Determining vibration signature of a defective planet bearing in a wind turbine epicyclic gearbox

Planet bearings of wind turbine epicyclic gearboxes are considered as one of the most critical components due to their high failure rate. In order to develop effective vibration based detection algorithms for these bearings, a thorough understanding of their vibration signature is required. In this paper, we investigate the vibration behaviour of an epicyclic gearbox in the presence of a defective planet bearing both theoretically and experimentally. We also identify different sources of modulation sidebands using an analytical model which includes ring gear flexibility and planet bearing defects. The findings from this work will help engineers to develop more effective fault detection algorithms.

Statistical gear health analysis which is robust to fluctuating loads and operating speeds

Condition-based maintenance is concerned with the collection and interpretation of data to support maintenance decisions. The non-intrusive nature of vibration data enables the monitoring of enclosed systems such as gearboxes. It remains a significant challenge to analyze vibration data that are generated under fluctuating operating conditions. This is especially true for situations where relatively little prior knowledge regarding the specific gearbox is available. It is therefore investigated how an adaptive time series model, which is based on Bayesian model selection, may be used to remove the non-fault related components in the structural response of a gear assembly to obtain a residual signal which is robust to fluctuating operating conditions. A statistical framework is subsequently proposed which may be used to interpret the structure of the residual signal in order to facilitate an intuitive understanding of the condition of the gear system. The proposed methodology is investigated on both simulated and experimental data from a single stage gearbox. © 2011 Elsevier Ltd. All rights reserved.

A dynamic model to predict the occurrence of skidding in wind-turbine bearings

Despite use of the best in current design practices, high-speed shaft (HSS) bearings, in a wind-turbine gearbox, continue to exhibit a high rate of premature failure. As HSS bearings operate under low loads and high speeds, these bearings are prone to skidding. However, most of the existing methods for analyzing skidding are quasi-static in nature and cannot be used to study dynamic operating conditions. This paper proposes a dynamic model, which includes gyroscopic and centrifugal effects, to study the skidding characteristics of angular-contact ball-bearings. Traction forces between rolling-elements and raceways are obtained using elastohydrodynamic (EHD) lubrication theory. Underlying gross-sliding mechanisms for pure axial loads, and combined radial and axial loads are also studied. The proposed model will enable engineers to improve bearing reliability at the design stage, by estimating the amount of skidding. © 2011 Published under licence by IOP Publishing Ltd.

Vibration response of a wind-turbine planetary gear set in the presence of a localized planet bearing defect

In a wind-turbine gearbox, planet bearings exhibit a high failure rate and are considered as one of the most critical components. Development of efficient vibration based fault detection methods for these bearings requires a thorough understanding of their vibration signature. Much work has been done to study the vibration properties of healthy planetary gear sets and to identify fault frequencies in fixed-axis bearings. However, vibration characteristics of planetary gear sets containing localized planet bearing defects (spalls or pits) have not been studied so far. In this paper, we propose a novel analytical model of a planetary gear set with ring gear flexibility and localized bearing defects as two key features. The model is used to simulate the vibration response of a planetary system in the presence of a defective planet bearing with faults on inner or outer raceway. The characteristic fault signature of a planetary bearing defect is determined and sources of modulation sidebands are identified. The findings from this work will be useful to improve existing sensor placement strategies and to develop more sophisticated fault detection algorithms. Copyright © 2011 by ASME.

Design of brushless doubly-fed machines based: On magnetic circuit modeling

This paper proposes a magnetic circuit model (MCM) for the design of a brushless doubly-fed machine (BDFM). The BDFM possesses advantages in terms of high reliability and reduced gearbox stages, and it requires a fractionally-rated power converter. This makes it suitable for utilization in offshore wind turbines. It is difficult for conventional design methods to calculate the flux in the stator because the two sets of stator windings, which have different pole number, form a complex flux pattern which is not easily determined using common analytical approaches. However, it is advantageous to predict the flux density in the teeth and air-gap at the initial design stage for sizing purposes without recourse finite element analysis. Therefore a magnetic circuit model is developed in this paper to calculate the flux density. A BDFM is used as a case study with FEA validation. © 1965-2012 IEEE.

Design and testing of a 250 kW medium-speed Brushless DFIG

This paper presents the design and testing of a 250 kW medium-speed Brushless Doubly-Fed Induction Generator (Brushless DFIG), and its associated power electronics and control systems. The experimental tests confirm the design, and show the system's steady-state and dynamic performance. The medium-speed Brushless DFIG in combination with a simplified two-stage gearbox promises a low-cost low-maintenance and reliable drive train for wind turbine applications.

Design and testing of a medium-speed 250 kW Brushless DFIG

This paper presents the design and testing of a 250 kW medium-speed Brushless Doubly-Fed Generator (Brushless DFIG), and its associated power electronics and control systems. The experimental tests confirm the design, and show the system's steady-state and dynamic performance. The medium-speed Brushless DFIG in combination with a simplified twostage gearbox promises a low-cost low-maintenance and reliable drive train for wind turbine applications.

Experimental LVRT performance of a 250 kW brushless DFIG

Nowadays, all new wind turbine generators have to meet strict grid codes, especially riding through certain grid faults, such as a low voltage caused by grid short circuits. The Low-Voltage Ride Through (LVRT) capability has become a key issue in assessing the performance of wind turbine generators. The mediumspeed Brushless DFIG in combination with a simplified two-stage gearbox shows commercial promise as a replacement for conventional DFIGs due to its lower cost and higher reliability. Furthermore, the Brushless DFIG has significantly improved LVRT performance when compared with the DFIG due to its inherent design characteristics. In this paper, the authors propose a control strategy for the Brushless DFIG to improve its LVRT performance. The controller has been implemented on a prototype 250 kW Brushless DFIG and test results show that LVRT is possible without a need for any external protective hardware such as a crowbar.

Performance analysis and testing of a 250 kW medium-speed brushless doubly-fed induction generator

This study presents the performance analysis and testing of a 250 kW medium-speed brushless doubly-fed induction generator (DFIG), and its associated power electronics and control systems. The experimental tests confirm the design, and showthe system's steady-state and dynamic performance and grid low-voltage ride- through capability. The medium-speed brushless DFIG in combination with a simplified two-stage gearbox promises a low-cost low-maintenance and reliable drivetrain for wind turbine applications. © The Institution of Engineering and Technology 2013.

Design and performance analysis of a 6 MW medium-speed Brushless DFIG

The paper presents the design and performance analysis of a 6 MW medium-speed Brushless Doubly-Fed Induction Generation (Brushless DFIG) for a wind turbine drivetrain. Two machines with different frame sizes have been designed to show the flexibility of the design procedure. The mediumspeed Brushless DFIG in combination with a two stage gearbox offers a low-cost, low-maintenance and reliable drivetrain for wind turbine applications.