Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative...

15
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC. Presenter Francisco Oyague May 23-26, 2010 Dallas, Texas NREL/PR-500-48176 Gearbox Reliability Collaborative Experimental Data Overview & Analysis

Transcript of Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative...

Page 1: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Presenter Francisco Oyague

May 23-26, 2010Dallas, Texas

NREL/PR-500-48176

Gearbox Reliability Collaborative Experimental Data Overview & Analysis

Page 2: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future2

Drivetrain and the Cost of Energy

Wind turbine gearboxes fail to meet 20-year design life

• Premature failure of gearboxes increases cost of energy– Turbine downtime– Unplanned maintenance – Gearbox replacement and rebuild– Increased warranty reserves

• The problem:– Widespread– Affecting many OEMs– Not caused by manufacturing practices

Page 3: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future3

• Facilitate dialog among all parties– Designers and consultants– Suppliers and rebuilders– Operations and maintenance

organizations

• Understand gearbox response to specific loading– Pure torque, bending, thrust

(dynamometer)– Turbulence (field)

• Understand physics of premature failure of wind turbine gearboxes

• Identify gaps in design process

• Suggest improvements in design practices and analytical tools

Field Test Dynamometer Test

Analysis• Load cases• System loads• Internal loads

• Test plan• Test turbine• Test setup & execution

Gearbox Reliability Collaborative (GRC)• Test plan• Test turbine• Test setup & execution

Page 4: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future4

Failure Database Condition Monitoring

Accelerometer

Acoustic emission sensor

Proximity probe

Frequency range to above 20 kHz

Photo Sources: ProvibTech, Machine Condition Monitoring Ltd, Physical Acoustics Corporation

Gearbox Reliability Collaborative (GRC)

Page 5: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future5

Gearbox RedesignGearbox redesign to reflect MW fleet• Floating sun• Bearing arrangement • Lubrication • Gearing micro geometry

DOE-owned GRC gearbox design distribution• Detailed technical specifications• Drawings and solid models • Material Round Robin Analysis• Standardized analytical approaches• Results from many commercial and in-house codes

Page 6: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Instrumentation

National Renewable Energy Laboratory Innovation for Our Energy Future6

• Relative motion

– Planet carrier

– Sun

– Planet

– Housing

• Forces, moments on main shaft

• Tooth load sharing between planet gears

• Bearing roller load distribution

• Temperature gradients of bearings

• Planet bearing collective roller slip

Page 7: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Planet Carrier Motion

National Renewable Energy Laboratory Innovation for Our Energy Future

• Implemented 4 sets of proximity sensor

• Machined Target surface

• Monitor of axis motions and angular motion

Planet Carrier

Planet Target surface

Page 8: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Planet Carrier Deformation

National Renewable Energy Laboratory Innovation for Our Energy Future

• Target surface deformation captured by the proximity sensors

• Deformation of planet carrier body correlated to planet pin misalignment

Page 9: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Planet Carrier Deformation

National Renewable Energy Laboratory Innovation for Our Energy Future

• Target surface deformation captured by the proximity sensors

• Deformation of planet carrier body correlated to planet pin misalignment

Page 10: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Analysis Versus Experimental Data

• Finite element model validation using 75% rated power

• Two gearboxes produced slightly different behavior

• Boundary conditions are adjusted to account for the differences

National Renewable Energy Laboratory Innovation for Our Energy Future

Experimental data

Simulated results

Page 11: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future

Gear Tooth Contact Stress

Force

Area

=Load

Page 12: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future

Gear Tooth Contact Stress

Force

Area

=Load

Page 13: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

Bearing Load

National Renewable Energy Laboratory Innovation for Our Energy Future

• Equivalent load location => Bearing load distribution

• Life reduction of 8% due to gearbox manufacturing variability (planet pin misalignment only)

Up-wind BNG Down-wind BNG

Page 14: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future14

GRC Current and Future Work• Facilitation and communication between the various

parties involved in the design process

• Multi-fidelity analysis validation through a round robin approach

• Acquisition of field and dynamometer test data for post-processing analysis

• Evaluation of analytical assumptions and other assumptions imbedded in the design process

• Implementation and population of database in order to truly understand the problem

Page 15: Gearbox Reliability Collaborative Experimental Data ... · Gearbox Reliability Collaborative Experimental Data Overview & Analysis (Presentation) Author: Francisco Oyague: NREL Subject:

National Renewable Energy Laboratory Innovation for Our Energy Future15

GRC Current and Future Work

• Long term– Produce multiple topical reports– Provide reference data set for future testing of analytical

tools and analysis approaches– Provide support for standards updates

• Redirect research and narrow focus by using the database statistics

• Expand project to include full drivetrain study

• Expand project to other drivetrain configurations