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Articles About wind turbine gearboxes
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Historically, wind turbine gearbox failures have plagued the industry. Yet an effective oil analysis program will increase the reliability and availability of your machinery, while minimizing maintenance costs associated with oil change-outs, labor, repairs and downtime. Practical action steps are presented here to improve reliability.
The wind turbine industry has been plagued with gearbox failures, which cause repair costs, legal expenses, lost energy production and environmental pollution.
This article describes some of the most important tests for prototypes conducted at Winergy AG during the product development process. It will demonstrate that the measurement results on the test rig for load distribution are in accordance with the turbine measurements.
This article shows the newest developments to reduce overall cycle time in grinding wind power gears, including the use of both profile grinding and threaded wheel grinding.
We talked energy efficiency with some major players in the lubricants industry— but with a focus on their products’ impact regarding energy efficiency of gears and gearboxes in wind turbines.
Gear flank breakage can be observed on edge zone-hardened gears. It occurs, for example, on bevel gears for water turbines, on spur gears for wind energy converters and on single- and double-helical gears for other industrial applications.
Industrial gear standards have been used to support reliability through the specification of requirements for design, manufacturing and verification. The consensus development of an international wind turbine gearbox standard is an example where gear products can be used in reliable mechanical systems today. This has been achieved through progressive changes in gear technology, gear design methods and the continual development and refinement of gearbox standards.
Big gears and wind turbines go together like bees and honey, peas and carrots, bread and butter and—well, you get the idea. Wind isn’t just big right now, it’s huge. The wind industry means tremendous things for the energy dependent world we live in and especially big things for gear manufacturers and other beleaguered American industries.
The global wind energy market has seen average growth rates of 28 percent over the last 10 years, according to the Global Wind Energy Council (GWEC), creating major challenges for the component supply industry. GWEC also forecasts an average growth rate of 22 percent for the next five years, which if realized, will continue to put pressure on suppliers of turbine components.
Although typically considered a late bloomer in the call to wind energy arms, the United States is now the number one wind power producer in the world with over 25,000 MW installed by the end of 2008, according to the Global Wind Energy Council in January 2009.
Faithful Gear Technology readers may recall that our July 2009 issue contained an update of the deliberations provided by Bill Bradley. Now, almost two years later, there is an ISO/IEC wind turbine gearbox standard out for draft international standard ballot (ballot closes 2011-05-17).
Much of the existing guidelines for making large, high-performance gears for wind turbine gearboxes exhibit a need for improvement. Consider: the large grinding stock used to compensate for heat treatment distortion can significantly reduce manufacturing productivity; and, materials and manufacturing processes are two other promising avenues to improvement. The work presented here investigates quenchable alloy steels that, combined with specifically developed Case-hardening and heat treatment processes, exhibits reduced distortion and, in turn, requires a smaller grinding stock.
Long before oil, climate change and energy demand were making headlines in Washington, Minnesota State Auditor Rebecca Otto and her husband installed a wind energy system on their property in Minnesota.
It seems that nothing can hold back the power of the wind—unless, of course, it's the availability of rugged, reliable, specially designed gearboxes. How Gleason is Keeping up with Demand.
"An industrial business with a very important growth potential for the next decade." That's the wind energy as described by Ivan Brems of gear manufacturer Hansen Transmissions International.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
The turbines are still spinning. They’re spinning on large wind farms in the Great Plains, offshore in the Atlantic and even underwater where strong tidal currents offer new energy solutions. These turbines spin regularly while politicians and policy makers— tied up in discussions on tax incentives, economic recovery and a lot of finger pointing—sit idle. Much like the auto and aerospace industries of years past, renewable energy is coping with its own set of growing pains. Analysts still feel confident that clean energy will play a significant role in the future of manufacturing—it’s just not going to play the role envisioned four to five years ago.
Having outlasted the worldwide Great Recession, the Global Wind Energy Council (GWEC) forecasts a constant growth in wind energy, i.e.: "increase in worldwide capacity to 460,000 MW by 2015."
Lamentations continue—legitimately so—over the second-citizen status of manufacturing in the United States. The need undoubtedly continues for renewed support by government and educators for making things here once again...
Recent breakthroughs in profile grinding software are helping Anderson Precision Gears and others meet wind power’s insatiable appetite for faster production of large, high-quality gears.
The United States’ long-held dream of energy independence—as in cheap, clean, free of overseas extortion and renewable energy—could very well be realized in part by the country-wide development of wind turbines...
It’s not too often a trade show so far surpasses organizers’ expectations for size that it must be relocated. This was just the dilemma the American Wind Energy Association (AWEA) faced with the Windpower 2009 Conference and Exhibition, which was originally scheduled to take place in Minneapolis, but will now be held at McCormick Place, Chicago.
When Belgium-based Hansen Transmissions was under the ownership of Invensys plc in the late 1990s, the parent company was dropping not-so-subtle hints that the industrial gearbox manufacturer was not part of its long-term plans. Yet Hansen’s CEO Ivan Brems never dreamed that, less than a decade later, he would be working for an Indian company.
The complete Industry News section from the July 2014 issue of Gear Technology.
In the August 2008 issue of Gear Technology, we ran a story (“Gearbox Speed Reducer Helps Fan Technology for ‘Greener” Jet Fuel Efficiency’) on the then ongoing, extremely challenging and protracted development of Pratt & Whitney’s geared turbofan (GTF) jet engine.
The goal of gear drive design is to transit power and motion with constant angular velocity. Current trends in gear drive design require greater load carrying capacity and increased service life in smaller, quieter, more efficient gearboxes. Generally, these goals are met by specifying more accurate gears. This, combined with the availability of user-friendly CNC gear grinding equipment, has increased the use of ground gears.
There's a reason they call it catastrophic gear failure: For example, if the line goes down at a large aluminum rolling mill because a gear set goes bad, the cost can run up to a whopping $200,000 a week. Even in smaller operations, the numbers alone (not to mention all the other problems) can be a plant manager's worst nightmare.
Over the past few months we've talked with a lot of gear manufacturers. Many of them tell us business is strong, while others are struggling with reduced demand. The difference between them isn't so much in the quality of their manufacturing operations, but rather trends in the end markets they serve.
Most research on micropitting is done on small-sized gears. This article examines whether those results are also applicable to larger gears.
Industry battles it out for World's Largest Gear title.
A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses. Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss.
The Fabyan Windmill in Geneva, IL
This article reviews mathematical models for individual components associated with power losses, such as windage, churning, sliding and rolling friction losses.
Capitalizing on a burgeoning new technology where gears are of great import, the gear community gathered en masse at the American Wind Energy Association’s Windpower Expo 2010.
Natural resources—minerals, coal, oil, agricultural products, etc.—are the blessings that Mother Earth confers upon the nations of the world. But it takes unnaturally large gears to extract them.
A series of short reports on global manufacturing growth and the gear industry's role.
When a customer needed gears delivered in three weeks, here’s how Brevini Wind got it done.
News Items About wind turbine gearboxes
1 ZF Opens First U.S. Plant for Wind Turbine Gearboxes (October 4, 2011)
ZF Friedrichshafen AG has opened a plant for the production of wind turbine gearboxes in Gainesville near Atlanta, Georgia. As of 2012, t... Read News
2 GE Energy Partners with Chinese Co. To Develop Wind Turbine Gearboxes (April 22, 2006)
GE Energy and Nanjing High Speed & Accurate Gear Company (NGC) have agreed to jointly develop gearboxes for GE's 1.5-megawatt wind tu... Read News