2012 09-27 opening-owi-lab-zf

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1 OWI-Lab, 27/09/2012 A brand of ZFPresentation Title, Date

Dr. Stefan Lammens, Vice President – Chief Sales & Marketing Officer Wind Power Technology

Competitive wind turbine drive trains

through representative testing

A brand of ZF

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2 OWI-Lab, 27/09/2012 A brand of ZF

1,5 MW to 6,15 MW

Customers

Production

Locations

Regions

+

Gainesville, USA

Products

2 MW

Source: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.10

Lommel, Belgium

Coimbatore, India Tianjin, China

Gainesville, USA Lommel, Belgium

Coimbatore, India Tianjin, China

Combination of ZF and Hansen

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The Business Unit Wind Power Technology is

part of the Industrial Technology Division of ZF

4) ZF Lenksysteme GmbH is a joint venture between

ZF Friedrichshafen AG and Robert Bosch GmbH.

Die Casting Technology2)

CEO, Market

Finance,

Controlling,

IT, Process Management

Human Resources

Materials Management

Operations and

Technology

ZF Services 3)

Compliance 1)

ZF Friedrichshafen AG Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup Foundation

Board of Management Organizational unit

Powertrain Technology

Transmissions

Axle Drives

Powertrain Modules

ChassisTechnology

Chassis Systems

Chassis Components

Rubber & Plastics

Suspension Technology

Commercial VehicleTechnology

Truck & Van Driveline Technology

Bus Driveline Technology

CV Axle Systems

CV Chassis Modules

CV Damper Technology

CV Powertrain Modules

IndustrialTechnology

Construction Machinery Systems

Agricultural Machinery Systems

Material Handling Systems

Test Systems

Special Driveline Technology

Electronic Systems

Marine Propulsion Systems

Aviation Technology

Wind Power Technology

Steering Systems 4)

50 %

Passenger Car Steering Systems

Commercial Vehicle Steering Systems

Passenger Car Steering Columns

Global Aftermarket

Joint VentureDivision Division Division Division

1) linked to CEO

2) linked to Materials Management domain

3) linked to Market domainIntegration of Hansen

TransmissionsPartial activities

in wind power

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Key Figures2011 Group

The ZF Group – An Overview 2011 2011/2010

Sales € 15,509 million 20 %

Employees (end of year) 71,488 11 %

Capital expenditure € 1,058 million 82 %

R&D expenditure € 754 million 17 %

121 production companies in 27 countries

8 main development locations in 4 countries

34 service companies and more than 650 service partners

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Source: ZF WPT Market Intelligence

Offshore wind power technology is still in the emerging stage and larger, more efficient turbines along with optimization of the nascent supply chain have large potential for reducing Cost of Energy (CoE)

Reducing CoE of offshore wind will help wind to become a base-load production for the grid in mid-long term

Flemish stakeholders take a pioneering role in offshore innovations and developments

Wind Market Segments

19.828.2

37.6 37.9 40.545.8

41.1 43.4 46.049.7 52.8

0.2

0.2

0.6 1.50.8

2.02.9

3.94.9

5.66.3

0 GW

10 GW

20 GW

30 GW

40 GW

50 GW

60 GW

2007 2008 2009 2010 2011 2012e 2013e 2014e 2015e 2016e 2017e

Global Annual Market Installations (in GW)

Onshore Offshore

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CoE Reductions Critical to Competitiveness

Cost of Energy (CoE) is defined as:

Onshore A reduction of 10% in onshore wind CoE will

make it directly competitive with natural gas at today’s lower energy prices

Offshore As wind farms are installed at sites further from

shore and in deeper water, the industry will have to work hard to decrease current levels of CAPEX per megawatt installed

Wind competitive with fossil fuels Cost of Energy (EUR/MWh)

Note: NG prices = USD 4.00-6.75/MMBTU, Coal = USD 1.60-

1.70.MMBTU, onshore wind capacity factor = 30%, no CO2 costs for

fossil technology, EUR = 1.45 USD.

