Abstract
This paper introduces an innovative approach for the creation of the robustness test against specific failures of the planetary and HSS bearings (e.g. classical fatigue, smearing, micro-pitting, and lip fractures) in the wind turbine gearboxes. The introduced Bearing Robustness Test (BRT) considers the system-dependent characteristics (e.g. drive train design, interaction between components, assembly process, lubricant aging) and real dynamic load conditions, frequencies and sequence. The creation of the BRT is based on field and simulation data. The core element is the simulative approach for the determination of the relation between external wind and grid loads on the one side and local loads of the bearing on the other side. BRT aims the mapping of the most critical, but real, field load situations in the bearing test rig. By means of the BRT it is possible to evaluate the robustness of bearing against specific field conditions in the early stage of the product cycle and consequently to enhance the quality and to reduce the failure rate of the bearing.
Highlights
This paper introduces an innovative approach for the creation of the robustness test against specific failures of the planetary and high-speed shaft (HSS) bearings in the wind turbine gearboxes
The objective of this paper is to introduce an approach for the creation of a bearing robustness test (BRT)
The classification of fatigue bearing loads is executed by time-at-level count method [19] and pictured as load revolution distribution (LRD) [18]
Summary
The cost-efficiency of the wind turbines is reduced by the frequent failures of the main gearboxes. The rolling contact bearings are the most critical component of the main gearbox They contribute to over 67 % of main gearbox failures according to the current research, see Figure 1. The first six years of the operating time are the most critical for the bearing failures according to the current research [6] For these critical six years, BRT shows a robustness of the original size planetary and HSS bearings against failures, such as classical fatigue and specific bearing failures such as smearing, micro-pitting, failures due to slippage or lip fractures. High dynamic loads) and subsequently to critical bearing behavior (e.g. low lubricant film height, high energy input) These operating modes are integrated in the fatigue load spectrum with the realistic sequence, amount and characteristics according to the field experience and simulations, see Figure 2.
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