Center for Wind Power Drives

Full Size Nacelle Ground Testing

Advanced testing at the

1 MW Test Bench Demonstrator
4 MW System Test Bench
5 MW High Speed Test Bench
Winergy HybridDrive

Direct Drive
Load Application System

HybridDrive

Geared Coupling

Rubber Bushings
 Specifications
DC-Bus

MV7308 Trafo

PCC

MV7308

Source: GE Source: MTS Filter

MV7308

PMSG Direct Drive Wind Load Simulator Grid

Nom. Power Pn = 4000 kW 5 DOF load application system 17 MVA converter power
Nom. Speed nn = 14 rpm Force capacity: ~ 3 MN High dynamic by three
Max. Speed nmax = 30 rpm Bending moment capacity: ~ 7 MNm interleaved converters
Const. Torque nTn = 4-14 rpm Backlash-free cylinders Galvanic isolation through four-
Nom. Torque Tn = 2,7 MNm pre-loaded in pairs winding transformer
Max. Torque Tmax = 3,4 MNm Static support for load compensation Minimum series inductance
Full sensoring for torque, through filter connection to an
bending and forces additional tertiary winding
Hardware in the Loop
Prime Mover
1 DOF 5 DOF Controller HIL User
Interface
10kV Grid Load Unit Wind

HIL Grid
=
Recuperation DC-Link _ 20 kV Drivetrain
_
Loop _
= Model

PCC

Wind Load Wind Field

RTDS
Calculator Generator

nrotor

Pitch System Emulated

Model Sensors

- set
point
Control
Units
-
Original WTG Controller
 HIL Validation
Grid Generator Mode Fast
Connection Switching Shutdown
30 1200
Windspeed m/s
Test campaign with 25 Pitchangle deg 1000
original WTG 20 Electric Power kW 800

controller on the 15 600

10 400
1MW test bench 5 200
demonstrator in HIL 0 0
operating mode -5 -200
35 350
Rotorspeed rpm
30 Torque kNm 300
realistic behaviour of 25 250
20 200
drivetrain and WTG
15 150
controller
10 100
5 50

original intended 0
200
0
200
control strategy 150 150
100 100
50 50
0 0
-50 Thrust kN -50
-100 Radial Force kN -100
-150 Tilt Bending Moment kNm -150
Yaw Bending Moment kNm
-200 -200
140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
 5 MW high speed test rig
Tests of
(high-speed) drives
generators
dc-dc converters
converters for doubly-fed generators
grid-connected converters

Specification
power: 5 MW
rotational speed: 15,000 min-1
ac voltage: 3.3 kV
Schematic of the test bench for medium-voltage high-
speed drives. Energy flow with DUT in motoring mode
 Future Projects
Torque measurement in the MNm range
Develop traceable measurement methods in the MNm range
Investigate effects of multi-comp- loading
Develop a calibration procedure for nacelle test benches

FVA-Nacelle
Reduction on local stresses in WTG-drivetrains
Validation
Local models (e.g. gears, bearings)
Global MBS-model
 Thank you for your attention

Dennis Bosse
Center for Wind Power Drives
RWTH Aachen
dennis.bosse@cwd.rwth-aachen.de