Héctor Águila Estrada

This paper presents a vibration analysis method for detecting typical faults in gears of the drive train of a 2 MW wind turbine. The data were collected over a one-year period from an operating wind turbine with a gearbox composed of one planetary stage and two helical gear stages. Failures in two pairs of helical gears were identified: one involving pitting and wear in the gears connecting the intermediate-speed shaft to the low-speed shaft, and another one involving significant material detachment in the gears connecting the intermediate-speed shaft to the high-speed shaft. The continuous evaluation of time signals, frequency spectra, and amplitude modulations allowed the most sensitive sensors and frequencies for predicting surface damage on gear teeth in this type of turbine to be determined. A steady-state frequency analysis was performed, enabling the detection of the aforementioned surface faults. This approach is simpler compared with more complex transient-state techniques. By tracking vibration signals over time, the importance of analyzing gear mesh frequencies and their harmonics was highlighted. Additionally, it was found that the progression of gear damage was dependent on the power output of the wind turbine. As a result, the most appropriate ranges of power were identified, within which the evolution of the vibration measurement was associated with the damage evolution. Since many turbines currently in operation have similar designs and power output levels, the present findings can serve as a guideline for monitoring an extensive number of units.

Associated vibrations in mechanical power transmission elements such as gears and bearings significantly contribute to the dynamic behavior of the system to which they belong. Most research in this field describes measurements and signal processing methods to determine the effect of some design modifications. However, the number of investigations that try to solve the problem from the design stage is much smaller. The following study presents a review of the trends in the analysis of vibrations of power transmission elements and their relationship to the use of systematic design methodologies in the principal power transmission elements. A revision is shown in design considerations to prevent mechanical vibrations or reduce them to acceptable levels. The effects in terms of improvement in reducing vibrations of the most important works that have taken into account the vibrations in design stages are shown. The results show the importance of considering the mechanical vibrations in the design of power transmission elements. Moreover, the analysis of the state of the art shows the areas to be investigated that contemplate the development or application of formal design methodologies that take into account mechanical vibrations.