Time Domain Modeling and Analysis of Dynamic Gear Contact Force in a Wind Turbine Gearbox with Respect to Fatigue Assessment

The gearbox is one of the most expensive components of the wind turbine system. In order to refine the design and hence increase the long-term reliability, there has been increasing interest in utilizing time domain simulations in the prediction of gearbox design loads. In this study, three problems in time domain based gear contact fatigue analysis under dynamic conditions are discussed: (1) the torque reversal problem under low wind speed conditions, (2) statistical uncertainty effects due to time domain simulations and (3) simplified long term contact fatigue analysis of the gear tooth under dynamic conditions. Several recommendations to deal with these issues are proposed based on analyses of the National Renewable Energy Laboratory’s 750 kW land-based Gearbox Reliability Collaborative wind turbine.