Modelling of wind turbine gear stages for Digital Twin and real-time virtual sensing using bond graphs

Abstract

Abstract In this paper a wind turbine high-speed gear stage model is developed for the purpose of real-time virtual sensing of gear and bearing loads in a Digital Twin framework. The model requirements are: accurate representation of gear meshing and shaft dynamics, high computational efficiency and compatibility with other Digital Twin components, such as physical sensors signals and virtual sensing methods. State equations are derived analytically using the Bond Graph method and implemented in the software 20sim for simulation. As opposed to standard multi-body simulation (MBS) software, 20sim allows for higher flexibility in implementing interfaces to other Digital Twin components. The model fidelity is close to state-of-the-art MBS models considering 6 DOF body motion, however a simplified gear contact formulation is used, which assumes ideal kinematic meshing. Nonetheless, the Bond Graph model is able to accurately reproduce the inhomogeneous load distribution over the tooth flank, as well as the cyclic compression and decompression for each meshing period. The results suggest that the presented model is capable of monitoring fatigue loads in gear contacts and bearings in a Digital Twin framework.