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The Role of Urelast in Enhancing Wind Turbine Efficiency

02 December 2024 Hazel Smeeth

Urelast, a high-performance elastomer, is increasingly being used in various components of wind turbines to improve their durability, efficiency, and maintenance. Urelast is a type of elastomer known for its exceptional load-bearing capacity, flexibility, and durability. It combines the best properties of polyurethane and rubber, making it an ideal material for applications that require high performance under demanding conditions.

Applications of Urelast in Wind Turbines

Gearbox Mountings: Urelast is used in the gearbox mountings of wind turbines, where it can withstand loads up to four times higher than conventional rubber-to-metal bonds. This allows for a significant reduction in the size and weight of the components, enhancing the overall efficiency of the turbine.

  • Longer service life in comparison to an unbonded spring.
  • Wearing of springs is minimised.
  • Optimised spring stiffness in comparison to rubber/metal-coated springs.
  • Improved vibration reduction in environment of torque arm gearbox.

 

Azimuth Brakes and Drive Systems: The azimuth system, which controls the orientation of the wind turbine, benefits from Urelast components, which are designed to avoid the loss of the braking effect of the claw bars in the azimuth system. These components provide reliable performance and reduce the need for frequent maintenance

  • Unbreakable - Elastomer compression springs retain force, with defined spring properties and can be customised.
  • Free from wear.
  • Flatter spring characteristic.
  • Larger permissible load range in comparison to plate springs, for same installation space.
  • Preload force adjustable by varying rotation angle.
  • Avoidance of total failure of azimuth drives.
  • Same installation space/connection dimensions.

 

Rotor Hubs and Bearings: Urelast is also used in the rotor hubs and bearings, where its flexibility and durability help in absorbing vibrations and reducing wear and tear. This leads to longer service life and lower maintenance costs.

Damping Systems: Wind turbines are subject to various dynamic forces that can cause vibrations and noise. These may be custom made, or from a choice of standard mounting elements. Urelast damping systems effectively mitigate these issues, ensuring smoother and quieter operation.

  • Source and receiver insulation.
  • Vibration insulation.
  • Structure-borne noise insulation.
  • Shock absorption.

 

Condition Monitoring: Some Urelast components are equipped with integrated sensors that monitor the load and performance of the wind turbine in real-time. This data is crucial for predictive maintenance and helps in preventing unexpected failures.

Benefits of Using Urelast

  • Reduced Maintenance Costs: The durability and reliability of Urelast components lead to fewer breakdowns and lower maintenance costs over the turbine’s lifespan.
  • Enhanced Efficiency: By reducing the size and weight of critical components, Urelast contributes to the overall efficiency of wind turbines.
  • Improved Reliability: The ability of Urelast to withstand high loads and harsh environmental conditions ensures that wind turbines operate reliably even in challenging settings.

Conclusion

The application of Urelast in wind turbines represents a significant advancement in renewable energy technology, and at Berger Tools, we are proud to play our part. By enhancing the durability, efficiency, and reliability of wind turbines, Urelast is helping to make wind energy a more viable and sustainable option for the future. As the industry continues to innovate, materials like Urelast will undoubtedly play a pivotal role in shaping the future of wind energy.

Feel free to contact us if you have any questions!





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