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NASA NTRS1987

Advanced gearbox technology

An advanced 13,000 HP, counterrotating (CR) gearbox was designed and successfully tested to provide a technology base for future designs of geared propfan propulsion systems for both commercial and military aircraft. The advanced technology CR gearbox was designed for high efficiency, low weight, long life, and improved maintainability. The differential planetary CR gearbox features double helical gears, double row cylindrical roller bearings integral with planet gears, tapered roller prop support bearings, and a flexible ring gear and diaphragm to provide load sharing. A new Allison propfan back-to-back gearbox test facility was constructed. Extensive rotating and stationary instrumentation was used to measure temperature, strain, vibration, deflection and efficiency under representative flight operating conditions. The tests verified smooth, efficient gearbox operation. The highly-instrumented advanced CR gearbox was successfully tested to design speed and power (13,000 HP), and to a 115 percent overspeed condition. Measured CR gearbox efficiency was 99.3 percent at the design point based on heat loss to the oil. Tests demonstrated low vibration characteristics of double helical gearing, proper gear tooth load sharing, low stress levels, and the high load capacity of the prop tapered roller bearings. Applied external prop loads did not significantly affect gearbox temperature, vibration, or stress levels. Gearbox hardware was in excellent condition after the tests with no indication of distress.

Anderson, N. E.↗

NASA NTRS1997

Diagnostic Analyzer for Gearboxes (DAG): User's Guide

This documentation describes the Diagnostic Analyzer for Gearboxes (DAG) software for performing fault diagnosis of gearboxes. First, the user would construct a graphical representation of the gearbox using the gear, bearing, shaft, and sensor tools contained in the DAG software. Next, a set of vibration features obtained by processing the vibration signals recorded from the gearbox using a signal analyzer is required. Given this information, the DAG software uses an unsupervised neural network referred to as the Fault Detection Network (FDN) to identify the occurrence of faults, and a pattern classifier called Single Category-Based Classifier (SCBC) for abnormality scaling of individual vibration features. The abnormality-scaled vibration features are then used as inputs to a Structure-Based Connectionist Network (SBCN) for identifying faults in gearbox subsystems and components. The weights of the SBCN represent its diagnostic knowledge and are derived from the structure of the gearbox graphically presented in DAG. The outputs of SBCN are fault possibility values between 0 and 1 for individual subsystems and components in the gearbox with a 1 representing a definite fault and a 0 representing normality. This manual describes the steps involved in creating the diagnostic gearbox model, along with the options and analysis tools of the DAG software.

Jammu, Vinay B.↗

DOE OSTI2014

Wind Turbine Gearbox Condition Monitoring Vibration Analysis Benchmarking Datasets

Wind turbine condition monitoring (CM) can potentially help the wind industry reduce turbine downtime and operation and maintenance (O&M) cost. NREL CM research has investigated various condition-monitoring techniques such as acoustic emission (AE specifically stress wave), vibration, electrical signature, lubricant and debris monitoring based on the Gearbox Reliability Collaborative dynamometer and field tests, and other test turbines and resources accessible by NREL. During the past several years, NREL CM research has shown that there are very few validation and verification efforts on commercial wind turbine CM systems. One of the reasons might be limited benchmarking datasets accessible by stakeholders. To fill this gap, NREL executed a data collection effort. The targeted users of these datasets include those investigating vibration-based wind turbine CM research, evaluating commercially available vibration-based CM systems, or testing prototyped vibration-based CM systems. NREL collected data from a healthy and a damaged gearbox of the same design tested by the GRC. Vibration data were collected by accelerometers along with high-speed shaft RPM signals during the dynamometer testing. The healthy gearbox was only tested in the dynamometer. The damaged gearbox was first tested in the dynamometer and later sent to a wind farm close to NREL for field testing. In the field test, it experienced two loss-of-oil events that damaged its internal bearings and gear elements. The gearbox was brought back to NREL and it was retested in the dynamometer with CM systems deployed under controlled loading conditions that would not cause catastrophic failure of the gearbox. The objective of releasing these datasets to the public along with information about the real damage that occurred to the damaged gearbox is to provide the wind industry with some benchmarking datasets. These datasets will benefit research, development, validation, verification, and advancement of vibration-based wind condition-monitoring techniques. By accessing this data you acknowledge the terms outlined in the "License Information" document. Please contract Shawn Sheng (NREL) if you have any questions on the data or would like to collaborate on publications based on the datasets.

