Abstract Stage I: Two-mass Oscillator Stage II: Torsional Multi-body Progressive Dynamical Drive Train Modeling As Part of NREL Gearbox Reliability Collaborative Progressive Dynamical Drive Train Modeling As Part of NREL Gearbox Reliability Collaborative Francisco Oyague Francisco Oyague Stage III: Gear Elements The information contained in this poster is subject to a government license | WINDPOWER 2008 | Houston, Tx | June 1–4, 2008 | PO-500-43068 Stage V: High Fidelity Semistatic Validation The Gearbox reliability Collaborative (GRC) seeks to develop a model representative of the current standards in the industry that can be extrapolated to a large number of turbines with different sizes and dimensions, but with the same configuration. Thus, the GRC’s analysis and experimentation is performed on a carefully selected, preexisting machine with a significant operating history. This approach assures that the information revealed by the testing and analysis will be more valuable and relevant to the current industry. The GRC analysis also seeks to integrate several numerical models that capture the dynamical nature of the drive train into the drive train design process. These dynamical models which are progressively complex aim to reveal new insight into the internal forces inherent to the dynamical behavior of the drive train. Additionally, the progressive nature of these models allows them to be validateed by comparing models of less complexity to models of higher complexity, thus eliminating error in the model development. These models will allow for the filtration of sensitive information between the different parties of the design process; therefore, ultimately increasing transparency. This model accounts for the torsional compliances of each individual stage of the gearbox, as well as, each individual shaft. It also accounts for the changes in torque and angular velocities generated by the gearbox. The overall response of the drive train should be similar to the response observed in the first model. This model implements gear elements capable of accounting for backlash, gear tooth contact and changes in center distances. The joints in this model have a single degree of freedom that only allows rotation. The compliances and clearance contribution of the bearings are neglected. Relevant load cases were generated in the aeroelastic software FAST_AD The load cases included: ¾Braking maneuvers ¾Fault loads cases ¾Turbulent conditions The load cases are imported into the models of higher fidelity The integration of FAST_AD and the multibody system models results in a comprehensive analytical tool. The two-mass oscillator, is the simplest simulated form of the drive train. It is a simple, two-mass torsional vibration system in which one mass represents the rotor and one mass represents the generator. The entire drive train is represented by a torsional spring damper connection. This rudimentary approach is used by many aeroelastic simulation codes. Stage IV: Bearing Compliance This model adds degrees of freedom to the joints in the stage III model. The joints are constrained by the use of force elements that represent the stiffness of the bearings. This model better represents the bearing load distribution, and gear misalignment. The different models and parameters calculated were validated with data collected from the field Validation included: ¾ Airfoils and power curve characteristics ¾ Modal behavior of the blades and tower Load Generation 4 Pole Generator Generator shift 6 Pole Generator -200 -100 0 100 200 300 400 500 600 0 100 200 300 400 500 600 Time [sec] Torque [kNm] 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 shaft bending [V] LSS Torque LSS Bending The stage of highest complexity includes a full finite element model of the gearbox. Housing deformation will be modeled to account for the overall misalignment of the internal components of the gearbox. High fidelity gear finite element analysis will be performed to reveal gear tooth load distribution. ¾ Natural frequency and drive train stiffness ¾ Inertial characteristics of the generator
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Abstract Stage I: Two-mass Oscillator Stage II: Torsional Multi-body
Progressive Dynamical Drive Train Modeling As Part of NREL
Gearbox Reliability Collaborative Progressive Dynamical Drive Train Modeling As Part of NREL
Gearbox Reliability Collaborative Francisco OyagueFrancisco Oyague
Stage III: Gear Elements
The information contained in this poster is subject to a government license | WINDPOWER 2008 | Houston, Tx
| June 1–4, 2008 | PO-500-43068
Stage V: High Fidelity Semistatic
Validation
The Gearbox reliability Collaborative (GRC) seeks to develop a model representative of the current standards in the
industry that can be extrapolated to a large number of
turbines with different sizes and dimensions, but with the same configuration. Thus, the GRC’s
analysis and
experimentation is performed on a carefully selected,
preexisting machine with a significant operating history. This approach assures that the information revealed by the testing and analysis will be more valuable and relevant to the current industry.The GRC analysis also seeks to integrate several numerical models that capture the dynamical nature of the drive train into the drive train design process. These dynamical models which are progressively complex aim to reveal new insight into the internal forces inherent to the dynamical behavior of the drive train. Additionally, the progressive nature of these models allows them to be validateed
by comparing models of less complexity to models of higher complexity, thus eliminating error in the model development. These models will allow for the filtration of sensitive information between the different parties of the design process; therefore, ultimately increasing transparency.
This model accounts for the torsional compliances of each individual stage of the gearbox, as well as, each individual shaft.
It also accounts for the changes in torque and angular velocities generated by the gearbox.
The overall response of the drive train should be similar to the response observed in the first model.
This model implements gear elements capable of accounting for backlash, gear tooth contact and changes in center distances.
The joints in this model have a single degree of freedom that only allows rotation.
The compliances and clearance contribution of the bearings are neglected.
Relevant load cases were generated in the aeroelastic software FAST_AD
The load cases included: Braking maneuversFault loads casesTurbulent conditions
The load cases are imported into the models of higher fidelity
The integration of FAST_AD and the multibodysystem models results in a comprehensive analytical tool.
The two-mass oscillator, is the simplest simulated form of the drive train.
It is a simple, two-mass torsional vibration system in which one mass represents the rotor and one mass represents the generator.
The entire drive train is represented by a torsional spring damper connection.
This rudimentary approach is used by many aeroelastic simulation codes.
Stage IV: Bearing Compliance
This model adds degrees of freedom to the joints in the stage III model.
The joints are constrained by the use of force elements that represent the stiffness of the bearings.
This model better represents the bearing load distribution, and gear misalignment.
The different models and parameters calculated were validated with data collected from the fieldValidation included:
Airfoils and power curve characteristicsModal behavior of the blades and tower
Load Generation
4 Pole Generator
Generator shift
6 Pole Generator
-200
-100
0
100
200
300
400
500
600
0 100 200 300 400 500 600
Time [sec]
Torq
ue [k
Nm
]
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
shaf
t ben
ding
[V]
LSS TorqueLSS Bending
The stage of highest complexity includes a full finite element model of the gearbox.
Housing deformation will be modeled to account for the overall misalignment of the internal components of the gearbox.
High fidelity gear finite element analysis will be performed to reveal gear tooth load distribution.
Natural frequency and drive train stiffness Inertial characteristics of the generator
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