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An update on the status of the Gearbox Reliability Collaborative (GRC) improved gearbox is presented, including a brief summary of key instrumentation.
Wind turbine gearboxes do not achieve their expected design life. The cost of gearbox replacements and rebuilds and the downtime associated with these failures increase the cost of wind energy. In 2007, the U.S. Department of Energy established the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC). Its goals are to understand the root causes of premature gearbox failures and improve their reliability. To date, the GRC has focused on a 750-kW drivetrain with a three-stage, three-point-mounted gearbox. A nonproprietary version of the gearbox containing CRBs with C3 clearances in the planetary stage was customized. Two of these gearboxes, GB1 and GB2, were manufactured and then tested in the National Wind Technology Center's 2.5-MW dynamometer and in the field. Major GRC findings include the detrimental effect of rotor moments on planetary load sharing and predicted fatigue, and the risk of bearing sliding in low-torque conditions for three-point configuration drivetrains. Based on the knowledge gained from testing and analysis of the original design, the GRC gearbox was redesigned to improve its load-sharing characteristics and predicted fatigue. This new gearbox is named GB3. As shown in Figure 1, its key improvement is the incorporation of preloaded TRBs that support the planet carrier and planets. Roller loads can be optimized and bearing life maximized with a small preload [4]. These preloaded bearings, along with interference-fitted planet pins, improve alignments and load-sharing characteristics. A semi-integrated planet bearing design also increases capacity and eliminates outer race fretting. Romax Technology, with Powertrain Engineers and the Timken Company (Timken), completed the redesign. Timken manufactured and instrumented the planet gears and bearings. Brad Foote Gearing manufactured the other gearing and assembled the gearbox.
Many gearboxes in wind turbines have not been achieving their expected design life [1]; they do, however, commonly meet or 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 downtime associated with these failures, has elevated the cost of wind energy. In 2006, the U.S. Department of Energy established the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC). Its key goal is to understand the root causes of premature gearbox failures and improve their reliability [2]. The GRC is examining a hypothesis that the gap between design-estimated and actual wind turbine gearbox reliability is caused by underestimation of loads, inaccurate design tools, the absence of critical elements in the design process, or insufficient testing. This test report describes the recent tests of GRC gearbox (GB) 2 in the National Wind Technology Center (NWTC) dynamometer and documents any modifications to the original test plan [3]. In this manner, it serves as a guide for interpreting the publicly released data sets with brief analyses to illustrate the data. Specific objectives of the test were to assess the effect of dynamic nontorque load (NTL) on the planetary section, generator misalignment on the highspeed shaft (HSS), and field representative conditions on the gearbox in general. Detailed analysis of those test objectives will be presented in subsequent publications.
The National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) is a project investigating gearbox reliability primarily through testing and modeling. Previous dynamometer testing focused upon acquiring measurements in the planetary section of the test gearbox. Prior to these tests, the strain gages installed on the planetary bearings were calibrated in a load frame.
The GRC uses a combined gearbox testing, modeling, and analysis approach disseminating data and results to the industry and facilitating improvement of gearbox reliability. This test data describes the tests of GRC gearbox 3 in the National Wind Technology Center dynamometer and documents any modifications to the original test plan. It serves as a guide to interpret the publicly released data sets with brief analyses to illustrate the data. TDMS viewer and Solidworks software required to view data files. 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.
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.
Many gearboxes in wind turbines do not achieve their expected design life; they do, however, commonly meet or 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 downtime associated with these failures, increases the cost of wind energy. In 2007, the U.S. Department of Energy established the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC). Its goals are to understand the root causes of premature gearbox failures and to improve their reliability. The GRC is examining a hypothesis that the gap between design-estimated and actual wind turbine gearbox reliability is caused by underestimation of loads, inaccurate design tools, the absence of critical elements in the design process, or insufficient testing. This report describes the recently completed tests of GRC Gearbox 3 in the National Wind Technology Center dynamometer and documents any modifications to the original test plan. In this manner, it serves as a guide for interpreting the publicly released data sets with brief analyses to illustrate the data. The primary test objective was to measure the planetary load-sharing characteristics in the same conditions as the original GRC gearbox design. If the measured load-sharing characteristics are close to the design model, the projected improvement in planetary section fatigue life and the efficacy of preloaded TRBs in mitigating the planetary bearing fatigue failure mode will have been demonstrated. Detailed analysis of that test objective will be presented in subsequent publications.