Array↗

NASA NTRSDate not supplied

Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept

Integration of electric machines with the shafts of gas turbine engines is implied in various electrified aircraft propulsion concepts. This includes implementation of the Turbine Electrified Energy Management (TEEM) concept, a motivator for the Versatile Electrically Augmented Turbine Engine (VEATE) gearbox. The VEATE gearbox is a mechanical power transmission concept that seeks to interface electric machines with a gas turbine engine in a synergistic manner. It enables a hybrid electro-mechanical approach for managing power in a gas turbine engine. It is hypothesized that the mechanical design of the VEATE gearbox could be leveraged to enhance the versatility of the present electrical hardware. The VEATE gearbox concept is first introduced and applied to an electrified two-spool advanced geared turbofan meant for powering a single-aisle commercial aircraft. A modeling approach for the gearbox is presented and studies are conducted to investigate the potential application to TEEM and power extraction. There is evidence that the VEATE gearbox could help to reduce the size of the TEEM power system, provide flexibility in power extraction implementation, and exhibit fail-safe design attributes.

Versatile Electrically Augmented Turbine Engine Ge↗

NASA NTRSDate not supplied

Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept

Electrified Aircraft Propulsion↗

DOE OSTI2017

A novel vibration-based fault diagnostic algorithm for gearboxes under speed fluctuations without rotational speed measurement

The localized failures of gears introduce cyclic-transient impulses in the measured gearbox vibration signals. These impulses are usually identified from the sidebands around gear-mesh harmonics through the spectral analysis of cyclo-stationary signals. However, in practice, several high-powered applications of gearboxes like wind turbines are intrinsically characterized by nonstationary processes that blur the measured vibration spectra of a gearbox and deteriorate the efficacy of spectral diagnostic methods. Although order-tracking techniques have been proposed to improve the performance of spectral diagnosis for nonstationary signals measured in such applications, the required hardware for the measurement of rotational speed of these machines is often unavailable in industrial settings. Moreover, existing tacho-less order-tracking approaches are usually limited by the high time-frequency resolution requirement, which is a prerequisite for the precise estimation of the instantaneous frequency. To address such issues, a novel fault-signature enhancement algorithm is proposed that can alleviate the spectral smearing without the need of rotational speed measurement. This proposed tacho-less diagnostic technique resamples the measured acceleration signal of the gearbox based on the optimal warping path evaluated from the fast dynamic time-warping algorithm, which aligns a filtered shaft rotational harmonic signal with respect to a reference signal assuming a constant shaft rotational speed estimated from the approximation of operational speed. The effectiveness of this method is validated using both simulated signals from a fixed-axis gear pair under nonstationary conditions and experimental measurements from a 750-kW planetary wind turbine gearbox on a dynamometer test rig. Lastly, the results demonstrate that the proposed algorithm can identify fault information from typical gearbox vibration measurements carried out in a resource-constrained industrial environment.

17 WIND ENERGY↗

DOE OSTI2018

Comparison of planetary bearing load-sharing characteristics in wind turbine gearboxes

