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Executive Summary
This report presents key findings from the Department of Energy’s Advanced Drivetrain Workshop, held on June 29‐30, 2010 in Broomfield, Colorado, to assess different advanced drivetrain technologies, their relative potential to improve the state‐of‐the‐art in wind turbine drivetrains, and the scope of research and development needed for their commercialization in wind turbine applications. The Advanced Drivetrain Workshop evaluated next‐generation technologies to identify those with potential to radically improve the reliability, performance, and capital cost of wind turbine drivetrains beyond the incremental improvements that might be expected for current state‐of‐the‐art technologies. The workshop featured four separate discussion tracks, each focused on a broad category of drivetrain technologies: Superconducting Drivetrains; Advanced Permanent Magnet Generators; Continuously Variable Transmissions and Fluid Drive Systems; and Innovative and Non‐Traditional Drivetrain Concepts. Workshop participants identified major research topics with the potential to improve on the state‐of‐ the‐art in wind turbine drivetrains for each of the four broad drivetrain technology categories. The participants also listed the major barriers to the commercialization of these technologies and potential research and development pathways for overcoming those barriers. Those results are summarized in Table 1 below.
Table 1. Benefits, Barriers, and Development Pathways for Advanced Drivetrain Technologies Superconducting Drivetrains Topic Superconducting Direct Drive Generators Next Generation Superconducting Technologies Advanced Magnetic Materials Benefits Capital costs; reliability; energy capture; supply chain security Energy capture Barriers Technical; perception; scaling; IP Technical Pathways Sub‐component reliability testing; demonstration project deployment; engage independent third parties Laboratory testing

Capital costs; reliability; energy capture; safety and serviceability Capital costs; reliability; energy capture; safety and serviceability Capital costs; reliability; performance Reliability;

Technical; commercial; perception; certification Technical; commercial; certification; Technical; perception; commercial; Reliability; operator training; certification Technical; scalability;

Permanent Magnet Generators

System Design and Topology

Materials science research; tradeoff analysis; cost/benefit analysis; International Electrotechnical Commission (IEC) standards development Laboratory research; cost/benefit analysis; IEC standards development

Power Electronics

Diagnostics and Maintenance

Laboratory research; workforce education and training cost/benefit analysis; Reliability research; workforce education and training; IEC standards development Cost‐benefit analysis; design and modeling tools; demonstration 2 | Page

Frictional Contact Drives

Capital costs; reliability; energy

Va ria ble Tr

Topic

Benefits capture

Barriers materials Technical; scalability; materials; perception Technical

Pathways projects; component development and testing Cost‐benefit analysis; design and modeling tools; component development and testing; demonstration projects Feasibility studies; equipment survey

Fluid Drives

Innovative Concepts

Uptower Direct Current (DC) Generator Ground‐Level Generators Rim‐Drive Turbines Tandem Generators Complete Up‐Tower Gearbox Reparability Other Innovative Drivetrains

Capital costs; reliability; energy capture; energy storage Reliability; grid benefits Reliability Reliability Availability; scalability Reliability Capital costs; reliability

Technical Technical Commercial Technical Technical; perception

Feasibility studies Feasibility studies Feasibility studies Feasibility studies Design studies

The technologies outlined above can be grouped into three broad categories based on their potential impact on the market for current and next‐generation drivetrains. The first category includes concept‐ stage designs for next‐generation wind turbines that offer potentially significant but still uncertain advantages over the state‐of‐the‐art. The second category includes technologies that are currently being considered for incorporation into current wind turbine drivetrain designs. The third category includes technologies that have potentially transformative application in next‐generation turbine designs with large nameplate capacities (5+ MW), particularly in offshore wind turbines. The unique challenges facing each category will require different research and development strategies in order to successfully commercialize these technologies.

