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IDP Final Report Final
IDP Final Report Final
School of Engineering
Mechanical Engineering
BEng
Team Number 2
Group Number 1
Mech 4 Civil
Nacelle
Yaw System type
Components
Yaw Brakes
Drivetrain
Nacelle Design
requierments
Interfaces Mech 2
3 Technical Evaluation
3.1 Design Requirements
The design requirements for the yaw drive and braking systems were found theoretically using
the method in Figure 2 below:
Literature
Validation and
Comparison
𝐼𝑦𝑎𝑤 = Moment of inertia about the yaw axis (𝑘𝑔𝑚2 ) 𝑑 = Distance to yaw axis (m)
The drive power was finally calculated using the following equation:
𝑃 =𝑇𝜔 Eq.6
Where:
The braking requirements were determined using Equations 5-6, where the time to achieve a
full stop of the system was determined to be 1 second to ensure a quick stop in case of a
failure.
A summary of the system requirements is displayed in Table 3.
3.2.4 Nacelle
Nacelle is the house of components that transform the wind kinetic energy into electricity, which
located on top of the wind turbine tower [17]. On top of the tower, the nacelle is more likely to
experience high speed wind. Due to this, the nacelle will experience lift and drag force from the
air flow [18]. If the lift force on the nacelle is greater than its drag force, there is a high chance
that the nacelle will lift and loosen a bolt joint between the nacelle and the tower. In order to
design the most suitable nacelle for this project, the aerodynamics of the nacelle was
considered. Moreover, a map inside the nacelle was also considered. The nacelle map is
related to size and weight of the nacelle [19]. Therefore, to minimise weight and size of the
nacelle, all the space inside the nacelle needed to be functionally used. However, the compact
design of the nacelle still needs to provide space for maintenance technicians to access the
nacelle with maximum safety and serviceability [20]. As a result, our group came up with the
design as shown in Figure 4 and Figure 5.
Figure 4. Nacelle fully enclosed Figure 5: Cross section of Nacelle and its components
Every year more than a hundred wind turbines catch on fire. One of the main reasons is from
equipment overheating. Highly flammable materials are housed inside the nacelle including
electric wire, electric device and lubricant oil. Therefore, when the fire ignites, the flame will
easily penetrate all over the nacelle. Most of the heat inside the nacelle is from the generator,
since it generates electricity from the shaft rotation [21]. In fact, generating electricity always
comes with heat and some of the heat will be lost to the surrounding. In this case, it means that
generator is the main component that can cause overheating inside the nacelle. Therefore, to
avoid overheating, nacelle need significant thermal management.
Table 7: cooling technology comparison.
Our group found that air-liquid-air cooling system (Figure 6, Table 7) is the most suitable for our
nacelle, since it provide higher heat transfer efficiency when compared to air-air and liquid-air
system. However, with similar working system, air-liquid-air and air-liquid-liquid system require
higher initial investment and more maintenance [6].
3.2.5 Lubrication
Inadequate lubrication is one of the main influencers on bearing life, it consists of issues such
as overfilling, underfilling, incorrect specification, mixing, incorrect lubrication intervals,
deteriorated grease, water contamination, and particulate contamination [22]. In order to keep
the bearing functioning, proper lubrication and maintenance are required. We chose to
incorporate an automatic lubrication with Lithium complex soap grease (mineral oil base) into
our system provided by SKF [14] with a temperature range of -25 oC to +150 oC and a kinematic
viscosity of 160. With the automatic lubrication system market expected to grow at a compound
annual growth rate of 4.5% between 2018 and 2023 [23] it is evident that factors such as
reduced down time, and increased safety are contributing greatly to the rise in use of automated
lubrications systems over manual lubrication systems.
4 Wider Implications
4.1 Industry ethical / Legal
A patent search was conducted on various configurations for the yaw system to make sure our
design doesn’t conflict with other patents. As most wind yawing systems will have similar
configuration, slight differences such as the number of motors and the position of sensors or the
direction of the drive units proved vital in differentiating our designs with other patents. M-G kim
and PH Dalhoff made references to these patents in their journal paper [4]. Their in-depth patent
analysis was accepted because their design is like ours.
As most of our components will be bought from reputable suppliers, it is assumed that there will
be no legal conflicts with their components if we correctly follow the product guidelines.
Table 10: The process costs for manufacture of the nacelle and yaw
system)
Process Labour intensity Capital cost (£)
Hot open die forging Low 2.86e5 - 7.15e5
Hot shape rolling Low 1.43e5 - 1.43e7
High pressure die casting Low 1.43e5 - 7.15e5
Figure 13: The price change in materials used for wind turbines between 2002 and 2016 (42)
The capital cost shown in table 10 above is the total cost of the equipment necessary to carry
system)
out the process. For the purpose of this project, only a cost range could be supplied which
would lead to an overall price estimate for the processes required. These estimates are in line
with the current market trends available for wind turbine design with rolled steel manufacturing,
speed reduction gearing, fiberglass fabric, and industrial control manufacturing accounting for
nearly 50% of wind turbine costs (8). However, only rolled steel and fiberglass apply to this
group in the wider team. The labour intensity was also added to provide an insight into how
employees would be affected by each process with an arbitrary scale from low to very high
being used. The lower the labour intensity, the lower the amount of labour needed to produce
goods or services.
