Test rig simulation and validation for reliable gearboxes

Dr.-Ing. F.-D. Krull, Eickhoff Antriebstechnik GmbH, Bochum

1. Abstract
Gearboxes are one of the key components of windturbines. The turbines reliability and
availability is strongly linked to the robustness and reliability of the main gearbox. With large
scale wind turbine gearboxes it becomes important to know more about the specific inner
dynamic behaviour and deflections between components of the gearbox.

Methods for the engineering of robust gearboxes, advanced calculation methods and
validation methods are key issues within the design process of gearboxes for wind turbines.
Fundamental simulations and advanced calculations of the gearbox within the test rig
environment in combination with excessive validation testing are the basis for a robust and
suitable gearbox design.

This contribution describes advanced multi body simulation models, methods and calculation
concepts for large gearboxes within a 5MW test rig environment. Concepts for excessive and
detailed validation measurement will show the suitability of the calculation models.
Examples for simulation and measurement results which are related to operating conditions
of the turbine will give an overview about new opportunities in gearbox engineering.

2. Development of wind energy

The energy of wind is an endless resource. It was used by human beings to drive machines
since the early days of industrialisation. Since the beginning, wind energy was used to drive
simple pumps and mills. People started to use the wind for the generation of electricity in the
middle of 80th of the 20th century. This was the starting point for a dramatic development of
wind power plant engineering and technology: Maximum power generating capacites of
windturbines have been increased from 60kW to 6MW with a factor of 100 within the last 20
years.

The Repower 6M with a rotor diameter of 126 m is the largest wind turbine in the world. This
wind turbine generates a power output of 6 MW, enabling it to generate the whole annual
power production of a former turbine within one day.
The fast growth of turbines and component sizes strengthens the need to consider scaling
effects within the engineering processes of bearings, toothings and structural components. In
addition, larger turbine sizes with a tower height up to 130 m lead to flexible structures which
cause corresponding interacting loads between components of the windturbine structure, the
drive train and the inner inertias of the gearbox. New and advanced engineering methods
such as multi body analyses or FEA are necessary to account for this wind turbine specific
behaviour.
Fig. 2.1 shows the development of wind turbine sizes between 1980 and 2008

160

140 600kW
120 46m
height [m]
Nabenhhe

100
250kW
80
80kW 30m
20m ?
Hub

60
30kW
15m
40
1500kW 6000kW
20 70m 126m
0
1975 1980 1985 1990 1995 2000 2005 2010 2015
Jahr
Year

1980 1985 1990 1995 2000 2008

Nabenhhe
Hub height[m]
[m] 30 40 50 79 100 135
Rotordurchmesser
Rotor diameter [m] 15 20 30 46 70 126
Nennleistung
Nominal [kW][kW]
power 30 80 250 600 1500 6000
Jahresenergieertrag
Annual [kWh] kWh
power production 35000 95000 400000 1250000 3500000 20000000

Fig. 2.1: Development of turbine sizes between 1980 and 2008

Avoiding overlapping of natural frequencies and stimulus frequencies is one of the key issues
to find robust system and component solutions.

3. Components of a wind turbine drive train

The core components of a wind turbine are the tower, the main frame, the rotor blades, the
generator and the gearbox. Those mechanical components in interaction with control and
converter systems are the main influencing parts for the dynamic behaviour of wind turbines.
Fig. 3.1 shows a typical drive train layout for wind turbines with gearboxes.
 Anemometer

Torque arm
Gearbox
Main bearing
Mech. brake
Mainshaft

Hub + Blades

Generator
Blades
Main frame
70-80 m Tower
Generator coupling
Azimut drives Bildquelle: REpower Systems AG

Fig. 3.1: Drive train components of a wind turbine

The rotor blades convert the wind energy into rotor torque and speed. The aeroelastic
behaviour of the rotor characterizes in combination with the grid, converter and control
systems kind and amplitude of the mechanical loads. The main bearing and the gearbox
housing support the main shaft and rotor loads against the mainframe of the windturbine.
The planet carrier bearings within the gearbox carry rotor loads and bending moments.
Coupled bending and torque cause multiaxial stresses within the planet carrier and the
torque arm. Those load combinations must be considered within the strength calculation.
Typical gearbox designs are based on two planetary and one helical or one planetary and
two helical stages.

