New bearing solutions for higher power density, longer operating times, and lower carbon footprint

At any given moment during the day, 2,000 thunderstorms are active around the world. That amounts to sixteen million of such severe weather events per year. With wind turbines stretching up to a couple hundred meters above ground, very often in flat areas with no other big structures nearby, they are easy targets for lightnings. Some estimate that every blade will be struck, on average, 128 times over a period of 20 years, potentially causing important economic damage.

Wind turbine manufacturers and operators are currently faced with enormouschallenges. How can higher performance be delivered on a permanent basis withinexactly the same installation space while simultaneously extending the lifetimes ofexisting wind farms, improving the carbon footprint, and ultimately reducing electricitygeneration costs? Schaeffler provides answers to these questions at WindEnergyHamburg from September 27-30, 2022. In Hall B5, Booth 333, visitors will beable to discover the innovative solutions being offered by the company and theresulting possibilities for producing wind turbines, and operating them sustainably andeconomically.

Series-ready hydro-dynamic plain bearings for planetary gears

Increasing power density in wind turbine gears, combined with the demand for reducedweight and cost, requires new bearings concepts. With planetary gears, this leads toa larger number of planets with smaller diameters, known as ‘multi-planet concepts.’This means that not enough space is available for rolling bearings in the planet gears.Hydro-dynamic plain bearings are the solution here because of their low cross-section. At WindEnergy Hamburg, Schaeffler is introducing its new hydro-dynamic plain bearingsand related engineering for planet gears. This is because a thorough understanding ofthe systems and new simulation and calculation methods, as well as the correspondingtools, is required to ensure that the bearings function smoothly.

Adjusted rotor bearings: compact and safe operation with PREMESY

Performance optimization has brought about a marked trend towards adjusted bearingswith two tapered roller bearings in an O arrangement. The increased support spacing ofthis bearing arrangement reduces the inner bearing loads, whereby the bearing can bemade smaller and lighter. To ensure that the adjusted bearings continue to function yearon year, Schaeffler engineers fall back on various options from the tapered roller bearingconstruction kit. Selection takes place as part of a multi-level system simulation, whichtakes into account the effect of forces and deformation on the bearings in operation. Thebearing details are checked, and in a simulation, the correct pre-load – essential for theadjusted bearings – is determined. In order to ensure this, both during the installationprocess and in operation, Schaeffler offers the PREMESY pre-load measuring system.

Split asymmetric spherical roller bearings: economical operation after a changeof bearings

Worldwide, a large proportion of the drive train concepts installed on rotors are fittedwith spherical roller bearings. If these bearings fail prematurely, the high replacementcost, e.g., for cranes, usually renders it uneconomical to replace them. For such cases, Schaeffler has developed a robust and innovative solution based on split asymmetricspherical roller bearings. This solution can reduce the cost of replacing the bearings by agood 50 percent. Since the entire replacement process takes place in the nacelle, it is notnecessary to disassemble the rotor star or powertrain. All the necessary components arelifted into the nacelle using the deck crane and assembled in situ. Therefore, Schaefflerenables operators to continue to operate existing wind turbines cost-effectively.

CO2 footprint: major progress possible in the manufacture of rolling bearings

Wind energy is second only to hydroelectric power as one of the most climate-friendlyenergy production technologies. However, emissions in the upstream chain are alsoconsidered, such as in the production and processing of steel to manufacture the variouscomponents of a wind turbine. In order to significantly reduce the carbon footprint of rollerbearings, Schaeffler implements CO2 savings potentials across the entire value chain, from the procurement of the steel, through the manufacturing process, to the logisticsand packing.

Strategic partner for the energy revolution with green hydrogen

Since 2021, Schaeffler has added its own hydrogen unit to its service offer. Togetherwith the wind power sector, this works on new, integrated solutions that supportthe achievement of Schaeffler’s sustainability targets. Among other developments, anelectrolyzer for the production of green hydrogen is scheduled to start operation at the Schweinfurt plant.

Stacks, the key components of these electrolyzers, form part of the Schaeffler productportfolio. The Schaeffler K-Series Hydron PowerStack will have an application rangeof 1 to 1000 kilowatts. It will be designed and produced at Schaeffler sites in Europe, according to the highest quality standards. Electrolyzers can also be installed locally asmodular systems. This makes it possible, for example, to link them with individual windturbines.