Tribological advancements for reliable wind turbine performance

Area of Science:

• Mechanical Engineering
• Materials Science
• Tribology

Background:

• Wind turbine mechanical systems face reliability challenges due to tribological problems, despite improvements in overall turbine performance.
• While electrical components fail more frequently, tribological failures in bearings and gearboxes incur higher repair costs and downtime.
• Key components affected include blade pitch systems, yaw systems, main shaft bearings, gearboxes, and generator bearings.

Purpose of the Study:

• To review major tribological issues in wind turbine mechanical systems.
• To discuss technological developments for understanding and solving these tribological challenges.
• To present the latest research on wear and damage modes in main shaft and gearbox bearings.

Main Methods:

• Overview of fretting corrosion, rolling contact fatigue, and frictional torque in pitch and yaw bearings.
• Examination of lubricant contamination in gearboxes and electrical discharge damage in generator bearings.
• Detailed analysis of micropitting and white-etch area flaking in main shaft and gearbox bearings.

Main Results:

• Identified fretting corrosion, rolling contact fatigue, and frictional torque as key issues in pitch and yaw systems.
• Highlighted lubricant contamination and electrical arcing as significant problems in gearboxes and generator bearings.
• Focused on micropitting and white-etch area flaking as prevalent damage modes in main shaft and gearbox bearings.

Conclusions:

• Tribological issues in main shaft and gearbox bearings are primary drivers of wind turbine repair costs and downtime.
• Technological advancements are crucial for mitigating wear and damage modes like micropitting and flaking.
• Continued research into the causes and solutions for these tribological problems is essential for improving wind turbine reliability.