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HIGHER PERFORMANCE FOR GEARBOXES AND ENGINES
WIND ENERGY | AUTOMOTIVE | MARINE | INDUSTRY
Higher Performance for Wind Turbines
REWITEC® 1
• REWITEC®
• Tribology
• Products
• Industries
• Field of applications
• Technology
• Scientific testing
• Practical applications
• Economic efficiency
• Conclusion
Content
REWITEC® 2
• Developer, manufacturer and distributor of nano and
micro particle based surface refinements for
protection and repair of tribologic systems
(gears/ bearings)
• Establishment in 2003, in the town of Lahnau, in
the State/Province of Hessen in Germany
• World wide sales and partner network
• Founder and Managing Partner: Stefan BillREWITEC® 3
Tribology, friction,
wear
• Tribology:
The science and engineering of interacting surfaces in
relative motion. It includes the study and application of the
principles of friction, lubrication and wear.
• Friction:
„Outer friction“, also known as Solid Body Friction, because
it appears between contact surfaces of touching solid bodies. It
is devided in
static friction, sliding friction and rolling friction.
• Wear:
Wear (abrasion) is the mass loss (surface erosion) of a
material surface due to grinding, rolling, hitting, scraping,
chemical or thermal load.
ab
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Products
REWITEC®
Target
Industries
Industry
Marine
Automotive
Wind Energy
22.06.2015 REWITEC® 6
Longer gearbox
life with
DuraGear® W100
REWITEC®
products
REWITEC® 7
Longer bearing and gear
life with GR400
REWITEC®
products
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Treated wind
turbines
Turbine
manufactrurer
Type of wind turbine
AN Bonus 1.000 kW
DeWind D4 (600 kW), D6 (1.000 kW), D8
(2.000 kW)
Gamesa G47 (600 kW)
GE GE1.5 sl, GE 2.3, GE3.6
Goldwind 750 kW
HSW 1.000 kW
Jacobs 600 kW
NEC Micon 600 kW, 800 kW, 1.000kW
Nordex N43, N52, N54, N60, N80, S70,
S77
REpower 5M
Siemens 1.000 kW, 1.300 kW
Suzlon Grease applications
Tacke TW80, TW600, TW1.500
Vestas V25, V39, V44, V47, V52, V66,
V80, V9022.06.2015 REWITEC® 9
10REWITEC®
Step 3New metal-ceramic
surface
Original material properties will be
improved in therms of friction,
temperature and wear siginficantly
Step 2Chemical reaction
The coating particles ceramize
the metal surfaces mixed friction
zone
Step 1Chemical-physical
process
The product uses the lubricant
as carrier to the mixed friction
zone
The coating
process
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2 Disc Assembly Rolling
Wear Tests
Scientific
testings
„Tribology is the science andtechnology of interactingsurfaces in relative motion“
Competence Center ofTribologyMannheim-Germany
Institute Director Prof. Dr.-Ing.-Paul FeinleLaboratory Manager Dr. Markus Grebe
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Scientific
testings
Test 10: Agip Blasia 320 without REWITEC® Test 11: Agip Blasia 320 with REWITEC®
Run 10 Run 11
Runingtime hours Runingtime hours
Run 10 Run 10
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without with
REWITEC® coating
SEM images after the 60
hours testing in 1:1
comparison:
Scientific
testings
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After 60 hours testings of Agip
SX320
synthetic oil*:
*University Mannheim
Scientific
testings
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Scientific
testings
RZ, before = 2,389 µm RZ, after = 1,129 µm
Ra, before = 0,360 µm Ra, after = 0,180 µm
Castrol Optigear Synthetic X320 with 0,2% REWITEC® added after 19
hours 39 minutes
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Scientific
testings
RZ, before = 2,389 µm RZ, after = 1,663 µm
Ra, before = 0,360 µm Ra, after = 0,285 µm
Castrol Optigear Synthetic X320 without
REWITEC®
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Scientific
testings
RZ, before = 2,389 µm RZ, after = 1,024 µm
Ra, before = 0,360 µm Ra, after = 0,151 µm
Castrol Optigear Synthetic X320 with
0,2% REWITEC®
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• Red graph without REWITEC®
• Blue graph with REWITEC® added after 20 hours
• Green graph with REWITEC® added at the beginning
• Reduction of the surface roughness due to wear
up to 47% (!)
• Reduction of the friction force up to 22% (!)
