Tribological advancements for reliable wind turbine performance

Abstract

Wind turbines have had various limitations to their mechanical system reliability owing to tribological problems over the past few decades. While several studies show that turbines are becoming more reliable, it is still not at an overall acceptable level to the operators based on their current business models. Data show that the electrical components are the most problematic; however, the parts are small, thus easy and inexpensive to replace in the nacelle, on top of the tower. It is the tribological issues that receive the most attention as they have higher costs associated with repair or replacement. These include the blade pitch systems, nacelle yaw systems, main shaft bearings, gearboxes and generator bearings, which are the focus of this review paper. The major tribological issues in wind turbines and the technological developments to understand and solve them are discussed within. The study starts with an overview of fretting corrosion, rolling contact fatigue, and frictional torque of the blade pitch and nacelle yaw bearings, and references to some of the recent design approaches applied to solve them. Also included is a brief overview into lubricant contamination issues in the gearbox and electric current discharge or arcing damage of the generator bearings. The primary focus of this review is the detailed examination of main shaft spherical roller bearing micropitting and gearbox bearing scuffing, micropitting and the newer phenomenon of white-etch area flaking. The main shaft and gearbox are integrally related and are the most commonly referred to items involving expensive repair costs and downtime. As such, the latest research and developments related to the cause of the wear and damage modes and the technologies used or proposed to solve them are presented.