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BS EN 61400-4:2013

BS EN 61400-4:2013

$215.11

Wind turbines – Design requirements for wind turbine gea

Published By Publication Date Number of Pages
BSI 2013 162
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IEC 61400-4:2012(E) is applicable to enclosed speed increasing gearboxes for horizontal axis wind turbine drivetrains with a power rating in excess of 500 kW. This standard applies to wind turbines installed onshore or offshore. It provides guidance on the analysis of the wind turbine loads in relation to the design of the gear and gearbox elements. The gearing elements covered by this standard include such gears as spur, helical or double helical and their combinations in parallel and epicyclic arrangements in the main power path. The standard is based on gearbox designs using rolling element bearings. Also included is guidance on the engineering of shafts, shaft hub interfaces, bearings and the gear case structure in the development of a fully integrated design that meets the rigours of the operating conditions. Lubrication of the transmission is covered along with prototype and production testing. Finally, guidance is provided on the operation and maintenance of the gearbox.

PDF Catalog

PDF Pages PDF Title
8 CONTENTS
13 INTRODUCTION
14 1 Scope
2 Normative references
16 3 Terms, definitions and conventions
3.1 Terms and definitions
19 3.2 Conventions
Figures
Figure 1 – Shaft designation in 3-stage parallel shaft gearboxes
20 Figure 2 – Shaft designation in 3-stage gearboxes with one planet stage
21 4 Symbols, abbreviations and units
4.1 Symbols and units
Figure 3 – Shaft designation in 3-stage gearboxes with two planet stages
22 Tables
Table 1 – Symbols used in the document
25 4.2 Abbreviations
Table 2 – Abbreviations
27 5 Design for reliability
5.1 Design lifetime and reliability
28 5.2 Design process
29 Figure 4 – Design process flow chart
30 5.3 Documentation
5.4 Quality plan
31 6 Drivetrain operating conditions and loads
6.1 Drivetrain description
6.1.1 General
6.1.2 Interface definition
32 6.1.3 Specified requirements across interfaces
6.2 Deriving drivetrain loads
6.2.1 Wind turbine load simulation model
33 6.2.2 Wind turbine load calculations
6.2.3 Reliability of load assumptions
6.3 Results from wind turbine load calculations
6.3.1 General
34 6.3.2 Time series
6.3.3 Fatigue load
35 6.3.4 Extreme loads
6.4 Operating conditions
6.4.1 General
6.4.2 Environmental conditions
36 6.4.3 Operating strategies
6.5 Drivetrain analysis
7 Gearbox design, rating, and manufacturing requirements
7.1 Gearbox cooling
37 7.2 Gears
7.2.1 Gear reliability considerations
7.2.2 Gear rating
38 7.2.3 Load factors
39 Table 3 – Mesh load factor K( for planetary stages
40 7.2.4 Gear materials
41 7.2.5 Subsurface initiated fatigue
7.2.6 Gear accuracy
7.2.7 Gear manufacturing
Table 4 – Required gear accuracy
42 7.3 Bearings
7.3.1 General
7.3.2 Bearing reliability considerations
43 7.3.3 Bearing steel quality requirements
7.3.4 General design considerations
Figure 5 – Examples of bearing selection criteria
46 7.3.5 Bearing interface requirements
47 7.3.6 Bearing design issues
48 Table 5 – Temperature gradientsfor calculation of operating clearance
49 Figure 6 – Blind bearing assembly
50 7.3.7 Bearing lubrication
Table 6 – Bearing lubricant temperaturefor calculation of viscosity ratio, (
51 7.3.8 Rating calculations
53 Table 7 – Guide values for maximum contact stress at Miner’s sum dynamic equivalent bearing load
54 7.4 Shafts, keys, housing joints, splines and fasteners
7.4.1 Shafts
7.4.2 Shaft-hub connections
Table 8 – Minimum safety factors for the different methods
55 7.4.3 Flexible splines
7.4.4 Shaft seals
7.4.5 Fasteners
56 7.4.6 Circlips (snap rings)
7.5 Structural elements
7.5.1 Introduction
57 7.5.2 Reliability considerations
7.5.3 Deflection analysis
7.5.4 Strength verification
58 7.5.5 Static strength assessment
59 Table 9 – Partial safety factors for materials
60 Figure 7 – Definition of section factor npl,( of a notched component
61 Figure 8 – Idealized elastic plastic stress-strain curve
62 7.5.6 Fatigue strength assessment
64 Figure 9 – Synthetic S/N curve (adapted from Haibach, 2006)
65 Table 10 – Partial safety factors (m for synthetic S/N-curves of cast iron materials
66 7.5.7 Material tests
67 7.5.8 Documentation
7.6 Lubrication
7.6.1 General considerations
68 7.6.2 Type of lubricant
69 7.6.3 Lubricant characteristics
70 7.6.4 Method of lubrication
71 7.6.5 Oil quantity
72 7.6.6 Operating temperatures
7.6.7 Temperature control
73 7.6.8 Lubricant condition monitoring
7.6.9 Lubricant cleanliness
74 7.6.10 Lubricant filter
Table 11 – Recommended cleanliness levels
75 7.6.11 Ports
7.6.12 Oil level indicator
7.6.13 Magnetic plugs
76 7.6.14 Breather
7.6.15 Flow sensor
7.6.16 Serviceability
8 Design verification
8.1 General
8.2 Test planning
8.2.1 Identifying test criteria
77 8.2.2 New designs or substantive changes
8.2.3 Overall test plan
8.2.4 Specific test plans
78 8.3 Workshop prototype testing
8.3.1 General
8.3.2 Component testing
8.3.3 Workshop testing of a prototype gearbox