Scientific
testings
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Microscopy bearing rolling elements, Castrol X320 without REWITEC®
Microscopy bearing rolling elements, Castrol X320 with 0,2% REWITEC®
Scientific
testings –
FE-8 test
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Scientific
testings –
FE-8 test
SEM Microscopy of bearing rolling elements, Castrol X320 without REWITEC®
SEM Microscopy of bearing rolling elements, Castrol X320 with 0,2% REWITEC®
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Microscopy bearing ring, Castrol X320 without REWITEC®
Microscopy bearing ring, Castrol X320 with 0,2% REWITEC®
Scientific
testings –
FE-8 test
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Scientific
testings –
FE-8 test
SEM Microscopy bearing ring, Castrol X320 without REWITEC®
SEM Microscopy bearing ring, Castrol X320 with 0,2% REWITEC®
REWITEC®
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Electrical Motor
Heatable oil well
Tribological contact
(steel sphere on a
plan steel substrate)Spring system to adjust
normal force
Micro
Tribometer
Scientific
testings
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Measurement procedure:
I. Run-in of the contact
until stable
interface conditions are
established
II. Additive is added
III. “2nd Run-in”: improved
tribo-contact
is developed due to additive
effects
IV. New stable interface
conditions are
established
V. Difference of friction
Scientific
testings
Additive is added
(schematic representation of typical measurement)
Decrease of friction
due to additive
Initial run-in
of contact
Stable interface
conditions after
run-in
2nd run-in
process
Figures shown later
focus on this region
relative
friction
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Scientific
testings
Measuring
parameter:
Rotation
speed:
1500 U/min
Oil
temperature
:
T = 70°C
Normal
force:
FN = 20N
Additiv
concentratiREWITEC®
26REWITEC®
Coating and analysis of a wind turbine gearbox
HSW1000: Results after 150 days:
• The teeth surfaces are much
smoother and more shiny
(replicas before/after)
• The coated teeth surfaces
had a significant higher
electric resistance of
about 150 Ω
Examples of
application
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27REWITEC®
3D topography analysis of
HSW1000-imprints by
NanoFocus AG• The 3D topography analysis by
NanoFocus AG with “ µsurf-
Technologie“ confirms the
smootheness of the gear surfaces
and a 18-times magnification of
the load carrying area zones
Examples of applicationuntreated treated
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28REWITEC®
Coating and analysis of a wind turbine
gearbox GE 1.5 SL:
afterbefore
before after
Examples of
application
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29REWITEC®
Coating and analysis of a wind turbine
gearbox GE 1.5 SL:
afterbefore
Examples of application
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Coating of a „Tacke TW600“ gearbox (Condition
Monitoring by CMC GmbH):
Downturn of vibration level (roughness in the area spur gear stage) over the seasonal
waviness of the vibration trend.
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REWITEC® applicationSeasonal trend: upper vibration level
without REWITEC®
Downturn of vibration level over the
seasonal waviness trend.
Further downturn of vibration level
over the following seasonal waviness
trend.
Examples of
application
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22.06.2015
Examples of
application
REWITE
C
Goal of application:
• Wear protection of a N60 gearbox due
to the use of REWITEC® coating
concentrat in May 2014
• Analysis via SKF Maintenance Services
GmbH
• Protection against further wear and
prolongation of lifetime
Results after 2 months:
• The report shows a significant difference.
A stop of the high level vibration decrease
of the damage frequency in the toothing
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Recommendations,
partners and
customers
REWITEC®
• Less friction and temperature in the tribologic
system means:
Less stress and wear for the gearbox and the
bearings
Higher efficiency
Less stress for the lubricants
Higher realiability and availabilty, no
downtime
Cost savings, higher earnings
Conclusion
REWITEC® 33
REWITEC® GmbHDipl.-Ing. Stefan Bill
Dr.-Hans-Wilhelmi-Weg 1
35633 Lahnau, Germany
Telefon: +49 (0) 6441/44599-0
E-Mail: [email protected]
www.rewitec.com
Visit us on Facebook or YouTube.
22.06.2015 REWITEC® 34
Our goal in Brazil:
Looking for:• Customers• Distribution partners• Representatives
Contact details:Michael Kö[email protected]: +55 (27) 99235 2008Tel. +55 (27) 3077 3012
Procuramos:• Clientes• Distribuidores• Representantes Comerciais
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