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Table of Contents
Executive Summary ....................................................................................................................................... 2 List of Tables ................................................................................................................................................. 4 List of Figures ................................................................................................................................................ 4 1.0 2.0 2.1 2.2 2.3 2.4 3.0 4.0 5.0 Introduction ...................................................................................................................................... 5 Workshop Results ............................................................................................................................. 8 Superconducting Drivetrains ........................................................................................................ 8 Permanent Magnet Generators .................................................................................................. 12 Continuously Variable Transmissions ......................................................................................... 18 Innovative Concepts ................................................................................................................... 22 Summary ......................................................................................................................................... 26 References ...................................................................................................................................... 27 Appendix: Workshop Agenda ......................................................................................................... 28

List of Tables
Table 1. Benefits, Barriers, and Development Pathways for Advanced Drivetrain Technologies ................ 2 Table 2. Benefits of Superconducting Direct Drive Generators .................................................................. 10 Table 3. Barriers to Commercializing Superconducting Direct Drive Generators ...................................... 11 . Table 4. Benefits of Permanent Magnet Technology Improvements ......................................................... 14 Table 5. Barriers to Commercializing Permanent Magnet Technology Improvements ............................. 17 Table 6. Benefits of Continuously Variable Transmissions ......................................................................... 20 Table 7. Barriers to Commercializing Continuously Variable Transmissions .............................................. 21 Table 8. Benefits of Innovative Drivetrain Concepts .................................................................................. 22 Table 9. Barriers to Commercializing Innovative Drivetrain Concepts ....................................................... 24

List of Figures
Figure 1. Conventional gearbox drivetrain configuration ............................................................................ 5 Figure 2. Cutaway of multi‐stage gearbox .................................................................................................... 7 Figure 3. Superconductor coils in vacuum‐insulated rotor .......................................................................... 8 . Figure 4. Benefits of permanent magnet technology improvements ........................................................ 12

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1.0

Introduction

This report presents key findings from the Advanced Drivetrain Workshop, which was organized by the U.S. Department of Energy (DOE) Wind and Water Power Program to discuss the next generation of wind turbine drivetrain technologies. The workshop, held on June 29‐30, 2010 in Broomfield, Colorado, convened experts from industry, academia, the federal government, and national laboratories. The purpose of the workshop was to assess different advanced drivetrain technologies, their relative potential to improve the state‐of‐the‐art in wind turbine drivetrains, and the scope of research and development needed for their commercialization in wind turbine applications. The Wind and Water Power Program sponsored the workshop as part of its larger efforts to reduce the cost of energy produced by wind turbines.

