Energy Brochure Cases a Siemens Business LR

7/29/2019 Energy Brochure Cases a Siemens Business LR

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Partnering with leading companies

Wind


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We truly believe that LMS has made a transformational impact on our industry.

Together with our customers and business partners, we have delivered engineering

solutions that have revolutionized how cars, airplanes, satellites, wind turbines

and other high-tech products are developed today.

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Your Leading Partner in

Test & Mechatronic SimulationPride,

is probably the one word that best sums up how we feel about what LMS has achieved during the

past 30 years.

Our passion for innovation is the key driver of our excellence in business and our success in driving

the industry forward.

The industry is facing major challenges inventing, developing and manufacturing the right products

efciently. Designed Right, First Time. Successful products must be attractive, ecological, smart and

distinctive with appealing brand values.

Mastering the complexity of next-generation products and development processes has

become a major challenge for most manufacturers. For LMS, this is the essence of what drives us:

the relentless pursuit of product and process innovation and the transformational solutions required

to achieve this.

With the current drive for smarter and more ecologic products, engineering innovation takes on a new

mission. Simulation and testing are being re-dened to support a novel approach to system-

level engineering. A paradigm shift whereby the mechanics, electronics and software in a new design

will simultaneously be optimized as an integrated mechatronics system.

With the integration of Imagine in 2007 and the 2010 acquisition of Emmeskay, we have expanded

our portfolio for multi-physics system simulation, plant modeling and controls. In 2011 we acquired

Samtech, a leading provider of Computer Aided Engineering and structural analysis software within the

European aviation and aerospace industry. We are well positioned to be the Leading Partner in Test

& Mechatronic Simulation. It is our aim to once again turn this compelling vision of Designed Right,

First Time into reality. Digital design, both testing and simulation, will become so authentic that every

customer expectation will have been exceeded by the time the rst prototype goes into production.

We thank you for your trust and long-term commitment to us and for the opportunity to deliver the

technology, systems and support that are critical for true product innovation for the next 30 years.

Thank you and pleasant reading,

Yours sincerely,

Dr. ir. Jan LeuridanCEO LMS, A Siemens Business

30 years of trust

3

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LMS,

the preferred partner of

Fortune 500 Manufacturers

Through 30 years of engineering innovation and worldwide expansion,

we are servicing more than 100.000 R&D engineers in more than

5.000 manufacturing companies.

LMS has become a trusted partner of the worlds leading automotivemanufacturers, aerospace companies, major energy producers and

manufacturers of other high tech equipment.

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A Scalable Partnering Model

Strategic partner in Product Development & Process Transformation programs

System integrator in Test and Mechatronic Simulation

Partner in attribute engineering for N&V, durability,system dynamics, performance, emissions...

Supplier of Testing Systems, Simulation

software and Engineering Services

LMS,auniqueproviderof

anintegrat

edportfolio

From Troubleshooting to Design-Right-First-TimeVision, Solutions and Best Practices

PartneringLevels

Breakthrough

Innovation

ROI - Protability

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Alstom chooses SAMCEF Wind Turbines (SWT),

SAMTECHs professional product for advanced

dynamic analysis and certication of Wind Turbines

The purchase of SWT is the natural result of the condence of Alstom in SAMTECHs software

solutions and the nal choice for SWT was further consolidated through the outcome of validationcampaigns that proved the accuracy of SWT when comparing numerical results with experimental

measurements. In fact, Alstom evaluated in depth several well-known software systems for aero-

elastic load computations and Multi-Body-System analysis.

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power train was set up. Successful

experimental validation was performed

on that model and triggered a long-term relationship between the two

companies in the domain of advanced

dynamic simulation of wind turbines.

Further collaboration, including intensive

validation campaigns, resulted in the

set up of advanced aero-elastic SWT

models of several Alstom Multi-Mega

Watt class wind turbines. Several key

features for accurate modeling of

wind turbines have been added to the

software over time to match the needs

of todays wind industry and makeSWT the most complete platform on

the wind turbine simulation market.

The collaboration between Alstom

and SAMTECH will continue in several

industrial domains including the simulation

of offshore wind turbines and the

evaluation of innovative Mechatronical

Systems for active damping.

The possibility to include the most

complex mechanical models in one

detailed aero-elastic wind turbinemodel, accurate results and a reduced

learning time were the features which

convinced ALSTOM to select SWT.

