EWEC’09 Dr. Sunny Zhang 18.03.09

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


Collapsed due toCollapsed due toGearbox failure?Gearbox failure?


No Gear No FearNo Gear No FearThe switch The switch

FinlandFinland

Direct Drive for Wind!Direct Drive for Wind!


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


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


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


Smelting&CastingSmelting&CastingPowder productionPowder production

Pressing&AligningPressing&AligningMouldingMoulding

SinteringSinteringHeat treatmentHeat treatment

Post-processingPost-processingCoating&QCCoating&QC


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


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


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


NdFeBNdFeB

NdFeBNdFeB

NdFeBNdFeB

Dolly tests show ourDolly tests show ourcoating has 25 MPacoating has 25 MPaadhesion strengthadhesion strength


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


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


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


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!!!


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

Documents

EWEC’09 Dr. Sunny Zhang 18.03.09