Figure 1. Conventional gearbox drivetrain configuration

The drivetrain of a wind turbine converts the low‐speed, high‐torque rotation of the turbine’s rotor (blades and hub assembly) into electrical energy. The most common drivetrain configuration (Figure 1) consists of a low‐speed shaft (also called a main shaft), a gearbox, a high‐speed shaft, and a generator (Hau 2006). The low‐speed shaft connects to the rotor hub and is supported by the main frame (or bedplate) through one or two main bearings. As a result, the low‐speed shaft rotates at a rotational speed of roughly 12‐30 revolutions per minute (rpm) for current utility‐scale wind turbines. A gearbox connected to the low‐speed shaft steps up the rotational speed to 1,200‐1,800 rpm via a set of gears in two or three stages, typically consisting of planetary and parallel gear configurations (Hau 2006). A high‐ speed shaft then transmits mechanical power from the gearbox to a generator, which requires high rotational speeds (1,200‐1,800 rpm) in order to economically generate electricity. Generators often use power electronics to allow variable speed operation and to condition the electrical power output of the turbine so that it can be integrated into the power grid easily and efficiently. Some wind turbine configurations forgo a gearbox and instead generate electricity by coupling the low‐frequency rotation of the main shaft directly to the generator. Such “direct‐drive” configurations typically require large
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diameter generators and extensive power electronics to allow variable speed operation and to condition the electrical output for the grid. Drivetrains contribute to the total cost of energy produced by wind turbines in multiple ways. First, the drivetrain includes some of the most expensive components in a wind turbine, namely the gearbox and generator, which account for nearly one half of the turbine’s total capital cost (Fingersh, Hand and Laxson 2006). Heavier drivetrains also require more substantial towers to support their weight, further driving up the turbine’s overall capital equipment costs. Second, drivetrains represent a significant proportion of the total energy losses within a wind turbine, reducing electrical power output, and thus revenue, of an individual turbine. Finally, conventional drivetrains are not meeting their expected 20‐ year operating lifetimes primarily due to premature gearbox and bearings failures that necessitate turbine downtime as well as expensive and time‐consuming repairs or replacements, often via the deployment of very large and expensive lifting cranes (Musial, Butterfield and McNiff 2007). In addition to the costs of replacement equipment, crane rental, and lost revenue, widespread gearbox failures can lead financiers to demand higher interest rates for project loans due to a higher perceived level of technology risk. To help lower the cost of wind energy, the Wind and Water Power Program works to improve reliability, increase performance, and decrease capital costs for wind turbine drivetrains. The program funds the Gearbox Reliability Collaborative, a public‐private partnership between national laboratories, universities, gearbox and component manufacturers, engineering consultants, and wind turbine manufacturers. The mission of the Gearbox Reliability Collaborative is to gather, analyze, and share data from operational and experimental gearboxes (Figure 2). The goal of this effort is to identify critical design parameters and root causes that are responsible for gearbox failures in the field. The program also funds the development of large dynamometers capable of testing next‐generation wind turbine drivetrains – this functionality allows turbine manufacturers to validate and refine new designs before deploying them in the field. In some cases, the program has worked with specific companies to develop new wind turbine designs that incorporate advanced drivetrain technologies, such as multi‐generator systems, gearbox component load mitigation, or permanent magnet replacements for wound electromagnets in the generator to reduce system size. Finally, the program funds laboratory research and development on a variety of topics with the potential to improve the reliability and performance of turbine drivetrains. Two key topics are advanced materials that improve the lubrication and wear resistance of drivetrains and drivetrain components, and the use of condition‐based health monitoring to reduce equipment failures through predictive maintenance.

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Figure 2. Cutaway of multi‐stage gearbox The Advanced Drivetrain Workshop evaluated next‐generation technologies to identify those with potential to radically improve the reliability, performance, and capital cost of wind turbine drivetrains beyond the incremental improvements that might be expected for current state‐of‐the‐art technologies. The workshop began with introductory remarks covering DOE’s existing portfolio of drivetrain research and development projects, the current state of the art in drivetrain design configurations, and the purpose and structure of the meeting. The workshop participants then split into four groups to discuss separate technologies: Superconducting Drivetrains; Advanced Permanent Magnet Generators; Continuously Variable Transmissions and Fluid Drive Systems; and Innovative and Non‐Traditional Drivetrain Concepts. Over a series of three sessions, the participants provided input on the current state of different advanced drivetrain technologies; described how these technologies could offer an improvement over the state‐of‐the‐art; listed some of the current uses of these technologies and the barriers to commercialization in wind turbine applications; and outlined potential paths to commercialization of these technologies, including estimated development timelines and key areas of research and development. The Workshop concluded with a report‐out session in which the four groups presented their key findings to the larger assembly.

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2.0

Workshop Results

The following sections describe the major technologies discussed in each of the four technology breakout sections, their potential benefits over the state‐of‐the‐art, and possible pathways for their commercialization.

2.1 Superconducting Drivetrains
This session discussed the potential application of superconducting materials (materials capable of conducting electricity with near‐zero direct‐current (DC) electrical resistance) in wind turbine generators. Superconducting materials only exhibit their superconducting properties at very low temperatures and are classified by the critical temperature at which they operate. Low temperature superconducting materials typically require temperatures below 20 Kelvin (‐253 Celsius), while high temperature superconducting materials operate between approximately 30 and 40 K. Superconducting materials and cooling systems are currently used in many non‐wind applications, including Magnetic Resonance Imaging machines, particle accelerators, electrical transmission, and prototype ship propulsion systems. Superconducting generators generally feature superconducting materials in the rotor (Figure 3) and a conventional (non‐superconducting) stator, although alternate topologies exist (including homopolar designs, “inside‐out” designs in which the rotor encloses the stator, and designs combining permanent magnets and superconducting materials). Future superconducting technologies may make it practical to also use superconducting material in the generator stator; however, with current technologies, the alternating current inherent in the stator results in time‐varying magnetic fields that incur substantial losses.

