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Project Name: Fatigue analysis of wind turbine bearings. A Wind Turbine converts wind’s kinetic energy into electrical power. After hydropower, wind power is the second biggest contributor to Australia’s renewable energy supply. Wind turbines capture wind energy within the area swept by their blades. They produce a power output proportional to the air density and the wind speed cubed. The spinning blades drive an electrical generator that produces electricity for export to the grid. Bearings are one of the most important components of wind turbines and require designs that optimize reliability and economic efficiency while taking into account the characteristics of the applications. Bearings of different types are being used in rotor shaft, gearbox (step-up gear), generator, yaw gearbox (reduction), yaw slewing table, blade pitch revolving seat and hydraulic pump in wind turbine. Slewing ring bearings are typically found in the pitch and yaw locations of a turbine and help ensure that the blades rotate smoothly. Spherical roller bearings are often used in the main shaft of the turbine and various combinations of CRBs, TRBs and ball bearings are used in the gearbox of a wind turbine. A wind turbine can be failed due to Gear box failures, generator failures and main shaft failure and so on. According to current trend 70% of gearbox and 67% of generator of wind turbine being failed due to Bearings. So fatigue analysis of bearings in wind turbine is very important and can play a major role to prevent the turbine failure. Existing literature has shown the importance and fatigue analysis of bearing in wind turbine for preventing the failures and I propose to investigate this area further and look at stress, forces and external loading of the bearings in wind turbine. My project will also perform an analysis of fatigue failure and fatigue life of bearing in wind turbine which will help to prevent mechanical failure because of early bearing fatigue such as excessive stress, loading and vibration. Method importing various bearings in solidwork This stage includes importing wind turbine bearings into solidwork for doing the further analysis. Use of solidwork simulation Here solidwork simulation software is used to analysis the stresses, maximum loading, forces of bearings and some calculation is done to determine fatigue life and fatigue failure of bearings. Collection of data and result Then all the data will be collected from different analysis of bearings and then result of different analysis would be compared with theoretical result. Conclusion Finally we will come up with a best result from the analysis and a conclusion will be made. A detailed report would be made after that for the project. Example Souichi YAGI, Nobuyuki NINOYU, Bearings for Wind Turbine, NTN Global Technical review No.71 (2014). This report introduces a method to optimize wind turbine bearing design and the features of bearings developed for wind turbines. It also cover the study to calculate and analyse the bearing life for the maximum required strength of the housing and the average deformation of the housing. I have also learned how to work with solidwork simulation software with different bearings of wind turbine. By studying this i got the idea of deflection analysis results of different bearing used for wind turbine gearbox. FEA analysis example of wind turbine main bearing Schaeffler Technologies GmbH & Co. KG, Modern simulation and calculation programs, Bearing Solutions and Service for Wind Turbines. This article presents information about most up-to-date simulation and calculation programs in order to ensure the optimum selection of products. I got the knowledge of using hybrid multi-body simulation (MBS) and how the dynamic behaviour of the entire wind turbine is displayed. Based on the model, individual components of the drive train and the entire wind turbine design can be improved as early as the development phase. By using Bearinx software, all bearing types, complex shafts, and shaft systems through to complete drive units can be modeled and calculated. The support reactions, the internal stresses of the bearings, the comparative stress of the shafts, and the most important parameters are calculated and can be displayed graphically or in a table. Comprehensive analysis example of Optimum bearing design of wind turbine MTS wind power solution, Improving Reliability through Mechanical Testing & simulation. http://www.mts.com/cs/groups/public/documents/generaldocuments/dev_004820.pdf viewed on June 2017. MTS solutions are deployed worldwide, subjecting wind turbine materials, components and structures to a full spectrum of mechanical testing, including characterization, strength testing, durability testing and systems testing. This literature describe about mechanical tests on a wide array of wind turbine bearings, including pitch, yaw and main bearing systems. By studying this paper I have learned about different testing procedure of Blade pitch bearing of a wind turbine. Different Wind turbine bearing are performed under load and the simulation and optimum test accuracy achieved with state-of-the-art FlexTest digital controls, Multipurpose TestWare software and RPC Pro software. 1. Emamode A Ubogu, High Reliability and low friction bearings for Wind Turbines, University of Sheffield. Viewed in May 2017. This literature describes the various bearing options available to the different bearing components of a wind turbine, wind turbine architecture and Bearing life calculation of a wind turbine. The basic life calculation formula was used for this project, which involves the steps below-

Project Name:  Fatigue analysis of wind turbine bearings.

