First results of Hansen's 13 MW test facility for wind turbine gearboxes

Hansen Transmissions has taken up the challenge to develop and build a highly dynamic test facility for testing wind turbine gearboxes under realistic conditions. The test rig is a back-to-back gearbox set-up and is one of the largest in the world. It has a nominal power of 13.2 MW and a peak power capacity of 16.8 MW. Hansen has solved the complexity of applying dynamics by identifying dedicated load cases which represent specific wind turbine behaviour. For the whole development process of this solution, a project of four phases is defined aiming at proving its functionality and robustness. In a first step, dedicated measurements and simulations are performed on a scaled set-up, which enables iterative optimization of the complex interaction between the mechanical dynamics and the electrical controller of the test rig. First results of these tests show examples of what dynamic events can include. The 13.2 MW test rig was taken into operation in 2008 and the final implementation of the dynamic controller functionality is planned for the end of 2009. This new and unique feature will be used in future R&D activities such as the experimental validation of dynamic load simulation models and an extension of the limits of standard prototype validation tests.