R&D Test Systems in Denmark has completed the 3700 metric tonne foundation for its 25MW turbine test bench.
Following the foundation’s (pictured) completion the centre is now designing and welding the test bench parts that will perform extreme test loads on main bearings for 25MW wind turbines.
LORC contracted R&D Test Systems to build the test bench for main bearings at Odense Port, Lindo, Denmark, with delivery slated for 2025.
“It’s in recognition of our large-scale testing capability that LORC has selected R&D Test Systems to build the most powerful test bench for main bearing arrangements,” said R&D Test Systems key account manager Peter Winther.
He added: “The foundation is complete, and our engineers have designed the systems that will apply the actual loads to simulate not only the harshest forces of wind but also the effect of wind coming from different directions.
“The main bearings take the impact of the rotor load and so must be able to withstand any extreme wind load scenarios that could occur with wind turbines as powerful as 25MW.
“Our tests will include twisting and bending in all six degrees of freedom.”
An essential part of the test bench is R&D Test Systems’ proven “test load unit”, which will be able to deliver extreme bending and forces to the main bearing arrangement under test.
Capable of supplying six axial loads to the main bearing arrangement – thrust, horizontal and vertical forces as well as torque, tilt and yaw moment – the test load unit will be able to apply bending loads of more than 100 Mega Newton metres and thrust force of more than 10 Mega Newton metres.
The test load unit enables the test bench to simulate the effect of years of wind conditions in just a few months.
“The test load unit that we are building for LORC’s new Main Bearing Test Facility will be the largest and most capable that R&D Test Systems has developed,” said Winther.
“This will be the sixth test load unit we build after completing the powertrain validation test bench at ZF Wind Power’s ‘Test & Prototype Center’ in Lommel, Belgium.”
In the future, more powerful turbines will be equipped with larger, heavier sub-systems in the nacelle, like the main bearing, which must withstand extreme loads and therefore require tests.
Concentrating on the main bearings, the test bench allows wind turbine manufacturers to conduct tests for this system in isolation rather than as part of a full powertrain test procedure.
The bench will be designed to test both geared and direct-drive main bearing arrangements, two principal systems for turbines.
Due for delivery in 2025, the test rig will be depicted at R&D Test Systems’ stand at WindEnergy Hamburg, 24-27 September 2024.