Source, MAKE, Lazard, others

Source: MAKE Consulting, ZF WPT Market Intelligence

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Impact of gearboxes on CoE

Offshore Wind Cost Drivers Offshore CAPEX structure

Foundations26%

Other Turbine Components

31%

Gearbox4%

Installations Vessels18%

Substation6%

Electrical Grid6%

Contingencies3%

Management2%

Insurance2%

Others1%

Preparational Work

1%

CAPEX impact of a gearbox is limited within a typical offshore project, however, turbine suppliers are continually looking for ways to reduce component weight and material usage

Not the offshore environment is changing wind turbine gearbox specifications, but the challenges in O&M are emphasizing the importance of reliability, with a direct impact on OPEX and AEP

Source: MAKE Consulting, ZF WPT Market Intelligence

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Our mission

We develop competitive products with proven reliability

to lower costs of unplanned OPEX

to guarantee AEP by increased availability

We reduce the kWh cost of renewable energy

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Trends in drive train technology

Diversity in solutions on the market

Search for the lowest CoE yields various industrial solutions for the drive train, being a trade-off between all design drivers:

reliability

weight and cost

efficiency

serviceability

grid compatibility

Mechanical power transfer:

gearbox

hydraulic converter

Electrical generator

gear driven or direct drive ?

high speed, medium speed, low speed ?

traditional or permanent magnet generator ?

Power conversion / transfer

low, medium, high voltage ?

AC or DC ?

All published solutions claim to be winners,

but few are proven by test and experience

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Representative testing is key to proof reliability of our competitive designs

Logistic complexity and uncontrolled environment of a wind turbine makes it a tough ‘test lab’

Short time-to-market requirements in new developments put time pressure on field validation campaign

Representative (lab) testing capabilities are a long-term key differentiator of ZF WP

What ?

Start the turbine !

Representative testing

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Representative testing

It is possible to

transform wind

turbine behaviour

into test rig

conditions…

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100% Serial testing, first at partial, later at full load

Evolution of wind turbines and testing procedures

ZF WP DORoTe

Dynamic Testing @

ZF WP 13.2 MW Test Bench

* Indicative Numbers & years

Industry Standard

ZF WP Capability

Overload Prototype Testing

ZF WP is continuously improving its testing procedures by implementing ZF WP

specific dynamic testing methods

Hansen Transmissions International

1970 1980 1990 2000 2010 2020

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Design verification proving reliability

Sta

te-o

f-the

-art

De

sig

n T

oo

ls

Field

Verification

Gearbox

Verification

Component and

Sub-assembly

Verification

Technology/

Materials

Verification

Re

liab

le D

es

ign

s

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Component and Sub-assembly Verification

ZF WP’s dynamic bearing system test rig

testing real size bearings

in their actual arrangement as built in the gearbox

under representative wind turbine loading and operational conditions

This pro-active testing method contributes largely to the design of robust

bearing arrangements for new reliable gearboxes

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Gearbox Verification

ZF WP’s 13.2 MW / 16.8 MW Dynamic Test Rig

- 13.2 MW rated power

- 16.8 MW peak power

- Investment

> 10 M EUR

- 1500 RPM nom speed

- 2600 RPM max speed

- 80 kNm at motors

- 1000 tons of steel

- 1000 tons of concrete

- 35m x 10m

- 100% Availability (24/7)

Motor GeneratorGB1 GB2

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From gearbox verification to complete drive train / wind turbine testing

Need for more large scale test infrastructure and prototype field testing

Research topics

• make tests even more representative by correlation between field and test rig conditions

• increase acceleration factor for life testing on test rigs

New conditions require dedicated testing

• cold / hot climate OWI climate chamber

• offshore e.g. corrosion testing

• grid codes e.g. grid compatibility testing

Next steps in representative testing

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Additional leverage to reduce CoE

Minimise OPEX and optimise availability in our service offering

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Additional leverage to reduce CoE

Minimise OPEX and optimise availability in our service offering

O&M business is evolving rapidly

ZF has a global footprint for offering service solutions for wind turbine gearboxes

Our unique gearbox know-how and large installed gearbox base will enable

intelligent preventive maintenance

Research challenge: innovation in performance and condition monitoring

create wind turbine data sets (SCADA, CMS, …)

develop intelligent processing algorithms

merge measurements and algorithms into added value for O&M

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Conclusions

ZF contributes to further proof competitive wind energy technology

Wind energy has grown significantly during last decades

Further CoE reduction will support wind to gain share in future energy mix, where offshore wind is still emerging

Proven reliability contributes to lower OPEX and higher AEP• Representative testing is key• ZF WP emphasizes this with large test capabilities• Next steps to focus on further improvement and expansion of test infrastructure

Additional leverage to reduce CoE by using intelligent preventive maintenance as part of our service solution

More and larger scale testing is better affordable in public test infrastructure (e.g. OWI), where governmental support increases regional competitiveness and contributes globally to stimulate renewable energy

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20 OWI-Lab, 27/09/2012 A brand of ZFPresentation Title, Date

Thank you very much for your attention!