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Keller, Jonathan

Publications and source records attributed to Keller, Jonathan.

At least 55 records · Page 3
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DOE OSTI2016

NREL-Prime Next-Generation Drivetrain Dynamometer Test Report

Advances in wind turbine drivetrain technologies are necessary to improve reliability and reduce the cost of energy for land-based and offshore wind turbines. The NREL-Prime Next-Generation Drivetrain team developed a geared, medium-speed drivetrain that is lighter, more reliable and more efficient than existing designs. One of the objectives of Phase II of the project was to complete the detailed design, fabrication, and dynamometer testing of a 750 kilowatt (kW) drivetrain that includes the key gearbox innovations designed by Romax Technology and power converter innovations designed by DNV Kema Renewables. The purpose of this document is to summarize these tests completed in NREL's National Wind Technology Center 2.5 megawatt (MW) dynamometer.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

Wind Turbine Drivetrain Reliability Collaborative Workshop: A Recap

The Wind Turbine Drivetrain Reliability Collaborative Workshop was convened by the National Renewable Energy Laboratory (NREL), Argonne National Laboratory, and the U.S. Department of Energy to explore the state of the art in wind turbine drivetrain mechanical system reliability as well as research and development (R&D) challenges that if solved could have significant benefits. The workshop was held at the Research Support Facility on NREL's main campus in Golden, Colorado, from February 16-17, 2016. More than 120 attendees participated from industry, academia, and government. Plenary presentations covered wind turbine drivetrain design, testing, and analysis; tribology -- the science and engineering of interacting surfaces in relative motion -- and failure modes; and condition monitoring and data analytics. In addition to the presentations, workshops were held in each of these areas to discuss R&D challenges. This report serves as a summary of the presentations, workshops, and conclusions on R&D challenges in wind turbine drivetrain reliability.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

Characterization of the High-Speed-Stage Bearing Skidding of Wind Turbine Gearboxes Induced by Dynamic Electricity Grid Events

Bearing behavior is an important factor for wind turbine drivetrain reliability. Extreme loads and dynamic excitations pose challenges to the bearing design and therefore its performance. Excessive skidding of the bearing rollers should be avoided because it can cause scuffing failures. Excitations coming from wind and the electricity grid can subject the drivetrain to fluctuating torque and nontorque loads. Wind-induced excitations have been investigated predominantly in literature. However, modern wind turbines are subjected more and more to grid-induced loads because of stricter electricity grid regulations. For example, during fault-ride-through events, turbines are required to stay connected for a longer period of time during the grid failure. This work investigates the influence of electrically induced excitations on the skidding behaviour of the tapered roller bearings on the high-speed stage of a wind turbine gearbox. This skidding behaviour during dynamic events is described as a potential bearing failure initiator by many researchers; however, only limited full-scale dynamic testing is documented. Therefore, a dedicated gridloss-type event is defined in the paper and conducted in a dynamometer test on a full-scale wind turbine nacelle. During the event, a complete electricity grid failure is simulated while the turbine is at rated speed and predefined torque levels. Particular focus is on the characterization of the high-speed shaft tapered roller bearing slip behavior. Strain-gauge bridges in grooves along the circumference of the outer ring are used to characterize the bearing load zone in detail. It is shown that during the torque reversals of the transient event, roller slip can be induced. This indicates the potential of the applied load case to go beyond the preload of the tapered roller bearing. Furthermore, the relation between the applied torque and skidding level is studied.

17 WIND ENERGY↗
DOE OSTI2016

Gearbox Reliability Collaborative Investigation of High-Speed-Shaft Bearing Loads

The loads and contact stresses in the bearings of the high speed shaft section of the Gearbox Reliability Collaborative gearbox are examined in this paper. The loads were measured though strain gauges installed on the bearing outer races during dynamometer testing of the gearbox. Loads and stresses were also predicted with a simple analytical model and higher-fidelity commercial models. The experimental data compared favorably to each model, and bearing stresses were below thresholds for contact fatigue and axial cracking.

17 WIND ENERGY↗
DOE OSTI2016

Characterization of the High-Speed-Stage Bearing Skidding of Wind Turbine Gearboxes Induced by Dynamic Electricity Grid Events: Preprint

