Exclusive: The inside story of Vestas' ground-breaking new platform
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<span style="font-size:12px;font-family:Arial;white-space:normal;word-spacing:0px;text-transform:none;float:none;font-weight:400;color:#000000;font-style:normal;orphans:2;widows:2;display:inline !important;letter-spacing:normal;background-color:#ffffff;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">Vestas' new onshore platform, christened EnVentus, propels medium-speed geared drivetrain technology and modular design into the mainstream market, setting new standards for power rating and rotor size at 5.6MW and 162 metres.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"Upgrades to the current two platforms caused a domino effect, with secondary challenges and issues popping up that had to be resolved in parallel," says chief technology officer Anders Vedel.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"It has been difficult to boost the main component volumes sufficiently, because only around 10% of all components could be standardised for cross-platform use. And each upgrade further requires enhanced installation, service and maintenance instructions."</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">As far back as 2012 it was clear to Vedel that Vestas would require new modular turbine architecture.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">The shift from the mainly seller-oriented approach towards much more competitive market-driven conditions was already becoming apparent.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">Modular construction would offer inherent benefits in the standardisation of main components and repetitive similar tasks with all the associated cost savings.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">Implementing advanced modularity would further allow Vestas to respond to energy-related challenges in a much more agile manner.</span>
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<strong style="font-size:16px;border-top:0px;border-right:0px;vertical-align:baseline;background:none transparent scroll repeat 0% 0%;border-bottom:0px;outline-width:0px;padding-bottom:0px;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;margin:0px;outline-color:invert;padding-right:0px;"><span style="font-size:12px;font-family:Arial;color:#000000;">Truck drivers</span></strong>
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<span style="font-size:12px;font-family:Arial;color:#000000;">Modularisation involves multiple interrelated aspects: product design, component sourcing, manufacture and assembly, transport logistics, installation, service and maintenance. The concept¡¯s principles are understood and appreciated in many other industries, including the manufacture of heavy trucks and excavation equipment.</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">"Wind turbine and truck manufacture both involve handling big pieces," says Vedel.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"But a truck plant¡¯s annual volume is much bigger than a turbine plant¡¯s. To gain series production experience with modular products in support of the EnVentus concept development, we gathered knowledge from a leading truck manufacturer.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"Modularisation has been an integral part of their business culture since the 1940s."</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">With the introduction of EnVentus, Vestas has become the first large-scale mover in the medium-speed geared sector of the onshore wind market.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">All of the platform¡¯s new models, starting with the V150-5.6MW and V162-5.6MW, will incorporate a compact, modular, semi-integrated medium-speed geared drivetrain.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"Medium-speed is a proven technology for Vestas because it builds on the design principles we introduced in our V164 offshore turbine in 2011," says Vedel.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"The V164-8.0MW series already has a substantial track record, and the 10MW uprate was announced last year.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"Additional EnVentus solutions are based on improved system designs from the 2MW and 4MW series, such as the single-web structural-shell-blade design.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"Our first in-house developed modular solution was the converter for the 4MW platform, and there are already over 800 units in operation," says Vedel.</span>
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<strong style="font-size:16px;border-top:0px;border-right:0px;vertical-align:baseline;background:none transparent scroll repeat 0% 0%;border-bottom:0px;outline-width:0px;padding-bottom:0px;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;margin:0px;outline-color:invert;padding-right:0px;"><span style="font-size:12px;font-family:Arial;color:#000000;">Virtual reality</span></strong>
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<span style="font-size:12px;font-family:Arial;color:#000000;">A virtual reality tour led by chief engineer Martin Skov Jensen inside a V90-3.0MW nacelle at Vestas¡¯ headquarters reveals more of the new platform¡¯s specific design details and modularised solutions, and the similarities and differences with the V164.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">The drivetrain¡¯s compactness is immediately apparent, as is the fact that the entire drive unit is shifted forward towards the approaching wind.</span>
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<span style="font-size:12px;font-family:Arial;color:#000000;">"The short rotor overhang, especially for the V162 blade, meant that we had to create sufficient clearance to prevent the blades striking the tower," says Skov Jensen.</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">"The measures include a combination of tilting the drivetrain, pre-bending blades and using forward-inclined blade bearing seats in the hub to alter the hub coning."</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">The main shaft with two pre-stressed taper-roller bearings, assembled in a cast housing, is functionally similar to the V164¡¯s.</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">Specific to the new platform is a modular main shaft front flange with multiple bolt circles of different radiuses to accommodate various size hubs.</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">A marked reduction in total drivetrain length ¡ª as well as mass and cost ¡ª is achieved by skipping the low-speed coupling between the main shaft unit and the gearbox.</span>
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<p style="font-size:0.93em;border-top:0px;font-family:UbuntuRegular, Helvetica, Arial, sans-serif;border-right:0px;vertical-align:baseline;background:#ffffff;white-space:normal;word-spacing:0px;border-bottom:0px;text-transform:none;font-weight:400;color:#333333;outline-width:0px;padding-bottom:0px;font-style:normal;padding-top:0px;outline-style:none;padding-left:0px;border-left:0px;orphans:2;widows:2;margin:0px 0px 1em;letter-spacing:normal;outline-color:invert;line-height:1.5em;padding-right:0px;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;">
<span style="font-size:12px;font-family:Arial;color:#000000;">Minimising deflection of these two main drivetrain components enabled this optimisation.</span>
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<span style="font-size:16px;font-family:UbuntuBold, Helvetica, Arial, sans-serif;white-space:normal;word-spacing:0px;text-transform:none;float:none;font-weight:400;color:#333333;font-style:normal;orphans:2;widows:2;display:inline !important;letter-spacing:normal;background-color:#ffffff;text-indent:0px;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;"></span>
25 Jan,2019