The SWT solver SAMCEF Mecano was

used for the rst time in a wind turbine

context in Alstoms Wind business 10

years ago. As early as in the year 2000,

the rst non-linear dynamic SAMCEF

Mecano model of a 600 kW wind turbine

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REpower Systems AGs

Advanced Drive Train Simulation

The SWT solver SAMCEF Mecano was used for the rst time in REpowers Wind business

in the year 2006 for the analysis of drive train dynamics of a REpower megawatt class windturbine. The initially applied aero-elastic SAMCEF Mecano model accounted for the most

relevant exible wind turbine components, including a detailed gearbox model and the

turbine control. A strong collaboration was then set-up in the frame of ADTS consortium

to introduce key features in the innovative SWT professional software product.

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REpower Systems AG, a Suzlon

group company, is one of the leading

manufacturers of onshore and offshorewind turbines. The international

mechanical engineering company

develops, produces and markets

wind turbines with rated outputs of 1.8

MW to 6.15 MW and rotor diameters

of 82 meters to 126 meters for almost

any location. The company also offers

a comprehensive portfolio of service

and maintenance packages.

The protable and reliable systems

are designed at the REpower

TechCenter in Osterrnfeld

and manufactured at its plants in

Husum (North Friesland), Trampe

(Brandenburg) and Bremerhavenas well as Portugal and China.

With more than 2,200 employees

worldwide, the company, which has

been listed since March 2002 and is

headquartered in Hamburg, can make

use of the experience gained from

the manufacture and installation of

around 3,000 wind turbines around

the world. REpower is represented by

distribution partners, subsidiaries and

participations in European markets

such as France, Belgium, the UK, Italy,

Portugal, Sweden, Poland and Spainas well as on a global level in the USA,

China, Australia and Canada.

In the year 2007, REpower AG supported

the creation of a consortium of leading

industrial experts for Advanced DriveTrain Simulation/ADTS to improve

further the SWT power train model.

The ADTS consortium was an intensive

technical collaboration in between

REpower Systems AG, Schaefer Group,

Eickhoff Antriebstechnik GmbH and

SAMTECH Iberica. Outcome of that

collaboration where specic extensions

of the SWT solver for advanced power

train modelling in order to match

the needs of todays wind industry.

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U.S. National Renewable Energy Laboratory

Dening the American bounds of wind energy

Engineers at the U.S. Department of Energys National Renewable Energy

Laboratory use LMS technology in performing modal testing on next-generation

wind power systems destined to radically change Americas energy policy.

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The use of wind power in the United

States has expanded quickly over the

last several years. Construction of new

wind power generation capacity in

2011 totaled 6810 megawatts bringing

the cumulative installed capacity to

46,919 MW. This capacity is exceeded

only by China. In 2011 the electricity

produced from wind power in the USamounted to 2.9% of all electric power.

The U.S. wind industry generates

tens of thousands of jobs and billions

of dollars of economic activity.

Wind projects boost local tax bases,

and revitalize the economy of rural

communities by providing a steady

income stream to farmers with

wind turbines on their land.

GE Energy is the largest domestic

wind turbine manufacturer.

Just like GE Energy, NREL

is working with LMS.

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Animated mode shape displays show engineers

how various parts of the wind turbine structurebend, twist and otherwise deform at resonant

frequencies.

The 96-channel LMS SCADAS mobile system

is a lightweight, battery-powered laptop-sizeunit less than a third the size of NRELs former

cumbersome UNIX-based system.

Resonant modes show up as peaks on frequency

response function (FRFs) plots.

Full modal survey

NWTC engineers have already used the

LMS system in performing a full system

model survey of a specially modied

three-bladed 600-kW wind turbine

system, known as the CART-3, which is

used for advanced controls research.

With its rotor xed in a parked position,

accelerometers were placed on the entire

structure, including points on the tower,

rotor blades, gearbox and nacelle. Blades

were excited to vibrate with impact from

an instrumented hammer. For other

parts of the structure, hydraulic shakers

were controlled by signals from the LMS

SCADAS data aquisition system, which

measured amplitude response of the

structure for various input frequencies.

According to NWTC test engineer

Richard Osgood, one of the major

advantages of using the LMS SCADAS

mobile data aquisition system was that

it could be used as a distributed data

acquisition system, with slave units on

the rotor, blades, nacelle, tower, and

even a remote meteorological tower to

measure wind speeds - all daisy-chained

together and connected by ber-optic

cables to a master unit on a truck on

the ground at the base of the tower.

