Wind turbine main-bearing lubrication – Part 2: Simulation-based results for a double-row spherical roller main bearing in a 1.5 MW wind turbine

Abstract

Abstract. This paper is the second in a two-part study on lubrication in wind turbine main bearings. Where Part 1 provided an introductory review of elastohydrodynamic lubrication theory, this paper will apply those ideas to investigate lubrication in the double-row spherical roller main bearing of a 1.5 MW wind turbine. Lubrication is investigated across a “contact conditions dataset” generated by inputting main-bearing applied loads, estimated from hub loads generated using aeroelastic simulation software, into a Hertzian contact model of the main bearing. From the Hertzian model is extracted values of roller load and contact patch dimensions, along with the time rate of change of contact patch dimensions. Also included in the dataset are additional environmental and operational variable values (e.g. wind speeds and shaft rotational speeds). A suitable formula for estimating film thickness within this particular bearing is then identified. Using lubricant properties of a commercially available wind turbine grease, specifically marketed for use in main bearings, an analysis of film thickness across the generated dataset is undertaken. The analysis includes consideration of effects relating to temperature, starvation, grease thickener interactions and possible non-steady effects. Results show that the studied main bearing is at risk of operating under mixed lubrication conditions for a non-negligible proportion of its operational life, indicating that further work is required to better understand lubrication in this context and implications for main-bearing damage and operational lifetimes. Key sensitivities and uncertainties within the analysis are discussed, along with recommendations for future work.