风电齿轮箱高速轴轴承疲劳寿命及动态可靠性分析

为探究风电机组齿轮箱高速轴圆柱滚子轴承在服役过程中的疲劳寿命和可靠度变化规律,以新疆达坂城风场年度风载荷为外部激励,建立基于威布尔分布的随机风速模型及考虑内部齿轮时变啮合刚度、轴承时变刚度等激励因素的风电齿轮传动系统齿轮-轴承耦合动力学模型,通过Newmark积分法求解高速轴轴承动载荷。运用雨流计数法及Goodman平均应力修正法得到对称循环应力,结合线性损伤理论和非线性损伤理论的对比,获得轴承的接触疲劳寿命和动态可靠度。结果表明：额定功率下,在外部随机风载激励和内部齿轮-轴承耦合共同作用下,内激励仍然对系统高速轴轴承动载荷起主要作用。与线性损伤累计理论相比,非线性损伤累计理论考虑载荷加载的顺序效应,能更好地描述轴承在整个疲劳寿命过程中各阶段的疲劳损伤情况。轴承在服役过程中,前15年的损伤较小,可靠度衰减缓慢,而在后期可靠度呈现出非线性迅速下降趋势,应及时调整维护策略。     

某型燃气轮机圆柱滚子轴承失效原因分析

某型燃气轮机圆柱滚子轴承在加速寿命试验时发生了外圈滚道承载区域疲劳剥落现象。为查明失 效原因，针对轴承试验件开展了尺寸精度、径向游隙、滚动表面轮廓、材料化学成分、显微组织等9项检测工 作，并复查了试验系统和设备的工装尺寸和加载头设计原理。经综合分析，判断轴承试验件的失效原因为： 加载套内径尺寸偏小，且选用材料硬度偏低，在使用紧固螺栓拉紧固定时，加载套导致自身及试验轴承的椭 圆变形，进而引起轴承外圈的提前疲劳剥落。上述分析工作准确地定位了轴承失效原因，改进试验系统，有 力地保证了某型燃气轮机圆柱滚子轴承加速寿命试验的顺利开展。     

双排圆锥滚子风电机组主轴承的接触载荷分布分析

本文针对大型双排圆锥滚子风电机组主轴承的载荷和结构特性推导了轴承外滚道、内滚道及挡边的接触载荷分布求解方法,在此基础上可以求解出每个滚子与外、内滚道及挡边的接触载荷,为轴承承载能力设计、结构优化等提供了依据。此外,本文结合实际工程案例,对该方法在轴承静承载能力设计中的应用作了说明。     

预负荷空心圆柱滚子轴承承载性能的有限元分析

利用有限元分析软件ANSYS对预负荷空心圆柱滚子(HCR)轴承的承载性能进行分析。主要计算预负荷空心圆柱滚子轴承的最底部滚子和次底部滚子的等效应力、接触应力和滚子内圈拉应力的分布情况,分析滚子空心度和过盈量对轴承应力和额定载荷的影响。通过分析和计算得到数据结果为预负荷空心圆柱滚子轴承的进一步优化提供参考依据。     

预负荷空心圆柱滚子轴承承载性能的有限元分析

利用有限元分析软件ANSYS对预负荷空心圆柱滚子（HCR）轴承的承载性能进行分析。主要计算预负荷空心圆柱滚子轴承的最底部滚子和次底部滚子的等效应力、接触应力和滚子内圈拉应力的分布情况，分析滚子空心度和过盈量对轴承应力和额定载荷的影响。通过分析和计算得到数据结果为预负荷空心圆柱滚子轴承的进一步优化提供参考依据。     

考虑风速风向联合概率分布的风电塔筒结构风致疲劳寿命评估

针对风向对风力机塔筒疲劳产生影响的问题,基于实测数据对考虑风速风向联合概率分布的风电塔筒结构的风致疲劳寿命展开研究。首先结合甘肃安西地区37 a的实测风速风向数据,给出风速风向联合概率分布。然后利用主S-N曲线法分别对不同风向和不同风速下风力机塔架结构法兰及门洞区域的响应规律进行分析。最后考虑风速风向联合概率分布,对风电塔筒结构风致疲劳寿命展开研究。结果表明：门洞朝向与风轮朝向的夹角变化和风速的改变均对风电塔筒的风致疲劳寿命有一定影响,其中门洞朝向与风轮朝向夹角为225°时疲劳寿命最长,风速为10~14 m/s时疲劳寿命变化幅度最大;考虑风速风向联合概率分布能更准确地计算风力机结构的风致疲劳寿命,且以此为依据对门洞朝向进行调整可延长其疲劳寿命,因此建议对风电塔架进行设计时,应考虑风电场所在地区的风速风向联合概率分布。     