Replacing the previous UNIX-

based system with the portable,

scalable and distributable LMS

SCADAS mobile system connected

with ber optics saves tens of

thousands of dollars for each test

set-up compared to cumbersome,

more-expensive long signal cables

that take lots longer to set up,

said Richard Osgood.

This level of cost and efciency is

important in operations such as ours in

which budgets are extremely tight. Also,

signal loss and background electronic

interference was signicantly reduced

with a distributed system based on

ber optics, so less time is requiredin correcting for these discrepancies,

especially in testing variable-speed

drive trains that tend to generate

considerable radio-frequency noise.

Using multiple-input/multiple-output

acquisition and analysis capabilities

for measured signals, the LMS system

created plots - including animated

mode-shape displays and frequency

response functions (FRFs) - identifying

ten fundamental system modes of

vibration of the structure, including rotorbending and twisting, blade torsion,

and tower fore-aft and side-to-side

bending. The LMS system also accurately

identied vibration modes often difcult

to predict solely through simulation,

such as coupled motion between the

nacelle, tower, and rotor bending.

Test engineers used LMS Virtual.Lab

software to correlate eld test

measurements with predicted results

from a dynamic simulation model

developed by NREL wind researchers.

Initial evaluations were performed using

a Modal Assurance Criteria (MAC) matrix

diagram showing where the experimental

and theoretical types of modal data

aligned and where they diverged.

Tools for advanced R&D testing

Work in addressing these requirements

is spearheaded by the National

Renewable Energy Laboratory

(NREL) - DOEs primary research and

development center for wind power.

A key focus of efforts at NRELs National

Wind Technology Center (NWTC) in

Golden, Colorado, is aimed at testing

proposed new concepts, as well as

improving existing designs, often in

connection with industry partners,

including wind turbine manufacturers

and component suppliers.

In particular, modal testing is performed

to identify resonant frequencies of the

wind machine. As a nationally certied

test facility, the NWTC also performs

modal analysis as part of a suite of

dynamic vibration tests for certifying

wind turbine designs. NREL installed

a LMS Test.Lab data acquisition and

analysis system for performing these

modal and vibration tests, and LMS

Virtual.Lab software for correlating

and updating simulation models.

Measurements are made using a

96-channel LMS SCADAS mobile data

aquisition system in a lightweight,

battery-powered laptop-size unit

that is easy to carry up into a wind

turbine nacelle and between the NWTC

and outdoor wind turbine sites. The

portable units are less than a third the

size and weight of the NWTC former

cumbersome UNIX-based system.

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From this comparison, the test engineers

were able to provide the dynamicist

with information conrming simulation

predictions and updating simulation

modes when discrepancies were found.

In addition, experimental identication

of the turbine drive train frequencieswere used to adjust the wind turbine

controller and resolve vibration problems

occurring during operation of the

variable speed power electronics.

Adjusting simulation models

work together properly, Osgood said.

If a problem arises, there is only one

vendor to contact, and LMS has been

extremely helpful in getting our engineers

up and running on the new system.

The major value of LMS technology

in our testing operations is that we

can operate more efciently and cost-

effectively, providing high-quality data

and greater insight into the vibration

characteristics of next-generation wind

turbines that will serve the nations

energy needs in the coming decades.

For a modal survey, engineer positions accelerometers on the blade of a 600 KW wind turbine

with a 40-meter rotor diameter.

Integration of these functions - plus a

fast processing speed enables NWTC

engineers to see results immediately

after measurements are taken instead of

waiting hours or days for post-processing.

This fast visualization helps engineers

verify the test on the spot, see right away

how the structure behaves, get a good

insight into the root cause of vibration

problems, and easily identify particular

areas that need further investigation.

A fully integrated system ensures that

all tools we need are compatible and

For obtaining accurate predictions

of turbine vibration characteristics,

test-based modal analysis is

critical to adjusting models for awide range of simulation including

nite element analysis, multi-

body dynamics, aerodynamics,

acoustics, and blade pitch

control, said Richard Osgood.

Stiffness attributes and damping

characteristics computed by LMS Test.Lab

from modal data is an essential

structural parameter needed as inputs

to the simulation model to accurately

represent structural members as exiblerather than entirely rigid bodies.

