Fusion Drive - Wind Energy Network

FusionDrive TMfrom 3 MW to offshore class The absolutely smartest gearand generator combo Optimal availability throughmedium speed technology Unbelievably compact size,the lowest weight in themarket

Moventas - Geared for New Energy• Moventas is one of the leading wind turbine gear manufacturers in the world• Moventas manufactures gear solutions also to other renewable energy and processindustries and provides services for their maintenance and overhaul• State-of-art technology, top quality craftmanship and long experience stand forreliability of Moventas productskW-platform Mainstream 1.5-2MW 2.5-5MW FusionDrive3

The Switch – Bringing you power• The Switch is a leading supplier of megawattclasspermanent magnet generator andfull-power converter packages.• Our technology ensures reliability, gridcompatibility and maximized energy yields.• More than 5 GW of installed capacityPMG FPC Solar FusionDrive

Our customersMoventas and The Switch supply• wind turbine gears• generators• converters• and related servicesto major wind turbine manufacturers globally.

FusionDrive TM main benefits1. Integrated drive train simplifies structural design2. The lowest nacelle weight improves total turbine cost competitiveness3. Reliable medium speed technology ensures the highest availability4. Compact size enables manageable transport and assembly5. Scalable platform extends from 3 MW to offshore class –in onshore size

Turbine dimensioningRotorBlades• Blade dimendioning depends on outputpower, wind class and rated windspeed• Shaft power depending on swept areaand wind speed ^3• Tip speed limits revolutions per minute(rpm)• Bigger blades (slower rpm) increasesshaft torque• FusionDrive dimensioning depends onshaft input torque, rotating speed andexternal loads• Gear is designed for certain torque• Design torque may not be exceededwith longer blades• Generator output power is ??FusionDrive2-stagegearGMSPMGFull PowerConverterTurbine power depends on:MainTransformerAux powerconsumption• Shaft power (blades and efficiency)• Gearbox losses• Generator losses• Converter losses• Aux power consumption• Transformer losses• Cable lossesGrid

Turbine dimensioning

Lowest drive train weight– cost competitive turbine3-4.5 MW FusionDrive 3 Hybrid (est.) High speed Direct drive*Total weight 35 t 40 t 40 t 75-85 tOverall lenght 3 m 5 m 6,5 m 2-2,5 mDiameter 2,3 m 2,3 m 2,3 m 5,5-6,5Min. efficiency** 0,96 0,96 0,96 0,946-7.7 MW FusionDrive 7 Hybrid (est.) High speed Direct drive*Total weight 90 t 95-100 t 100-105 t 120-130 tOverall lenght 4 m 6 m 8 m 2,5-3 mDiameter 2,8 2,8m 2,8 m 8-10 mMin. efficiency** 0,96 0,96 0,96 0,94*) Depends heavily on turbine mechanical concept**) Total efficiency including gear and generator losses

Reliable medium speed technology –highest availability• No slip-rings, no rotor windings• Low cogging torque• No bearing currents• Medium speed bearings – no smearing risk• Low number of bearings – no high speed bearings or generator bearings• A common lubricant oil space provides controlled environment for force transferringrolling components• Perfect alignment between gear stages and generator• No extra bearing forces or induced vibration• Efficient air cooling inside the generator

Integrated drive train – simple structural designPermanentMagnetrotorMedium Speed PMGFirst Stage Planetary GearPlanet CarrierCommonBearingSupportSecond Stage Planetary Gear

FusionDrive specificationsFusionDrive 3 FusionDrive 7Maximum shaft torque 3000 kNm 7000 kNmMaximum rotor speed 13,6 rpm 11 rpmGenerator output power 3-4,1 MW 6-7,7 MWTotal max efficiency 0,96 0,96Overall weight 35-40 t 85-95 tOverall lenght 3-3,5 m 4-4,5 mDiameter(Excluding auxilliaries and torque supports)2,3 m 2,8mWeight and total lenght depending on rated generator output power

Reliable permanent magnet generatorMaximium annual energy productionOptimized effiency for partial loadsForm wound windingsStrong medium voltage insulation,field proven in harsh conditions.Surface-mounted magnets forlow and medium speed machinesFull excitation advantage of the magnets inlow spherical speed machines.Full protection with module construction.

Proven gear technology from Moventas• Installed base over 13.000 units - first windturbine gear delivered in 1980• Customers include all major wind turbinemanufacturers• Uncompromising reliability• Low noise and vibration levels• Unique power density• Minimum life cycle cost

Adaptive lubrication and cooling• Lubrication system is controlled with customer WTGspecific parameters.• Pump and cooler motors are variable speed operatedcontrolled by oil pressure and bearing temperatures.• Oil flow is secured to the most critical targets withcontrol valves.• Oil level in sump is controlled to ensure lubrication incold start and idling.• FusionDrive cooling is executed with water-air andwater-oil heat exchangers.• Generator is air cooled inside with water to airheat exchanger• Internal air cooling ensures optimal rotor magnettemperature

Condition and Management System CMaS• Moventas CMaS condition management system isdeveloped to prevent any unexpected disturbances inwind energy generation.• CMaS helps our customers to keep their operationsrunning reliably at peak performance, and lengthenthe lifetime of their machinery.• Management instead of monitoring• From failure detection to failure mode control• From analogic sensors to intelligent digitalmulti-sensor network• From vibration measurement to adaptive riskmanagement

Key parameters and CMaS layout• Oil Ageing• RPM• Wear Particles• Temperature• Pressure• Vibration• Load

Maintenance in the nacelleMaincomponentsGearcomponents1. 1st stage 1. IntermediateconeGeneratorcomponents1. Stator2. 2nd stage 2. 2nd Ring 2. Rotor outer hub1 2 33. Generator 3. 2nd Stage (Innerparts)3. Shield4. Back cover 4. Rotor inner hub5. High speed shaftassembly6. Cover pipeassembly5. Coupling6. Cover7. Brake discs1 2 3 4 5 6Dismountable Generator and Gearbox partswithout removing stator1234567

Moventas Gear Technology Center• Testing power up to 2 x 10.5MW• Automatic station allowing longperiods of unmanned testing• Extreme loading conditions• Accelerated testing• Dynamic behavior• Verification of calculated simulations• Optimization of weight/power-ratio,sound and vibration behavior• External forces can be simulated• Cold laboratory

The Switch back to back testingCooling water stationsTransformer& SwitchgearCouplingMotor Motor side sideconverter converterMGGener. sideGener. sideconverterconverterDRIVE TRAINPower analysers• Enables comprehensive type testing including full power heat run testing• Both Fusion Drive and converter efficiency can be determined• All components can be cooled independently

Keep turbines up and runningTechnical customer supportRepair servicesTraining servicesSpare parts servicesCondition management

Moventas and The Switch global presenceManufacturingService CenterSales

How to sell Fusion Drive to Your customers?Lowest totals• Lowest total investment and Lowest O&M costHighest energy yield• Efficiency in partial loadsHighest availability• Reliable concept• No fragile slip-ringsServiceability• PMG rotor and bearing disassembly in nacelleCombined expertise and global presence• Moventas and The Swich – stronger together

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