风电圆锥滚子轴承大挡边-滚子球端面接触分析方法

针对点接触假设的传统模型无法获得接触应力区域的分布特征参数,基于大挡边-滚子球端面接触关系和Hertz接触理论,提出大挡边-滚子球端面接触应力分布区域的理论计算模型,并用有限元方法验证模型的有效性;基于该模型分析载荷、滚子端面球半径及挡边锥度角对接触状态的影响。最后以某风电主轴承为例,建立该轴承大挡边-滚子球端面的设计图谱。结果表明:风电主轴承挡边接触状态受载荷影响明显,接触区域位置对挡边锥角变化非常敏感,滚子球端面与挡边需匹配设计。     

基于单神经元权系数的风电机组独立变桨控制

针对风电机组大型化造成风轮受风剪切效应不良影响的问题,提出了采用模糊PID功率控制器与单神经元动态权系数分配的独立变桨距控制方案。使用Matlab软件对该方案应用于1 MW双馈型风电机组独立变桨距的运行工况进行仿真研究。仿真结果显示,独立变桨距控制方案在保证机组输出功率稳定的前提下,显著改善了风机叶片与风轮承受的轴向不平衡气动力的幅值与波动,进而降低了机组运行过程中受到的气动疲劳载荷,有助于延长机组寿命。     

发动机主轴承盖/壁结构分析

在爆发压力以及往复惯性力的作用下,曲轴轴颈中心会承受随机载荷,另外螺栓预紧力的作用,会使轴瓦、主轴承盖/壁产生强度、疲劳影响,主轴承壁和主轴承盖接触部位产生相对滑移量。通过在主轴承壁两侧增加螺栓,使主轴承盖/壁承受沿螺栓水平方向的预紧力。对增加两侧螺栓与否的情况,进行对比计算分析,查看零件的滑移量、强度和疲劳是否满足要求。     

一种风电机组轴承简化建模方法的研究

针对风电机组变桨轴承及偏航轴承结构与受力的复杂性,提出了一种新的滚动轴承简化建模方法。通过利用有限元分析软件MSC.Marc/Mentat中的GAP单元模拟滚动体与内、外圈之间的接触来实现对轴承建模的简化,同时对简化模型进行加载计算,得到内、外圈的应力及应变结果;并用Hertz理论及Newton迭代法计算同种工况下内、外圈的应力值及位移值,来验证此种建模方法的可行性和正确性。结果表明:滚动轴承的内、外圈接触可采用GAP单元进行模拟,从而为风电机组轴承有限元建模提供了一种简便且有效的方法。     

Long‐term contact fatigue analysis of a planetary bearing in a land‐based wind turbine drivetrain

This paper presents an approach for performing a long‐term fatigue analysis of rolling element bearings in wind turbine gearboxes. Multilevel integrated analyses were performed using the aeroservoelastic code HAWC2, the multibody dynamics code SIMPACK, the three‐dimensional finite element code Calyx and a simplified lifetime prediction model for rolling contact fatigue. The National Renewable Energy Laboratory's 750 kW wind turbine and its planetary bearing were studied. Design load cases, including normal production, parked and transient load cases, were considered. To obtain the internal bearing load distribution, an advanced approach combining a finite element/contact mechanics model and a response surface model were used. In addition, a traditional approach, the Harris model, was also applied for comparison. The long‐term probability distribution of the bearing raceway contact pressure range was then obtained using Weibull and generalized Gamma distribution functions. Finally, we estimated the fatigue life of the bearing, discussed the differences of the methods used to obtain the bearing internal loads and analyzed the effects of the environmental conditions and load cases on the results. The Harris model may underestimate the inner raceway life by 55.7%, which can cause large load fluctuations along the raceways. The bearing fatigue life is very sensitive to the wind distribution and less affected by the transient and parked load cases. Copyright © 2014 John Wiley & Sons, Ltd.     

燃气轮机滚动轴承故障及振动传递特性研究

针对燃气轮机动力涡轮转子系统中滚动轴承故障高发的问题,基于赫兹接触理论建立了滚动轴承故障激励力模型,并验证了其准确性。基于有限元法建立了转子-轴承-机匣-固定平台整机模型以揭示振动传递特性。频域分析结果表明：单故障条件下不平衡激励力与滚动轴承故障激励力是单向耦合的关系;双故障条件下,若故障点直径相同,加速度信号中滚子故障主要频率对应的加速度幅值最大,外圈故障主要频率对应的加速度幅值最小。     

Experimental investigation of bearing slip in a wind turbine gearbox during a transient grid loss event

This work investigates the behaviour of the high‐speed stage of a wind turbine gearbox during a transient grid loss event. Dynamometer testing on a full‐scale wind turbine nacelle is used. A combination of external and internal gearbox measurements are analysed. Particular focus is on the characterization of the high‐speed shaft tapered roller bearing slip behaviour. This slipping behaviour is linked to dynamic events by many researchers and described as a potential bearing failure initiator; however, only limited full‐scale dynamic testing is documented. Strain gauge bridges in grooves along the circumference of the outer ring are used to characterize the bearing behaviour in detail. It is shown that during the transient event the high‐speed shaft experiences a combined torsional and bending deformation. These unfavourable loading conditions induce roller slip in the bearings during the torque reversals, indicating the potential of the applied load case to go beyond the preload of the tapered roller bearing. Copyright © 2016 John Wiley & Sons, Ltd.     

