Abstract
This paper examines failure of helical gear in speed increasing gearbox used in the wind turbine generator (WTG). In addition, an attempt has been made to get suitable gear micro-geometry such as pressure angle and tip relief to minimize the gear failure in the wind turbines. As the gear trains in the wind turbine gearbox is prearranged with higher speed ratio and the gearboxes experience shock load due to atmospheric turbulence, gust wind speed, non-synchronization of pitching, frequent grid drops and failure of braking, the gear failure occurs either in the intermediate or high speed stage pinion. KISS soft gear calculation software was used to determine the gear specifications and analysis is carried out in ANSYS software version.11.0 for the existing and the proposed gear to evaluate the performance of bending stress tooth deflection and stiffness. The main objective of this research study is to propose suitable gear micro-geometry that is tip relief and pressure angle blend for increasing tooth strength of the helical gear used in the wind turbine for trouble free operation.Electronic supplementary materialThe online version of this article (doi:10.1186/2193-1801-3-746) contains supplementary material, which is available to authorized users.
Highlights
The function of gear drive is to transmit high power with compact design as to run with free of noise and vibration with least manufacturing and maintenance cost
Many works have been done to improve the gear tooth strength out of which most of them attempted with positive profile shifting (Fredette and Brown 1997; Ciavarella and Demelio 1999)
Based on the results obtained in this study, the following conclusions can be drawn, 1
Summary
The function of gear drive is to transmit high power with compact design as to run with free of noise and vibration with least manufacturing and maintenance cost. Many research papers have been published towards reducing noise and vibration of spur gears by make use of tooth profile modification towards involute curve but an attempt has not been made to propose simultaneous optimum profile modification towards involute curve for various pressure angle of helical gears employed in the wind turbine generator gearbox, to the best knowledge of the investigator. If addendum of the cutter is 5.288 mm without tip fillet rounding based on Equation 7, the minimum number of teeth to avoid undercut–free operation for 15° pressure angle pinions is 20. The maximum tooth bending stress (σ) for the particular pinion speed is calculated (Table 6) using the Lewis formula (Equation 8) and are compared with the ANSYS result (Shigley 2008)
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