Friction and Wear Performance of Candidate Surface Treatments for Wind Turbine Gearbox Bearings in High Slip Contacts

2009 ◽  
Author(s):  
Ryan D. Evans ◽  
Carl H. Hager ◽  
Roger D. Logsdon
Keyword(s):  
Wind Turbine ◽  
Boundary Lubrication ◽  
Friction And Wear ◽  
Adhesive Wear ◽  
Ring Rolling ◽  
Wear Testing ◽  
Wind Turbine Gearbox ◽  
Wind Turbine Gearbox Bearings ◽  
Wear Protection ◽  
The Impact

Ring-on-ring rolling/sliding contact tests were conducted to evaluate the impact of ground, black oxided, isotropically finished (ES20), and tungsten carbide-incorporated amorphous hydrocarbon coated surfaces (ES322) on friction and wear in high slip contacts relevant to wind turbine gearbox bearings. The testing was performed in three phases, including Stribeck testing, adhesive wear testing, and cyclic acceleration testing. Results indicated that neither black oxide treatment nor ES20 had long-term adhesive wear protection benefits. However, ES20 exhibited the lowest traction coefficients in boundary lubrication during run-in as compared to the other test surfaces. Only the contacts containing the ES322 hard-coated surface consistently survived the harshest slip and boundary lubrication conditions.

Comparison of Blind Diagnostic Indicators for Condition Monitoring of Wind Turbine Gearbox Bearings

2021 ◽  
Author(s):  
Junyu Qi ◽  
Alexandre Mauricio ◽  
Konstantinos Gryllias
Keyword(s):  
Wind Turbine ◽  
Condition Monitoring ◽  
Wind Turbines ◽  
Fossil Fuels ◽  
Conditional Entropy ◽  
Approximate Entropy ◽  
Permutation Entropy ◽  
Wind Turbine Gearbox ◽  
Data Set ◽  
Wind Turbine Gearbox Bearings

Abstract Under the pressure of climate change, renewable energy gradually replaces fossil fuels and plays nowadays a significant role in energy production. The O&M costs of wind turbines may easily reach up to 25% of the total leverised cost per kWh produced over the lifetime of the turbine for a new unit. Manufacturers and operators try to reduce O&M by developing new turbine designs and by adopting condition monitoring approaches. One of the most critical assembly of wind turbines is the gearbox. Gearboxes are designed to last till the end of asset's lifetime, according to the IEC 61400-4 standards but a recent study indicated that gearboxes might have to be replaced as early as 6.5 years. A plethora of sensor types and signal processing methodologies have been proposed in order to accurately detect and diagnose the presence of a fault but often the gearbox is equipped with a limited number of sensors and a simple global diagnostic indicator is demanded, being capable to detect globally various faults of different components. The scope of this paper is the application and comparison of a number of blind global diagnostic indicators which are based on Entropy, on Negentropy, on Sparsity and on Statistics. The performance of the indicators is evaluated on a wind turbine data set with two different bearing faults. Among the different diagnostic indicators Permutation entropy, Approximate entropy, Samples entropy, Fuzzy entropy, Conditional entropy and Wiener entropy achieve the best results detecting blindly the two failure events.

scholarly journals Investigation of Dynamic Loads in Wind Turbine Drive Trains Due to Grid and Power Converter Faults

Energies ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 8542
Author(s):  
Julian Röder ◽  
Georg Jacobs ◽  
Tobias Duda ◽  
Dennis Bosse ◽  
Fabian Herzog
Keyword(s):  
Wind Turbine ◽  
High Speed ◽  
Power Converter ◽  
Wind Turbine Gearbox ◽  
Wind Turbine Gearbox Bearings ◽  
Grid Connection ◽  
Drive Trains ◽  
Electrical Faults ◽  
Doubly Fed ◽  
Component Loading

