Simulation methodology for the identification of critical operating conditions of planetary journal bearings in wind turbines

Abstract

The usage of journal bearings as planetary bearings in wind turbines instead of roller bearings has become more common in recent years. Their usage is advantageous, due to smaller installation space needed compared to roller bearings allowing for higher power densities of wind turbine drive trains. However, this technology presents a challenge since there is currently no standardized approach for the design of planetary journal bearings regarding wear. Due to varying wind speeds and dynamic operating events a large variation of loads has to be considered in the design process of a planetary journal bearing for wind turbines. Some of these loads are considered potentially critical to the journal bearing in terms of wear. Identifying these critical load areas early in the design phase supports a reliable bearing design and wind turbine operation.This paper introduces a method to identify critical operating conditions for planetary journal bearings using a simulation tool chain, which couples a multi body simulation (MBS) model of a wind turbine with an elasto-hydrodynamic (EHD) model of the planetary journal bearing. Based on the EHD results critical operating conditions are determined for the planetary bearing. Furthermore, methods are implemented to reduce the number of required EHD simulations for analysing the bearing design. The combination of the identification of critical operating conditions, while reducing the computational effort leads to a simulation methodology, which enables a faster bearing design assessment considering the wide variation of wind turbine operating conditions. The applicability of this method is demonstrated by a simplified use case.Firstly, this paper introduces the MBS model and the parameter space that describes possible combinations of bearing loads such as forces, moments and rotational speed. Due to the number of combinations and the EHD computing effort, the identified parameter space is secondly sampled statistically to reduce the simulation effort. A risk map is derived from the EHD results, to easily indicate potentially critical operating conditions for the planetary journal bearing.

Evaluation of Wear Models for the Wear Calculation of Journal Bearings for Planetary Gears in Wind Turbines

“…In this way, it can be evaluated whether the selected wear approach and the developed method are suitable for the wear calculation of planetary gear bearings under real load conditions or whether further development is necessary. In combination with the published work Simulation methodology for the identification of critical operating conditions of planetary journal bearings in wind turbines [15], both studies represent the first steps towards the development of a framework for the use of planetary journal bearings in wind turbines. This study addresses the screening, implementation and evaluation of the wear approaches (Step 1) and wear calculations of the component test rig bearing (Step 2) considering materials and lubricants used in wind turbines.…”