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Original Article
Abstract
A 2.5 MW wind turbine gearbox design was considered to perform a power loss prediction using different wind turbine
gear oil formulations. A gearbox power loss model, previously validated with experimental results, was used to predict
the efficiency of a full wind turbine planetary gearbox. The power loss model account the gears and rolling bearing losses
using well established models calibrated with a method proposed by the author. The calculations clearly showed that
significant energy savings can be achieved by selecting different base oils, modifying gear tooth geometry, or combining
both.
Keywords
Wind turbine gearbox, gears, rolling bearings, efficiency, power loss, lubrication
Date received: 5 May 2015; accepted: 18 November 2015
Introduction
Wind turbines have a signicant contribution to the
electrical power generation from renewal sources
around the world.1 The blades of a wind turbine
rotate at very low speeds, typically 20 r/min, which
are not suitable for conventional power generation
using an electrical generator. This constraint is
solved using a multiplying gearbox between the hub
and the electrical generator.
While the main focus of researchers and engineers
for the wind turbine applications is mainly the gearbox reliability, the energetic eciency of such
large machines should not be disregarded. The gearbox eciency of the car or the bus of daily use is
often considered very high and the power loss problem is mainly focused on the engine and vehicle
weight.2,3 However, wind turbine gearboxes, handle several megawatt and even a small eciency
increase can save energy useful for several more
households.
The gearbox might have dierent congurations,
although one of the most used designs has two planetary stages plus a helical gear stage at the end. The
eciency of these multiplying gearboxes, with such
arrangement or a similar one, is good. Nevertheless,
any eciency increase will have a signicant impact,
reducing the power loss and the operating temperature. If the eciency of a 1 MW wind turbine gearbox
is increased by 1%, something like 10 kW of additional power would be available in only one machine.
The 1 MW wind turbines are very rare nowadays,
2
the use of the new SKF model,8 after a calibration
procedure for each oil formulation.
Ohlendorfs9 model is currently used to predict
the average gear mesh losses, a constant and average
coecient of friction along the path of contact is
assumed. The average CoF is usually calculated with
formulations like the ones proposed by Schlenk,10
Michaelis et al.,11 and Matsumoto and Morikawa.12
In a previous work,13 the authors showed that a
properly calibrated Schlenks model can be used to
accurately estimate the average gear mesh power
losses.7,13,14
The previous works of the authors7,1323 aimed to
fully characterize wind turbine gear oils in terms of
physical properties and friction, both on gears and
rolling bearings. Experimental tests were performed,
allowing to calibrate each power loss source and then
a gearbox power loss model was developed.
Furthermore, the experimental results clearly
showed that it is possible to increase gearbox eciency through an improved gear tooth design or
selecting the most suitable gear oil formulation, or
even, combining these two possibilities.
The present work intends to predict the power loss
of a 2.5 MW wind turbine gearbox lubricated with
dierent fully formulated ISO VG 320 wind turbine
gear oils. The gearbox and the power loss model considered allowed to show the inuence of rolling bearings, gears, oil formulation, and operating conditions
on a real application.
power loss
gears
Fernandes et al.
3
The rolling bearing drag losses are given by equation
(9) for ball bearings or by equation (10) for roller
bearings
XL
MINR
PAOR
PAGD
0.85
0.70
0.60
MINR:
mineral;
PAOR:
PAGD: polyalkylene glycol.
polyalpholephin;
Z bZ
0
FN x, y vg x, y
dxdy
Fbt
vtb
Equation (7) denes the inlet shear heating and equation (8) shows the replenishment/starvation reduction
factor, both for the rolling element raceway contact.
ish
1 1:84
1
rs
e
Krs ndD
109
1
n dm 1:28 0:64
p
K
z
2Dd
10
7
8
11
Schlenck10 equation (3) was used to predict the meshing gears coecient of friction. The corresponding
lubricant parameter XL (see Table 1) was determined
with experimental results for each oil formulation.
0:2
Fbt =b
mZ 0:048
0:05 R0:25
XL
3
a
C redC
HVL
bl
1
1,4
e2,6108 n dm
12
13
Seal losses
Seal power loss is due to friction in the contact zone.
The friction has been the scope of many researchers
but the problem of seal losses is not very well understood yet.44 The contact zone is very small and the
microscopic phenomena is dicult to parametrize.
Freudenberg Simrit performed a large number of
measurements and observed that the seal losses are
function of seal diameter and rotational speed.
Valid for:
Bearing type
Oil
Parameter
TBB
RTB
MINR
bl
EHD
bl
EHD
bl
EHD
0.058
0.056
0.049
0.044
0.054
0.044
0.035
0.018
0.039
0.010
0.025
0.010
PAOR
PAGD
14
Auxiliary losses
The auxiliary losses take into account other dissipative sources that are not generated by gears, bearings
or the sealing elements.
