A Parametric Investigation of the Effect of Generator Misalignment upon Bearing Fatigue Life in Wind Turbines Matthew Whittle 1 , Won Shin 2 , Jon Trevelyan 1 , and Junjie Wu 1 . Future Reliable Renewable Energy Conversion Systems & Networks (FRENS) www.reliable-renewables.com 14 th -17 th March EWEA 2011 Brussels, Belgium. School of Engineering and Computing Sciences 1. Durham University, 2. Romax Technology Ltd.
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Matthew Whittle 1 , Won Shin 2 , Jon Trevelyan 1 , and Junjie Wu 1 .
A Parametric Investigation of the Effect of Generator Misalignment upon Bearing Fatigue Life in Wind Turbines. Matthew Whittle 1 , Won Shin 2 , Jon Trevelyan 1 , and Junjie Wu 1 . Future Reliable Renewable Energy Conversion Systems & Networks (FRENS) www.reliable-renewables.com - PowerPoint PPT Presentation
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A Parametric Investigation of the Effect of Generator Misalignment upon Bearing
Fatigue Life in Wind TurbinesMatthew Whittle1, Won Shin2, Jon Trevelyan1, and Junjie Wu1.
Future Reliable Renewable Energy Conversion Systems & Networks (FRENS)
www.reliable-renewables.com14th-17th March
EWEA 2011Brussels, Belgium.
School of Engineering and Computing Sciences
1. Durham University, 2. Romax Technology Ltd.
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Collaboration with Romax Technology• Durham University are collaborating with Romax Technology to
understand wind turbine generator failures.• Romax are global experts in drivetrain design and simulation.• To date, Romax has designed 11 different multi-megawatt wind turbine
gearbox designs ranging from 1.5MW – 5MW. These are used by over 9 different turbine manufactures worldwide.
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Contents1. Wind Turbine Reliability2. Wind Turbine Generator Failure3. Drivetrain Misalignment4. The Turbine Data5. Modelling Methodology6. Modelling Software7. Results8. Conclusions9. Further Work
Offshore wind farm, near Utgrunden, SwedenGE Energy [www.ecomagination.com]
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Wind Turbine Reliability
Public domain data from Landwirtschaftskammer Wissenschaftliche Mess- und Evaluierungsprogramm, reproduced from Introduction to Wind Turbines and their Reliability & Availability. Feng, Y, and Tavner, P. Warsaw : EWEC 2010, 2010.
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Wind Turbine Generator Failures
•A number of large industrial surveys of electrical machine failures show that in low voltage machines bearing failures dominate.•This is supported in the wind industry by a survey of over 800 failed wind turbine generators in the USA which shows a similar picture.
Source: Alewine, K., Chen, W., “Wind Turbine Generator Failure Modes Analysis and Occurrence”, Windrower 2010, Dallas, Texas, May 24-26, 2010.
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Drivetrain Misalignment
HSS Pinion
Flexible Linksets (low tilt stiffness)
Generator Rotor
Parallel Misalignment
Brake disc
• Misalignment is a very common problem for rotating machinery; it may be the root cause of 20-30% of downtime.
• In wind turbines the gearbox and generator are mounted on rubber bushings– Under large torque the gearbox torque arm bushing deflect (mm)– Rubber sensitive to environmental conditions– Creep– Fatigue
• d
• Restoring force of coupling must be reacted by bearings.• Failure Mode: classical rolling contact fatigue.
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The Turbine• 750 kW variable speed wind
turbine considered (though analysis could easily be scaled to multi-MW turbines).
• An all-in-one system analysis ensures that all interactions between drivetrain components are considered
Bearing loads; bearing stiffness
Housing and planet carrier flexibility
Gear loads considering geometry and micro-geometry
Shaft flexibility
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RomaxWIND Software• RomaxWIND is the first software certified by GL for gear analysis
“RomaxWIND is the first software of its kind to meet the stringent certification requirements of GL, and is the result of a number of years of close working between Romax and GL”
- Dr Karl Steingroeverfrom GL Renewables Certification
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Generator Drive End Results
Increasing negative misalignment
Increasing positive misalignment
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Generator Non-Drive End Results
Increasing negative misalignment
Increasing positive misalignment
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Gearbox HSS Upwind Results
Increasing negative misalignment
Increasing positive misalignment
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Gearbox HSS Downwind Results
Increasing negative misalignment
Increasing positive misalignment
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Increasing negative misalignment
Increasing positive misalignment
Increasing negative misalignment
Increasing positive misalignment
Increasing negative misalignment
Increasing positive misalignment
Increasing negative misalignment
Increasing positive misalignment
Gearbox HSS Upwind Gearbox HSS Downwind
Generator DEGenerator NDE
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Conclusions•In line with expectation, as coupling tilt stiffness increased the bearing fatigue damage became more sensitive to misalignment.•The gearbox HSS bearings are very heavily loaded and are expected to fail prematurely.•The reduction in damage to the gearbox upwind bearing with increased misalignment and increased coupling stiffness was at the cost of increased fatigue damage to the gearbox HSS downwind bearing. •The generator DE bearing fatigue life was found to be most sensitive to misalignment.•It is recommended to conduct integrated system analyses in wind turbine design and development as the interaction between assemblies is non-trivial and may have a significant impact upon the wind turbine reliability.
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Future Work
The following aspects should be explored in further work:•Characterise coupling stiffness.•Assess impact of axial misalignment.•Testing to verify modelling.
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Thanks for listeningAny Questions?
This work was funded by the EPSRC through the FRENS joint UK-China project (www.reliable-renewables.com).
References1. Faulstich, S. et al. Windenergie Report Deutschland. Kassel : Institut fur solare Energieversorgungstechnik, 2008.2. Landwirtschaftskammer Windenergie. [Online] http://lwksh.de/cms/index.php?id=2875. 3. Reliawind Design for Reliability. Hendriks, Ben. Warsaw : EWEC 2010, 2010.4. Reliability of wind turbine subassemblies. Spinato, F., Tavner, P., van Bussel, G., and Koutoulakos, E. 2009, Renewable Power Generation, IET, pp. 287-401.5. Tavner, P., Ran, L., Penman, J. and Sedding, H. Condition Monitoring of Rotating Electrical Machines. London : IET, 2008.6. Wind turbine generator failure modes analysis and occurence. Chen, W. and Alewine K. Dallas : s.n., May 24-26 2010. WindPower 2010.7. Introduction to Wind Turbines and their Reliability & Availability. Feng, Y, and Tavner, P. Warsaw : EWEC 2010, 2010.8. Vibration analysis of misaligned shaft –ball bearing system. Hariharan, V., and Srinivasan, P. s.l. : Indian Journal of Science and Technology, 2009.9. The Truth Behind Misalignment Vibration Spectra of Rotating Machinery. Ganeriwala, S., Patel, S., and Hartung, H. s.l. : Proceedings of International Modal Analysis Conference, 1999.10. RomaxWIND. Nottingham, UK : Romax Technology Ltd.11. GH Bladed. Bristol, UK : GL Garrad Hassan. Matthew Whittle