Bearing behavior is an important factor for wind turbine drivetrain reliability. Extreme loads and dynamic excitations pose challenges to the bearing design and therefore its performance. Excessive skidding of the bearing rollers should be avoided because it can cause scuffing failures. Excitations coming from wind and the electricity grid can subject the drivetrain to fluctuating torque and nontorque loads. Wind-induced excitations have been investigated predominantly in literature. However, modern wind turbines are subjected more and more to grid-induced loads because of stricter electricity grid regulations. For example, during fault-ride-through events, turbines are required to stay connected for a longer period of time during the grid failure. This work investigates the influence of electrically induced excitations on the skidding behaviour of the tapered roller bearings on the high-speed stage of a wind turbine gearbox. This skidding behaviour during dynamic events is described as a potential bearing failure initiator by many researchers; however, only limited full-scale dynamic testing is documented. Therefore, a dedicated gridloss-type event is defined in the paper and conducted in a dynamometer test on a full-scale wind turbine nacelle. During the event, a complete electricity grid failure is simulated while the turbine is at rated speed and predefined torque levels. Particular focus is on the characterization of the high-speed shaft tapered roller bearing slip behavior. Strain-gauge bridges in grooves along the circumference of the outer ring are used to characterize the bearing load zone in detail. It is shown that during the torque reversals of the transient event, roller slip can be induced. This indicates the potential of the applied load case to go beyond the preload of the tapered roller bearing. Furthermore, the relation between the applied torque and skidding level is studied.

17 WIND ENERGY↗
DOE OSTI2016

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test

The National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) was established by the U.S. Department of Energy in 2006; its key goal is to understand the root causes of premature gearbox failures and improve their reliability. The GRC uses a combined gearbox testing, modeling, and analysis approach disseminating data and results to the industry and facilitating improvement of gearbox reliability. This test data describes the tests of GRC gearbox 2 in the National Wind Technology Center dynamometer and documents any modifications to the original test plan. It serves as a guide to interpret the publicly released data sets with brief analyses to illustrate the data. TDMS viewer and Solidworks software required to view data files.

17 WIND ENERGY↗
DOE OSTI2015

Next Generation Drivetrain Development and Test Program

This presentation was given at the Wind Energy IQ conference in Bremen, Germany, November 30 through December 2, 2105. It focused on the next-generation drivetrain architecture and drivetrain technology development and testing (including gearbox and inverter software and medium-voltage inverter modules.

17 WIND ENERGY↗
DOE OSTI2015

Economic and Performance Analysis of Gear Box Failures. Cooperative Research and Development Final Report, CRADA Number CRD-07-236

The National Renewable Energy Laboratory (NREL) in Golden, CO, USA is forming a collaborative within the wind energy industry to address reliability issues on wind turbines. The National Wind Technology Center (NWTC), leading the collaborative effort, will allow gearbox manufacturers, bearing manufacturers, wind turbine owner/operators, and wind turbine manufacturers to team up for joint projects that address specific issues regarding design and reliability of wind turbine gearboxes. The primary means of investigation will be through full scale testing and analysis of actual gearboxes, both in the field and in the NREL 2.5 MW dynamometer test facility. These teams would contribute resources into a campaign that is intended to serve the mutual interests of a majority of the wind and gearbox industry stakeholders in addition to the specific project team objectives. that address specific issues regarding design and reliability of wind turbine gearboxes. The primary means of investigation will be through full scale testing and analysis of actual gearboxes, both in the field and in the NREL 2.5 MW dynamometer test facility. These teams would contribute resources into a campaign that is intended to serve the mutual interests of a majority of the wind and gearbox industry stakeholders in addition to the specific project team objectives.

17 WIND ENERGY↗
DOE OSTI2015

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test Report

Many gearboxes in wind turbines have not been achieving their expected design life [1]; they do, however, commonly meet or exceed the design criteria specified in current standards in the gear, bearing, and wind turbine industry as well as third-party certification criteria. The cost of gearbox replacements and rebuilds, as well as the downtime associated with these failures, has elevated the cost of wind energy. In 2006, the U.S. Department of Energy established the National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC). Its key goal is to understand the root causes of premature gearbox failures and improve their reliability [2]. The GRC is examining a hypothesis that the gap between design-estimated and actual wind turbine gearbox reliability is caused by underestimation of loads, inaccurate design tools, the absence of critical elements in the design process, or insufficient testing. This test report describes the recent tests of GRC gearbox (GB) 2 in the National Wind Technology Center (NWTC) dynamometer and documents any modifications to the original test plan [3]. In this manner, it serves as a guide for interpreting the publicly released data sets with brief analyses to illustrate the data. Specific objectives of the test were to assess the effect of dynamic nontorque load (NTL) on the planetary section, generator misalignment on the highspeed shaft (HSS), and field representative conditions on the gearbox in general. Detailed analysis of those test objectives will be presented in subsequent publications.