15
16
1 13:2 p0 =E L 0:42
1 0:2131 2:23 S0:83 L 0:64
17
L U S
kL
18
h0C
19
Fernandes et al.
Stage 2
Stage 3
Parameter
Sun
Planet
Ring
Sun
Planet
Ring
Pinion
Wheel
z
b
i
m
z
z
a0
xz
SF
SH
21
320
5.587
16
20
10
476
0.71
1.68
1.09
35
320
96
331.5
23
168.4
5.464
9
20
10
290
0.6464
1.98
1.18
38
168.4
103
177.4
117
245
3.343
7
20
10
550
0.769
2.74
2.02
35
240
0.8031
1.19
1.15
0.2093
1.89
1.79
Rolling bearing
Location
Stage 1
carrier
carrier
planets
planets
carrier
carrier
planets
planets
pinion shaft
pinion shaft
pinion shaft
wheel shaft
wheel shaft
wheel shaft
Stage 2
Stage 3
Quantity
1
1
3
3
1
1
3
3
1
1
1
1
1
1
0.7693
1.39
1.22
0.0639
2.18
2.25
0.7176
2.91
1.99
Value
Input torque
Input speed
Output speed
Nominal power
Operating temperature
Lubrication method (gears)
Lubrication method (rolling bearings)
1200 kNm
20 r/min
2040 r/min
2.5 MW
60 C and 80 C
Oil jet lubrication
Dip lubrication
i.e. planet/ring or planet/carrier. No matter the operating temperature considered, the oils allow to keep
the risk of failure below 5%,50 since the specic lm
thickness calculated is higher than that required.
Stage 2
Stage 3
Property
Unit
P/S
P/R
P/S
P/R
Helical
n
vt
p0
r/min
m/s
MPa
111.4
1.867
1028
34.9
0.974
699
610.4
6.302
921
190.6
3.251
624
610.4
24.933
567
(a)
(b)
Figure 3. Specific film thickness calculated at 60 C and 80 C for each gear mesh and oil formulation.
PVZ0 PVZP
|{z}
|{z}
Disregarded
PVD
|{z}
Disregarded
PVX
|{z}
PVL
|{z}
20
Disregarded
PIN
3 vt
21
The mesh power in each meshing pair should be calculated as presented in equation (22), and so the relative speed was considered. The mesh power (PM)
should be used in equation (1) instead of input
power (PIN) for the case of planetary gears.
Regarding the coecient of friction the sum velocities
in the pitch point (vC ) should also be calculated using
the relative velocities.
PM Fbt v0t
22
Fernandes et al.
VZP
VL
VZP
80
80
Power Loss [kW]
(b) 100
(a) 100
60
40
20
(c)
MINR
PAOR
Oil []
[kW]
VZP
[kW]
VZP
40
MINR
PAOR
Oil []
PAGD
Stage 1
Stage 2
Stage 3
60
40
PAGD
(f)
100
[kW]
40
20
PAOR
Oil []
PAGD
Stage 1
Stage 2
Stage 3
80
VL
60
MINR
100
Stage 1
Stage 2
Stage 3
[kW]
PAOR
Oil []
20
80
VL
MINR
80
20
40
100
(d)
60
60
PAGD
Stage 1
Stage 2
Stage 3
80
(e)
VL
20
100
60
40
20
MINR
PAOR
Oil []
PAGD
MINR
PAOR
Oil []
PAGD
Simulation results
Considering the main sources of power loss in each
gearbox stage, gears and rolling bearings, antagonistic
eects were observed, as presented in Figure 4. PAGD
reduced the gears power loss but slightly increased the
rolling bearing losses. The opposite behavior is
observed for MINR.
Table 7. Gear geometric properties of the modified (MOD) wind turbine gearbox.
Parameter
Stage 1
Sun
Z
B
i
M
z
z
a0
xz
SF
SH
28
320
5.587
12
20
10
476
0.7742
1.29
1.10
Stage 2
Sun
Planet
Ring
47
320
128
331.5
1.0280
0.94
1.16
0.2110
1.41
1.86
30
168.4
5.495
7
20
10
290
0.4330
1.64
1.20
Table 8. Gear loss factors for the standard (STD) and modified (MOD) wind turbine gearbox.
HV L (STD)
HV L (MOD)
Stage 1
P/S
P/R
Stage 2
P/S
P/R
Stage 3
Helical
0.1482
0.1132
0.1093
0.1005
0.1391
0.1245
0.1055
0.0676
0.0955
0.0752
Stage 3
Pinion
Planet
Ring
50
168.4
135
177.4
0.4342
1.14
1.24
0.9927
1.49
1.90
150
245
3.333
5.5
20
10
550
0.7464
2.23
2.03
Wheel
45
240
0.2850
2.29
2.00
Gearbox efficiency
The eciency of each gearbox stage is presented in
Table 9 for each gearbox design and for each oil
formulation.