79 8.3.4 Lubrication system testing
8.4 Field test
8.4.1 General
8.4.2 Validation of loads
80 8.4.3 Type test of gearbox in wind turbine
81 8.5 Production testing
8.5.1 Acceptance testing
8.5.2 Sound emission testing
8.5.3 Vibration testing
8.5.4 Lubrication system considerations
8.5.5 System temperatures
8.6 Robustness test
8.7 Field lubricant temperature and cleanliness
82 8.8 Bearing specific validation
8.8.1 Design reviews
8.8.2 Prototype verification/validation
83 8.9 Test documentation
9 Operation, service and maintenance requirements
9.1 Service and maintenance requirements
9.2 Inspection requirements
9.3 Commissioning and run-in
84 9.4 Transport, handling and storage
9.5 Repair
9.6 Installation and exchange
9.7 Condition monitoring
9.8 Lubrication
9.8.1 Oil type requirements
9.8.2 Lubrication system
85 9.8.3 Oil test and analysis
9.9 Operations and maintenance documentation
86 Annex A (informative)Examples of drivetrain interfaces and loads specifications
Figure A.1 – Modular drivetrain
87 Figure A.2 – Modular drivetrain with 3-point suspension
Figure A.3 – Integrated drivetrain
88 Table A.1 – Drivetrain elements and local coordinate systems
89 Figure A.4 – Reference system for modular drivetrain
Table A.2 – Drivetrain element interface dimensions
90 Figure A.5 – Rear view of drivetrain
Table A.3 – Interface requirements for modular drivetrain
91 Figure A.6 – Reference system for modular drivetrain with 3-point suspension
Table A.4 – Interface requirements for modular drivetrain with 3-point suspension
92 Figure A.7 – Reference system for integrated drivetrain
Table A.5 – Interface requirements for integrated drivetrain
93 Table A.6 – Engineering data and required design load descriptions
Table A.7 – Rainflow matrix example
94 Figure A.8 – Example of rainflow counting per DLC
95 Figure A.9 – Example of load revolution distribution (LRD)
Table A.8 – Example of load duration distribution (LDD)
96 Table A.9 – Extreme load matrix example
97 Annex B (informative)Gearbox design and manufacturing considerations
98 Table B.1 – Recommended gear tooth surface roughness
100 Annex C (informative)Bearing design considerations
Table C.1 – Guide values for basic rating life Lh10 for preliminary bearing selection
101 Figure C.1 – Load bin reduction by lumping neighbouring load bins
103 Figure C.2 – Consumed life index (CLI)
Figure C.3 – Time share distribution
105 Table C.2 – Static load factors for radial bearings
106 Figure C.4 – Effects of clearance and preload on pressure distribution in radial roller bearings (from Brandlein et al, 1999)
107 Figure C.5 – Nomenclature for bearing curvature
109 Figure C.6 – Stress distribution over the elliptical contact area
114 Table C.3 – Bearing types for combined loads with axial loads in double directions
115 Table C.4 – Bearing types for combined loads with axial loads in single direction
116 Table C.5 – Bearing types for pure radial load
117 Table C.6 – Bearing types for axial load
118 Figure C.7 – Examples of locating and non-locating bearing arrangements
Figure C.8 – Examples of locating bearing arrangements
Figure C.9 – Examples of accommodation of axial displacements
119 Figure C.10 – Examples of cross-locating bearing arrangements
Figure C.11 – Examples of bearing arrangements with paired mounting
120 Table C.7 – Bearing selection: Legend
121 Table C.8 – Bearing selection: Low speed shaft (LSS) / planet carrier
122 Table C.9 – Bearing selection: Low speed intermediate shaft (LSIS)
123 Table C.10 – Bearing selection: High speed intermediate shaft (HSIS)
124 Table C.11 – Bearing selection: High speed shaft (HSS)
125 Table C.12 – Bearing selection: Planet bearing
126 Annex D (informative)Considerations for gearbox structural elements
Table D.1 – Typical material properties
127 Figure D.1 – Locations of failure for local (A) and global (B) failure
Figure D.2 – Local and global failure for two different notch radii
128 Figure D.3 – Haigh-diagram for evaluation of mean stress influence (Haibach, 2006)
129 Annex E (informative)Recommendations for lubricant performance in wind turbine gearboxes
130 Figure E.1 – Viscosity requirements versus pitch line velocity
131 Table E.1 – Viscosity grade at operating temperature for oils with VI = 90
132 Table E.2 – Viscosity grade at operating temperature for oils with VI = 120
133 Table E.3 – Viscosity grade at operating temperature for oils with VI = 160
134 Table E.4 – Viscosity grade at operating temperature for oils with VI = 240
136 Table E.5 – Standardized test methods for evaluating WT lubricants (fresh oil)
137 Table E.6 – Non-standardized test methods for lubricant performance (fresh oil)
138 Figure E.2 – Test apparatus for filterability evaluation
140 Table E.7– Guidelines for lubricant parameter limits
142 Figure E.3 – Example for circuit design of combined filtration and cooling system
144 Annex F (informative)Design verification documentation
Table F.1 – Design validation and verification documentation
147 Annex G (informative)Bearing calculation documentation
155 Bibliography

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BS EN 61400-4:2013
$215.11