A Wind Turbine converts wind’s kinetic energy into electrical power. After hydropower, wind power is the second biggest contributor to Australia’s renewable energy supply. Wind turbines capture wind energy within the area swept by their blades. They produce a power output proportional to the air density and the wind speed cubed. The spinning blades drive an electrical generator that produces electricity for export to the grid.

Bearings are one of the most important components of wind turbines and require designs that optimize reliability and economic efficiency while taking into account the characteristics of the applications. Bearings of different types are being used in rotor shaft, gearbox (step-up gear), generator, yaw gearbox (reduction), yaw slewing table, blade pitch revolving seat and hydraulic pump in wind turbine. Slewing ring bearings are typically found in the pitch and yaw locations of a turbine and help ensure that the blades rotate smoothly. Spherical roller bearings are often used in the main shaft of the turbine and various combinations of CRBs, TRBs and ball bearings are used in the gearbox of a wind turbine.

A wind turbine can be failed due to Gear box failures, generator failures and main shaft failure and so on. According to current trend 70% of gearbox and 67% of generator of wind turbine being failed due to Bearings. So fatigue analysis of bearings in wind turbine is very important and can play a major role to prevent the turbine failure. Existing literature has shown the importance and fatigue analysis of bearing in wind turbine for preventing the failures and I propose to investigate this area further and look at stress, forces and external loading of the bearings in wind turbine. My project will also perform an analysis of fatigue failure and fatigue life of bearing in wind turbine which will help to prevent mechanical failure because of early bearing fatigue such as excessive stress, loading and vibration.

Method

importing various bearings in solidwork

This stage includes importing wind turbine bearings into solidwork for doing the further analysis.

Use of solidwork simulation

Here solidwork simulation software is used to analysis the stresses, maximum loading, forces of bearings and some calculation is done to determine fatigue life and fatigue failure of bearings.

Collection of data and result

Then all the data will be collected from different analysis of bearings and then result of different analysis would be compared with theoretical result.

Conclusion

Finally we will come up with a best result from the analysis and a conclusion will be made. A detailed report would be made after that for the project.

Example

 

Souichi YAGI, Nobuyuki NINOYU, Bearings for Wind Turbine, NTN Global Technical review No.71 (2014).

 

This report introduces a method to optimize wind turbine bearing design and the features of bearings developed for wind turbines. It also cover the study to calculate and analyse the bearing life for the maximum required strength of the housing and the average deformation of the housing.

I have also learned how to work with solidwork simulation software with different bearings of wind turbine. By studying this i got the idea of deflection analysis results of different bearing used for wind turbine gearbox.

 

FEA analysis example of wind turbine main bearing

 

 

 

Schaeffler Technologies GmbH & Co. KG, Modern simulation and calculation programs, Bearing Solutions and Service for Wind Turbines.

 

This article presents information about most up-to-date simulation and calculation programs in order to ensure the optimum selection of products. I got the knowledge of using hybrid multi-body simulation (MBS) and how the dynamic behaviour of the entire wind turbine is displayed. Based on the model, individual components of the drive train and the entire wind turbine design can be improved as early as the development phase.

By using  Bearinx software, all bearing types, complex shafts, and shaft systems through to complete drive units can be modeled and calculated. The support reactions, the internal stresses of the bearings, the comparative stress of the shafts, and the most important parameters are calculated and can be displayed graphically or in a table.

 

Comprehensive analysis example of Optimum bearing design of wind turbine

 

 

 

 

MTS wind power solution, Improving Reliability through Mechanical Testing & simulation.

http://www.mts.com/cs/groups/public/documents/generaldocuments/dev_004820.pdf viewed on June 2017.

 

 

MTS solutions are deployed worldwide, subjecting wind turbine materials, components and structures to a full spectrum of mechanical testing, including characterization, strength testing, durability testing and systems testing. This literature describe about mechanical tests on a wide array of wind turbine bearings, including pitch, yaw and main bearing systems. By studying this paper I have learned about different testing procedure of Blade pitch bearing of a wind turbine. Different Wind turbine bearing are performed under load and the simulation and optimum test accuracy achieved with state-of-the-art FlexTest digital controls, Multipurpose TestWare software and RPC Pro software.

 

 

 

 

 

 

 

  1. Emamode A Ubogu, High Reliability and low friction bearings for Wind Turbines, University of Sheffield. Viewed in May 2017.

 

This literature describes the various bearing options available to the different bearing components of a wind turbine, wind turbine architecture and Bearing life calculation of a wind turbine. The basic life calculation formula was used for this project, which involves the steps below-

 

 

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