The gear stages adapt the input speed and torque to the generator level. A coupling
connects the high speed shaft of the gearbox with the generator input shaft. Double universal
spring systems compensate small static and dynamic misalignments of the shafts. A GRP
shaft connection realizes an electrical isolation between the generator shaft and the gearbox
shaft. Elastomer bushings support the connecting bolds of the torque arm and isolate the
solid born sound of the gearbox housing.

4. Components of advanced WT-simulation models and specific parameters

Components and the control of a wind turbine have a strong impact on the operational
behaviour of the turbine. The control as the core of the turbine manages the component
loads with its influence on transient actions to the pitch, yaw, brake and transformer. Those
actions are depending on the strategies for the transformation of wind into electrical energy.

To receive authentic simulation results it is necessary to implement all these coherences.

Accurate sub-models on a high detailed level as well as all controller strategies are
fundamental values. The implementation of all this diversity of information into one suitable
simulation model needs a multi domain engineering software environment.

Fig. 4.1 shows the different engineering domains, which have to be backed by suitable
software arrays within one simulation model.

CFD Electrical
System
BEARINX
Main- Gearbox
bearing MBS
Generator
Grid

Rotor Control

Tower

FEA Multi domain

3D Windfield
engineering
Fig. 4.1: Multi domain engineering environment of a wind turbine
A fundamental understanding of each component is the basis for accurate model
parameters. An advantage of an interdisciplinary engineering team is that each party is able
to provide its specific core competence and know how to the simulation model.

In difference to commercially available state of the art tools like those from FLEX5 or
BLADED the detailed hybrid FEA-MKS model of the wind turbine includes detailed sub-
models (stiffness-matrices and masses) for all elastic structural components such as main
frame, gearbox housing and planet carrier as well as for gears and bearings. Fig. 4.2 shows
figures of the whole drive train model for the wind turbine with its sub components.
 Aerodynamic Controller-dll Mechanic BEARINX Elektric

3-D-Wind

FEA-Superelements
BEAMS Periodic N-dimensional
tooth contact Bearing stiffness

Bushings

BEAMS

FEA-Superelements

Mass-distribution

Fig. 4.2: Drive train model of the wind turbine with its detailed sub-models
The main frame, the gearbox housing and the planet carrier of the planetary stage are
considered as elastic elements (FEA-super elements). The technology for those
considerations is a modal reduction of the finite element models.

The gearbox model contains accurate toothing models and characteristic stiffness matrices
for bearings. This is the precondition for a realistic stimulus behaviour, dynamic forces,
moments and displacements within the gearbox.

The handling of parameter data for the whole wind turbine within a hybrid finite element
approach needs a software environment, which is able to connect the simulation data and
parameters of the model.

5. Gearbox simulation models and test rig environment

The gearbox is the most complex dynamic subsystem within the mechanical drive train.
Hence it is important to create an accurate simulation model which is valid and suitable to
show the most important inner dynamics.

The test rig environment helps to validate the gearbox simulation models and helps to
understand the gearbox specific dynamics. The complexity level of the environment is
simpler and better controlled than within the wind turbine environment. This allows planning
test run parameters based on first simulation results. Test rig simulation and measurement
gives the opportunity to plan sensors for the validation measurement of the model under
controlled and repeatable conditions. This will close the first development loops within the
design phase and helps to save costs and reduce risks.

Fig. 5.1 shows the coherence between development phase and cost increasing due to
necessary design changes of the gearbox.
Field validation
Initial start up on power plant
Costs due to design changes

Validation on gearbox test rig

Validation with
virtual power plant
Validation with
virtual test rig

Design
Start of development Product development progress
=> Reduced risk of system caused failures

Fig. 5.1: Early stage validation of the gearbox

In the first step it is necessary to keep the test rig model as simple as possible. This allows a
focus on the gearbox specific dynamic behaviour and shows the limits and suitability of the
model to show known and expected effects. Support structures and components of the drive
train, such as motor, generator and slave gearbox should be considered as simple inertias
and springs. Super elements for structural parts might be used to cover the influence of
significant Eigen modes and stiffness behaviour.

