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Case Studies

Analyzing the Life Impact of REWITEC® DuraGear® W100 Treatment of GE 1.5 SLE Winergy 4410.2 Gearbox

Wind turbine operators are seeking a solution to extend the life of their gearboxes that are failing prematurely. REWITEC® developed DuraGear® W100 of nano and micro-particle based lubricant additives treatment to improve performance and life extension in gearboxes.

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Published October 20, 2016

Evaluation of High Speed Bearing Life Extension with Aerotorque WindTC

Aerotorque WindTC shown to reduce overload and torque events that can lead to white etch area formation by 4x. High speed bearing life in 1.5MW gearbox could be improved by factor of 2x by avoiding WEA.

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Published May 12, 2016

Boeing Designs and Maintains Next Generation Rotorcraft Drive Systems with DigitalClone® Prognostic Models

The U.S. Army was seeking technologies that could help more efficiently design and maintain their rotorcraft fleet. Boeing selected Sentient Science to provide prognostic life prediction models for the Apache gearbox. In design and testing, These models are used to quickly evaluate trade-off studies of reliability and performance. Once the aircraft are deployed in the field, the same models will interface with real operating conditions and sensors to evaluate how duty cycle or remanufacturing changes will extend life. By harnessing the DigitalClone application over the Industrial Internet, Boeing now has the most advanced prognostic health management and condition based maintenance program in the world.

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Published March 19, 2015

The University at Buffalo Enables Sentient Science to Become a Powerful Application on the Industrial Internet

Sentient Science is the leading provider of prognostic technology and services. Since 2001, the company developed multi-physics models, called DigitalClone, that predict mechanical failures. This research led to a series of commercial tools and services to help manufacturers and operators of rotating equipment predict and extend their products’ life and performance. By interfacing customers’ DigitalClone prognostic models with high performance cloud computing infrastructure to run hundreds of simulations, Sentient Science supports what GE and others now call the Industrial Internet. Because Sentient Science has access to the most powerful computational resources in Western New York through the University at Buffalo’s Center of Computational Research, they are now at the forefront of this new technology.

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Published June 5, 2014

National Science Foundation Finds Solution to Reduce the Time and Cost to Develop New Products

In 2001, the U.S. Government agencies began to look for solutions to reduce the time and cost to develop, test, and launch new products. They identified computational testing – predicting future machine performance with computer simulations – as a key area to improve the competitiveness of manufacturers. Since 2001, these agencies invested in Sentient Science and our DigitalClone technology to push new breakthroughs. Now, that investment has paid off in commercial software and services that support advanced manufacturing by giving companies more information about their designs’ future life and performance faster and more efficiently.

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Published March 17, 2014

Moog Solves Bearing Life Issues with the Computational Testing Technology of DigitalClone

When Moog experienced a bearing failure in testing before their new actuator launch, they needed a solution immediately. They turned to DigitalClone Component computational testing to quickly evaluate the best methods to solve the failure. With hardware testing, Moog could perform 1-2 endurance tests before product launch. Now, by adding computational testing, Moog can evaluate over 1,000 computational test points to determine the best design and duty cycle changes to extend the actuator’s bearing life.

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Published March 6, 2014

Broadwind Achieves 8x Life Extension in DriveMAX Ring Gear

Broadwind approached Sentient Science to use DigitalClone modeling capability to compare and validate the upgraded DriveMAX ring gear life. With the outputs of the life extension model, Broadwind could quantify how the improvements at the component level of a gearbox remanufacture design could extend future turbine life. And, ultimately, Broadwind could understand any warranty risk and have a third-party assessment of life extension and how to value their solution to the marketplace.

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Published April 22, 2013