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A high number of wind turbine gearboxes do not meet their expected design life, despite meeting the design criteria of current bearing, gear and wind turbine industry standards and certifications.
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.
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.
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.
We talked energy efficiency with some major players in the lubricants industryâ but with a focus on their productsâ impact regarding energy efficiency of gears and gearboxes in wind turbines.
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).
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.
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.
Big gears and wind turbines go together like bees and honey, peas and carrots, bread and butter andâwell, you get the idea. Wind isnât just big right now, itâs 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.
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.
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.
The Fabyan Windmill in Geneva, IL
The complete Industry News section from the July 2014 issue of Gear Technology.
Let's talk about large gears. Not the size or scope or inspection process, but the forecast and market potential in areas that utilize these massive components. We'll examine key industry segments like energy and mining and tap IHS Economics for a forecast for 2016 and 2017 (spoiler alert: it's not great). Additionally, we'll discuss some of the critical factors influencing global big gear manufacturers Ferry-Capitain and Hofmann Engineering.
Onshore and offshore wind turbines boast some of the most critical assets in order to run effectively.
Amidst the energy industry's uncertain future, gearbox manufacturers are focusing on supplying the aftermarket.
In the wind power industry, the reliability of powertrain components plays a major role. Especially in multi-megawatt offshore applications, an unplanned replacement of drivetrain components can lead to extremely high costs. Hence, the expectation of wind farm operators is to forecast the system reliability. Under the leadership of the VDMA (Mechanical Engineering Industry Association), the standardization paper 23904 "Reliability Assessment for Wind Turbines" was published in October 2019.
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.
This study deals with the modeling and consideration of misalignments in planetary gearboxes in the optimization and design process. Procedures for taking into account misalignments in cylindrical gearboxes are standardized and established in industry. Misalignments of central elements like carrier, sun gear or ring gear in planetary gearboxes, cause varying contact positions and variable loads, depending on the angular position of the central elements. This load, which is variable over the circumference, is not taken into account in the standardized procedures, despite its effects on the loads on the gears.
Most research on micropitting is done on small-sized gears. This article examines whether those results are also applicable to larger gears.
In the August 2008 issue of Gear Technology, we ran a story (âGearbox Speed Reducer Helps Fan Technology for âGreenerâ Jet Fuel Efficiencyâ) on the then ongoing, extremely challenging and protracted development of Pratt & Whitneyâs geared turbofan (GTF) jet engine.
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.
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.
In this paper a thermal network model is developed to simulate the thermal behavior of a high-speed, one-stage gear unit which is jet-lubricated.
This paper outlines the comparison of efficiencies for worm gearboxes with a center distance ranging from 28 - 150 mm that have single reduction from 5 to 100:1. Efficiencies are calculated using several standards (AGMA, ISO, DIN, BS) or by methods defined in other bibliographic references. It also deals with the measurement of torque and temperature on a test rig — required for the calibration of an analytical model to predict worm gearbox efficiency and temperature. And finally, there are examples of experimental activity (wear and friction measurements on a blockon- ring tribometer and the measurements of dynamic viscosity) regarding the effort of improving the efficiency for worm gear drivers by adding nanoparticles of fullerene shape to standard PEG lubricant
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."
Industry battles it out for World's Largest Gear title.
When a customer needed gears delivered in three weeks, hereâs how Brevini Wind got it done.
Natural resourcesâminerals, coal, oil, agricultural products, etc.âare the blessings that Mother Earth confers upon the nations of the world. But it takes unnaturally large gears to extract them.
Lamentations continueâlegitimately soâover 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...
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.
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.
"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.
This article reviews mathematical models for individual components associated with power losses, such as windage, churning, sliding and rolling friction losses.
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.
Capitalizing on a burgeoning new technology where gears are of great import, the gear community gathered en masse at the American Wind Energy Associationâs Windpower Expo 2010.
The United Statesâ long-held dream of energy independenceâas in cheap, clean, free of overseas extortion and renewable energyâcould very well be realized in part by the country-wide development of wind turbines...
A series of short reports on global manufacturing growth and the gear industry's role.
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 Hansenâs CEO Ivan Brems never dreamed that, less than a decade later, he would be working for an Indian company.
Recent breakthroughs in profile grinding software are helping Anderson Precision Gears and others meet wind powerâs insatiable appetite for faster production of large, high-quality gears.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
The turbines are still spinning. Theyâre 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 makersâ tied up in discussions on tax incentives, economic recovery and a lot of finger pointingâsit 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 manufacturingâitâs just not going to play the role envisioned four to five years ago.
Itâs not too often a trade show so far surpasses organizersâ 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.
The usage of modern thrusters allows combining the functions of the drive and the ship rudder in one unit, which are separated in conventional ship propulsion systems. The horizontally oriented propeller is supported in a vertically rotatable nacelle that is mounted underneath the ship's hull. The propeller can directly or indirectly be driven by an electric motor or combustion engine. Direct drive requires the installation of a low-speed electric motor in the nacelle. This present paper concentrates on indirect drives where the driving torque is transferred by bevel gear stages and shafts from the motor to the propeller.