Table 11 below shows the main bought out components and their average cost as provided by
each of their suppliers. These average costs allow us to gain an initial estimate of the type of
investment necessary to carry out the design of the nacelle and yaw system.
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1_2005.pdf [Accessed 28 Nov. 2018].
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13. https://www.skf.com/uk/products/bearings-units-housings/slewing-
bearings/index.html"https://www.skf.com/binary/tcm:12-182061/Slewing/index.html
14. https://www.liebherr.com/en/gbr/products/components/large-diameter-bearing/product-portfolio-large-
diameter-bearing/details/kud03839050zj15900000.html
15. https://www.silverthin.com/news/articles/moment-load-basics.php
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17. http://www.alternative-energy-tutorials.com/wind-energy/wind-turbine-design.html
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International Conference on Advanced Design and Manufacturing Engineering 2015 Oct 15. Atlantis Press.
21. Folger R. BEARING KILLERS: Preventing the top causes of bearing damage [Internet]. Cleveland: Machine
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22. Automatic Lubrication System Market worth 958.5 million USD by 2023 [Internet]. Marketsandmarkets.com.
2019 [cited 24 April 2019]. Available from: https://www.marketsandmarkets.com/PressReleases/automatic-
lubrication-system.asp
23. Pedersen H, Marin E. Yaw Misalignment and Power Curve Analysis. EWEA Analysis of Operating Wind
Farms. Bilbao: Wind Europe; 2016.
24. Declercq B, Bronckers S, Terris G, Quievy N. A more efficient method for static yaw misalignment detection
and correction. Analysis of operating wind farms. Vilnius: ENGIE; 2018.
25. Yaw Misalignment Correction Case study. Hinesburg: Wind Iris; 2019.
26. Cox, I. (2017). Common concerns about wind power. 2nd ed. Bristol: Centre for Sustainable Energy.
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http://www.afs.enea.it/project/neptunius/docs/fluent/index.htm [Accessed 27 Feb. 2019].
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OF A MULTI PURPOSE VEHICLE USING CFD. ARPN Journal of Engineering and Applied Sciences, 12(7),
pp.2345-2350.
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effects of direct water injection parameters on engine performance in a six-stroke engine. Energy
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30. Jonkman J, Butterfield S, Musial W, Scott G. Definition of a 5-MW Reference Wind Turbine for Offshore
System Development. Colorado: National Renewable Energy Laboratory; 2009.
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32. https://sites.google.com/a/cornell.edu/wind-energyjwk84/social-impacts.
33. https://www.cse.org.uk/downloads/reports-and-
publications/planning/renewables/common_concerns_about_wind_power.pdf
34. https://esmap.org/sites/default/files/esmap-
files/ESMAP_IFC_Wind_Module_RE_Training_World_Bank_Rapp_March_2012_Optimized.pdf
35. https://www.windpowerengineering.com/projects/many-jobs-wind-farms-create/
36. Sainz, J. (2015). New Wind Turbine Manufacturing Techniques. Procedia Engineering, 132, pp.880-886.
37. https://recyclenation.com/2014/09/recycle-fiberglass/
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39. Morgan E, Manwell J, McGowan J. A Methodology for Updating Wind Turbine Capital Costs. Wind
Engineering. 2012;36(4):485-492.
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8 Appendix
8.1 Minutes of Meeting
Date Meeting topic Decisions/Discussion Results of meeting
30/10/18 Initial team discussion - Location for wind farm chosen. - Group meeting date
- Group roles distributed. selected.
- Design week presentation - Each member to carry out
highlighted. research no the yaw
- Khalid selected as group system and nacelle.
communicator/leader.
1/11/18 First group meeting. - Research on yaw and nacelle - Each member to research
system presented by group their assigned area.
members. - Slides to be prepared in
- Group members assigned roles. next meeting.
- Next meeting arranged for
5/11/18.
5/11/18 Group meeting on - Research presented by - Members to fill in their
design week members. sections on PowerPoint
presentation. - Active yaw system selected. using OneDrive.
- Initial sketches of yaw system - Next meeting set for
and nacelle presented. 7/11/18 as a practice
- Group roles chart created. meeting for presentation.
- Project Gantt chart created
- Presentation slides outlined.
21/11/18 Group progress - Members gave updates on - Deadline for prelim report
meeting. progress for individual sections set as 27/11/18.
questions.
- Members presented any
queries they had for
group/team.
- Concept designs edited further.
27/11/18 Group work on prelim - Compiling of report began. - Interface drawings to be
report. - Format of report agreed upon. completed on 28/11/18.
- TRIZ model incomplete. - TRIZ model to be
- Concept designs completed completed on 28/11/18.
28/11/18 Report finalisation and - Interfaces and TRIZ completed.
hand in - Report compiled and submitted.
