Conventional methods for designing rolling bearings against fatigue assume that a bearing ring is fully rotating and that the load is ideally distributed over the rolling elements. Blade bearings in wind turbines, are operated under oscillating motions and dynamic loads. The load distribution is strongly dependent on the stiffness of the bearing rings and the surrounding structural components. This has been shown in numerous studies using FEM simulations for static load cases. In this paper a method is presented that reduces the calculation effort of the deformation of the bearing rings, so that a flexible integration into an aeroelastic mbs model of a wind turbine is possible. Thereby an average accuracy of 6.5% between FEM and mbs could be achieved. The model allows the determination of time series of the global load distribution of each raceway. By data processing of the simulation results, the number of load cycles and the maximum contact pressure for individual segments of the raceways could be determined and their fatigue probability could be estimated using the linear damage hypothesis according to Palmgren-Miner.
相似文献With the possibility to replace sliding segments on the tower without disassembling the drivetrain, the use of segmented plain bearings with conical sliding surfaces as main bearing in wind turbines has a great potential to reduce the maintenance costs and thus the levelized cost of energy (LCOE). Furthermore, the short axial design leads to lower investment costs. Since this design is totally new and no design guidelines are available so far, the objective of this paper is to investigate the influence of the geometric parameters on the hydrodynamic pressure distribution of the bearing. In this context a parameter screening is performed using a suitable test field according to Plackett and Burman in order to determine the most relevant parameters. With the help of the simulations carried out after this test field, correlations between the geometric parameters and the hydrodynamic pressure distribution are evaluated. To be able to quantitatively analyze the three-dimensional pressure distribution, several key values are defined in this paper that describe the pressure distribution. The content of this paper is part of a methodology with the goal of developing a design guideline for conical plain bearings.
相似文献A current development trend in wind energy is characterized by the installation of wind turbines (WT) with increasing rated power output. Higher towers and larger rotor diameters increase rated power leading to an intensification of the load situation on the drive train and the main gearbox. However, current main gearbox condition monitoring systems (CMS) do not record the 6‑degree of freedom (6-DOF) input loads to the transmission as it is too expensive. Therefore, this investigation aims to present an approach to develop and validate a low-cost virtual sensor for measuring the input loads of a WT main gearbox. A prototype of the virtual sensor system was developed in a virtual environment using a multi-body simulation (MBS) model of a WT drivetrain and artificial neural network (ANN) models. Simulated wind fields according to IEC 61400‑1 covering a variety of wind speeds were generated and applied to a MBS model of a Vestas V52 wind turbine. The turbine contains a high-speed drivetrain with 4‑points bearing suspension, a common drivetrain configuration. The simulation was used to generate time-series data of the target and input parameters for the virtual sensor algorithm, an ANN model. After the ANN was trained using the time-series data collected from the MBS, the developed virtual sensor algorithm was tested by comparing the estimated 6‑DOF transmission input loads from the ANN to the simulated 6‑DOF transmission input loads from the MBS. The results show high potential for virtual sensing 6‑DOF wind turbine transmission input loads using the presented method.
相似文献Three phase short circuit power converter faults in wind turbines (WT) result in highly dynamic generator torque reversals, which lead to load reversals within the drivetrain. Dynamic load reversals in combination with changing rotational speeds are, for example, critical for smearing within roller bearings. Therefore, an investigation of the correlation between three phase short circuit converter faults and drivetrain component failures is necessary.
Due to the risk of damage and the resulting costs, it is not economically feasible to extensively investigate three phase short circuit converter faults on test benches. Valid WT drivetrain models can be used instead. A WT drivetrain model, which has been developed and validated in a national project at the CWD, is used and a three phase short circuit converter fault is implemented. In this paper, the resulting torque load on the drivetrain for a three phase short circuit converter fault in rated power production is presented. This converter fault leads to a highly dynamic reversing electromagnetic torque which exceeds the rated torque by a factor of three. As a result the load on the rotor side high speed shaft (HSS) bearing oscillates and increases by around 15 per cent compared to rated power production. Simultaneously the rotational velocity of the HSS oscillates with an amplitude of 10 rpm. Therefore an increase in the risk of smearing is expected.
