hydraulik - HANSA-FLEX Hydraulics Canada Inc.

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�� HYDRAULIKPRESSE INDUSTRIAL INSTALLATION Nothing goes around without brakes! At least, not the turbine of a wind power plant, which could not operate without powerful braking systems. The heart of a wind turbine is in its gondola. Like a ship’s engine room, it houses all the driving units and subsystems, ensuring reliable operation of the plant and continuous electricity generation. It also houses the brakes, which intervene to control the motion when the gondola is automatically rotated to the ideal position to make maximum use of the wind power during operation. Once aligned to the wind, the brakes hold the gondola head stable in position to ensure the hub, with the rotor blades attached to it, rotates smoothly. Most of the systems, which are deployed by virtually every manufacturer in Europe, America, China and India, originate from Svendborg Brakes, the world market leader in wind turbine brakes. Founded way back in 1893, Svendborg Brakes is a leader in the 14 Putting a brake on the wind Nothing revolves without Svendborg Brakes HYDRAULIKPRESSE fi eld of industrial braking systems. Since the early days of wind power use back in 1989, the company has been involved intensively in the manufacture of hydraulic, electronic and mechanical braking systems. It produces for the fast-growing wind power sector, for the mining industry, for off shore and onshore oil rigs, as well as for crane manufacturers. Since 1999 the Wind Know-how Center of Svendborg Brakes has been based in the town of Bünde in Westphalia. It is not by chance that the company has attained its position on the global market, as sales director Max Altenähr explains: “The key factors are the certifi ed high quality of our products and, of course, the technical support we provide. We supply customers with brakes which precisely meet the demands of their markets. We develop and test custom solutions to that end.” All manufacturers are seeking the optimum method of enhancing the effi ciency of their wind power plants. Svendborg Brakes develops tailored braking systems conforming in design and manufacture to the precise specifi cations laid down. The centre in Bünde is investing rapidly in targeted research and development to deliver ever more effi cient braking systems. To remain at the forefront of global developments, Svendborg Brakes is today already busy developing the brakes of the future. While 6-megawatt plants are the current state-of-theart, its wind engineers are working on the nextgeneration 7.5-megawatt systems. Brakes for all conditions In Bünde, Svendborg Brakes manufactures rotor brakes and azimuth brakes as passive and active machine elements as well as compact hydraulic power units. The rotor brakes reliably hold the rotor steady when in service mode so that service technicians cannot be injured by unexpected rotation. Svendborg Brakes off ers an additional safeguard with its newly developed rotor-lock, to lock the rotor hub in place when at a standstill. The function of the azimuth brakes is to brake the gondola and hold it in the optimum position aligned to the wind direction so that the wind does not move it in an uncontrolled manner. The gondola is also braked lightly when the gear mechanism is rotating the head into its working position. This is done to ensure that the gear wheels have a smooth frictional connection and wear is minimised. ISSUE AUGUST 2008
Information on the direction and strength of the wind is supplied by a anemometer mounted on the gondola roof, which transmits all the relevant data to the wind turbine’s automatic control system. It then rotates the gondola into the wind and locks it immovably in place by the azimuth brakes. The engineers from Bünde are involved at an early stage of planning the new wind turbine to ensure the brakes are correctly dimensioned. For the systems to run virtually trouble-free over some 25 years of electricity generating operation, the demands they must meet are high. Thorough and extreme test series safeguard the long-term availability of the brakes. The complete package undergoes testing in Bünde. Hendrik Voß, head of technical support, is proud of the range of test rigs the company operates - covering all possible test cases, and all built in-house. There is even a low-temperature test chamber, enabling testing under Arctic conditions down to -40 degrees Celsius. “Frog” and “Toad” on continuous duty All the brake components are placed under the microscope of testing, including brake tests, reallife tests, full and part load tests and endurance tests. Friction tests and brake lining limit tests are conducted by Svendborg Brakes on a rod-type test rig by application of brute force: two powerful hydraulic cylinders drag the rod with a pull force of more than 100 tonnes through the brake shoes to simulate braking. Dynamic and static test series are also employed to check the rotor hub braking under full load. On the “Toad”, a test rig for the azimuth brakes, the cast steel brake calipers must prove that the can withstand a minimum of 20 million braking cycles. On the “Frog“ rig the brakes are subjected continuously to alternating operating pressures of 0 to 180 bar in order to test their material strength. Only when 20 million cycles have been undertaken without trouble is the quality mark passed. ISSUE AUGUST 2008 HANSA-FLEX assisted in constructing the test rigs by providing tailored hose lines and components from HKO in Dresden. The business relationship with Svendborg Brakes began four years ago. Today HANSA-FLEX supports its customer’s prototyping by means of the FLEXXPRESS service, ensuring the practicalities of hydraulic line engineering are quickly and effi ciently handled. The service technicians fabricate the hose lines, documenting all the data for subsequent mass production. HANSA-FLEX then supplies ready-to-install connecting elements such as hose lines and screw fi ttings in kit form for integration into the braking systems in production. The commitment shown by HANSA-FLEX to its customer extends well beyond the line engineering though. It also provides specially fabricated stainless steel blanking plugs for instance. They are manufactured in large volumes precisely to the drawing specifi cations of Svendborg Brakes in Shanghai. The plugs close off all the openings in the brake systems for factory testing purposes. This ensures that no dirt can penetrate and that the residual hydraulic fl uid in the system does not leak out. Unquenchable thirst for knowledge Svendborg Brakes makes use of training centre INDUSTRIAL INSTALLATION As Svendborg Brakes operates on markets all over the world, HANSA-FLEX is ideally matched to it as an expert global service provider. Coordination meetings are currently being held to deliver the customary high standard of HANSA-FLEX service quality for a new customer in Ukraine through the Dnepropetrovsk branch. Engineers, technicians and staff from the Wind competence centre in Bünde attend the “Components 1, 2 and 3” training courses held at the HANSA-FLEX training centre in Weixdorf near Dresden in order to refresh their knowledge and skills in hydraulic line engineering. Hendrik Voß, head of technical support at Svendborg Brakes, is unstoppable in his praise of the training centre: “The well structured and clearly laid-out training documentation package is very impressive, and the practical exercises in constructing hydraulic circuits on the experimental units underpin the theoretical learning.” HYDRAULIKPRESSE 15 H��
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