In this manner, simulations can more

accurately predict the realistic bending

and twisting motion of components that

sometimes can lead to unacceptable

deformations and instabilities.

Value of an integrated system

Osgood noted that having this wide range

of capabilities in a single system was

an important criterion in their selection

process, with LMS Test.Lab providing afully integrated suite of tools - test set-up,

control, measurement, signal conditioning,

result analysis, data management, and

report generation - all in the portable test

unit. The PolyMAX feature, for example,

automatically highlights resonances so

engineers can visually identify natural

frequencies in minutes instead of

spending hours looking through raw data.

With an Active Pictures capability, live test

data in the form of interactive, animated

plots can be cut-and-pasted into Microsoft

Ofce tools like Word and PowerPoint.

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The resulting full-scale acoustic wind

turbine model enabled engineers to

predict far-eld wind turbine acoustics

with adequate accuracy and efciency.

Collaboration, commitment and expertise

helped the team to overcome theprojects extreme modeling and testing

challenges and allowed the wind turbine

manufacturer to establish a robust

virtual path for mastering wind turbine

acoustics. Advanced testing efforts

were deployed to create and validate

the vibro-acoustic simulation model, and

additionally allowed modeling challenges

to be better understood in facilitation

of future wind turbine developments.

Optimizing wind turbineacoustics throughvirtual simulation

The noise wind turbines generate is

inuenced by many factors, includingblade size and design; drivetrain operation

as well as the orientation, force and

turbulence of the wind. Roughly speaking,

a megawatt wind turbine generates a

relatively at 45-55 dBA broadband noise

spectrum at a distance of 130-150 meters.

At average wind speed, wind turbine

noise only drowns out wind turbulence,

vegetation and/or trafc noise that

is present in the background by

approximately 10-15 dBA. Specic tonal

noise components occur as a result of

dynamic forces that come into play insidethe gearbox (teeth meshing), the generator

(electro-mechanical poles interaction),

and system hydraulics equipment.

The large physical size and characteristic

acoustic radiation of wind turbines

make it a real challenge to accurately

simulate wind turbine acoustics early

in development. A leading wind turbine

manufacturer and LMS EngineeringServices joined forces to meticulously

build a hybrid vibro-acoustic simulation

model, and validate the wind turbine

model through operational measurements

executed 100 meters above the ground.

Building a robust path for virtual wind turbine designLeading wind turbine manufacturer partnered with LMS Engineering Services tosharpen capability to master wind turbine acoustics

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These dynamic forces cause local housing

surface vibrations, which distribute the

noise to the surrounding area through

radiation. The noise generated by driveline

rotating machinery also propagates

directly through structural noise paths.

To accelerate efforts to reduce the noise

of its comprehensive range of wind

turbines, the manufacturer contracted

LMS Engineering Services to run a

number of joint hybrid vibro-acoustic

modeling and simulation projects.

Our motivation to engage in these

projects relates to the capability of

acoustic simulation in identifying design

improvements up-front in the development

process, Laurent Bonnet, Leader of

Acoustic & Vibration Engineering at themanufacturer in Germany, stated.

The advanced modeling expertise

acquired through these projects

represents the foundation for

building accurate wind turbine

models, and enables us to predictthe acoustic performance of

multiple design variants. Acoustic

simulation insight is most helpful

in tracing individual noise sources

and adapting the design for

enhanced acoustic performance

early on in the process.

For the initial project, the manufacturer

selected its 1.5 Megawatt wind turbine

platform, which is currently in operation

at a large international install base.

LMS engineering consultants helped

develop a validated vibro-acousticmodel of the full-scale wind turbine,

using a method combining structural FE

(Finite Element), acoustic BE (Boundary

Element) and ATV (Acoustic Transfer

Vector) modeling and simulation.

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Challenging tests to create/validate wind turbine FE model

In the process of building a complete,

accurate and full-scale FE model of

the wind turbine, the engineering team

faced the challenge of characterizing all

principal components that make up

a wind turbine, such as the blades, hub,

rotor, tower, gearbox, brake, bedplate

and nacelle. An exceptional modal

testing experience was undoubtedly thedetailed structural characterization of

a 37- meter rotor blade. Such a blade

almost entirely consists of a complex

laminated composite construction with

various curvature geometrical topology

with relatively low initial structural

damping. Other complex subsystems

that were characterized include the

large oil-cooled gearbox assembly

and the 160-tons and 100-meter tall

carbon-steel wind turbine tower.

