Development of a wind turbine gearbox virtual load sensor using multibody simulation and artificial neural networks

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.