Simulation of wind turbine wake interaction using the vorticity transport model

The aerodynamic interactions that can occur within a wind farm can result in the constituent turbines generating a lower power output than would be possible if each of the turbines were operated in isolation. Tightening of the constraints on the siting of wind farms is likely to increase the scale of the problem in the future. The aerodynamic performance of turbine rotors and the mechanisms that couple the fluid dynamics of multiple rotors can be most readily understood by simplifying the problem and considering the interaction between only two rotors. The aerodynamic interaction between two rotors in both co‐axial and offset configurations has been simulated using the Vorticity Transport Model. The aerodynamic interaction is a function of the tip speed ratio, and both the streamwise and crosswind separation between the rotors. The simulations show that the momentum deficit at a turbine operating within the wake developed by the rotor of a second turbine is governed by the development of instabilities within the wake of the upwind rotor, and the ensuing structure of the wake as it impinges on the downwind rotor. If the wind farm configuration or wind conditions are such that a turbine rotor is subject to partial impingement by the wake produced by an upstream turbine, then significant unsteadiness in the aerodynamic loading on the rotor blades of the downwind turbine can result, and this unsteadiness can have considerable implications for the fatigue life of the blade structure and rotor hub. Copyright © 2009 John Wiley & Sons, Ltd.     

Changes in design driving load cases: Operating an upwind turbine with a downwind rotor configuration

This work considers the design driving load cases from a full design load basis analysis on an upwind turbine changed into a downwind configuration. The upwind turbine is a commercial class IIIA 2.1‐MW turbine, manufactured by Suzlon. The downwind turbine shows an increase in the normalized tower clearance by 6%, compared with the upwind concept. Removing the blade prebend increases the normalized minimum tower clearance by 17% in the downwind configuration compared with the upwind configuration. The extreme loads on the longitudinal tower bottom bending moment are seen to generally increase by 17% because of the overhanging gravity moment of the rotor‐nacelle assembly. The extreme blade root bending moments are reduced by 10% flapwise, because of the coning of the rotor in downwind direction. The fatigue loads suffer from the tower shadow, leading to an overall increase of the fatigue loads in the blades with up to 5% in flapwise direction in the downwind configuration. Because of blade deflection and coning direction, the downwind configuration shows a 0.75% lower annual energy production. Removing the prebend increases the annual energy production loss to 1.66%.     

Effects of wind shear on wind turbine rotor loads and planetary bearing reliability

Recent studies suggest that wind shear and the resulting pitch moments increase bearing loads and thereby contribute to premature wind turbine gearbox failure. In this paper, we use momentum‐based modeling approaches to predict the pitch moments from wind shear. The non‐dimensionalized results, which have been validated against accepted aeroelastic results, can be used to determine thrust force, pitch moment and power of a general rotor as a function of the wind shear exponent. Even in extreme wind shear (m = 1), the actual thrust force and power for a typical turbine (R* < 0.5) were within 8% and 20% of the nominal values (those without wind shear), respectively. The mean pitch moment increased monotonically with turbine thrust, rotor radius and wind shear exponent. For extreme wind shear (m = 1) on a typical turbine (R* = 0.5), the mean pitch moment is ~25% the product of thrust force and rotor radius. Analysis of wind shear for a typical 750 kW turbine revealed that wind shear does not significantly affect bearing loads because it counteracts the effects of rotor weight. Furthermore, even though general pitch moments did significantly increase bearing loads, they were found to be unlikely to cause bearing fatigue. Analyses of more common low wind‐speed cases suggest that bearing under‐loading and wear are more likely to contribute to premature bearing failure than overloading and classical surface contact fatigue. Copyright © 2015 John Wiley & Sons, Ltd.     