In addition to transfer functions(Frequency Response Functions FRFs)

that were acquired for modal analysis

and general dynamic assessments,

engineers measured and validated FRFs

to characterize the interface between

various wind turbine parts. This testing

approach enabled them to properly

dene appropriate stiffness and contact

area representations. After modeling all

individual components and interfaces, they

grouped a number of related components

into partial system assemblies, such as

the rotor hub in combination with thethree rotor blades. For each subassembly

that was considered, they updated the

overall FRF analysis and junction transfer

functions by specic measurement

blocks. Subsequently, the project team

performed FRF analysis on the complete

wind turbine assembly in order to update

the structural full-system FE model and

to validate all cross transfer functions.

Running operationalmeasurements frominside the nacelle

Besides experimental modal analysis,

testing efforts also included operational

full-turbine measurements to be able to

qualify acoustic sound levels, vibrations

and forces, Laurent Bonnet stated.

The test crew for this extraordinary test

campaign consisted of test personnel

from both the wind turbine manufacturerand LMS. Overall, it deployed 6

LMS SCADAS front-end stations totaling

nearly 400 measurement signals to

acquire deection, vibration and acoustic

responses in, on and around the wind

turbine. Members of the crew used

the LMS Test.Lab software suite to

control synchronous data acquisition,

and to perform any data analysis action

they required. An extra measurement

system, equipped with a wireless LAN,

operated strain gauge measurements

on the rotating rotor blades. In additionto providing lots of data in support

of accurate acoustic simulations,

Operation Deection Shapes (ODS), for

example, immediately provided valuable

insight into the structural operation of

various wind turbine components.

During the time of intensive measurement,

the crew, packed inside the compact

nacelle, faced harsh winter time weather

circumstances. On the coldest days,

nearly-frozen testing professionals relied

on LMS SCADAS front-ends with dripping

icicles to fulll their duties faithfully.

Accurate acoustic simulationand exible design optimization

Based on the structural full-system FEmodel created earlier on, engineers

derived a Boundary Element (BE) model

of the wind turbine through a dedicated

skinning procedure. The acoustic BE

model makes it possible to simulate the

acoustic power generated by the wind

turbine through local surface vibrations

of various system parts. This information

serves as input for the innovative

LMS proprietary ATV method that is

integrated into the LMS Virtual.Lab

software suite, which accurately and

effectively translates the acousticpower into fareld noise emissions.

The ATV method demonstrates the

feasibility of reaching our ultimate goal,

which is reliably determining the noise

radiation of the entire wind turbine

conguration through simulation,

Laurent Bonnet commented.

The satisfactory level of correlation

between the simulated and measured

acoustic radiation proves that the

new vibro-acoustic simulation method

lives up to our high expectations.

One of the major advantages of this

deterministic acoustic simulation

approach is that it supports dif ferent

kinds of analyses that provide detailed

insight into particular noise sources.

Through post-processing, engineers are

able to trace the modal contribution

of specic system parts, or analyze

the effect of individual panels and

loads on overall noise radiation.

It took a lot of energy and

perseverance from the testing

crew to successfully complete this

challenging testing assignment,

which lasted several weeks.

Installing sensor instrumentation

required acrobatic skills rather

than any other specialty.

To equip strain gauge sensors inside

the blades, the operator needed to

exit through the nacelle roof, climb

inside the rotor and enter the interior

of the blade, which for the occasion,

was positioned horizontally.

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The engineering information resulting from

these investigations is vital for driving

development improvements and new

wind turbine development. Deterministic

acoustic simulations were performed

up to a frequency of 200 Hertz, which

allowed signicant structure-borne noise

phenomena to be traced and tackled with

sufcient reliability. To keep the massive

processing workload that is involved in

vibro-acoustic simulation within

acceptable levels, multiple processing

stations were used to crunchdata simultaneously.

In parallel with this hybrid vibro-acoustic

simulation approach, the wind turbine

manufacturer additionally performed

hybrid SEA (Statistic Energy Analysis)

and far-eld acoustic holography.

Their engineers used hybrid SEA to

model the wind turbine and investigate

non-deterministic noise and vibration

sources. Far-eld acoustic holography,

a second high-frequency modeling

method, was deployed to qualify

noise emissions in the far eld andto extract statistically signicant

acoustic phenomena.

