Research Papers

Large Scale Validation of a Flexible Multibody Wind Turbine Gearbox Model

[+] Author and Article Information
Frederik Vanhollebeke

ZF Wind Power Antwerpen NV,
Ottergemsesteenweg 439,
Gent B-9000Belgium
Division PMA,
Department of Mechanical Engineering,
Celestijnenlaan 300B,
Heverlee B-3001, Belgium
e-mail: frederik.vanhollebeke@zf.com

Pepijn Peeters, Jan Helsen, Dirk Vandepitte, Wim Desmet

Division PMA,
Department of Mechanical Engineering,
Celestijnenlaan 300B,
Heverlee B-3001, Belgium

Emilio Di Lorenzo, Simone Manzato

Siemens PLM,
Test RTD Siemens Industry Software N.V.,
Interleuvenlaan 68,
Leuven B-3000, Belgium

Joris Peeters

ZF Wind Power Antwerpen NV,
De Villermontstraat 9,
Kontich B-2550, Belgium

Contributed by the Design Engineering Division of ASME for publication in the JOURNAL OF COMPUTATIONAL AND NONLINEAR DYNAMICS. Manuscript received November 28, 2013; final manuscript received September 17, 2014; published online April 3, 2015. Assoc. Editor: Carlo L. Bottasso.

J. Comput. Nonlinear Dynam 10(4), 041006 (Jul 01, 2015) (12 pages) Paper No: CND-13-1305; doi: 10.1115/1.4028600 History: Received November 28, 2013; Revised September 17, 2014; Online April 03, 2015

Although wind turbine noise is mainly dominated by aero-acoustic noise, mechanical noise, coming from gearbox or generator, could—especially when it contains audible tonal components—result in nonconformity to local noise regulations. To reduce the mechanical noise from the gearbox, focus is put on first time right design. To achieve this, simulation models are being used earlier in the design process to predict possible issues. This paper starts with a short overview of the used model and gives additional insight in how forces from planetary gear stages should be introduced in the flexible housing. Main focus of this paper however is the approach that is being used to validate such a complex multibody model of a wind turbine gearbox. The validation approach consists of five levels: (1) individual components, (2) assembly of the empty gearbox housing, (3) the assembled gearbox, (4) the gearbox on the end-of-line (EOL) test rig, and (5) the gearbox in the wind turbine. This paper focuses on the experimental measurement results, the correlation approach for such complex models, and the results of this correlation for the first four levels showing the usability of these models to accurately predict the modal behavior.

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Fig. 1

Sectional drawing of the wind turbine gearbox used throughout this paper

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Fig. 2

Graphical representation of the flexible MBS model. Left: without flexible housing, right: with flexible housing.

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Fig. 3

Comparison of gear force FRFs from intermediate speed planetary gear stage to TA, vertical direction. Full line: RBE3 approach, dashed line: individual teeth.

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Fig. 4

Comparison of gear force FRFs from intermediate speed planetary gear stage to intermediate speed ring wheel, vertical direction. Full line: RBE3 approach, dashed line: individual teeth.

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Fig. 5

Graphical representation of the multilevel validation strategy

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Fig. 6

Measurement setup for HSH + MC

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Fig. 7

Typical FRF from TA: full gray line: measured; black dashed line: synthesized

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Fig. 8

TA mode shape pair. Blue: FE mesh, red: EMA measurement

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Fig. 9

MAC matrix for HSH + MC

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Fig. 10

Influence of bolt pretension α on the merged nodes

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Fig. 11

Measurement setup for assembly

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Fig. 12

Typical FRF from assembly: full gray line: measured; black dashed line: synthesized

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Fig. 13

Measurement setup for the HSH + MC assembly

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Fig. 14

Measurement setup for the complete gearbox

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Fig. 15

Measurement setup for the complete gearbox on the test rig




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