Integrated Approach Using Condition Monitoring and Modeling to Investigate Wind Turbine Gearbox Design

Vibration-based condition monitoring (CM) of geared utility-scale turbine drivetrains has been used by the wind industry to help improve operation and maintenance (O&M) practices, increase turbine availability, and reduce O&M cost. This study is a new endeavor that integrates the vibration-based CM technique with wind turbine gearbox modeling to investigate various gearbox design options. A team of researchers performed vibration-based CM measurements on a damaged wind turbine gearbox with a classic configuration, (i.e., one planetary stage and two parallel stages). We observed that the acceleration amplitudes around the first-order sidebands of the intermediate stage gear set meshing frequency were much lower than that measured at the high-speed gear set, and similar difference was also observed in a healthy gearbox. One factor for a reduction at the intermediate stage gear set is hypothesized to be the soft sun-spline configuration in the test gearbox. To evaluate this hypothesis, a multibody dynamic model of the healthy test gearbox was first developed and validated. Relative percent difference of the first-order sidebands - of the highspeed and intermediate stage gear-meshing frequencies - in the soft and the rigid sun spline configurations were compared. The results verified that the soft sun-spline configuration can reduce the sidebands of the intermediate stage gear set and also the locating bearing loads. The study demonstrates that combining vibration-based CM with appropriate modeling can provide insights for evaluating different wind turbine gearbox design options.