Designing Large Segmented Flexible Conical Plain Bearings as Wind Turbine Main Bearings

Abstract

Main bearings are failure-prone components in wind turbines, significantly increasing the LCOE of wind energy. Therefore, segmented plain bearings are being discussed as replacement for the currently used rolling bearings. Segmented plain bearings allow an up-tower replacement of faulty segments without the need to dismantle the WT drivetrain, as is required for rolling bearing replacements. One such bearing is the segmented, flexible, conical “FlexPad” plain bearing as alternative to existing double row tapered roller bearings. Designing the FlexPad bearing manually is very complex and thus time-consuming. Hence, during the research project a new holistic design method for large and highly loaded, conical plain bearings was developed. To prove the suitability of the method, two bearing prototypes were built and tested. The prototype, designed with the new method, outperformed the first, manually designed bearing, in terms of the design objectives. Most importantly, the friction losses were reduced by 32.1%. The project results show that the new method is able to efficiently design safely operating FlexPad bearing variants for wind turbines.