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INTRODUCTION
As
wind
turbine
manufactures
gain
experience with turbine and gearbox designs,
they are elevating the need to improve the
reliability of drivetrains while employing an
architecture that optimizes the cost structure
of turbines and towers.
Drive
Type
Tapered
Single
Tapered
Double
Tapered
Double +
Cylindrical
3 & 4 Point
SRB
Hybrid
Direct
Modular
Hybrid Drive
Direct Drive
Modular Drive
MW
2.5
10
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DIRECT/HYBRID DRIVE
CONSIDERATIONS
Fig. 4 shows loads in a coordinate axis
imposed by the rotor blades on a typical
wind turbine.
800
My
600
Mz
400
200
Fx
0
Fy
-200
Fz
-400
0
1.5
2.5
3.5
4.5
Time (s)
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0.5
Typically,
bearing
manufacturers
are
provided the binned duty cycle from wind
turbine OEMs and/or gearbox manufacturers.
Equally important as the correct time series
data is the method of the reduction. While
each manufacturer can have its own method
for the reduction of time series data, it is also
important
that
they
understand
the
significance of the reduction methods on the
load/moment relationship on predicted
bearing life.
Fy
Fx
Mz,2
Mz,3
My,1My,2My,3My,4
My,1My,2My,3My,4
My,1My,2My,3My,4
Fz,3
Mz,1
Fz,2
Fz,1
increased
significantly
to
dramatically
increase the load zone above 110 degrees.
Fig. 9 shows a typical bearing life versus
lateral setting curve. Peak life tends to be in
slight preload where optimum roller sharing
occurs. When analyzing bearing life for a
two-row arrangement, it is more appropriate
to focus on system life, which is a measure of
the life associated with both bearings and
accounts for the likelihood of either bearing
reaching a failure point. This can be seen in
the system life curve for a given condition in
Fig. 10.
Low Load
300
250
200
Medium Load
150
100
High Load
50
0
-0.300
-0.250
-0.200
-0.150
-0.100
-0.050
0.000
Setting (mm)
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A previous technical paper compared tworow TRBs versus two-row SRBs in the fixed
position of a wind turbine mainshaft. One
focus of the paper was load zone and the
impact on bearing life.
THERMAL EFFECTS
Temperature can impact bearing life in
multiple ways, all of which must be taken
into account when trying to perform
advanced life calculations. Areas in which
thermal gradients can impact are listed
below:
Lubricant viscosity
Operating setting
Bearing arrangement
Dissimilar material thermal expansion
LUBRICATION
For direct drive mainshaft bearings, grease is
a very viable solution due to low operating
speeds. Although grease may result in a
thinner film thickness, it is the preferred
option for direct drive applications. It will
have a lower chance of leakage, will not
migrate as easily, and will exclude
contaminants more effectively than oil.
Common considerations for the grease
selection process include:
Higher viscosity (ISOVG 460 or 320) is
better for maintaining good film strength
8
MISALIGNMENT/RACEWAY STRESSES
RELIABILITY REQUIREMENTS
There have been many bearing life
expectations from various customers. Some
have used 150,000 hours, while others have
used 175,000 or even 200,000 hours life
calculation for which 90 percent of the
population will reliably survive (e.g. L10).
Life
Reliabilit
y
a1
L10
L5
L3
L2
L1
90
95
97
98
99
1
0.64
0.47
0.37
0.25
20-year
L10 Life
175,000
274,000
376,000
478,000
706,000
30-year
L10 Life
263,000
411,000
564,000
717,000
1,060,00
0
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CONCLUSION
There is a strong drive in the industry to
improve wind turbine reliability. Proper
bearing design and application are key
factors in helping to increase turbine uptime
and reducing maintenance costs. Accurately
defining system loading and environmental
conditions and translating them for use into
advanced analytical programs is a key first
step to achieving improvements.
SEALS
Sealing is more critical in direct drive
generator wind turbines than hybrid and
other drivetrain designs. The seals need to
control grease/oil leakage and also exclude
contaminants from entering the bearing.
Direct drive generators can be damaged if
lubricants leak from the bearing seals into the
generator. Seals are also critical in off-shore
applications where exposure to salt water
spray causes a harsh operating environment.
2)
3)
4)
5)
6)
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Bearings Steel
Precision Components Lubrication
Seals Remanufacture and Repair
Industrial Services
www.timken.com
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The Timken Company.
2009 The Timken Company
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