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.
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. The GRC uses a combined gearbox testing, modeling, and analysis approach disseminating data and results to the industry and facilitating improvement of gearbox reliability. This test data describes the tests of GRC gearbox 2 in the National Wind Technology Center dynamometer and documents any modifications to the original test plan. It serves as a guide to interpret the publicly released data sets with brief analyses to illustrate the data. TDMS viewer and Solidworks software required to view data files.
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.
This paper experimentally investigates a worst case grid loss event conducted on the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) drivetrain mounted on the 2.5MW NREL dynamic nacelle test-rig. The GRC drivetrain has a directly grid-coupled, fixed speed asynchronous generator. The main goal is the assessment of the dynamic content driving this particular assess the dynamic content of the high-speed stage of the GRC gearbox. In addition to external accelerometers, high frequency sampled measurements of strain gauges were used to assess torque fluctuations and bending moments both at the nacelle main shaft and gearbox high-speed shaft (HSS) through the entire duration of the event. Modal analysis was conducted using a polyreference Least Squares Complex Frequency-domain (pLSCF) modal identification estimator. The event driving the torsional resonance was identified. Moreover, the pLSCF estimator identified main drivetrain resonances based on a combination of acceleration and strain measurements. Without external action during the grid-loss event, a mode shape characterized by counter phase rotation of the rotor and generator rotor determined by the drivetrain flexibility and rotor inertias was the main driver of the event. This behavior resulted in significant torque oscillations with large amplitude negative torque periods. Based on tooth strain measurements of the HSS pinion, this work showed that at each zero-crossing, the teeth lost contact and came into contact with the backside flank. In addition, dynamic nontorque loads between the gearbox and generator at the HSS played an important role, as indicated by strain gauge-measurements.
Bearing failures in the high speed output stage of the gearbox are plaguing the wind turbine industry. Accordingly, the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) has performed an experimental and theoretical investigation of loads within these bearings. The purpose of this paper is to describe the instrumentation, calibrations, data post-processing and initial results from this testing and modeling effort. Measured HSS torque, bending, and bearing loads are related to model predictions. Of additional interest is examining if the shaft measurements can be simply related to bearing load measurements, eliminating the need for invasive modifications of the bearing races for such instrumentation.
Alstom Power has a desire to locate its latest entrance into the U.S. market at a location that truly tests the durability of the machine in a turbulent environment as well as verify the basic operating characteristics of the machine on a 60 Hz grid. The DOE/NREL National Wind Technology Center (NWTC) is well suited for this goal. The DOE/NREL Wind Program is working on improving drivetrain reliability through its Gearbox Reliability Collaborative (GRC). Alstom is also interested in performing research on their innovative drivetrain that is aligned with the objectives of the GRC. The tasks outlined in this Joint Work Statement are intended to accomplish these goals to the mutual satisfaction of both parties and the advancement of the understanding of wind turbine drivetrain behavior.
A collaborative at the National Renewable Energy Laboratory's (NREL's) National Wind Technology Center (NWTC) leads to wind turbine gearbox reliability and lowers the cost of wind energy.
This presentation was given at the Sandia Reliability Workshop in August 2013 and provides information on current statistics, a status update, next steps, and other reliability research and development activities related to the Gearbox Reliability Collaborative.
Predetermine the nature of HSS bearing responses and their sensitivity to gearbox dynamic behavior.
An update on the Reliability focus area of the Atmosphere to Electrons (A2e) center is provided, including highlighted projects from each of the four major work packages.
A collaborative at the National Renewable Energy Laboratory's (NREL's) National Wind Technology Center (NWTC) leads to wind turbine gearbox reliability and lowers the cost of wind energy.