17 WIND ENERGY↗
DOE OSTI2013

Gearbox Reliability Collaborative Analytic Formulation for the Evaluation of Spline Couplings

Gearboxes in wind turbines have not been achieving their expected design life; however, they commonly meet and exceed the design criteria specified in current standards in the gear, bearing, and wind turbine industry as well as third-party certification criteria. The cost of gearbox replacements and rebuilds, as well as the down time associated with these failures, has elevated the cost of wind energy. The National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) was established by the U.S. Department of Energy in 2006; its key goal is to understand the root causes of premature gearbox failures and improve their reliability using a combined approach of dynamometer testing, field testing, and modeling. As part of the GRC program, this paper investigates the design of the spline coupling often used in modern wind turbine gearboxes to connect the planetary and helical gear stages. Aside from transmitting the driving torque, another common function of the spline coupling is to allow the sun to float between the planets. The amount the sun can float is determined by the spline design and the sun shaft flexibility subject to the operational loads. Current standards address spline coupling design requirements in varying detail. This report provides additional insight beyond these current standards to quickly evaluate spline coupling designs.

17 WIND ENERGY↗
DOE OSTI2012

Combined Effects of Gravity, Bending Moment, Bearing Clearance, and Input Torque on Wind Turbine Planetary Gear Load Sharing: Preprint

This computational work investigates planetary gear load sharing of three-mount suspension wind turbine gearboxes. A three dimensional multibody dynamic model is established, including gravity, bending moments, fluctuating mesh stiffness, nonlinear tooth contact, and bearing clearance. A flexible main shaft, planetary carrier, housing, and gear shafts are modeled using reduced degrees-of-freedomthrough modal compensation. This drivetrain model is validated against the experimental data of Gearbox Reliability Collaborative for gearbox internal loads. Planet load sharing is a combined effect of gravity, bending moment, bearing clearance, and input torque. Influences of each of these parameters and their combined effects on the resulting planet load sharing are investigated. Bendingmoments and gravity induce fundamental excitations in the rotating carrier frame, which can increase gearbox internal loads and disturb load sharing. Clearance in carrier bearings reduces the bearing load carrying capacity and thus the bending moment from the rotor can be transmitted into gear meshes. With bearing clearance, the bending moment can cause tooth micropitting and can induce planetbearing fatigue, leading to reduced gearbox life. Planet bearings are susceptible to skidding at low input torque.

17 WIND ENERGY↗
DOE OSTI2012

Dynamic Analysis of Wind Turbine Planetary Gears Using an Extended Harmonic Balance Approach: Preprint

The dynamics of wind turbine planetary gears with gravity effects are investigated using an extended harmonic balance method that extends established harmonic balance formulations to include simultaneous internal and external excitations. The extended harmonic balance method with arc-length continuation and Floquet theory is applied to a lumped-parameter planetary gear model including gravity,fluctuating mesh stiffness, bearing clearance, and nonlinear tooth contact to obtain the planetary gear dynamic response. The calculated responses compare well with time domain integrated mathematical models and experimental results. Gravity is a fundamental vibration source in wind turbine planetary gears and plays an important role in system dynamics, causing hardening effects induced by toothwedging and bearing-raceway contacts. Bearing clearance significantly reduces the lowest resonant frequencies of translational modes. Gravity and bearing clearance together lowers the speed at which tooth wedging occurs lower than the resonant frequency.

17 WIND ENERGY↗
DOE OSTI2012

Gearbox Reliability Collaborative Phase 1 and 2: Testing and Modeling Results; Preprint

The Gearbox Reliability Collaborative (GRC) investigates root causes of wind turbine gearbox premature failures and validates design assumptions that affect gearbox reliability using a combined testing and modeling approach. Knowledge gained from the testing and modeling of the GRC gearboxes builds an understanding of how the selected loads and events translate into internal responses ofthree-point mounted gearboxes. This paper presents some testing and modeling results of the GRC research during Phase 1 and 2. Non-torque loads from the rotor including shaft bending and thrust, traditionally assumed to be uncoupled with gearbox, affect gear and bearing loads and resulting gearbox responses. Bearing clearance increases bearing loads and causes cyclic loading, which couldcontribute to a reduced bearing life. Including flexibilities of key drivetrain subcomponents is important in order to reproduce the measured gearbox response during the tests using modeling approaches.

17 WIND ENERGY↗
DOE OSTI2012

Gearbox Reliability Collaborative: Test and Model Investigation of Sun Orbit and Planet Load Share in a Wind Turbine Gearbox; Preprint

This paper analyzes experimental measurement of the sun gear orbit in dynamometer testing and describes its relation to the other measured responses of the planetary stage. The relation of the sun orbit to component runout, component flexibility, gear coupling alignment, planet load share, and planet position error will be investigated. Equations describing the orbit of the sun gear in the testcases are derived. Rigid and flexible multibody models of the full gearbox are investigated and compared to sun and planet measurements. This paper shows that the sun gear's path may be influenced by gear coupling responses and gearbox structural flexibilities.

17 WIND ENERGY↗