Developing wind turbines withsuperior acoustic performance

The deployment of the hybrid

vibro-acoustic simulation in future

wind turbine development processes

will help the company in cascading

structural and acoustic targets for

the complete wind turbine down to

subassembly and component level.

As such, the engineering consultancy

project provides us a head start in

tackling the root causes of wind turbine

noise and in designing countermeasures

that further reduce radiated noise

levels. Advanced testing efforts provide

detailed insight into mechanical wind

turbine operation, help create/validate

vibro-acoustic simulation models

and allow modeling challenges to be better

understood in facilitation of future wind

turbine development. For a large part, the

success of this innovative engineering

project was founded on the specialized

skills and experience of LMS engineering

consultants and our own engineers,

which really made the difference.

This new innovative approach

strengthens the capability

of our engineering teams in

efciently identifying the most

promising design concepts

and in developing the most

effective component variants,

Laurent Bonnet concluded.

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Harnessing Wind Power:

Natures Inexhaustible Energy Resource

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Speeding up development is a daunting

task, however, given the increasing

complexity of the designs and the need for

machines to operate reliably for decadesin adverse weather conditions. These

issues all come down to considerably

more tests to be performed on each of

the custom-designed units. Jari Toikkanen,

Manager of the Research and Test Group

at Moventas has seen the number of noise

and vibration tests quadruple in the last

ve years, with many projects requiring

same-day turnaround.

In addition to greater product

development efforts for these units,

wind turbine OEMs are demanding more

vibration tests that measure behaviorin greater detail than ever before, says

Toikkanen. Tests are done primarily to

meet strict demands from regulatory

agencies such as the AGMA (American

Gear Manufacturers Association) and

European ISO standards.

Studying gearbox resonances

He notes that particular attention is

focused on studying vibrations of the wind

turbines massive gearbox, which uses

a combination of planetary and helical

gearing to step up rotor speed 100-fold for

driving the electrical generator. Another

major component of interest is the torque

arm connecting the gearbox to the turbine

framework. For large three-megawatt

rated models made by Moventas,

the gearbox weighs 30 tons and measures

two meters in diameter and two-and-a-half

meters in length.

The torque arm is four meters wide from

bushing to bushing, a half meter thick and

weighs another ve tons.

Engineers perform extensive modal

impact testing to ensure that resonances

of these components do not match the

natural frequencies of the surrounding

structure, thus exciting potentially

damaging vibrations in the framework,

rotor blades, drive shafts and the huge

tower the tallest of which is over 200

meters. Generally, the goal is to avoid the

modal frequency range of 80 to 150 Hz for

the torque arm and 400 to 800 Hz. When

resonances are identied within or near

these ranges, engineers shift the modalfrequencies by modifying the geometry of

the gearbox components and torque arm

typically increasing wall thicknesses or

adding ribs to stiffen parts. The stiffness

of torque arm bushings may also adjusted

if necessary.

Toikkanen notes that the process is

complicated by the variable gearing

frequencies that excite gearbox and torque

arm vibration modes at different rotor

blade speeds from an input rotation of

ve rpm for a light breeze to a maximum

of 60 rpm for gale-force winds. Further,

Moventas is sometimes required to

perform additional tests and studies of

fatigue life or torsional vibration beyond

the scope of their resources.We can easily carry the unit

between test rigs at our facility,

and if necessary our engineers can

go at a customer or end-user site

very quickly to provide support or

troubleshooting, says Toikkanen.

LMS helps Moventas increase testing efciency and shorten customer turnaround

time in developing wind turbine gearboxes

Boosting test productivity

Unfortunately, limitations of the former

test solution hampered Moventas in

always meeting these challenges in a

timely manner. Test equipment was

awkward to move between test rigs, test

setups were typically lengthy ordeals, and

engineers had to spend time on multiple

test runs because only two channels

were available for modal analysis. Also,

measurement data had to be post-

processed before results could be viewed,

thus requiring tests to be completely

re-run if sensors were not properly

connected, for example, or if more

detailed study was needed to troubleshoot

unexpected problems.

These limitations were overcome when

Moventas implemented the LMS Test.

Lab software with an LMS SCADAS

Mobile data acquisition system that has

eight channels, enough to take all modal

analysis measurements in a single run.

The system contains an integrated suite

of tools Moventas engineers need for

modal analysis test set-up, control ,

measurement, signal conditioning, result

analysis, data management and report

generation all in a lightweight, portable

laptop-size unit.