Conclusions
A power loss model previously validated with experimental results was used to perform a power loss
Fernandes et al.
PVZP
PVL
PVZP
80
80
Power Loss [kW]
(b) 100
(a) 100
60
40
20
0
(c)
MINR
PAOR
Oil []
(d)
[kW]
VZP
40
20
MINR
PAOR
Oil []
PAGD
100
Stage 1
Stage 2
Stage 3
60
40
PAGD
100
(f)
Stage 1
Stage 2
Stage 3
VL
[kW]
60
40
20
MINR
PAOR
Oil []
PAGD
100
Stage 1
Stage 2
Stage 3
80
[kW]
VL
PAOR
Oil []
20
80
MINR
80
PVZP [kW]
60
40
PAGD
Stage 1
Stage 2
Stage 3
80
(e)
60
20
100
PVL
60
40
20
MINR
PAOR
Oil []
PAGD
MINR
PAOR
Oil []
PAGD
10
Table 9. Wind turbine gearbox efficiency (%) and total power loss for each oil formulation and gearbox configuration at 80 C.
Oil
Gearbox design
Stage 1
Stage 2
Stage 3
Global
PV (W)
MINR
Standard
Modified
Standard
Modified
Standard
Modified
98.93
99.10
99.12
99.26
99.26
99.38
99.12
99.27
99.28
99.39
99.38
99.48
98.20
98.25
98.20
98.23
98.18
98.21
96.25
96.62
96.59
96.90
96.82
97.07
93,597
84,942
85,043
78,009
79,423
73,537
PAOR
PAGD
at 15 C
t 104
at 40 C
at 70 C
at 100 C
mA
nA
VI
Unit
g/cm
cSt
cSt
cSt
MINR
PAOR
PAGD
0.902
5.8
319.22
65.81
22.33
9.066
3.473
85
0.859
5.5
313.52
84.99
33.33
7.351
2.787
153
1.059
7.1
290.26
102.33
51.06
5.759
2.151
252
23
The density was measured with an Anton Par densimeter, a portable unit. The range of temperature
available goes from 15 C up to 40 C, which is
enough to know the density of a uid under ambient
temperature conditions. It is known that the density
24
Pressureviscosity
Under elastohydrodynamic lubrication conditions,
the formation of the lubricating lm is strongly
dependent on the pressureviscosity behavior of
a lubricating oil, as shown in Dowson and
Higginson.55
The kinematic viscosities measured and presented
in Table 10 may be used to determine the pressure
viscosity coecient using Golds equation (25). The
pressureviscosity coecient can be determined for a
pressure of 0.2 GPa, usual value of the pressure in the
inlet zone of the contact, where the lm formation
occurs.55 Depending on the base oil, the s and t
values are provided by Gold et al.56
s t 108
25
Fernandes et al.
11
MINR
PAOR
PAGD
s
t
108 (1/Pa)
0.9904
0.1390
1.677
0.7382
0.1335
1.279
0.5489
0.1485
1.061
Unit
MINR
PAOR
PAGD
Sulphur (S)
Phosphorus (P)
Boron (B)
Calcium (Ca)
Zinc (Zn)
Magnesium (Mg)
ppm
ppm
ppm
ppm
ppm
ppm
11200
354.3
22.3
2.5
0.9
0.9
5020
415.9
28.4
0.5
3.5
0.5
362
1100
1.0
0.8
1
1.4
Mia et al.57 determined the pressureviscosity coefcient from high-pressure rheology for a mineral oil
and dierent PAO wind turbine oil formulations. The
values found are slightly lower than those calculated
through Golds equation. Mia et al. values are 15%
lower in the case of mineral oil and 9% lower in the
case of the PAO (Table 12).
Funding
This research received no specic grant from any
funding agency in the public, commercial, or not-for-prot
sectors.
Acknowledgements
This study was funded by:
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12
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Appendix
Notation
a0
aA
b
Fernandes et al.
B
Cw
d
dm
D
ft
Fa
FN
Fbt
Grr
Gsl
h0
h0C
HV L
HSS
i
Kball
Kroller
KS1 , KS1
Krs
KZ
LSS
LIS
m
mA
M0rr
Msl
Mdrag
Mseal
Mt
n
nA
pb
P/S
P/R
PIN
PV
13
PVZ0
PV ZP
PV L
PV D
R1
Ra
Rs
s
S1
SF
SH
t
vg
vtb
vC
VM
xz
z
t
z
R
z
bl
EHD
sl
bl
ish
rs