In most cases results out of the simulation with pure torsional simulation models are close to
reality. This effect results from the high torsional stiffness rate of the drive train components.
Within the first verification loop a comparison between the results of the multi body simulation
and a simple torsional analyses gives a good basis to check the quality and plausibility of the
model parameters. A comparison between measuring results coming from torque
measurement sensors can be used as real verification basis. Fig. 5.2 shows a view on the
whole drive train of the 5 MW test rig which is the object of further investigations. Fig. 5.3
shows a MBS of the gearbox in a reduced test rig environment.
Motor

Slave gearbox
Master gearbox Generator
Crankshaft

Foundation supports

Drivetrain baseplates

Fig. 5.2: Full view on the 5 MW testrig drivetrain

The test rig is driven by a 5 MW motor and a slave gearbox. The slave gearbox with a shift
stage adapts the torque and speed to the input level of the master gearbox. The generator is
connected to the output shaft of the master gearbox via an original wind turbine coupling
including the brake disc. Original rubber bushings from the wind turbine isolate the gearbox
torque arm from the fundament support structure. The mounting angle of the drive train
corresponds to the original mounting angle of the windturbine drivetrain.

Fig. 5.3: Photograph and simulation basis for a 5 MW Wind turbine testrig
The fundament supports, the gearbox housing and the planet carrier of the planetary stages
are considered as elastic elements (FEA-super elements blue coloured). The technology
for those considerations is a modal reduction of the finite element models. Periodic tooth
stiffnesss realise authentic model stimulations with tooth mesh frequency. The sub models
account overlapping effects of real toothings. Accurate n-dimensional stiffness characteristics
of the bearings include the information of the bearings micro geometry. The displacement
between outer ring and inner ring causes reaction forces on the shafts and on the housing.
Forces and displacements oft the shafts depend on the kind of bearing models.

Different opportunities to take bearing stiffnesses into account exist as optional parameters
for sub models. Bearing stiffnesses can be modelled with linear and/or non linear properties.
The degrees of freedom (DOF) of real bearings are constrained by coupling stiffnesses.
Hence the simulation results for bearing models with constrained DOF and not constrained
DOF will be different. The choice of a suitable bearing model depends on the simulation
targets (calculation efficiency and/or result accuracy).

The support structure and complex structural parts of the drive train such as parts of the
crank shaft are considered as super elements.

Excessive analyses and verification of the gearbox in a test rig environment due to
measurement and simulation is necessary for an excellent validation of the gearbox model.
The quality of the gearbox model has a big impact on the quality of the simulation within the
wind turbine model. It is to recommend to spend investigations on a high level to get an
accurate validation of the gearbox model. Closing engineering loops supported by multi body
simulation results will help to increase the suitability of the gearbox design and the reliability
for the application in a wind turbine.

6. Simulation results and validation of the simulation model

In most cases the input torque of an application is the design driver for gearboxes and other
drive train components. The most common and typical values for the analysis and verification
of simulation results are different shaft torques and frequencies which can lead to high
accelerations within resonances.

Key issues within the design loops are stimulus and natural frequencies (CAMPBELL
diagram), transient time series for torque, bending and displacements at significant locations.
Waterfall diagrams of signals measured during test rig start ups are a common basis for
resonance analyses compared with the campbell diagram.
Fig. 6.1 shows the coherences between different analyse parameters and the design loop
which covers the test rig gearbox simulation and measurement.
Simulation within test rig environment
Camp- Influence Design
Mode
Frequencies Bell Run up Para- Opti-
shapes
diagram meter mization

Analyse

Paramet. Run up Meas. meas.

