Gearbox Reliability Collaborative Investigation of Gearbox ... Gearbox Reliability Collaborative Investigation

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  • Gearbox Reliability Collaborative Investigation of Gearbox Motion and High-Speed-Shaft Loads Jon Keller, Yi Guo, and Latha Sethuraman National Renewable Energy Laboratory

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

    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    Technical Report NREL/TP-5000-65321 March 2016

    Contract No. DE-AC36-08GO28308

  • National Renewable Energy Laboratory 15013 Denver West Parkway Golden, CO 80401 303-275-3000 • www.nrel.gov

    Gearbox Reliability Collaborative Investigation of Gearbox Motion and High-Speed-Shaft Loads Jon Keller, Yi Guo, and Latha Sethuraman National Renewable Energy Laboratory

    Prepared under Task No. WE15.3D10

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

    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    Technical Report NREL/TP-5000-65321 March 2016

    Contract No. DE-AC36-08GO28308

  • NOTICE

    This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.

    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

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  • iii

    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    Acknowledgments This work was supported by the U.S. Department of Energy under Contract No. DE-AC36- 08GO28308 with the National Renewable Energy Laboratory. Funding for the work was provided by the DOE Office of Energy Efficiency and Renewable Energy, Wind and Water Power Technologies Office.

  • iv

    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    List of Acronyms CRB cylindrical roller bearing

    GB gearbox

    GRC Gearbox Reliability Collaborative

    HSS high-speed shaft

    kN kilonewton

    kNm kilonewton-meter

    m meter

    mm millimeter

    NREL National Renewable Energy Laboratory

    NWTC National Wind Technology Center

    TRB tapered roller bearing

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    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    Nomenclature

    , ,,y z y zA B Stiffness coefficients for gearbox bushing

    cd Distance from high-speed shaft end to location C

    id Inner diameter of gearbox bushing

    od Outer diameter of gearbox bushing

    sd Distance from trunnion to downwind end of high-speed shaft

    td Distance from main bearing to trunnion

    , , b

    x y zF Forces induced by gearbox bushing

    , c

    y zF Forces induced by generator coupling

    g zF Forces induced by generator misalignment

    , b y zk ′ ′ Linear stiffnesses of gearbox bushing in bushing coordinate system

    , , b x y zk Linear stiffnesses of gearbox bushing in gearbox coordinate system

    , ,x y z bkθ θ θ Rotational stiffnesses of gearbox bushing

    , c y zk Linear stiffnesses of generator coupling

    ,y z ckθ θ Rotational stiffnesses of generator coupling

    bL Length of gearbox bushing

    cL Length of generator coupling

    sL Length of high-speed shaft

    , , b x y zM Moments induced by gearbox bushing

    , c y zM Moments induced by generator coupling

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    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    C yM Moments induced by brake disk and generator coupling weight

    g yM Moments induced by generator misalignment

    sr Distance from gearbox center to high-speed shaft center

    tr Distance from gearbox center to trunnion center

    dW Weight of brake disc

    cW Weight of generator coupling

    sW Weight of high-speed shaft

    , ,x y z Displacements of gearbox

    , ,, ,ts tp tp ts tpx y z Displacements of starboard and port gearbox bushings

    ,s sy z Displacements of high-speed shaft

    gz Static vertical offset of generator

    gφ Static misalignment angle of generator

    oφ Operational misalignment angle of generator

    , ,x y zθ θ θ Roll, pitch, and yaw angles of gearbox

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    This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

    Table of Contents 1 Introduction ........................................................................................................................................... 1 2 Test Description.................................................................................................................................... 3

    2.1 Test Article .................................................................................................................................... 3 2.1.1 Gearbox ............................................................................................................................ 3 2.1.2 Bushings ........................................................................................................................... 3 2.1.3 Gearbox Motion Instrumentation ..................................................................................... 5 2.1.4 High-Speed Shaft and Bearings ....................................................................................... 7 2.1.5 High-Speed-Shaft Instrumentation ................................................................................... 7 2.1.6 Brake Disk and Generator Coupling ................................................................................ 8

    2.2 Dynamometer Testing ................................................................................................................... 9 2.2.1 Drivetrain Power Tests ..................................................................................................... 9 2.2.2 Rotor Moment Tests ......................................................................................................... 9 2.2.3 Generator Misalignment Tests ......................................................................................... 9

    3 Model Description............................................................................................................................... 11 3.1 Gearbox ....................................................................................................................................... 11 3.2 Bushings ...................................................................................................................................... 11 3.3 High-Speed Shaft and Bearings .................................................................................................. 13 3.4 Brake Disk and Generator Coupling ........................................................................................... 13 3.5 Solution Determination ............................................................................................................... 14

    4 Results ................................................................................................................................................. 15 4.1 Gearbox Motion .......................................................................................................................... 15

    4.1.1 Vertical Displacement, Roll, and Pitch of the Gearbox ...............................................

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