22/01/19 First group meeting of - Feedback from prelim report - Team meeting to be
new year. discussed. arranged.
30/01/19 Team meeting - Parameters finalised. - Group to speed up work
- Overall design established. on CAD models.
4/02/19 Group meeting. - Team meeting discussed. - Information shared
- Roles assigned for CAD between groups about
designs, calculations of requirements.
individual sections, and material - Members to carry out
selection. calculations and search
- Requirements from other for suppliers.
groups discussed.
11/02/19 Group meeting to - Possible suppliers discussed. - Content of design week
provide progress - CAD design beginning to form presentation to be
update. properly. prepared.
- Validation methods like CFD
and Simulink discussed.
18/02/19 Group meeting on - Presentation slides planned out. - Presentation slides to be
presentation - Sections assigned. prepared.
- Design details such as - Presentation practice date
bearings, and braking system set for 20/02/19.
chosen.
20/02/19 Presentation run - Each member presented their - Members to memorise
through section in front of group. scripts before
- Members discussed any presentation on 21/02/19.
possible additions to slides.
21/02/19 Presentation 2 - - Meeting set for 27/02/19
to discuss feedback and
next steps.
27/02/19 Meeting to discuss - Feedback discussed. - Members to begin work
feedback. - Members gave each other on final report based on
feedback on presentation. feedback given.
- Final report discussed.
12/03/19 Meeting to discuss - CAD models presented. - Members to continue
progress. - Update on calculation process working on their tasks.
for different members.
- Each member presented plan
for forward steps.
22/03/19 Meeting on final report - Report structure created. - Routing sheets to be
- Members to fill in sections via created.
OneDrive. - Final meeting before
- All work to be uploaded to break
OneDrive folder.
22/04/19 Meeting to compile - Different sections updated. - Poster to be worked on in
report - Unassigned sections next meeting.
highlighted and worked on.
- Final CAD models and drawings
presented.
25/04/19 Meeting to create - Poster divided into different - Team meeting discussing
poster. sections. poster to be set.
- Members added their parts to
the poster.
30/04/19 Team meeting on - Final report and poster -
poster and report. compiled.
8.2 Manufacturing Routing Sheets
Table 13: Manufacturing routing sheet for the platform
Routing sheet
Part name: Part no.: N/A Drg. No.:
Platform
Quantity: Material: Steel (S500) Planner: Group 2-1
Revision no.: Date: Page: 1 of 1 Order No.: N/A
Op. No. Description Machine tool Fixtures
10 Molten metal is poured Casting machine clamp
into pattern of the
shape
20 Drill 8 30 mm bolt Drill press Clamp
holes around 500 mm
hole.
30 Drill 50 30 mm holes Drill press Clamp
in a circular pattern
2200 mm away from
centre
40 Deburr Tumbler N/A
50 Polish Bench grinder N/A
60 Inspect N/A N/A
Table 14: Manufacturing routing sheet for the Nacelle bed
Routing sheet
Part name: Part no.: N/A Drg. No.:
Nacelle bed
Quantity: Material: Cast iron Planner: Group 2-1
Revision no.: Date: Page: 1 of 1 Order No.: N/A
Op. No. Description Machine tool Fixtures
10 Molten metal is poured Die casting clamp
in a mold to acquire its
shape
Routing Sheet
Part name: Yaw Drive and Part no: N/A Drg no: 1
Brake
Quantity: N/A Material: N/A Planner: Muhammad Salihu
Date:
Table 20 Operation sheet for the Platform
19/04/2019
Batch size
Component: Platform Drawing No. 1 Planner: Team 2 Group 1
50
Set-up Operating
Operation Speed Feed
Description Machine Tooling time time Remarks
number (RPM) (mm/min)
(mins) (mins)
Pack sand and clay to form basic pattern
10
shape
Crucible Tongs, Pouring 10 1
Pour molten metal, rest until solidification, Shank (Cranked Lift),
20 Metal foundry Sand Casting
retrieve the casting. Shakedown Mallet
Hammer
Visual
40 Initial Inspection Visual 2
Inspection
Ensure flatness of the surface and polish the
50 Sanding wheel 2 5
surface
Drill M30 holes around the edges for bolting,
Ø10 and Ø30 mm High
60 start with an M10 drill to ensure guided Press drill 5 15
Speed Steel Drill Bits (HSS)
drilling.
Visual indication,
80 Final Inspection Digital Dial and, 1 10
calliper
Date:
Table 21 Operation sheet for the Nacelle
19/04/2019
Batch size
Component: Nacelle Drawing No. 1 Planner: Team 2 Group 1
50
Operating
Operation Speed Feed Set-up time
Description Machine Tooling time Remarks
number (RPM) (mm/min) (mins)
(mins)
Visual
60 Initial Inspection Visual 2
Inspection
Drill holes on the component edge with Ø10 and Ø30 mm High
80 Press drill 5 15
size of 30M Speed Steel Drill Bits (HSS)
Grind the edges of the drilled holes to
90 Convolute tool 2 5
avoid sharpness