Influence Gearbox
Opti- Meas. Displace- Torque
Paramet. testing
mization results ments Bending
Test rig measurement

Fig. 6.1: Analyse of test and simulation within the optimitation loop
Campbell diagrams are one of the most common tools to analyze the resonance behaviour
of drive trains. It contains information about natural frequencies, stimulus frequencies (even
for different tooth numbers of different gearbox versions), areas of operational speed and
torque. Critical operational speed areas, such as important points for noise and vibration, can
be marked. This gives the opportunity to set a priority focus on parameter optimization.

Fig. 6.2 shows a Campbell diagram for a wind turbine drive train, focused on mesh and
rotational frequencies of the gearbox.

B
Operationsbereich

A
C

Fig. 6.2: Campbell diagram of a windturbine drivetrain with tooth mesh frequencies
The first evaluation step contains the resonance analyses of the Campbell diagram. Potential
resonances are intersections between lines of stimulus and Eigen frequencies. Potential
resonances within the operation speed area should be avoided. Regarding the diagram in
Fig. 6.2 points A, B and C should be optimized by the change of significant parameters. That
could be masses of inertia, stiffnesses or the mesh frequencies. To focus on the relevant
parameter the evaluation of a start up simulation and a frequency analysis is necessary.
Waterfall diagrams compared to the Campbell diagrams will show the relevant resonances.

Fig. 6.3 shows the frequency analyses of a time domain run up simulation as waterfall
diagram
2xFz1 Fz2
Fz2

Fz1 2xFz1 1400 rpm

2xFz2 3xFz2

Simulation
Fz1

2xFz2

3xFz1
(3xfwab)
2xFz2

Fz3

3xFz2

600 rpm

Fz2
2xFz1

Fz1 3xFz1
(3xfwab)
(7xfwab) (9xfwab) 2xFz2 3xFz2 1400 rpm

Measurement

Fz3

600 rpm

Fig. 6.3: Comparison between waterfall plots of the output shaft torque simulated (top) and
measured (bottom)
The comparison between measurement and simulation in Fig. 6.3 shows a good correlation.
Resonances occur at comparable speeds and in comparable amplitude ratios. Compared to
the simulation the measurement shows more harmonics of the tooth mesh frequencies. The
number of occuring harmonics within the simulation results depends on the level of the tooth
stiffness function for the toothing models.
Today wind turbine manufacturers require low noise and vibration levels for the gearbox.
Hence it is important to find good correlations between structural resonances, load
depending tooth stimulus levels and the inner dynamic behaviour of the gearbox. The
implementation of FEA super elements into the simulation model of a gearboxe allows to
validate the simulation results at positions for solid born sound measurement sensors.

Fig. 6.4 show a comparison of the development of structural accelerations during a run up
between measurement and simulation.
Fz2 2xFz2 3xFz2

vertikal
Measurement
1200 rpm

Fz3

600 rpm

Fz2 vertikal

Simulation

2xFz2 1400 rpm

3xFz2

Fz3

600 rpm

Fig. 6.4: Comparison of the structural accelerations at the torque arm between measurement
and simulation during a run up of the test rig
The resonance points in Fig. 6.4 are comparable between measurement and simulation. This
analyses allows to make conclusions and decisions for design loops based on simulation
results for parameter variations. The benefit is to safe hardware time on the test rig. After a
full validation of the gearbox the implementation of the gearbox model into a full wind turbine
model will lead to reliable simulation results and is the basis for the optimization of the full
wind turbine drive train.

7. Summary
Modern engineering methods such as multi body simulation, FEA, torsional analyses and the
combination of MBS and FEA in combination with measurements on test rigs allow to make
parameter studies in each step of the development loop. This will shorten development and
test rig hardware times. The cost efficiency of developments will increase based on the same
quality level of the gearbox design.

Complex simulation models for the test rig environment and the full wind turbine drive train
allow to optimize the gearbox and other drive train components to reduce dynamic loads and
the noise behaviour of the gearbox and the wind turbine.
This helps to increase the reliability of the gearbox and drive train components and the
availability of the wind turbine. Lifecycle costs and herewith costs of energy will be
decreased.