The major components / assemblies of Wind Energy Systems, which require testing and certification are Generator System, Main Drive Gearbox (Planetary Gear Sets), Pitch Drive System (Electro-mechanical / Hydraulic), Yaw Drive System (Electro-mechanical / Hydraulic), Controller for Windmill Management, Hydraulic / Electro-mechanical Braking System and Blades.
Testek has over 40 years of proven, undisputed capability, experience and knowledge in the design and manufacture of Test Systems for Generators, Gearboxes, Planetary Gear Sets, Rotary Actuators (Electro-mechanical / Hydraulic) and Heat Exchangers / Oil Coolers. This extension of our products into these emerging energy industries is possible due to the similarities in OEM test requirements for these types of components, resulting in our talents being successfully applied to the testing of the various windmill components. Just a few similar Test Systems developed by Testek are introduced herein
The asynchronous generator is used in windmills to convert rotational movement into electrical energy which can be stored or distributed.
Testek builds Generator Test Systems for the aircraft industry with up to 2,000 Kw capacity. These Test Systems are for automatic and semi-automatic power testing of all such generators. As a part of the Generator Test Systems, Testek also manufactures a wide variety of Load Banks and GVR (Generator Voltage Regulators) to load and control the generators during testing. Our flexible design also offers load banks that can operate on their own in order to load test generators at the customer’s location.
The windmill gearbox consists of a planetary gear set which converts the low speed of 10 – 20 RPM, high torque input from the blades to high speed of 1,500 – 1,800 RPM / low torque power. This power is inputted to the generators.
Testek has developed Hydraulic Automated Test Systems for V-22 Osprey Tilt Rotor Aircraft Hydraulic Servo Actuators which are used for engine and other aircraft surface positioning systems. Testek has vast experience with developing RAT (Ram Air Turbine) Actuator Test Stands. This related experience will help in designing similar Test Systems for pitch and yaw actuators used in windmills.
Testek has developed several Planetary Gear Set Test Stands for automotive industry applications. These systems test planetary gear sets to maximum speeds of 14,000 RPM, and torque loads up to 4,000 ft. lbs. These Test Stands are for testing the reliability of gear sets which are used in high-power, high-speed gearboxes.
In addition, Testek designs and manufactures its own gearboxes for use in all Generator Test Stands with gearbox power capability from 5 HP to 3,000 HP, speed capability from 100 RPM to 100,000 RPM and speed ratios from 1 to 25. These gearboxes are tested extensively as part of the Test Stand Drive System for varying speed and load requirements.
The rotary actuator is the main drive component for the pitch and yaw drive systems on a windmill. These rotary actuators can be electro-mechanical or hydraulic-operated based on the design.
Testek has developed a number of Rotary Actuator Test Systems for both electro-mechanical and hydraulic type actuators. These Test Stands have capacities ranging from 9,000 RPM @ 150 in. lbs. torque load, up to 40 RPM @ 3,500 ft. lbs. torque load.
The controller of the windmill monitors and controls the various subsystems of the windmill. These could be PLC-based, or microprocessor-
Testek has developed several Power Control ATE Test Systems for aircraft industry applications. These Universal Test Systems can test all aircraft electrical system controls (GCU, BCU, BPCU, ELCU, VR, etc.) for most aircraft types. These Test Systems are also equipped to test avionics such as PSEU, ASCU, ELMS, audio and other “black boxes” within its frequency and power range.
Please contact Testek to discuss your specific testing requirements.
