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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Gearbox Reliability Collaborative Gearbox 3 Planet Bearing Calibration

The Gearbox Reliability Collaborative gearbox was redesigned to improve its load-sharing characteristics and predicted fatigue life. The most important aspect of the redesign was to replace the cylindrical roller bearings with preloaded tapered roller bearings in the planetary section. Similar to previous work, the strain gages installed on the planet tapered roller bearings were calibrated in a load frame. This report describes the calibration tests and provides the factors necessary to convert the measured units from dynamometer testing to bearing loads, suitable for comparison to engineering models.

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DOE OSTI2012

Gearbox Reliability Collaborative Gearbox 1 Failure Analysis Report: December 2010 - January 2011

Unintended gearbox failures have a significant impact on the cost of wind farm operations. In 2007, NREL initiated the Gearbox Reliability Collaborative (GRC). The project combines analysis, field testing, dynamometer testing, condition monitoring, and the development and population of a gearbox failure database in a multi-pronged approach to determine why wind turbine gearboxes do not achievetheir expected design life. The collaborative of manufacturers, owners, researchers, and consultants focuses on gearbox testing and modeling and the development of a gearbox failure database. Collaborative members also investigate gearbox condition monitoring techniques. Data gained from the GRC will enable designers, developers, and manufacturers to improve gearbox designs and testing standardsand create more robust modeling tools. GRC project essentials include the development of two identical, heavily instrumented representative gearbox designs. Knowledge gained from the field and dynamometer tests conducted on these gearboxes builds an understanding of how the selected loads and events translate into bearing and gear response. This report contains the analysis of the first gearboxdesign.

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DOE OSTI2010

Gearbox Reliability Collaborative: Gearbox Inspection Metadata

NREL has developed a software application called GearFacts that will be distributed to Database Collaborative participants to capture failure information when gearboxes are rebuilt. This publication names and describes each field used in GearFacts and can be used as a reference to the software's design.

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DOE OSTI2013

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test Plan

Gearboxes in wind turbines have not been achieving their expected design life even though they commonly meet or exceed the design criteria specified in current design standards. One of the basic premises of the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) is that the low gearbox reliability results from the absence of critical elements in the design process or insufficient design tools. Key goals of the GRC are to improve design approaches and analysis tools and to recommend practices and test methods resulting in improved design standards for wind turbine gearboxes that lower the cost of energy (COE) through improved reliability. The GRC uses a combined gearbox testing, modeling and analysis approach, along with a database of information from gearbox failures collected from overhauls and investigation of gearbox condition monitoring techniques to improve wind turbine operations and maintenance practices. Testing of Gearbox 2 (GB2) using the two-speed turbine controller that has been used in prior testing. This test series will investigate non-torque loads, high-speed shaft misalignment, and reproduction of field conditions in the dynamometer. This test series will also include vibration testing using an eddy-current brake on the gearbox's high speed shaft.

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DOE OSTI2016

Gearbox Reliability Collaborative Phase 3 Gearbox 3 Test Plan

This document describes the Phase 3 test plan for the Gearbox Reliability Collaborative Gearbox #3. The primary test objective is to measure the planetary load sharing characteristics in the same conditions as the original gearbox design. If the measured load-sharing characteristics are close to the design model, the projected three-times improvement in planetary section predicted fatigue life and the efficacy of preloaded tapered roller bearings in mitigating the planetary bearing fatigue failure mode will have been demonstrated.

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DOE OSTI2016

Gearbox Reliability Collaborative Phase 3 Gearbox 3 Test

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.

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DOE OSTI2015

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test Report

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.

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DOE OSTI2017

Gearbox Reliability Collaborative Phase 3 Gearbox 3 Test Report

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.

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DOE OSTI2016

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test

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.

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DOE OSTI2016

Gearbox Reliability Collaborative Investigation of Gearbox Motion and High-Speed-Shaft Loads

This paper extends a model-to-test validation effort to examine the effect of different constant rotor torque and moment conditions and intentional generator misalignment on the gearbox motion and high-speed-shaft loads. Fully validating gearbox motion and high-speed-shaft loads across a range of test conditions is a critical precursor to examining the bearing loads, as the gearbox motion and high-speed-shaft loads are the drivers of these bearing loads.

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DOE OSTI2011

Gearbox Reliability Collaborative Bearing Calibration

NREL has initiated the Gearbox Reliability Collaborative (GRC) to investigate the root cause of the low wind turbine gearbox reliability. The GRC follows a multi-pronged approach based on a collaborative of manufacturers, owners, researchers and consultants. The project combines analysis, field testing, dynamometer testing, condition monitoring, and the development and population of a gearboxfailure database. At the core of the project are two 750kW gearboxes that have been redesigned and rebuilt so that they are representative of the multi-megawatt gearbox topology currently used in the industry. These gearboxes are heavily instrumented and are tested in the field and on the dynamometer. This report discusses the bearing calibrations of the gearboxes.

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DOE OSTI2021

Gearbox Reliability Collaborative 1.5 (GRC1.5) Project: Joint Industry Megawatt Scale Gearbox Field Tests: Cooperative Research and Development (Final Report) CRADA Number CRD-16-00608

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative 1.5 (GRC1.5) will undertake field testing on a commercial multi-megawatt wind turbine gearbox to collect loading data as installed in the turbine to thoroughly characterize gearbox loads and responses during actual in-field conditions. A chief outcome is to provide publicly available operational loading data to the industry. 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 components, lubrication system, power converter or turbine controller.

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DOE OSTI2013

Gearbox Reliability Collaborative High Speed Shaft Tapered Roller Bearing Calibration

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.

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DOE OSTI2012

Gearbox Reliability Collaborative Phase 1 and 2: Testing and Modeling Results; Preprint

The Gearbox Reliability Collaborative (GRC) investigates root causes of wind turbine gearbox premature failures and validates design assumptions that affect gearbox reliability using a combined testing and modeling approach. Knowledge gained from the testing and modeling of the GRC gearboxes builds an understanding of how the selected loads and events translate into internal responses ofthree-point mounted gearboxes. This paper presents some testing and modeling results of the GRC research during Phase 1 and 2. Non-torque loads from the rotor including shaft bending and thrust, traditionally assumed to be uncoupled with gearbox, affect gear and bearing loads and resulting gearbox responses. Bearing clearance increases bearing loads and causes cyclic loading, which couldcontribute to a reduced bearing life. Including flexibilities of key drivetrain subcomponents is important in order to reproduce the measured gearbox response during the tests using modeling approaches.

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DOE OSTI2014

Gearbox Reliability Collaborative High-Speed Shaft Calibration

Instrumentation has been added to the high-speed shaft, pinion, and tapered roller bearing pair of the Gearbox Reliability Collaborative gearbox to measure loads and temperatures. The new shaft bending moment and torque instrumentation was calibrated and the purpose of this document is to describe this calibration process and results, such that the raw shaft bending and torque signals can be converted to the proper engineering units and coordinate system reference for comparison to design loads and simulation model predictions.

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