相似文献Requirements for the design of wind turbines advance facing the challenges of a high content of renewable energy sources in the public grid. A high percentage of renewable energy weaken the grid and grid faults become more likely, which add additional loads on the wind turbine. Load calculations with aero-elastic models are standard for the design of wind turbines. Components of the electric system are usually roughly modeled in aero-elastic models and therefore the effect of detailed electrical models on the load calculations is unclear. A holistic wind turbine model is obtained, by combining an aero-elastic model and detailed electrical model into one co-simulation. The holistic model, representing a DFIG turbine is compared to a standard aero-elastic model for load calculations. It is shown that a detailed modelling of the electrical components e.g., generator, converter, and grid, have an influence on the results of load calculations. An analysis of low-voltage-ride-trough events during turbulent wind shows massive increase of loads on the drive train and effects the tower loads. Furthermore, the presented holistic model could be used to investigate different control approaches on the wind turbine dynamics and loads. This approach is applicable to the modelling of a holistic wind park to investigate interaction on the electrical level and simultaneously evaluate the loads on the wind turbine.
相似文献Model predictive control (MPC) is a strong candidate for modern wind turbine control. While the design of model predictive wind turbine controllers in simulations has been extensively investigated in academic studies, the application of these controllers to real wind turbines reveals open research challenges. In this work, we focus on the validation of a linear time-variant MPC system for a 3 MW wind turbine in a full-scale field test. First, the study proves the MPC’s capability to control the real wind turbine in the partial load region. Compared to the turbine’s baseline PID controller, the MPC system offers similar results for the electrical power output and for the occurring mechanical loads. Second, the study validates a previously proposed, simulation-based rapid control prototyping process for a systematic MPC development. The systematic development process allows to completely design and parameterize the MPC system in a simulative environment independent of the real wind turbine. Through the rapid control prototyping process, the MPC commissioning in the wind turbine’s programmable logic controller can be realized within a few hours without any modifications required in the field. Thus, this study establishes the proof of concept for a linear time-variant MPC system for a 3 MW wind turbine in a full-scale field test and bridges the gap between the control design and field testing of MPC systems for wind turbines in the multi-megawatt range.
相似文献As one kind of gas bearings, foil bearings that are commonly made of one top foil and at least one bottom foil, have many attractive advantages such as low power loss, wide work temperature range, high rotating speed, low maintenance cost, simple system construct, etc. Nevertheless, foil bearings also have some disadvantages including low carrying load at low speed, wear at start-stop procedure, not easy to predict bearing performance due to the complex bearing structure and so on.
For the sake of better understanding and further utilization of foil bearings, many researchers, institutions and countries have paid great attention to study these special rolling elements in recent decades. The purpose of this paper is to explore the research status of foil bearings performance based on the Web of Science datasets and related tools, meanwhile, the cooperative relationship among individuals or organizations is further studied. Moreover, to figure out influential countries, institutions and authors, the analysis of cited frequency is adopted. In addition, keywords frequency analysis and co-occurrence analysis are applied to explore the future trend of foil bearing. The results identify influential countries, institutions and authors in the research of foil bearings performance and show that whether in quantity or in quality, research of foil bearings performance in developed countries holds a significant lead over that in developing countries. Moreover, the current hot topics are figured out as well as future direction of development is predicted. This study presents intuitive state of research of foil bearings performance and proposes a fresh perspective for relevant researchers to perform foil bearings research in the future.
相似文献Wind turbines are a major source of renewable energy. Load monitoring is considered to improve reliability of the systems and to reduce the cost of operation. We propose a load monitoring system which consists of inertial measurement units. These track the movement of rotor blade, hub and tower top. In addition, wind turbine states, e.g. yaw angle, pitch angle and rotation speed, are recorded. By solving a navigation algorithm with a Kalman Filter approach, the raw sensor data is combined with an error model to reduce the tracking error. In total, five inertial measurement units are installed on the research wind energy converter AD 8–180 on the test site in Bremerhaven. Results show that tracking the blade movement in full operation is possible and that loads can be estimated with a model-based approach. In comparison to simulations, the blade deflections can be approximated by an aeroelastic model. The presented approach can be used as basis for comprehensive load monitoring and observer system with additional increase of system robustness by measurement redundancy.
