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A brief overview of Orbital2 and our technology
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O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential 1
An Overview Of
Orbital2
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/20102
Driven by the high failure rate experienced on current wind turbine
gearboxes,(>40%) and given such failure rates are not sustainable in
capital machinery, certainly for “off shore” turbines
Ray J Hicks MBE - & - Dr Frank Cunliffe who have an association
spanning over 40 years
decided to formed ORBITAL2 in September 2003 to exploit the long
history of the novel Ray Hicks flexible pin epicyclic gear designs and
their application to Renewable Energy Turbines
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/20103
R J Hicks MBE – Inventor of Flexible Pin
• Started working on Aerospace epicyclic gears in 1954
• Invented the “Hicks” flexible pin in 1964.
• Set up Compact Orbital Gears (COG) to design & manufacture
epicyclic gears for a variety of applications
• Applied the “Hicks” design principles to wind turbine gears in the
UK in the 1980’s. (Orkney 3MW torque controlling features 1982)
• Formed ORBITAL2, to carry forward the application of “Hicks”
epicyclic gear designs.
• Co-Founder of Orbital2
• Consultant to Orbital2
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/20104
Dr Frank Cunliffe – Managing Director
• 1st Class Hons Mechanical Engineering / Student Apprentice
Mirlees Blackstone Diesel engines, Fellow Inst Mech, Eng C Eng
• Research PhD Cambridge, epicyclic gear dynamics
• Senior Engineer COG, R J Hicks
• Chief Design Development Engineer, Lucas CAV, Diesel systems
• Technical Director, Cable Belt, long distance conveyers
• Engineering Director, Massey Ferguson Tractors
• Managing Director, Albion Automotive, commercial vehicle axles
• Co-Founder of ORBITAL2, to carry forward the application of “Hicks
flexible pin” epicyclic gear designs.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/20105
Prof R Parker - none executive member of the ORBITAL2 board.
Professor Parker is a world leading expert on dynamics
Professor and Associate Dean for Education at the University of
Michigan-Shanghai Jiaotong University Joint Institute.
/ / / / /
Antonin Ruzicka – none executive member of the ORBITAL2 board.
Antonin Ruzicka is the CEO of WIKOV INDUSTRY a Czech gearbox
company and manufacturing partner of ORBITAL2.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
ORBITAL2 UKInnovation,Marketing,
Project managementTechnical CentreDesign Layout
5 engineers
Czech ORBITAL2Prague & Hronov
Design / Manufacturing Drawings,
Supervision of assembly test and development
15 Design engineers
SoftwareSolid Edge ST 3D CAD
KISSsoft
MASTA
ANSYS V11Professional NLS
nCode DESIGNLIFE
Dynamic/Specialist Analysis
Prof. Parker University of
Michigan-Shanghai Jiaotong University Joint
Institute
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/20107
Prof Parker super analysis
• TNF
• Phasing
• Micro Geometry
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
1987 ORKNEY 3 MW Original
flexible pin wind turbine gearbox.
• Flexible pins with load limiting.
• Torque split on input.
• Torque limiting on input.
• Gear case free from deflection.
• Integrated planet wheel taper
bearings.
• Synchronous generator.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010Commercially Confidential
ORBITAL2 Ltd
9
8 planet input train from a 20
year old wind turbine gearbox
with 10+ years of operation
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Why the failures
1. Load distribution across teeth and between planets
2. Rotor loads imposed on gear case
3. Power input not controlled
4. Absolute gear rating
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Carrier
Planet
Hicks - Flexible Pin
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201012
Flexible Pin provides:-
• Multi-planet applications.
• Equal loads between planet wheels (K < 1.1 for eight planets agreed GL)
• Uniform load across face width of teeth sun/planet &
planet / annulus contacts (K < 1.35 agreed GL)
• Uniform loads on planet wheel bearings
• Uniform load under overload and shock load conditions
• Dual rate Flexible pin Over Load Stop Protects from over stress under
dynamic overload conditions.
• Taper bearings with outer races incorporated in the planet wheel bore
provides maximum planet bearing capacity.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Multiplanet – 4 or greater – flexible pin
Manufacturing error in pin position: 0,1 mm
Incremental force in tooth mesh: 16,9 kNm
Incremental load is 8%
Full load torque:
Deflection of pin: 1,2 mm
Force in pin: 367,2 kNm
Force in tooth mesh: 202,6 kNm
Stage II – MS 3
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Multi Planet Epicyclics
3 planets statically determinant 3>Statically in determinant
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
W2000spg
8 planet wheel stage
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201016
2MW variable ratio back to back mechanical load test
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201017
Load balance between planets on the four planet train
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201018
Load distribution across the face width, helical gears.
Load sharing between planets with in 3%
Load sharing across the face in the centre
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
MINI-MASS Flexible Pin Gearboxes for wind turbines
•low mass high - reliability wind turbine drive trains with :-.
• Flex pins dual rate stiffness
• uniform tooth / planet load - multi planet
• Torque split - single plane of reaction - gear train.
• Gear case free from rotor loads and deflections.
• Variable ratio drive train for Dynamic control of input torque and
simple high voltage electrics.
PHOTO – 2MW SPG
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Flexible pin-Multi planet-Split torque
single reaction load free gear case
3MW- weight 22 tons
01/07/2010 20
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
ORBITAL2 - Mission Statement
The supply of market leading innovative gearbox designs for
WIND and TIDAL Turbines that offer low weight and high
reliability via ORBITAL2 flexible pin, multi planet epicyclics.
