ewec’09 dr. sunny zhang 18.03.09 gearbox – a well-known trouble maker for wind! courtesy of...
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EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Gearbox – A Well-known Trouble Maker for Wind! Gearbox – A Well-known Trouble Maker for Wind!
Courtesy of Johan Ribrant et alCourtesy of Johan Ribrant et alIEEE Transactions on Energy Conversion, March 2007IEEE Transactions on Energy Conversion, March 2007
Courtesy of Richard Dupuis, GasTops LtdCourtesy of Richard Dupuis, GasTops LtdWWEC 2008WWEC 2008
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Collapsed due toCollapsed due toGearbox failure?Gearbox failure?
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
No Gear No FearNo Gear No FearThe switch The switch
FinlandFinland
Direct Drive for Wind!Direct Drive for Wind!
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
NdFeB Magnet Technology forNdFeB Magnet Technology forLow Speed Direct DriveLow Speed Direct Drive
Warmup of high performance Warmup of high performance NdFeB magnet ProductionNdFeB magnet Production
Availability of NdFeB magnetsAvailability of NdFeB magnets
Reliability & Integrity/DurabilityReliability & Integrity/Durability
Flexibility & InnovatabilityFlexibility & Innovatability
ConclusionConclusion
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
More Than 35 Years of Know-hows in Permanent MagnetsMore Than 35 Years of Know-hows in Permanent MagnetsMore Than 10 Years of Expertises for Wind/Wave Power Applications More Than 10 Years of Expertises for Wind/Wave Power Applications
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Bakker Magnetics Bakker Magnetics in Facts & Figures in Facts & Figures
- Group Headquarter: Eindhoven/NL.
- Founded by Mr. Gerard Bakker in 1971.
- Total employees: 750 (EU 100 + CN 650).
- Family owned company.
- Joint venture in Ningbo, China
- Design, development & prototype in NL & CN.
- Quality assurances in NL & CN.
- Warehouse & logistics in NL.
- Long term experiences & expertises
- Turnover of 2008 in NL: 20 KK EURO Mr. Geert-Jan BAKKER
Warmup of Sintered NdFeB Magnet ProductionWarmup of Sintered NdFeB Magnet Production
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Smelting&CastingSmelting&CastingPowder productionPowder production
Pressing&AligningPressing&AligningMouldingMoulding
SinteringSinteringHeat treatmentHeat treatment
Post-processingPost-processingCoating&QCCoating&QC
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Conventional & Advanced Alloy Conventional & Advanced Alloy Productions for Productions for
Making NdFeB Permanent MagnetsMaking NdFeB Permanent Magnets
Strip-casting Strip-casting Conventional casting Conventional casting
NdFeBNdFeBMother alloyMother alloy
DD PMSG Trend & NdFeB/Raw Materials DD PMSG Trend & NdFeB/Raw Materials RequiredRequired
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Newly-installed GW: based on BTM, DKNewly-installed GW: based on BTM, DKMachine units: based on 2 MW averagedMachine units: based on 2 MW averaged
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Ningbo region20K – 30K T50-60% ofCN output
Taiyuan region~ 10K T20% ofCN output
Beijing-TianjingYantai region~ 7K T~ 15% ofCN output
Global Output NdFeB in 2008:Global Output NdFeB in 2008:
Total: ~ 65K TonTotal: ~ 65K Ton CN: ~ 52KCN: ~ 52K JP: ~ 11KJP: ~ 11K EU (VAC/NeoremEU (VAC/Neorem /Schramberg): ~2K(?)/Schramberg): ~2K(?)
Nd required: ~ 20 K TonNd required: ~ 20 K TonNd2O3 required: ~ 23-24 K TonNd2O3 required: ~ 23-24 K Ton
World Reserve:World Reserve:RE oxides: >100,000 K TonRE oxides: >100,000 K TonChinese share: ~ 43%Chinese share: ~ 43%Other main countries: US, RU,Other main countries: US, RU,India, AU.India, AU.
