Esteve Jou

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.

To study the effects of fluid compressibility on the dynamics of a cavitating vortex street flow in a regime where the vortex shedding frequency increases as a result of the cavitation increase, the cavitating wake behind a wedge was simulated employing both incompressible and compressible solvers. To do this, a compressible cavitation model was implemented, modifying the Zwart-Gerber-Belamri (ZGB) incompressible solver and including a pressure limit and absorbing boundary conditions to prevent a non-physical pressure field. To validate the performance of the compressible model, preliminary simulations were carried out on a 1D Sod cavitating tube and the cavitating vortex shedding behind a circular body at laminar flow conditions. The results of the cavitating wake behind the wedge with the incompressible and the compressible solvers showed similar predictions in terms of pressure, vortex shedding frequency, and instantaneous and average vapor volume fraction profiles. In spite of this, differences were obtained in the energy content of the fluid force fluctuations on the body at higher frequencies, which appear to be better resolved and amplified when the compressibility model is considered. Overall, both solvers provided comparable results in terms of cavitation phenomena that are well aligned with experimental observations.

The cavitating wake behind a wedge has been simulated employing both incompressible and compressible solvers with the purpose of comparing their performance. To develop the compressible solver, the ZGB cavitation model for incompressible flows has been modified to consider the compressibility effects. First, the equations of state for the vapor and liquid phases have been implemented. Then, a pressure limit and absorbing boundary conditions have been set to prevent a non-physical pressure field. To test the developed compressible solver, a series of verification tests have been conducted comprising a 1D sod cavitating tube and the cavitating vortex shedding behind a circular body at laminar flow conditions. After that, the incompressible and the validated compressible solvers have been applied to simulate the cavitating wake behind a wedge. The obtained results show similar predictions with the two solvers in terms of pressure, vortex shedding frequency and instantaneous and average vapor volume fraction profiles. Moreover, it is interesting to note that the components of the fluid force fluctuations on the body at the lowest frequencies, as predicted by both solvers, are indistinguishable. However, the higher frequency fluctuations of the forces tend to be better resolved and amplified when the compressibility is considered. Overall, both flow solvers have provided comparable cavitation phenomena, yielding results well aligned with experimental observations.

The operation of submerged rotating machines, such as marine current or tidal turbines, can present deleterious fluid phenomena that may provoke extreme structural vibrations. To predict their dynamic responses, it is necessary to know the added modal coefficients of their runners under a whirling motion. For that purpose, a bespoke test rig was designed to investigate the added modal coefficients of a submerged cylinder, which could rotate at different speeds both in air and completely submerged in water inside a cylindrical tank. First, the modes of vibration were experimentally measured by exciting the cylinder with a push-release method during steady tests or with ramps in rotating speed during transient tests. The calculated natural frequencies and damping ratios were then used in a mathematical model of the dynamic system to calculate the added modal coefficients. During steady tests, the natural frequencies and damping ratios of the whirling modes changed significantly as a function of the rotating speed. Additionally, a whirling mode was observed to change its direction at a given rotating speed. During transient tests, rotating speed ramps with high accelerations were found to present lower lock-in amplitude and frequencies. Moreover, fast downward ramps presented lock-in amplitudes four times higher than fast upward ramps. Consequently, the added modal coefficients changed accordingly as a function of the rotating speed, ramp acceleration, and ramp direction. For these reasons, it was confirmed that the modal responses of submerged rotating bodies must be calculated for each operational rotating speed, even at low velocities, and for each transient event in order to precisely predict their vibration behaviors.