Abstract. In this paper, the planetary load-sharing behavior and fatigue life of different wind turbine gearboxes when subjected to rotor moments are examined. Two planetary bearing designs are compared – one design using cylindrical roller bearings with clearance and the other design using preloaded tapered roller bearings to support both the carrier and planet gears. Each design was developed and integrated into a 750 kW dynamometer tests, the loads on each planet bearing row were measured and compared to finite-element models. Bearing loads were not equally shared between the set of cylindrical roller bearings supporting the planets even in pure torque conditions, with one bearing supporting up to 46 % more load than expected. A significant improvement in planetary bearing load sharing was demonstrated in the gearbox with preloaded tapered roller bearings with maximum loads 20 % lower than the gearbox with cylindrical roller bearings. Bearing life was calculated with a representative duty cycle measured from field tests. The predicted fatigue life of the eight combined planet and carrier bearings for the gearbox with preloaded tapered roller bearings is 3.5 times greater than for the gearbox with cylindrical roller bearings. The influence of other factors, such as carrier and planet bearing clearance, gravity, and tangential pin position error, is also investigated. The combined effect of gravity and carrier bearing clearance was primarily responsible for unequal load sharing. Reducing carrier bearing clearance significantly improved load sharing, while reducing planet clearance did not. Normal tangential pin position error did not impact load sharing due to the floating sun design of this three-planet gearbox.

17 WIND ENERGY↗

DOE OSTI2013

NREL Collaborative Improves the Reliability of Wind Turbine Gearboxes [Fact Sheet]

Gearbox failures have a significant impact on the cost of wind farm operations. To help minimize gearbox failures, in 2007 the National Renewable Energy Laboratory (NREL) initiated the Gearbox Reliability Collaborative (GRC), which consists of manufacturers, owners, researchers, and consultants. Based on all the lessons learned from the past five years, the GRC has now produced a new and improved design, which is projected to yield an operating lifetime of 12 years, more than triple that of the previous redesigned gearbox. The GRC findings will result in increased gearbox reliability and an overall reduction in the cost of wind energy.

17 WIND ENERGY↗

NASA NTRS2010

Two-Speed Gearbox Dynamic Simulation Predictions and Test Validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox as part of the drive system research activities of the NASA Fundamental Aeronautics Subsonics Rotary Wing Project. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multi-disk clutches to control output speed. A dynamic model of the system was created which included a direct current electric motor with proportional-integral-derivative (PID) speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.

Lewicki, David G.↗

DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2013

Gearbox Reliability Collaborative Analytic Formulation for the Evaluation of Spline Couplings

Gearboxes in wind turbines have not been achieving their expected design life; however, they commonly meet and exceed the design criteria specified in current standards in the gear, bearing, and wind turbine industry as well as third-party certification criteria. The cost of gearbox replacements and rebuilds, as well as the down time associated with these failures, has elevated the cost of wind energy. The National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) was established by the U.S. Department of Energy in 2006; its key goal is to understand the root causes of premature gearbox failures and improve their reliability using a combined approach of dynamometer testing, field testing, and modeling. As part of the GRC program, this paper investigates the design of the spline coupling often used in modern wind turbine gearboxes to connect the planetary and helical gear stages. Aside from transmitting the driving torque, another common function of the spline coupling is to allow the sun to float between the planets. The amount the sun can float is determined by the spline design and the sun shaft flexibility subject to the operational loads. Current standards address spline coupling design requirements in varying detail. This report provides additional insight beyond these current standards to quickly evaluate spline coupling designs.

17 WIND ENERGY↗

DOE OSTI2017

Planetary Load Sharing in Three-Point Mounted Wind Turbine Gearboxes: A Design and Test Comparison

This work compares the planetary load-sharing characteristics of wind turbine gearboxes supported by cylindrical roller bearings (CRBs) and preloaded tapered roller bearings (TRBs) when subjected to rotor moments. Planetary bearing loads were measured in field-representative dynamometer tests and compared to loads predicted by finite-element models. Preloaded TRBs significantly improved load sharing. In pure torque conditions, the upwind planet bearing load in the gearbox with preloaded TRBs was only 14% more than the assumed load compared to 47% more for the gearbox with CRBs. Consequently, the predicted fatigue life of the complete set of planetary bearings for the gearbox with preloaded TRBs is 3.5 times greater than that of the gearbox with CRBs.

17 WIND ENERGY↗

DOE OSTI2024

GRC1.5 Project: Joint Industry Megawatt Scale Gearbox Field Tests (Final Report)

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative (GRC) 1.5 will undertake field testing on current commercial multi-megawatt wind turbine gearboxes to collect loading data from installed turbines to thoroughly characterize gearbox input loads and responses during actual in-field conditions. A chief outcome is to provide operational loading data relative to the most common failure modes. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox, thus facilitating improvements in the gearbox, power converter or turbine controller.