相似文献Wind energy is an essential source of renewable energy. However, to compete with conventional energy sources, energy needs to be produced at low costs. An ideal situation would be to have no costly, unscheduled maintenance, preferably. Currently, O&M are half of the yearly expenses. The O&M costs are kept low by scheduled and reactive maintenance. An alternative is predictive maintenance. This method aims to act before any critical and costly repair is required. Additionally, the component is used to its full potential. However, such a strategy requires a damage indication, similar to one provided by a condition monitoring system (CMS). This paper investigates if Supervisory Control and Data Acquisition (SCADA) can be used as a damage indicator and CMS. Since 2006, every wind turbine is obliged to use such a SCADA-system. SCADA records a 10-minute average, maximum, minimum, and standard deviation of multiple technical information channels. Analytics can use those data to determine the normal behavior and a prediction model of the wind turbine. The authors investigated statistical and data mining methods to predict main bearing faults. The methods indicated a defect of up to 6 months before its maintenance.
相似文献White Etching Cracks (WEC) in gearbox bearings is a major concern in the wind turbine industry, which can lead to a premature failure of the gearbox. Though many hypotheses regarding the generation of WEC have been proposed over the decades, the answer is still disputable. To trace back the failures to earlier stages before they occur, an innovative sensor-set has been utilized on a test rig to monitor the influencing factors that lead to WEC. This paperwork seeks to recognize abnormal patterns from recorded sensor data and derive statements of sensible sensor combinations in WEC early detection. A Long Short Term Memory (LSTM) network-based autoencoder is proposed for the anomaly detection (AD) task. Employing an auto-associative sequence-to-sequence predictor, a model is trained to reconstruct the normal time series data without WEC. The reconstruction error of testing time series data is evaluated for the determination of its anomaly. The results show that the specified LSTM autoencoder framework can qualitatively distinguish anomalies from collected multivariate time series data. Moreover, the anomaly score evaluated via reconstruction-error-based metrics can discriminate normal and abnormal behaviors in the study. This investigation’s results entail a significant step towards early WEC risk detection and more cost-efficient wind turbine technology if this approach can be further applied on stream data with plausible thresholds in monitoring system.
相似文献One of the central goals during the design of helical gear systems is the achievement of a well-distributed contact load in the gear mesh. An equal load distribution is a key factor for a high load carrying capacity, the economic use of materials and a long lifetime. Mesh misalignment can be caused by tooth deflections, manufacturing deviations or elastic deformation of the shaft-bearing system and the gearbox housing. Those deformations have to be taken into account during the design process of adequate tooth-flank geometry. Elastic deformations of gearbox housings can be significant, especially in the case of automotive applications with aluminium cases. This paper presents an advanced method of including housing stiffness into the calculation of gear systems. A validation of the approach is carried out by comparing the calculated deformations with measurements of a static test rig of a hypoid gearbox.
Many calculation programs offer the opportunity to analyse the deformation behaviour of the shaft-bearing-housing system. Most of the components in these programs are described by analytic approaches. However, components that are geometrically more complex, like the housing or planet carriers cannot be represented as easily as that by analytic expressions. There are several alternatives to take into account the elasticity of those objects. One way is to model the stiffness of the bores using imported stiffness matrices. These matrices contain the elasticity of the bores itself as well as crossover influences between the bearings. The reduced stiffness matrices may be the result of a static reduction of the geometry using the finite element method (FEM). As state of the art, the reduction is mostly carried out at the centre points of the bearing bores. The proposed advanced method uses the static reduction of geometries on several points at the bores, distributed over the circumference. This approach offers a more detailed modelling of the elastic behaviour of complex geometries within the analytic deformation calculation of gear systems. To validate the advanced approach, the calculation results of the elastic deflections of the shaft-bearing-housing system is compared with measurements of a static test rig. In the course of these comparisons, the influence of different modelling methods of gearbox housings on the accuracy of the calculation results is discussed.
相似文献This paper presents measurement results of the world wide first successful certification the electrical properties of a wind turbine, solely based upon measurements obtained at a system test bench with HiL-System and grid emulator. For all certification relevant tests the results are compared to field measurements. The impact of the real-time models in the HiL-System as well as the converter-based grid emulator are discussed in this paper. For full converter wind turbine, different requirements for the model depth could be determined depending on the tests. Nevertheless, higher-quality models that reflect the plant behaviour better are recommended to reduce uncertainties within the certification process. This paper also shows that especially for grid failure events grid emulators require real-time impedance control, in order to emulate grid failures properly. Based on these findings, recommendations for the requirements on test bench components are formulated in this paper, in order to contribute to new certification guidelines. Overall, we conclude that based on the experiences made at two different system test benches, the vast majority of certification measurements can be carried out without limitation at such system test benches.
