Abstract. This paper is the first in a two-part study on lubrication in wind turbine main bearings. Elastohydrodynamic lubrication is a complex field, the formulas and results from which should not be applied blindly, but with proper awareness and consideration of their context, validity and limitations in any given case. The current paper, “Part 1”, therefore presents an introductory review of elastohydrodynamic lubrication theory in order to provide this necessary background and context in an accessible form, promoting cross-disciplinary understanding. Fundamental concepts, derivations and formulas are presented, followed by the more advanced topics of starvation, non-steady effects, surface roughness interactions and grease lubrication. “Part 2” applies the presented material in order to analyse wind turbine main-bearing lubrication in the context of available film thickness formulas and related results from lubrication theory. Aside from the main-bearing, the material presented here is also applicable to other lubricated non-conformal contacts in wind turbines, including pitch and yaw bearings and gear teeth.

Abstract. This paper is the second in a two-part study on lubrication in wind turbine main bearings. Where Part 1 provided an introductory review of elastohydrodynamic lubrication theory, this paper will apply those ideas to investigate lubrication in the double-row spherical roller main bearing of a 1.5 MW wind turbine. Lubrication is investigated across a “contact conditions dataset” generated by inputting main-bearing applied loads, estimated from hub loads generated using aeroelastic simulation software, into a Hertzian contact model of the main bearing. From the Hertzian model is extracted values of roller load and contact patch dimensions, along with the time rate of change of contact patch dimensions. Also included in the dataset are additional environmental and operational variable values (e.g. wind speeds and shaft rotational speeds). A suitable formula for estimating film thickness within this particular bearing is then identified. Using lubricant properties of a commercially available wind turbine grease, specifically marketed for use in main bearings, an analysis of film thickness across the generated dataset is undertaken. The analysis includes consideration of effects relating to temperature, starvation, grease thickener interactions and possible non-steady effects. Results show that the studied main bearing is at risk of operating under mixed lubrication conditions for a non-negligible proportion of its operational life, indicating that further work is required to better understand lubrication in this context and implications for main-bearing damage and operational lifetimes. Key sensitivities and uncertainties within the analysis are discussed, along with recommendations for future work.

This paper presents a data driven case study of two outer-race spalling faults in double-row spherical roller main-bearings, with the purpose of identifying key features and relevant measurements associated with this failure mode in wind turbine main-bearings. Supervisory data is analysed for one fault case and vibration data for the other. The aim of this work is to inform practitioners and assist in improving fault detection systems for this component.