Feasibility study on preloaded flexible conical plain bearings as wind turbine main bearings

Abstract

Wind turbines (WT) are a key technology towards a carbon neutral energy production worldwide. Currently about 30 % of the Levelized Cost of Electricity (LCoE) consist of service and maintenance. Critical components are the main roller bearings which have a failure probability between 15 and 30 % within 20 years. Main bearing replacements are expensive maintenance procedures because an external crane is needed which cost about $250.000 per day for offshore WTs. Hence, a discussed countermeasure within the wind industry is to use segmented plain bearings in future WTs. These types of bearings allow an up-tower sub-component wise replacement of faulty parts without the need to dismantle the whole drivetrain. Therefore, the Chair for Wind Power Drives (CWD) developed, tested and validated a segmented conical plain bearing concept for the use as a main bearings for WTs. To function properly common plain bearings need a minimum clearance to allow the formation of a convergent lubrication gab. This initial clearance negatively influences run-out, as the shaft con move freely within the limits of the clearance. As WT drivetrain concepts become more integrated, main bearings for WTs need to fulfill higher requirements regarding the allowable run-out of the main shaft. Therefore, a fundamental design challenge arises for plain bearings as rotor main bearings. One approach to reduce run-out for roller main bearings is to use preloaded tapered roller bearings. For common plain bearings however preloading is not possible. However, the concept of preloading was successfully transferred to the flexible conical plain bearing concept developed at the CWD and the main shaft run-out severely reduced. In this work the feasibility of a preloaded flexible conical plain bearing as a WT rotor main bearing is evaluated and the advantages and disadvantages contrasted.