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KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
KENERSYS. DRIVEN BY INTELLIGENCE
MANUFACTURER-SUPPLIER CO-DEVELOPMENT: LESSONS LEARNEDHANNOVER, APRIL, 2013
MARKUS BECKER, CTO KENERSYS GMBH
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
KENERSYS IN SHORT
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
*Technically feasible
KENERSYS IN SHORT
IEC II IEC III (IEC IV)
LARGER ROTOR-DIAMETERS AND HIGHER HUB HEIGHTS
CAN COMPENSATE LOWER WIND SPEEDS
Low WindMedium Wind
An
nu
al
En
erg
y Y
ield
Mean wind speeds at 100 m hub height (m/s)
WIND
RESOURCE
POTENTIAL:
~ 75%
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
KENERSYS IN SHORT
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
DRIVERS FOR MANUFACTURER SUPPLIER
CO-DEVELOPMENT
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
• From rotor blade down to the foundation - the complex wind
energy turbine reflects all main areas of the engineering:
machine-, electrical-and constructional engineering.
• There are mainly two integration strategies:
VERTICAL INTEGRATION SYSTEM INTEGRATION
• Planning, developing and
building a large amount/ all the
components (total integration)
• Buying the components
• Focus on developing the whole
system (some key components)
• developing components
together with supplier
+ High degree of influence + some influence by co-
development
+ Independence regarding
supplier
+ Insensibility regarding market
fluctuation
+ All rights reserved + flexibility
- High personnel and
development costs and risk
+ lower costs
VERTICAL & SYSTEM INTEGRATION
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
ADVANTAGES
MANUFACTURER
ADVANTAGES SUPPLIER
Cost benefits Long term partnership
provides planning certainty
Quality benefits More market insight –
chance of increasing the
market share
Time benefits Chance to enter new
markets with new
development
Taking benefit out of
suppliers know-how and
experience
Sharing development cost -
Sell new product to other
customers
ADVANTAGES FOR CO-DEVELOPMENT
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
SUPPLIER SELECTION
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
QUALITY GATE PROCESS -
DESIGN AND DEVELOPMENT
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
QUALITY GATE PROCESS –
TEST PHASE
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
EXAMPLE – GENERATOR FROM LEROY SOMER
Facts & figures:
• November 2007 start technical discussion between Kenersys
and L+S
• After first layout from Leroy Somer period of development,
exchange of designs, ideas and corrections
• February 2008 finalisation of calculations
• March 2008 handover of technical documentation from L+ S
to KENERSYS
• June 2008 prototype
• Subsequently tests at Leroy Somer test bench
• Design team exists of around 5 engineers
Generator:
• Electrically excited synchronous generator
• The generator was specially developed for KENERSYS
• Just two manufacturers in the wind branch worked with
electrically excited generators before, but as high-speed
version and as direct drive.
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
EXAMPLE – GENERATOR FROM LEROY SOMER
KENERSYS design:
• KENERSYS specified the whole generator
including power conversion system
existing of rectifier and converter + all
interfaces details.
LEROY SOMER design:
• Leroy Somer in charge for the detailed
design technical implementation
• Several design review processes between
Kenersys and L+S for fulfillment of
specification
• e.g. the cooling jacket design
• winding allocation for high
redundancy
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
EXAMPLE – GENERATOR FROM LEROY SOMER
RESULTS:
• 4 Stator-windings combined with single rotor with
electrical excitation machine
� Split solution allows „full-load-operation“ of single
strings also in partial load for increased efficiency
• Robust curtailment in case of failure of generator
elements
• Advanced water cooling � Higher efficiency, corrosion
protection
• Permanent magnet in exciter � possibility of a black start
• System allows to use quite simple converters
• IMPORTANT FACTORS:
• Some factors hastened the development period essential:
• Engineering tools like 3D-CAD
• 3D-FEM for mechanical design but also magnetic circuit
• Fluid dynamical simulations for the inner aero loop and
the water jacket cooling
• High performance test bay used for system tests with
converter and a complete standard test bay for all
pretests.
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
EXAMPLE – HYBRID TOWER
Facts and Advantages pf the Hybridtower:
• Consists of 8 segments per ring
• Just two mold forms needed – high modularity
• Fast production set-up in different locations
• Easy transport of segments to site
Facts &Figures:
• ATS design was developed by MECAL 2003 – Today ATS
majority is owned by JUWI
• First ATS prototype with Siemens nacelle in Grevenbroich
• First meeting between Kenersys and ATS end of 2008.
• Project team exists of 2 engineers from KENERSYS and 3-5
engineers from ATS
– Load calculation by Kenersys
– Structural design ATS
– Internal design Kenersys
• First serial towers in with KENERSYS nacelle were erected
in 2010
• 22 more hybrid towers with Kenersys machines installed in
2011 until now
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
EXAMPLE – HYBRID TOWER
KENERSYS design
• KENERSYS defines
specifications and
requirements (tower internals
e.g. lift, cabling, cellar ) and
cares for the internal design
• Close coordination between
KENERSYS and ATS regarding
the tower interface (steel and
concrete)
ATS design
• ATS cared for the concrete
design
• Execution of construction
ATS with construction
company KENERSYS
accompanies the project
• After every project – review and redesign
• Continuous improvement concerning details
• ATS profits from KENERSYS` turbine know how and
KENERSYS profits form the tower know how of ATS/Mecal
• ATS has the chance to sell the tower to other manufacturers
with some adjustments
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
• Co-developments were important for KENERSYS to
enter the market in short time
• Co-development of components enables the
development of the whole turbine with a small
team
• Ensures flexibility
• Due to the platform concept the components are
implemented in all turbine types/ OEMS, therefore
highly developed components with already
available track record are crucial
• A large part of the cooperation is strategic due to
the big amount of tailor-made components
SUMMARY: SYSTEM INTEGRATION AT KENERSYS
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.comwww.kenersys.com
Many Thanks for your Attention!
DIPL.-ING. MARKUS BECKER
CHIEF TECHNOLOGY OFFICER
KENERSYS GMBH
PortAL 10 | Albersloher Weg 10
48155 Münster | Germany
Tel.: +49 251. 210 99 – 0
Fax: +49 251-21099-200
17
KENERSYS GROUP portAL 10 | Albersloher Weg 10 | 48155 Münster | Germany www.kenersys.com
Quellen
• http://books.google.de/books?id=KV_B0n507QEC&pg=PA111&lpg=PA111&dq=Fertigungstiefe+Windenergieanlagen&sourc
e=bl&ots=rMbGAfYM0C&sig=ZG9oQTz829iWHhNhn0wmCqREPRo&hl=de&sa=X&ei=PxYeUYrSLs7VsgaK9oCQAQ&ved=0CC4
Q6AEwAA#v=onepage&q=Fertigungstiefe%20Windenergieanlagen&f=false
• http://www.tcw.de/news/systemlieferanten-fuer-oems-im-bereich-erneuerbarer-energien-632