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Also, the system is extremely convenientto set up. Built-in workbooks and prompts

show us step-by-step where to enter

parameters and how to proceed through

the process. Templates even ll in values

weve used in the past that arent likely

to change. Geometry models showing

the placement of accelerometers on the

gearbox housing are especially useful

and easy to congure. From start-to-

nish, set-ups with LMS Test.Lab are

very fast and easy, so were ready to take

measurements in a few minutes rather

than several hours.

Another capability of LMS Test.Lab that

greatly improves testing productivity is

on-line monitoring. We can see results

immediately as measurements are being

taken instead of waiting hours for post-

processing, says Toikkanen.

With its mobility, test set-up, on-linemonitoring, visualization and report-

generation capabilities LMS Test.Lab

boosts our test productivity immensely,

he notes.

Using a combination of planetary and helical gearing, wind turbine

gearboxes step up rotor speed 100-fold for driving electrical

generators. Moventas uses LMS Test.Lab for modal analysis in

studying resonances created by gear-tooth meshing in these units.

With real-time visualization, we can

verify the test on the spot, see rst-

hand how the structure deforms

with every hammer impact, and

readily identify the root cause of any

unexpected resonances.

Visualization is particularly helpful toMoventas engineers with the animated

mode shapes displayed together on the

same screen with plots such as frequency

response functions (FRFs) showing

vibration amplitude versus frequency at

key locations on the gearbox.

This enables engineers to see immediately

how the gearbox housing bends and twists

at various frequencies so they can readily

identify which bearings are transmitting

vibrations and determine critical gear-

mesh harmonics.

When testing is done, report generation

features allow Moventas engineers

to efciently create the necessary

documentation, complete with LMS

Active Pictures that show live test data

including mode shape animations in

Microsoft Word documents as well as

PowerPoint presentations. LMS Test.Lab

report generation with Active Pictures lets

us quickly create reports that clearly show

our designers, customers and regulatory

agencies the modal behavior of the

gearbox. says Toikkanen.

Now we can complete routine tests

in a few days instead of weeks.

When faster turnaround is needed,

our team can run an entire battery

of modal tests in the morning

and have results analyzed and

documented that afternoon.

Fast-response engineeringprojects

In addition to implementing LMS Test.Lab,

the company has worked closely with LMS

Engineering Services on projects beyond

the scope of Moventas resources

projects where fast response was needed

to meet requirements for key wind-turbine

manufacturer customers.

In one such project, LMS Engineering

Services was called upon to provide

critical fatigue life data needed by

Moventas customer REPower in Germany

for certifying a wind turbine.

| 20 |LMS Wind


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The study was to verify that two critical

wind-turbine gearbox cylindrical

components a torque arm and gear

carrier would withstand expected loadsover a 20-year operational lifetime. LMS

engineers created nite element models

of the components and applied unit load

cases to determine the stress-time series

on each part. This stress-time series

together with the complete load time

histories for the components were then

used with LMS Virtual.Lab Durability

simulation software to determine fatigue

life prediction for the base material.

Results were provided within two weeks

from the start of the project, thus enabling

Moventas to give a fast response inverifying that cumulative damage values

were well within the safety factor of the

designs.

In another project, Moventas contracted

LMS Engineering Services to measure

the rotational vibration on the low-speed

input and high-speed output shafts ona gearbox developed for Spanish wind

turbine manufacturer Acciona. Signals

from accelerometers mounted directly on

the low-speed shaft were fed into LMS

Test.Lab for analysis. Signals for the high-

speed shaft were obtained from a laser

vibrometer system measuring rotational

velocity. A series of operating response

color maps accurately identied rotational

vibration and related resonances for both

shafts. In less than one week, Moventas

was provided valuable data needed by the

wind turbine manufacturer in simulatingthe dynamic performance of the entire

drivetrain.

The collaboration with LMS

Engineering Services demonstrates

that LMS goes far beyond sellinghardware and software, says

Toikkanen. Their industry-wide

expertise in performing this work and

fast response in providing exactly

the right data made us look good

in the eyes of our customers and

made a lasting impression that has

immeasurable business value for us.

LMS SCADAS Mobile data aquisition system has an integrated suite of vibration analysis all in a lightweight, portable laptop-size unit that Moventas

engineers can easily carry between test rigs.