Effect of load reduction mechanisms on loads and blade bearing movements of wind turbines

The power control of wind turbines is usually realized via a change in the pitch angle of the rotor blades. Pitching facilitates the exact control of the turbines and the reliable deceleration of the rotor when required. Pitch movements can moreover be used for load control. One of these methods is called individual pitch control (IPC). IPC controls the blades individually and brings about a significant reduction in the fatigue loads and extreme loads placed on the structural components, while at the same time reducing the yield of the turbine only slightly. The lower loads reduce material costs, and thus, the cost of energy (CoE) is reduced, despite the slight reduction in yield. The method is nevertheless not used everywhere since the additional movement cycles put the rotor blade bearings in particular under stress. Special attention must be paid to small amplitude oscillating movements, which carry a high risk of inducing surface damage in the rolling contacts of the blade bearings. This paper uses a cycle analysis of the IWT7.5‐164 reference turbine to illustrate the differences in the movement patterns of wind turbine blade bearings with and without IPC. Moreover, model calculations with single contacts are used to show which of the movement patterns carries a risk of inducing surface damage. The use of IPC leads to the expected load reduction at the blade root. In current literature, IPC is usually assumed to have a negative influence on the life expectancy of blade bearings, but the findings of this study contradict this. The summed blade bearing movement is increased, although the number of very small pitch angles occurring is reduced. This reduction reduces the risk of wear in the blade bearings.     

Planetary gear load sharing of wind turbine drivetrains subjected to non‐torque loads

An analytical formulation was developed to estimate the load‐sharing and planetary loads of a three‐point suspension wind turbine drivetrain considering the effects of non‐torque loads, gravity and bearing clearance. A three‐dimensional dynamic drivetrain model that includes mesh stiffness variation, tooth modifications and gearbox housing flexibility was also established to investigate gear tooth load distribution and non‐linear tooth and bearing contact of the planetary gears. These models were validated with experimental data from the National Renewable Energy Laboratory's Gearbox Reliability Collaborative. Non‐torque loads and gravity induce fundamental excitations in the rotating carrier frame, which can increase gearbox loads and disturb load sharing. Clearance in the carrier bearings reduces the bearing stiffness significantly. This increases the amount of pitching moment transmitted from the rotor to the gear meshes and disturbs the planetary load share, thereby resulting in edge loading. Edge loading increases the likelihood of tooth pitting and planet‐bearing fatigue, leading to reduced gearbox life. Additionally, at low‐input torque, the planet‐bearing loads are often less than the minimum recommended load and thus susceptible to skidding. Copyright © 2014 John Wiley & Sons, Ltd.     

Identification of loading conditions resulting in roller slippage in gearbox bearings of large wind turbines

The dynamic loads on the rollers inside the bearings of large wind turbine gearboxes operating under transient conditions are presented with a focus on identifying conditions leading to slippage of rollers. The methodology was developed using a multi‐body model of the drivetrain coupled with aeroelastic simulations of the wind turbine system. A 5 MW reference wind turbine is considered for which a three‐stage planetary gearbox is designed on the basis of upscaling of an actual 750 kW gearbox unit. Multi‐body dynamic simulations are run using the ADAMS software using a detailed model of the gearbox planetary bearings to investigate transient loads inside the planet bearing. It was found that assembly and pre‐loading conditions have significant influence on the bearing's operation. Also, the load distribution in the gearbox bearings strongly depends on wind turbine operation. Wind turbine start‐up and shut‐down under normal conditions are shown to induce roller slippage, as characterized by loss of contacts and impacts between rollers and raceways. The roller impacts occur under reduced initial pre‐load on opposite sides of the load zone followed by stress variation, which can be one of the potential reasons leading to wear and premature bearing failures. Copyright © 2017 John Wiley & Sons, Ltd.     

不同海况下近海超大型风力机动力学响应及结构损伤分析

以超大型DTU 10 MW单桩式近海风力机为研究对象,通过p-y曲线和非线性弹簧建立桩-土耦合模型,选取Kaimal风谱模型建立湍流风场,基于P-M谱定义不同频率波浪分布,并利用辐射/绕射理论计算波浪载荷,采用有限元方法对不同海况下单桩式风力机进行动力学响应、疲劳及屈曲分析。结果表明：不同海况波浪载荷作用下塔顶位移响应及等效应力峰值远小于风及风浪联合作用,其中风浪联合作用下风力机塔顶位移响应及等效应力略小于风载荷;波浪载荷对风载荷引起的单桩式风力机动力学响应具有一定抑制作用,此外相较于波浪载荷,风载荷为控制载荷;风载荷与风浪联合作用下风力机等效应力峰值位于塔顶与机舱连接处,波浪载荷风力机等效应力峰值位于支撑结构与桩基连接处;仅以风载荷预估风力机塔架疲劳寿命将导致预估不足;随着波浪载荷的增大,风力机失稳风险加大,波浪载荷不可忽略;不同海况下,风浪联合作用局部屈曲区域位于塔架中下端,在风力机抗风浪设计时,应重点关注此处;变桨效应可大幅降低风力机动力学响应、疲劳损伤及发生屈曲的风险。