ORBITAL2 – Deliverables
• INOVATIVE Licensed Design gearbox solution with a full set
of manufacturing drawings
• Prototype build and test supervision
• GL or others approval documentation
• Supervision and Training of gearbox manufacturer
in the production of the licensed design
• Ongoing audit of gearbox build quality by licensee
• In service improvements of the gearbox via updates
of the manufacturing drawings
A Full design and engineering service from concept to end of life
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Documentation Control
ORBITAL2 gearboxes can be offered either as
Licensed designs for third party manufacture
or completely finished gearboxes from our
manufacturing partner, WIKOV CZ.
ORBITAL2 main design office is adjacent to
the WIKOV factory to facilitate control and
supervision of prototype gearbox build and test
by WIKOV.
Engineers fully integrated to support the
product from the spec, through production, to
ongoing maintenance support.
2MW SPG IN ACTION
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Examples of Orbital2>>>>>>
MS3 – Stage I
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
24
ORBITAL2 – gearbox history / projects
1986 – First European 3MW wind turbine and the first flexible pin wind turbine gearbox. UK
1990’s – 350 kW production wind turbine gearboxes. (100 plus), UK
2002 – World’s first production (100 Turbines) variable ratio wind turbine 650kW. NZ
2004 – 3.4 MW variable ratio prototype wind turbine. Norway
2006 – 1.3 MW the world’s first production tidal turbine. UK
2007 – 2 MW variable ratio prototype wind turbine. CZ
2008 – 500 kW tidal turbine prototype. UK
2008 – 3 MW off shore wind turbine production gearboxes. Korea DOOSAN
2009 – 3 MW off shore wind turbine production gearboxes. China SINOVEL (160 )
2010 – 1.6 MW wind turbine production gearboxes.
2010 – 3.6 MW Wind Turbine China SEWIND (20)
2010 – 1.5 MW Wind Turbine China
2010 – 2 MW Rotor Turbine licence to China
2010 – 2 MW Rotor Turbine – India
2011 – 5 MW Rotor Turbine – China
PHOTO- 2MW SPG IN ACTION
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Wind Flow (NZ) 2002
650 KW Wind turbine for high wind
states (16m/s )
Gearbox designed by Hicks and
manufactured in NZ.
With flexible pins, torque limiting and
synchronous generation,
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201026
3.4 MW SCANWIND turbine converted to a VR gear drive - 2004
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201027
3.4 MW variable ratio gearbox on part load test.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201028
TIDAL TURBINES – new applicationsMCT Production Turbine
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201029
MCT tidal gearbox on load test
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201030
Marine Current Turbines installation April 2008
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 31
MCT Tidal - Installed
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential 01/07/2010 32
MCT Tidal – Installed
Orbital2 – unrivalled experience
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
33
MCT Tidal – Installed
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201034
Tidal Generation
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 35
Tidal Generation
Pre-series turbine
during test
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Prototype 2MW SPG turbines now operating
in Czech Republic
Power train assembly of W2000spg
Wind Turbine in Wikov’s assembly
hall in Hradec Králové, Czech
Republic
01/07/2010 36
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
W2000SPG Drivetrain
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
20.10.200938
• Allows ratio of the gearbox to be continuously
varied throughout the whole range of the wind
turbine rotor operating speed; making it
possible to maintain constant speed of the
synchronous generator
• 6.3 kV nominal voltage is generated by the
wind turbine => lower costs of connection to
the grid
• High voltage synchronous or fixed speed
induction generators can be used without full
power converters.
• Allows all of the main power electrics and
transformers to be placed on shore in a
central point further reducing the weight in the
nacelle and improving reliability.
• Provides torque protection of the gear train
and rotating elements against wind gusts
resulting in high reliability.
Gearbox with variable gear ratio
patented SPG (super position gear)
system
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 39
2MW – Installed
W2000SPG Drivetrain in Operation in Czech Republic
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
• 3MW gearbox - China
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/201041
• 1.25MW IWP Type
• Optimised for balance between cost of energy,
logistics and service life-time cost.
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
• 1,5MW China
• Areodyn Type
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 43
W1650
WindTec Type
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 44
Main Frame Layout – W2000 Fixed Ratio
WindTec Type
O R B I T A L 2Flexible Pins – Driving Renewables
20.10.2009ORBITAL 2
• 3MW main drive gearbox
• Offshore version
3 MW
O R B I T A L 2Flexible Pins – Driving Renewables
20.10.2009ORBITAL 2
Commercially Confidential
ORBITAL 246
• Normal or Cold Climate version
• For 90/100/112m rotor diameter
• Torque reaction linkage (not shown)
• 3MW main drive gearbox
• Offshore/Onshore version
• 50 Hz or 60 Hz option available
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
3,6 MW
• 3.6MW ORBITAL2 Flexible Pin, Multi-Planet,
• Offshore China
• Torque 2806 kNm
• Ratio 1:84
• Weight 37 ton
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential 01/07/2010 48
Doosan 3MW – Test Rig
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
01/07/2010 49
Doosan 3MW – Test Rig
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
50
Sinovel 3MW – Test Rig
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Building in Korea
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Building In China
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential
Opportunities ……………
O R B I T A L 2Flexible Pins – Driving Renewables
ORBITAL 2
Commercially Confidential PHOTO – 2MW SPG
DRIVING RENEWABLE ENERGY VIA
HIGH RELIABILITY, LOW WEIGHT,
MULTI PLANET, FLEXIBLE PIN,
EPICYCLIC GEARBOXES.
O R B I T A L 2