Current Status of Global NdFeB Production 2008 in BriefCurrent Status of Global NdFeB Production 2008 in BriefWorldwide Rare Earth (RE) LandscapeWorldwide Rare Earth (RE) Landscape
Advanced Epoxy Spray Technology for High Advanced Epoxy Spray Technology for High Performance NdFeB Magnet AssembliesPerformance NdFeB Magnet Assemblies
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
NdFeBNdFeB
NdFeBNdFeB
NdFeBNdFeB
Dolly tests show ourDolly tests show ourcoating has 25 MPacoating has 25 MPaadhesion strengthadhesion strength
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Sal
t Spra
y Te
st (SST)
Sal
t Spra
y Te
st (SST)
For
20 D
ays
For
20 D
ays
Ep
oxy e
ncap
su
lati
on
Ep
oxy e
ncap
su
lati
on
befo
re S
ST
befo
re S
ST
Ep
oxy e
ncap
su
lati
on
Ep
oxy e
ncap
su
lati
on
aft
er
SS
Taft
er
SS
T
Advanced Epoxy Encapsulating/Moulding Advanced Epoxy Encapsulating/Moulding Technology for NdFeB Magnet AssembliesTechnology for NdFeB Magnet Assemblies
NdFeBNdFeBmagnetmagnet
EpoxyEpoxy
BackingBackingsteelsteel
Cut-offCut-offCross-sectionCross-section
Cros
s-se
ctio
n
Cros
s-se
ctio
n
Cut-off
Cut-off
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Magnets gluedMagnets gluedWith smart toolingWith smart tooling
Magnets assembledMagnets assembledin placein place
Magnet EncapsulatedMagnet EncapsulatedWith stainless steelWith stainless steel
Durable Stainless Steel Encapsulating Durable Stainless Steel Encapsulating Technology for Advanced NdFeB Magnet Technology for Advanced NdFeB Magnet
AssembliesAssemblies
NdFeBNdFeB
NdFeBNdFeB
Smart Smart tooltool
Maximum Corrosion Protection & Durability (Hybrid)Maximum Corrosion Protection & Durability (Hybrid)Coating+Epoxy Encapsulation+Stainless steel shellCoating+Epoxy Encapsulation+Stainless steel shell
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
NdFeB magnetsNdFeB magnetsglued on the rotorglued on the rotor
Epoxy to beEpoxy to beinjectedinjected
EpoxyEpoxyinjectioninjection
The NdFeB rotor of D400x1000(+) rotates @ 3000 rpmThe NdFeB rotor of D400x1000(+) rotates @ 3000 rpmIn addition to stainless steel reinforcement, we can offerIn addition to stainless steel reinforcement, we can offer►► Glass fiber reinforcementGlass fiber reinforcement►► Carbon fiber reinforcementCarbon fiber reinforcement
StainlessStainlesssteel shellsteel shellfitted tofitted tothe NdFeBthe NdFeBrotorrotor
StainlessStainlesssteel shellsteel shell
Summary of Permanent Magnet Generator Summary of Permanent Magnet Generator TopologiesTopologies
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
SlottedSlotted
SlotlessSlotless
RotatingRotating
LinearLinear
DistributedDistributedWindingWinding
ConcentratedConcentratedWindingWinding
Innovative & Flexible NdFeB magnet design technologyInnovative & Flexible NdFeB magnet design technologyCan be further explored to enhance power density!!!Can be further explored to enhance power density!!!
Fighting against Leakage!!!Fighting against Leakage!!!
EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang 18.03.0918.03.09
Bakker Magnetics PM Assemblies, Magnet Bakker Magnetics PM Assemblies, Magnet Modules, in Reallife Wind turbines !!!Modules, in Reallife Wind turbines !!! Scanwind SW-90-3500 DL Turbines (3,5 Scanwind SW-90-3500 DL Turbines (3,5 MW), Installed in Hundhammerfjellet, MW), Installed in Hundhammerfjellet, Norway. Norway. EWEC’09 Dr. Sunny Zhang EWEC’09 Dr. Sunny Zhang
18.03.0918.03.09
Conclusion: Conclusion: Solution Is Always SimpleSolution Is Always Simple