Challenges and Opportunities of Full Size Nacelle Testing of Wind Turbine Generators

Reisch, Sebastian; Jacobs, Georg; Bosse, Dennis; Matzke, Daniel

doi:10.1299/jsmeimpt.2017.10-01

Cited by 9 publications

(6 citation statements)

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“…State-of-the-art modelling techniques are used to model the individual components in the force transmission path. Both main bearing designs have also been tested on a full scale test bench [4]. Based on measurement data the FEM models are validated and fundamental relationships are derived from experiment and simulation.…”

Section: Methodsmentioning

confidence: 99%

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Experimental and simulation-based analysis of asymmetrical spherical roller bearings as main bearings for wind turbines

Loriemi

Jacobs

Reisch

et al. 2021

Forsch Ingenieurwes

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Symmetrical spherical roller bearings (SSRB) used as main bearings for wind turbines are known for their high load carrying capacity. Nevertheless, even designed after state-of-the-art guidelines premature failures of this bearing type occur. One promising solution to overcome this problem are asymmetrical spherical roller bearings (ASRB). Using ASRB the contact angles of the two bearing rows can be adjusted individually to the load situation occurring during operation. In this study the differences between symmetrical and asymmetrical spherical roller bearings are analyzed using the finite element method (FEM). Therefore, FEM models for a three point suspension system of a wind turbine including both bearings types are developed. These FEM models are validated with measurement data gained at a full-size wind turbine system test bench. Taking into account the design loads of the investigated wind turbine it is shown that the use of an ASRB leads to a more uniform load distribution on the individual bearing rows. Considering fatigue-induced damage an increase of the bearing life by 62% can be achieved. Regarding interactions with other components of the rotor suspension system it can be stated that the transfer of axial forces into the gearbox is decreased significantly.

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Section: Methodsmentioning

confidence: 99%

“…The analysis of this study refers to a generic 2.75 MW research nacelle that has been built in the context of the project "Loads on Drivetrain Components of Wind Turbine Generators" [4]. The rotor suspension system is designed as a three-point suspension, using a spherical roller bearing as a main bearing (Fig.…”

Section: Rotor Suspension Systemmentioning

confidence: 99%

Experimental and simulation-based analysis of asymmetrical spherical roller bearings as main bearings for wind turbines

Loriemi

Jacobs

Reisch

et al. 2021

Forsch Ingenieurwes

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“…Therefore, a four-point suspension 1 MW nacelle with a gearbox ratio of 61.9 was investigated on a system test bench at the Center for Wind Power Drives (CWD). [14] The test bench can apply all six mechanical degrees of freedom to the hub of the WT using a direct drive and wind load application system [15]. In addition to the gearbox itself, the test setup includes the main bearing assembly, the machine carrier, and a higher power generator that allows overload tests to be performed.…”

Section: Test Setup and Experimentsmentioning

confidence: 99%

Development of a Methodology for a WT Gearbox Robustness Test

Gnauert

Krause²,

Jacobs³

et al. 2022

J. Phys.: Conf. Ser.

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The paper presents a novel test method to address non-calculative failure modes in wind turbine gearboxes through a metrological robustness evaluation. The method is exemplarily shown for the evaluation of the failure mode “fretting corrosion” which is caused by ring creep at roller bearings. The method was also verified for the failure modes smearing and rehardening. Through the proposed gearbox robustness test, it is for the first time possible to test gearboxes against relevant failure modes and to establish a baseline to compare the robustness of gearboxes with each other. This allows identifying design elements that increase the gearbox robustness and boosters a further increase in availability and reliability of wind turbines.

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“…The test bench can apply all six mechanical degrees of freedom at the WT's hub with the help of a direct drive and a wind load application system [19]. Besides the gearbox itself the test setup includes the main bearing arrangement, the machine carrier and a higher power generator, which allows to perform overload test.…”

Section: Fig 3 Gearbox Test At System Level [18]mentioning

confidence: 99%

Simulation based prediction of ring creep on a planetary bearing of a 1MW wind turbine gearbox

Gnauert¹,

Krause²,

Jacobs³

et al. 2022

J. Phys.: Conf. Ser.

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Wind turbines (WT) must be further optimized concerning availability and reliability. One of the major reasons of WT downtime is the failure of gearbox bearings. Some of these failures occur due to the ring creep. Ring creep is a failure mechanism, which is mostly detected in the planetary bearings. Ring creep describes a relative movement of the outer ring to the planetary gear. In order to improve the understanding of ring creep, the finite element method (FEM) is used to simulate ring creep in a full-scale planetary bearing (NJ2330) of a 1MW WT planetary gear. The simulation results are validated with experimental data, obtained on a nacelle test bench. The study shows that the simulative prediction of ring creep is of the correct order of magnitude, but no accurate prediction of ring creep can be made without accounting for manufacturing tolerance classes.

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Challenges and Opportunities of Full Size Nacelle Testing of Wind Turbine Generators

Cited by 9 publications

References 0 publications

Experimental and simulation-based analysis of asymmetrical spherical roller bearings as main bearings for wind turbines

Experimental and simulation-based analysis of asymmetrical spherical roller bearings as main bearings for wind turbines

Development of a Methodology for a WT Gearbox Robustness Test

Simulation based prediction of ring creep on a planetary bearing of a 1MW wind turbine gearbox

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