Electrical faults can lead to transient and dynamic excitations of the electromagnetic generator torque in wind turbines. The fast changes in the generator torque lead to load oscillations and rapid changes in the speed of rotation. The combination of dynamic load reversals and changing rotational speeds can be detrimental to gearbox components. This paper shows, via simulation, that the smearing risk increases due to the electrical faults for cylindrical roller bearings on the high speed shaft of a wind turbine research nacelle. A grid fault was examined for the research nacelle with a doubly fed induction generator concept. Furthermore, a converter fault was analyzed for the full size converter concept. Both wind turbine grid connection concepts used the same mechanical drive train. Thus, the mechanical component loading was comparable. During the grid fault, the risk of smearing increased momentarily by a maximum of around 1.8 times. During the converter fault, the risk of smearing increased by around 4.9 times. Subsequently, electrical faults increased the risk of damage to the wind turbine gearbox bearings, especially on the high speed stage.

Serial sectioning investigation of butterfly and white etching crack (WEC) formation in wind turbine gearbox bearings

Wear ◽  
2013 ◽  
Vol 302 (1-2) ◽  
pp. 1573-1582 ◽  
Author(s):  
M.-H. Evans ◽  
A.D. Richardson ◽  
L. Wang ◽  
R.J.K. Wood
Keyword(s):  
Wind Turbine ◽  
Serial Sectioning ◽  
Wind Turbine Gearbox ◽  
Wind Turbine Gearbox Bearings

Wear Morphology and Mechanism Analysis of Plasma Spraying Nanometer Al2O3-13%wtTiO2 Coating Material

2012 ◽  
Vol 164 ◽  
pp. 174-177 ◽  
Author(s):  
Zhi Fang Cheng ◽  
Fu Chi Wang ◽  
Zhuang Ma
Keyword(s):  
Plasma Spraying ◽  
Wear Mechanism ◽  
Friction And Wear ◽  
Adhesive Wear ◽  
Testing Machine ◽  
Wear Testing ◽  
Mechanism Analysis ◽  
Worn Surface ◽  
Plasma Spraying Process ◽  
Spraying Process

Nanometer Al2O3-13%wtTiO2 wear-resistant coating was prepared by The plasma spraying process , and the coating was tested through a SRV friction and wear testing machine, the worn surface and wear debris were observed by scanning electron microscopy, and the wear mechanism was analyzed. The friction coefficient of Nanometer Al2O3-13%wtTiO2 decreases with the increase of the load. The main wear mechanism is adhesive wear, accompanied by a small amount of abrasive wear.

scholarly journals Design and development of a novel sliding friction and wear tester with complex working conditions

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Jinrong Chai ◽  
Zihao Zhou ◽  
Cheng Ye ◽  
Chen Yao ◽  
Guohua Li
Keyword(s):  
Abrasive Wear ◽  
Working Conditions ◽  
Friction And Wear ◽  
Sliding Friction ◽  
Adhesive Wear ◽  
Corrosive Wear ◽  
Wear Testing ◽  
Test Conditions ◽  
Wear Tests ◽  
Wear Condition

AbstractSerious wear phenomena occur in mining machinery under complex working conditions, and the wear of machine parts is primarily caused by the synergistic effect of adhesive wear, abrasive wear, corrosive wear, etc. However, the existing friction and wear testing equipment cannot be used to carry out wear tests under complex working conditions. To simultaneously meet the test requirements of adhesive wear, abrasive wear, and corrosive wear, a novel sliding friction and wear tester that can simulate complex working conditions was developed in the present research. The tester is composed of a loading mechanism, a speed-regulating mechanism, a corrosion chamber, and a control and display system. Wear tests of the middle plate of a scraper conveyor, a key equipment of coal mining, were carried out to verify the consistency and effectiveness of the tester. The test results were consistent, and those under the same test conditions were similar with a maximum standard deviation of 2.4 mg. The wear condition of the middle plate specimens was close to the actual wear condition of the middle plate. Moreover, the surfaces of the middle plate specimens after grinding exhibited obvious adhesive, abrasive, and corrosive wear characteristics, and the wear degrees of the specimens under the same test conditions were similar. The quality loss of the middle plate specimens was found to increase with the increase of coal gangue percentage, and the main wear mechanism was the synergistic action of abrasive, adhesive, and corrosive wear.

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