17 WIND ENERGY↗

DOE OSTI2017

Planetary Load Sharing in Three-Point-Mounted Wind Turbine Gearboxes: A Design and Test Comparison

The planetary load sharing characteristics of wind turbine gearboxes supported by cylindrical roller bearings (CRBs) and preloaded tapered roller bearings (TRBs) when subjected to rotor moments are compared in this work. Planetary bearing loads were measured in field-representative dynamometer tests and compared to loads predicted by finite-element models. Load sharing was significantly improved with preloaded TRBs. In pure torque conditions, the upwind planet bearing loads in the gearbox with preloaded TRBs were a maximum of 1.14 compared to 1.47 in the gearbox with CRBs. Consequently, the predicted fatigue life of the complete set of planetary bearings for the gearbox with preloaded TRBs is 3.5 times greater than that of the gearbox with CRBs.

17 WIND ENERGY↗

NASA NTRS1985

Fatigue life analysis of a turboprop reduction gearbox

A fatigue life analysis of the Allison T56/501 turboprop reduction gearbox was developed. The life and reliability of the gearbox was based on the lives and reliabilities of the main power train bearings and gears. The bearing and gear lives were determined using the Lundberg-Palmgren theory and a mission profile. The five planet bearing set had the shortest calculated life among the various gearbox components, which agreed with field experience where the planet bearing had the greatest incidences of failure. The analytical predictions of relative lives among the various bearings were in reasonable agreement with field experience. The predicted gearbox life was in excellent agreement with field data when the material life adjustment factors alone were used. The gearbox had a lower predicted life in comparison with field data when no life adjustment factors were used or when lubrication life adjustment factors were used either alone or in combination with the material factors.

Lewicki, D. G.↗

NASA NTRS1986

Fatigue life analysis of a turboprop reduction gearbox

Lewicki, D. G.↗

NASA NTRS1992

Comparison of analysis and experiment for gearbox noise

Low contact ratio spur gears were tested in the NASA gear-noise rig to study the noise radiated from the top of the gearbox. Experimental results were compared with a NASA acoustics code to validate the code for predicting transmission noise. The analytical code is based on the boundary element method (BEM) which models the gearbox top as a plate in an infinite baffle. Narrow band vibration spectra measured at 63 nodes on the gearbox top were used to produce input data for the BEM model. The BEM code predicted the total sound power based on the measured vibration. The measured sound power was obtained from an acoustic intensity scan taken near the surface of the gearbox at the same 63 nodes used for vibration measurement. Analytical and experimental results were compared at four different speeds for sound power at each of the narrow band frequencies over the range of 400 to 3200 Hz. Results are also compared for the sound power level at meshing frequency plus three sideband pairs and at selected gearbox resonant frequencies. The difference between predicted and measure sound power is typically less than 3 dB with the predicted value generally less than the measured value.

Oswald, Fred B.↗

NASA NTRS1992

Optimum design of a gearbox for low vibration

A computer program was developed for designing a low vibration gearbox. The code is based on a finite element shell analysis, a modal analysis, and a structural optimization method. In the finite element analysis, a triangular shell element with 18 degrees-of-freedom is used. In the optimization method, the overall vibration energy of the gearbox is used as the objective function and is minimized at the exciting frequency by varying the finite element thickness. Modal analysis is used to derive the sensitivity of the vibration energy with respect to the design variable. The sensitivity is representative of both eigenvalues and eigenvectors. The optimum value is computed by the gradient projection method and a unidimensional search procedure under the constraint condition of constant weight. The computer code is applied to a design problem derived from an experimental gearbox in use at the NASA Lewis Research Center. The top plate and two side plates of the gearbox are redesigned and the contribution of each surface to the total vibration is determined. Results show that optimization of the top plate alone is effective in reducing total gearbox vibration.

Inoue, Katsumi↗