相似文献In this publication, the methods will be presented that are deployed to formulate a multi-physical system model of a direct drive wind turbine in order to calculate structure borne sound. The model includes excitation effect as well as sound radiating behaviour. The mechanical structure as a medium partner between excitation and radiation will be formulated through a multi-body simulation model in the time domain. In the multi-body simulation model, all relevant drivetrain components are considered with their structural eigenmodes in the frequency range of interest. The electromagnetic forces of the multi-pole ring generator are calculated and introduced into the mechanical structure at each stator tooth, rotor pole and various axial positions individually. Similarly, the modelling of the bearings is investigated for a range of available methods. Sound emission is evaluated at the large outer surface structures like tower, blades and nacelle cover. To minimize computational effort, the surface accelerations are not calculated for each surface node, instead a modal approach is used. Through a combination of mode shapes with mode participation factors of the respective structures, the surface accelerations can be regained during a post-processing step. Those results are used as input for airborne sound calculations. Nevertheless, the high number of modal and spatial degrees of freedom results in high computing costs.
相似文献The optimization of load sharing between planets is one of the most important goals in planetary gearbox design. Unevenly distributed load will cause locally higher flank pressures and therefore, less durability of gears and bearings. Furthermore, unevenly distributed or fluctuating loads can cause excitations in the gear mesh and structural vibrations. The load sharing in planetary gear stages depends on the individual stiffness conditions in each mesh position. The stiffness is not only influenced by the gear geometry but also by the surrounding structural elements like shafts, housings and torque arms. In wind industry these components are often designed very stiff in order to reduce their effect on the operational behavior.
Within this paper, a method is presented, which allows combining the structural optimization process with a tooth contact analysis for planetary gearboxes. By means of this combined approach, it is possible to optimize the housing structure of the ring gear in terms of mass reduction while keeping the operational behavior in focus. With a weighted design objective function, it is possible to decide whether the main objective should be load distribution, excitation behavior, low mass or a balanced design.
相似文献As a regenerative energy source, tidal energy can significantly contribute to greenhouse gas reduction, even though the potentially achievable energy output is lower than that of wind or solar energy. The decisive advantage of tidal turbines lies in the simply and reliably predictable energy output. However, their commercial use has so far been impeded by the fact that on the one hand complex mechanical systems are required to convert energy of tidal currents and on the other hand multi-axial loading conditions caused by turbulent ocean currents act on the turbine. For this reason, field tests on prototypes are an essential part of the development strategy to ensure operational reliability. However, in-field tests do not allow for accelerated lifetime testing, so that test bench experiments are becoming an increasingly important alternative. Today, established procedures for testing the turbines main bearings and gearing system are already available, both for setting up the required test configuration and for determining the corresponding test loads. However, the use of advanced calculation methods, such as the finite element method for stress calculation, requires a deep understanding of the examined components and hinders the transfer of the approaches to other components.
To simplify the process of test loads determination, a general methodology is presented, which relies exclusively on standardized empirical calculation rules. Doing this, fatigue equivalent loads can be determined for any component in a simple process. It was shown that the achieved reduction in complexity opens further potential for test acceleration, since several components can be tested simultaneously.
相似文献The aim of a transfer path analysis (TPA) is to view the transmission of vibrations in a mechanical system from the point of excitation over interface points to a reference point. For that matter, the Frequency Response Functions (FRF) of a system or the Transmissibility Matrix is determined and examined in conjunction with the interface forces at the transfer path. This paper will cover the application of an operational TPA for a wind turbine model. In doing so the path contribution of relevant transfer paths are made visible and can be optimized individually.
相似文献This paper introduces a novel electromechanical model for calculating electromagnetic excited structural vibrations and structure borne acoustics for gearless wind turbines. Therefore, the wind turbine model structure is explained and a drivetrain model is derived to investigate the drivetrain decoupled from the aerodynamic excitations. The drivetrain model is fed with results from an electromagnetic finite element model of the generator considering air gap width changes and the wind turbine torque and speed characteristics. Furthermore, an exemplary ramp-up of the drivetrain is simulated. It can be seen, that generator structure oscillations are excited during certain rotational speeds, which may be relevant for the acoustic behavior of the turbine.
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