LMS Wind| 21 |


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A Unique Portfolio of Software

Platforms and Engineering Services

Much of the potential gains individual tools offer are lost in developing unique interfaces and error-prone

data translations. Each major application family has been built with a consistent user interface paradigm

and data model resulting in a consistent platform for numerous application modules. Each modular family is

packaged in such a way that users are assured maximum flexibility at the most economical price point.

SAMCEF Wind Turbines & LMS Virtual.Lab platform

for 3D Performance Simulation

SAMCEF Wind Turbines is the worlds most advanced computation platform dedicated towind turbine design. From the early stages in the design process, thanks to the integrated

parametrized model, down to component vibration analysis, SAMCEF Wind Turbines approach

exceeds todays certication requirements. SAMCEF Wind Turbines brings coherence to your

design process by providing a common interface to various engineering disciplines, hence

improving team work.

LMS Imagine.Lab platform

for Mechatronic System Simulation... is a complete 1D system simulation platform to model and analyze multi-domain,

intelligent systems and predict multi-disciplinary performance. Model components

are described using validated analytical models that represent the systems actualhydraulic, electric or mechanical behavior. LMS Imagine.Lab frontloads mechatronic

system simulation for multi-physics modeling and full system analysis.

LMS Test.Lab platform

for Test-Based Engineering... an integrated platform offering a complete software and hardware portfolio for

noise and vibration testing including solutions for acoustic, rotating machinery,

and structural testing, reporting and data management. With its unied interface

and seamless data-sharing capability between different applications, LMS

Test.Lab offers users tremendous efciency gains and ease-of-use.

LMS Engineering Services

LMS engineers work with customers to solve their most critical problems and often make the

difference between successful product launches and costly repairs or even failures. Experienced

in critical performance attributes the teams unique balance of skills, engineering experience

and process know-how turns attribute engineering into a strategic competitive advantage.

| 22 |LMS Wind


23/24

Design - CAD Controls

Structural integrity

System dynamics

Vehicle dynamics

Comfort

Noise and vibration

Sound quality

Durability

Safety

Performance

Power management

LMS Customer Services

LMS supports its customers with engineers who not only understand the hardware and

software, but also master the related engineering applications. Extensive training, seminars,

and on-site services help our clients technical staff gain and maintain their software and

system know-how. LMS offers a complete portfolio of professional services, including

full installation management, on-site training and support, and continuous knowledge transfer.

LMS Virtual.Lab LMS Samtech suite

LMS Imagine.Lab

LMS Test.Lab

System Synthesis System Data Management Multi-physics Modeling

Laboratory TestingLMS SCADAS

Data Acquisition SystemsMobile Testing

Fuel economy and emissions

Fluids

Electromechanical systems

Thermal management

...

LMS Wind| 23 |


24/24

LMS INTERNATIONAL

Researchpark Z1, Interleuvenlaan 68

B-3001 Leuven [Belgium]

T +32 16 384 200 | F +32 16 384 350

[email protected] | www.lmsintl.com

Worldwide For the address of your local representative,

please visit www.lmsintl.com/lmsworldwide

L

MS2013.

Allrightsreserved.

Thematerialspresentedherearesummaryinnature,subjecttochange,andintendedforgeneral

info

rmationonly.

Additionaldetailsandtechnicalspecificationsareavailable

atwww.lmsintl.com.

LMSINTERNATIONAL,

LMSTest.Lab,

LMSVirtual.Lab,

LMSVirtual.LabDesigner,LMSImagine.LabAMESim,

LMS

SCADAS,

LMSSoundBrush,

LMSTest.Xpress,

LMSTec.Manager,LMSCADA-X,

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LMSPolyMAX,

LMSTecWare,

LMSTWRandLMSCDTire,

SAMCEF,

are

registeredtrademarksofLMSINTERNATIONALNV.

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acknowledged.

LMS, A Siemens Business, is a trusted

partner of the worlds leading automotive

manufacturers and their suppliers, leading

aerospace companies, major energy

producers and innovative manufacturers of

other high tech equipment. As a business

segment within Siemens PLM, LMS

offers a unique combination of best-in-class mechatronic simulation and testing

solutions, and engineering services. We help

to get better products faster to the market

and turn superior process efficiency into key

competitive advantages. Through 30 years

of engineering innovation, 1,200 people

and 40 offices worldwide, we are servicing

more than 100,000 R&D engineers in more

than 5,000 manufacturing companies. LMS

partners with all of the Fortune 500 top

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