Francisco Gutiérrez Guzmán

To increase the power density of the electromechanical drive train of wind turbines, journal bearings can be used as planetary gear bearings instead of rolling bearings. This technological change presents new challenges. For example, wind turbine drive systems are subject to dynamic and low-speed operating conditions, which can lead to accelerated abrasive wear of the journal bearings. In addition, oil supply failure or peak loads due to wind gusts and grid and power converter faults could potentially result in catastrophic failure due to adhesive wear in a very short time. Such operating characteristics are, therefore, critical regarding the journal bearing wear lifetime and must be considered in the design. The successful implementation of journal bearings in wind turbines depends on a reliable estimation of adhesive and abrasive wear. In this paper, five different models for the wear calculation of journal bearings are evaluated regarding their suitability for the wear calculation of planetary gear bearings in wind turbines. For this purpose, the following evaluation criteria were defined: parameter uncertainty, parametrization effort, in particular number of parameters, parameterization method, load case dependency of parameters and calculation effort. In order to be able to evaluate the wear models, the wear models are numerically implemented, and the wear of a test journal bearing is exemplarily calculated under load conditions, which are comparable to load conditions in a wind turbine. Relevant influences from the wind turbine system, such as lubricant, material and manufacturing-dependent surface influences, such as roughness and hardness, are considered. The wear models are evaluated with respect to their fulfillment of the defined criteria. The resulting evaluation allows the selection of a wear model that can be used to calculate the wear of planetary gear journal bearings in wind turbines, considering the available input variables.

To increase the power density of the electromechanical drive train of wind turbines, journal bearings can be used as planetary gear bearings instead of rolling bearings. This technological change presents new challenges. For example, wind turbine drive systems are subject to dynamic and low-speed operating conditions which can lead to an accelerated abrasive wear of the journal bearings. In addition, oil supply failure or peak loads due to wind gusts and grid and power converter faults could potentially result in catastrophic failure due to adhesive wear in a very short time. Such operating characteristics are, therefore, critical regarding the journal bearing wear lifetime and must be considered in the design. The successful implementation of journal bearings in wind turbines depends on a reliable estimation of adhesive and abrasive wear. In this paper, five different models for the wear calculation of journal bearings are evaluated regarding their suitability of wear calculation of planetary gear bearings in wind turbines. For this purpose, the following evaluation criteria were defined: parameter uncertainty, parametrization effort, in particular number of parameters, parameterization method and load case dependency of parameters and calculation effort. In order to be able to evaluate the wear models, the wear models are numerically implemented and the wear of a test journal bearing is exemplarily calculated under load conditions, which are comparable to load conditions in a wind turbine. Relevant influences from the wind turbine system such as lubricant, material and manufacturing dependent surface influences like roughness and hardness are considered. The wear models are evaluated with respect to their fulfillment of the defined criteria. The resulting evaluation allows the selection of a wear model that can be used to calculate the wear of planetary gear journal bearings in wind turbines, considering the available input variables.

The usage of journal bearings as planetary bearings in wind turbines instead of roller bearings has become more common in recent years. Their usage is advantageous, due to smaller installation space needed compared to roller bearings allowing for higher power densities of wind turbine drive trains. However, this technology presents a challenge since there is currently no standardized approach for the design of planetary journal bearings regarding wear. Due to varying wind speeds and dynamic operating events a large variation of loads has to be considered in the design process of a planetary journal bearing for wind turbines. Some of these loads are considered potentially critical to the journal bearing in terms of wear. Identifying these critical load areas early in the design phase supports a reliable bearing design and wind turbine operation.This paper introduces a method to identify critical operating conditions for planetary journal bearings using a simulation tool chain, which couples a multi body simulation (MBS) model of a wind turbine with an elasto-hydrodynamic (EHD) model of the planetary journal bearing. Based on the EHD results critical operating conditions are determined for the planetary bearing. Furthermore, methods are implemented to reduce the number of required EHD simulations for analysing the bearing design. The combination of the identification of critical operating conditions, while reducing the computational effort leads to a simulation methodology, which enables a faster bearing design assessment considering the wide variation of wind turbine operating conditions. The applicability of this method is demonstrated by a simplified use case.Firstly, this paper introduces the MBS model and the parameter space that describes possible combinations of bearing loads such as forces, moments and rotational speed. Due to the number of combinations and the EHD computing effort, the identified parameter space is secondly sampled statistically to reduce the simulation effort. A risk map is derived from the EHD results, to easily indicate potentially critical operating conditions for the planetary journal bearing.

