turbine gearboxas an example.
Normally, the metal friction pairs are separated by
way of an cil film, so that “in principle” no problems
should occur.
l s that possible? A gearbox with damaged tooth
But they do occur, as numerous gearbox defects
today and in the past have shown. Unconventional
load profiles, ie. unexpected dynamic loads which
have not been taken into account, result in a failure
‘of the classic lubrication. This, in tur, results in tiny
defects of the surface in the first phase ~ so-called
micropitting visible asa dullgrey appearence of the
formerly bright metal surfaces. Micropitting is not a
cosmetic problem but can critically reduce the bear-
ing strength ofthe tooth profiles inthe long run.
New metal-ceramic layer
Now Rewitec claims to be able to undo these defects
at least partially, thus improving the contact pattern
Sun Wd nee 12010,‘of the tooth profiles permanently. This is apparently
attributable toa concentrate of metal silicate which is
added to the lubricating oll. That may sound lice the
cil additives we know from the automotive branch,
butis actualy something completely different. n con-
trast to the additives, the metal silicate does not re-
main in the oil, ut is deposited on the loaded metal
surfaces, where it forms a chemical compound with
the molecules of the metal surface.
Stefan Bill explains: “The temperatures resuiting
from the friction and high partial pressures cause the
‘metal surfaces to react and trigger a chemical inking
process.” Inotherwords:
the coating particles in
the concentrate ceramise
the metal surfaces dur
Micropitting
‘ates with the gearbox manufacturers Zoller and
Hansen Transmission, as well as with the turbine
manufacturer Nordex.
Scepticism in parts of the branch
Nevertheless, there are sceptical voices in the
branch, “I see things with mixed emotions,” says
FrankcKrull, Design Manager at the gearboxmanufac-
turer Elekhoff. “The interaction with the roller bear-
ings is not clear. They are dependent on a correct
supply of oll. Exaggerating slightly, the concentrate
slike dropping. tittle
stones into the gearbox.
This doesn't fit in with
state-ofthe-art oils and
This is the way how Rewitec
‘explains the process (from top
ing running, The quanti--Micropitting, or greystaining, is@phenome- __thelrsuperfinefilratin.” to bottom): the temperatures
tes ofconcetate wed gn ofsutacewearon high loaded meta," alo, Krull isnot resulting from metal ction
fe relatively small: ‘ : seein sureoftherealuse ofthe and high partial pressures
bout 6 ltresof concen. Amultude of microscopically smlldefectsIM ceramic coating: “The cause the coating particles to
trateareaddedto 3001i- the material givethe metaladull-grey appear questioniswhetherthere react on the metal surfaces.
‘ance, Micropitting may result in deeper cracks
and can progress to more extensive loss of.
material from the surface. If micropitting isnot
tres of oll- the common
‘quantity for a 1.5 MW
gearbox. The full coating,
reallyisa need for action
‘The micropitting is by no
means a forever continu
Giaphics()-Retar
process is completed af-
ter about 500 operating
hours. The result, Billex:
plains, is a new, ex
tremely wear-resistant
metal-ceramic surface.
Inthis way, itis possible
to refill “valleys” in the
surface up to @ depth of
30 microns, Avaluable side-effect: the metalceramic
coating itself provides extraordinary emergency run-
ning properties and can thus provide protection in
case of a total loss of oil
Growing wind-energy market
‘with this technology, the service life of gearbox and
bearings can be increased significantly,” he claims,
and refers to tests at the University of Bochum and
ongoing analyses at Germanischer Lloyd (G1). The lat-
ter already confirmed in aletter from the beginning of
2008 that metal silicates reduce the fiction in a die~
‘sel motor and the wear in a ball bearing. Currently, GL
is running test series with the objective oftesting the
‘suitability of metal silicates for use in wind turbine
gearboxes.
‘And this growing market is actually the more in-
teresting field of business for Bil: "15 % of our sales
turnover isin the automotive branch, and 80 % in the
field of industrial gearboxes, of which about three
{quarters is in wind energy, with an upward tenden-
cy.” First experience has already been gained. “For
example,” Bill continues, “a clear smoothing of the
‘tooth profile surface showed on the Flender gearbox
ofa 1 MWAN Bonus.” Ashe also reports, similar suc-
cess was already achieved with several older Tacke
‘machines ofthe output classes 250, 500 and 600 KW
in 2007 and 2008. At the moment, Rewitec cooper-
ee
property treated, the component can eventual
ly fal. To rectify the damage, cutting technolo-
gies (grinding, lapping, milling) with subse-
‘quent tempering have established themselves
‘as conventional methods. Missing material
‘can be applied by welding.
Ing process. Moreover, if
the material oss has pro-
gressed to a point at
which it becomes danger-
ous for the gearbox, the
concentrate will also no
longer achieve that much
improvement.” Krull is
committed to fighting the
‘actual causes. Much can already be done with lubri-
‘cants featuring higher resistance to micropitting and
a careful calculation ofthe critical points in the gear-
box.
‘A maintenance specialist who asked not to be
named sees things similarly. “I don’t now any appli
cations,” he says, “but nevertheless, | am sceptical.
For example, there is no guarantee of success. But
that, particulary, is what | would expect if Rewitec
‘were convinced by their own product.” Obviously, the
high price is also a deterrent, as could be heard be-
tween the lines, The price for treatment with the con-
centrate is indeed quite high: about € 6,300 for a
41.5 MW gearbox. And the treatment must be repeat
ed after two to three years.
Klaus Wolters, the Oil Service Manager at
Deutsche Windtechnik in Bremen, shares Eickhoff-
expert Krull's opinion that there is noimperativeneed
for action. “My experience tells methat, in some cas:
es, gearboxes run smoothly for a long time despite
mictopitting and broken teeth.” The exchange or
‘overhaul ofthe gearbox could be prepared during this
time without the need for silicate concentrate.
This does not really bother Stefan Bill. After all,
he can refertoafirst commendation: in 2009, Rewitec
was voted a finalist in the Husum WindEnergy Award
for outstanding innovations and was only just beaten
inthat final.
orate
particles ceramise the metal
surfaces during running.
The final resutis anew,
extremely wear-resistant
surface, The
material properties
reference to friction and wear,
Rewitec claims, ae improved
significantly.
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