Fatigue life is an important performance for wind turbine gearboxes. A fatigue damage calculation model for wind turbine gearboxes was proposed under random wind loads based on wind turbine global analysis, gearbox dynamic analysis and gear fatigue damage analysis. Firstly, the wind turbine global analysis was done to calculate a gearbox’s input torque and output rotating speed under random wind loads. Then, based on the acquired input torque and output rotating speed, each gear’s dynamic contact force and rotating speed were calculated with the gearbox dynamic analysis. Finally, the gear fatigue damage analysis was done, gear’s contact force was converted into loads causing gear’s bending and contact stresses, according to Miner linear damage accumulation theory, each gear’s bending and contact fatigue damages were calculated. In the discussion part, each gear’s bending fatigue damage and contact fatigue damage were calculated using the proposed model under wind conditions with the mean wind of 11.5m/s and 18m/s, and the turbulence density of 14%. The most dangerous one in all gears was found. The study results were meaningful for detecting wind turbine gearboxes’ failure sources.
[1] 张立勇, 王长路, 刘法根, 等. 风力发电及风电齿轮箱概述[J]. 机械传动, 2008, 32(6): 1-4.
ZHANG Li-yong, WANG Chang-lu, LIU Fa-gen, et al. Overview of Wind Power and Wnd Turbine Gearbox [J]. Mechanical Drive, 2008, 32(6): 1-4.
[2] Amir Rasekhi Nejad, Erin E. Bachynski, Marit I. Kvittem, et al. Stochastic dynamic load effect and fatigue damage analysis of drivetrains in land-based and TLP, spar and semi-submersible floating wind turbines[J]. Marine Structures, 2015, 42: 137-153.
[3] 谢双义. 变速变桨风力发电机组的运行控制策略研究[D]. 重庆:重庆大学, 2013.
XIE Shuang-yi. Research on the Operating Control Strategies of the Variable Speed Variable Pitch Wind Turbine [J]. Chongqing: University of Chongqing, 2013.
[4] 张晨虬. 风电传动链关键件载荷及疲劳技术研究, 浙江大学, 2013.
ZHANG Chen-qiu. Research on the Technology of Loads and Fatigue for critical components of wind turbine drivetrain [D]. Zhejiang: Zhejiang University, 2013.
[5] 付长江, 崔新维. 风力发电机动力学仿真研究[J]. 新疆农业大学学报, 2010, 33(2): 177-181.
FU Chang-jiang, CUI Xin-wei. Study on Dynamic Simulation of Wind Turbine [J]. Journal of Xinjiang Agricultural University, 2010, 33(2): 177-181.
[6] T. Osman, Ph. Velex. A model for the simulation of the interactions between dynamic tooth loads and contact fatigue in spur gears[J]. Tribology International, 2012, 46(1): 84-96.
[7] M. Ajmi, P. Velex. A model for simulating the quasi-static and dynamic behaviour of solid wide-faced spur and helical gears[J]. Mechanism and Machine Theory, 2005, 40(2): 173-190.
[8] 秦大同, 古西国, 王建宏, 等. 兆瓦级风力机齿轮传动系统动力学分析与优化[J]. 重庆大学学报, 2009, (04): 408-414.
QIN Da-tong, GU Xi-guo, WANG Jian-hong, et al. Dynamic analysis and optimization of gear trains in a megawatt level wind turbine [J]. Journal of Chongqing University, 2009, (04): 408-414.
[9] 徐向阳. 柔性销轴式风电齿轮箱动力学研究[D]. 重庆:重庆大学, 2012.
XU Xiang-yang. Dynamics Research of Wind Turbine Gearbox with Flexible Planet Gear Pins [D]. Chongqing: University Of Chongqing, 2012.
[10] Dong W, Xing Y, Moan T, et al. Time domain-based gear contact fatigue analysis of a wind turbine drivetrain under dynamic conditions [J]. International Journal of Fatigue, 2013, 48: 133-146.
[11] Sheng Li, Ahmet K. A micro-pitting model for spur gear contacts. International Journal of Fatigue, 2014. 59:224-233.
[12] José A Brandão, Ramiro Martins, J.H.O. Seabra, et al. An approach to the simulation of concurrent gear micropitting and mild wear[J]. Wear, 2015, 324-325: 64-73.
[13] Martin O.L.Hansen. 风力机空气动力学(第二版)[M]. 肖劲松, 北京: 中国电力出版社, 2009.
Martin O.L.Hansen. Aerodynamics of Wind Turbines(2nd edition) [M]. XIAO Jing-song, Beijing: China Electric Power Press, 2009.
[14]熊海洋
[15] Fabien Lescher, Jing Yun Zhao, Pierre Borne. Robust gain scheduling controller for pitch regulated variable speed wind turbine [J]. Studies in Informatics & Control, 2006, 14
[16] Jason M. Jonkman, Marshall L. Buhl Jr. FAST User's Guide [EB/OL]. http://wind.nrel.gov/public/bjonkman /TestPage/FAST.pdf, 2005.
[17]Jonkman B J. TurbSim User's Guide[M]. National Renewable Energy Laboratory(NREL), 2009.
[18] Kaimal J C, Wyngaard J C, Izumi Y, et al. Spectral characteristics of surface-layer turbulence[J]. Quarterly Journal of the Royal Meteorological Society. 1972, 98(417): 563-589.
[19]Wind Turbines - Part 1: Design Requirements[S]. Europe: European Committee for Electro-technical Standardization. 2005.
[20] 姜京旼. 轴孔位置误差对风机齿轮箱行星轮均载及寿命影响分析 [D]. 清华大学, 2015.
KANG Kyung-min. A Study on the influence of pin-hole positionalerror to load sharing and fatigue life of wind turbine planetary gear system [D]. Beijing: Tsinghua University, 2015.
[21] Jochem Giesbers. Contact Mechanics in MSC ADAMS [EB/OL]. http: //essay.utwente.nl/62109/1 /BSc_J_Giesbers.pdf, 2011.
[22] Calculation of load capacity of spur and helical gears-Part 2: Calculation of surface durability (pitting) [S]. Switzerland: International Organization for Standardization, 2006.
[23] Calculation of load capacity of spur and helical gears-Part 3: Calculation of tooth bending strength [S]. Switzerland: International Organization for Standardization, 2008.
[24] Calculation of load capacity of spur and helical gears-Part 5: Strength and quality of materials [S]. Switzerland: International Organization for Standardization, 2003.
[25] Miner M A. Cumulative damage in fatigue [J]. 1945.
[26] Dong W, Xing Y, Moan T. Time Domain Modeling and Analysis of Dynamic Gear Contact Force in a Wind Turbine Gearbox with Respect to Fatigue Assessment[J]. Energies, 2012, 5(12): 4350-437
[27] Nejad A R, Gao Z, Moan T. Fatigue Reliability-based Inspection and Maintenance Planning of Gearbox Components in Wind Turbine Drivetrains [J]. Energy Procedia, 2014, 53: 248-257.