Plain bearings are increasingly being used under mixed friction, resulting in a higher risk of wear-induced failure. Therefore, the relevance of condition monitoring is increasing, which can enable the early detection of wear inducing conditions. The presented work focuses on the development of an energy-autonomous, temperature-based condition monitoring system for plain bearings. The components of the condition monitoring system are to be integrated directly into the machine element and operating data to be transmitted wirelessly.The fundamental monitoring approach pursued, is the in-operando calculation of the lubrication gap height via the standardized Gümbel-curve based on the temperature map in the plain bearing. If the gap height undercuts a critical threshold, the plain bearing will operate in mixed friction. Thus, representing a potentially wear-causing operating point. The energy required for operating the system is harvested thermoelectrically within the plain bearing via thermo-generators, which use the temperature gradients in the plain bearing during operation.In this work, the simulative evaluation of the harvestable energy will be presented. The usable temperature difference will be determined for varying positioning of the energy harvester. The results obtained allow the subsequent manufacture of a first Sensor integrating Machine Element (SiME)-prototype. In this context a feasible setup regarding the types and number of sensors as well as a microcontroller for processing the measured data will be defined with respect to the harvestable energy. Furthermore, the principle for temperature-based gap height determination will be introduced, applied for different operating points and compared to simulative results.

Rolling bearings face different damaging effects: Besides mechanical effects, current-induced bearing damage occurs in electrical drive systems. Therefore, it is of increasing interest to understand the differences leading to known electrical damage patterns. It is of utmost importance not to consider the harmful current passage in the machine element as an isolated phenomenon but to take into account the whole drive system consisting of the machine elements, the electric motor and the connected power electronics. This publication works toward providing an overview of the state-of-the-art of research regarding electrical bearing currents.

This paper presents the state-of-the-art technologies and development trends of wind turbine drivetrains – the system that converts kinetic energy of the wind to electrical energy – in different stages of their life cycle: design, manufacturing, installation, operation, lifetime extension, decommissioning and recycling. Offshore development and digitalization are also a focal point in this study. Drivetrain in this context includes the whole power conversion system: main bearing, shafts, gearbox, generator and power converter. The main aim of this article is to review the drivetrain technology development as well as to identify future challenges and research gaps. The main challenges in drivetrain research identified in this paper include drivetrain dynamic responses in large or floating turbines, aerodynamic and farm control effects, use of rare-earth material in generators, improving reliability through prognostics, and use of advances in digitalization. These challenges illustrate the multidisciplinary aspect of wind turbine drivetrains, which emphasizes the need for more interdisciplinary research and collaboration.

This paper presents the state-of-the-art technologies and development trends of wind turbine drivetrains – the energy conversion systems transferring the kinetic energy of the wind to electrical energy – in different stages of their life cycle: design, manufacturing, installation, operation, lifetime extension, decommissioning, and recycling. Offshore development and digitalization are also a focal point in this study. The main aim of this article is to review the drivetrain technology development as well as to identify future challenges and research gaps. Drivetrain in this context includes the whole power conversion system: main bearing, shafts, gearbox, generator, and power converter. The paper discusses current design technologies for each component along with advantages and disadvantages. The discussion of the operation phase highlights the condition monitoring methods currently employed by the industry as well as emerging areas. This article also illustrates the multidisciplinary aspect of wind turbine drivetrains, which emphasizes the need for more interdisciplinary research and collaboration.

This paper presents the state-of-the-art technologies and development trends of wind turbine drivetrains – the energy conversion systems transferring the kinetic energy of the wind to electrical energy – in different stages of their life cycle: design, manufacturing, installation, operation, lifetime extension, decommissioning, and recycling. Offshore development and digitalization are also a focal point in this study. The main aim of this article is to review the drivetrain technology development as well as to identify future challenges and research gaps. Drivetrain in this context includes the whole power conversion system: main bearing, shafts, gearbox, generator, and power converter. The paper discusses current design technologies for each component along with advantages and disadvantages. The discussion of the operation phase highlights the condition monitoring methods currently employed by the industry as well as emerging areas. This article also illustrates the multidisciplinary aspect of wind turbine drivetrains, which emphasizes the need for more interdisciplinary research and collaboration.