Figure 3. Superconductor coils in vacuum­insulated rotor

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Superconducting generators have the potential to offer several cost and reliability improvements over conventional wind turbine drivetrains when scaled up to very high capacities (5 MW and larger) and when used in direct drive systems. Direct drive wind turbines do not require a gearbox, thereby eliminating a major source of reliability failures. Although superconducting generator technology can be used with a gearbox, this session focused on the application of superconducting generators in direct drive wind turbines due to perceived advantages in commercial and economic viability of such designs. Superconducting generators have less mass and require less volume than comparable permanent‐ magnet direct drive generators, particularly as wind turbine capacity ratings continue to increase (power output tends to scale with volume more quickly in superconducting generators than in conventional direct‐drive generators). Lower generator mass and size reduces the capital cost of generator and reduces the loads on the tower, resulting in an overall reduction in turbine capital costs. Cost advantages produced by such weight savings are most likely to be realized initially in large turbines (roughly 5+ MW). In addition to weight savings, superconducting generators have the potential to increase drivetrain reliability by allowing a much larger air gap tolerance between rotor and stator as compared to permanent‐magnet direct drive designs. Conventional direct‐drive generators must maintain an air gap between rotor and stator of only a few millimeters, making contact between rotor and stator much more difficult to avoid, and ultimately leading to increased weight due to increased structural support requirements (Mueller and McDonald 2008). It can be difficult to manufacture and operate conventional direct‐drive generators with such tight tolerances. Superconducting direct‐drive generators, with air gaps on the order of several centimeters, can be more easily designed to avoid this mode of failure. Superconducting direct‐drive generators are especially suited for offshore wind applications, because there is an economic incentive to place as large of a turbine as possible on a single foundation to compensate for the high installation costs for offshore wind, and because these designs have the potential to offer greater reliability and require less maintenance than both geared and conventional direct‐drive designs.

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Table 2 below lists major areas of interest in superconducting direct‐drive generator research and development and the potential benefits that these areas of interest offer over the state‐of‐the‐art in wind turbine drivetrains.
Table 2. Benefits of Superconducting Direct Drive Generators

Area of Interest Low‐Temperature and High‐Temperature Superconducting Direct Drive Generators

Description
Superconducting direct‐drive generators eliminate electrical resistance in rotor coils by super‐ cooling them, allowing for extremely strong magnetic flux and high torque densities without the need for adding material (larger coils or permanent magnets). As a result, superconducting generators tend to be less massive and much smaller in size than conventional direct drive generators, especially at generating capacities of 5 MW and higher.

Benefits
Reduced Capital Costs: potentially significant drivetrain mass advantage begins around 5 MW and scales rapidly with generating capacity. The lighter construction and reduced material usage can result in a lower drivetrain cost, decreased tower loading, and easier installation logistics. Improved Reliability: larger air gap between rotor and stator leads to reliability and design benefits compared to permanent‐magnet direct‐drive designs. This may lead to reductions in unscheduled maintenance. Increased Energy Capture: superconducting direct‐drive designs promote scalability to taller and higher generating capacity turbines due to smaller and lighter nacelles. Supply Chain Security: Superconducting direct‐drive generator designs use readily available materials to generate magnetic flux, thereby providing an alternative to the rare earth magnet materials, typically mined outside the U.S., used in other direct‐drive designs. Increased Energy Capture: advances in superconducting technology will increase the efficiency of superconducting direct‐drive systems; increased efficiency may result in higher magnetic flux densities, lower parasitic losses (currently

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