English English

Wind turbine gearbox manufacturers

With the continuous development of science and technology, wind power has become a hot spot in the world's new energy industry. Combining the research status and development trend of wind power technology at home and abroad, the characteristics and analysis of wind turbine special gear oil are compared and summarized. At the same time, according to the rapid development of wind power technology at home and abroad, it shows that wind turbine related lubrication products will have a broad Market application prospects

Basic Information: Wind turbine gear oils are generally selected from high-quality polyalphaolefin fully synthetic base oils and high-performance composite additives, which are carefully prepared by special preparation processes. It can be used under extreme environmental temperature and severe working conditions, which can effectively prevent the generation of micro-pitting in the running of the gear. At the same time, it has the characteristics of anti-extreme pressure and heavy-duty industrial gear oil, forming a strong oil film on the tooth surface and prolonging. Gear life. The high viscosity index polyalphaolefin fully synthetic base oil has excellent high and low temperature performance, and can be used for long life gear oil in high temperature areas and cold regions. Well-known wind turbine gear oil like WIND TURBINE GEAR OIL wind turbine gear oil is made of high-quality poly-α-olefin synthetic base oil and high-performance composite additives, and has excellent performance.

Wind turbine gearbox manufacturers

Performance characteristics: Wind turbine gear oil has excellent anti-wear protection. It is produced with advanced formula of high-performance extreme pressure additive system and high-quality base oil. It provides efficient protection for heavy-duty gear systems working under high impact load. Micro pitting protection. Of course, only surface protection is not enough. It also requires comprehensive protection. Due to the high durability additive formulation, it can maintain low foaming performance and maximum oil film thickness protection performance for a long working time. Not only that, but also has excellent water separation characteristics, providing excellent protection against cyclic damage to circulating lubrication systems where water pollution can cause significant harm.

In addition, due to the use of high quality synthetic base oils and high performance composite additives, wind turbine gear oils have good shear resistance, oxidation resistance and high and low temperature suitability, and can be used in the range of -40 ° C to 200 ° C.

Technical indicators: Micropitting protection To minimize the weight of the tower's up-tower, the gearbox is typically compact, including the hardened design of the gears. Gears that have been surface hardened (carburizing, nitriding, induction, and flame hardening) are highly susceptible to micropitting under complex climatic conditions and operating loads. Therefore, the gear lubricant selected must have the function of preventing such wear. Micropitting is a phenomenon of surface wear that occurs primarily on gears and rolling bearings. Within a few hours after the start of the run, micropitting can cause surface cracking. These subtle cracks continue to expand at a shallow oblique angle (usually less than 30 degrees) to the surface, which in turn forms micro-dots with diameters below 10 microns. Under the combined effect of these micro-dots, the surface cracks will continue to expand. A micro dot size between 5 microns and 20 microns and a depth of up to 10 microns, so what is the concept of size? To make a comparison, a human hair is about 40 microns thick, so people can't see them with the naked eye. However, although these micro-dots seem to be small, they can reduce the fit of the teeth, which can cause serious gear breakage.

The drive motor frequency is variable and the AC supply is controlled by the solid state drive. The drive converts the DC power to AC power so that the two DC circuits of the drive can be connected to each other, and the generated power is treated as a load, which is then fed back to the drive motor converter to simulate the input power of the wind turbine generator. GE Transportation also manufactures wheeled motors and drives for surface mining trucks and locomotives. Analysis shows that two GEB-16A4 wheel motors provide the required speed, torque and power for testing. Similarly, the blocking function of the drive motor can effectively simulate the load of the generator.



Wind turbine gearbox manufacturers

To minimize the risk of unplanned downtime and gear replacement, maintenance personnel can use lubricants specifically designed to prevent micropitting. The protection effectiveness of gear lubricants for micropitting is generally measured by the FVA54 micropitting test (FVA54 MicropittingTest). The test consisted of two parts, six incremental loads, 16 hours per run, and an 80-hour high load endurance test. Both tests were performed at 1500 rpm and C-faced gears were used for micropitting testing. Lubricating oils are classified into different grades according to the degree of conformity of the tooth profile, the proportion of the micropitting area, and the weight loss, expressed by numbers and high/medium/low durability. All major gear manufacturers recommend that maintenance personnel use lubricants that are at least “=10 high” (=10 high).

It should be noted that secondary oiling cannot repair the gears that have previously been micropitting. But once the gear is replaced, the injected lubricant can help increase productivity and extend the life of the new gear.

Filterability: Select the right lubricant to reduce replacement cost In general, the filterability index is in micrometers (μ). We typically use a 2μ renal circulation filter and a 5μ main filter to filter the oil and protect the wind turbine gearbox components. The filterability of the lubricating oil changes depending on its wet and dry state, especially when the lubricating oil contains water, the additive may be filtered out or there is a tendency to be discharged from the lubricating oil. If an effective additive is added to the lubricating oil, the filterability of the lubricating oil is greatly improved. Since maintenance personnel do not know much about filterability, consult the lubricant manufacturer and filter supplier for product performance when selecting a lubricant to determine which lubricant is best for the filter you are using.

Wind turbine gearbox manufacturers

Anti-wear and bearing protection: Wear is mainly caused by material movement between the sliding tooth faces. When the oil film thickness of the gear oil is insufficient, contact between the metal parts between the gears is caused. If the wear continues, the gears have to be replaced too early. The FZG wear test (DIN 51354-2 mod) tests the scratch and wear resistance at different temperatures and speeds using standard gear units. The grade of the lubricant is based on its failure rating (FLS). Ironmaster Lubricants recommends that maintenance personnel use lubricants with a failure rating (FLS) greater than 14.

Damage to the bearing due to poor lubricant quality is also one of the most common causes of gearbox downtime. The FAGFE8 Class 4 test of the fan gear oil tests the performance of the lubricant on the bearings under different load, speed and temperature conditions. The four levels of the test are wear test, mixed friction, life test and sludge test. The grade of lubricant varies from 1 to 5 from the overall results of these four-level tests. Level 1 indicates that the lubricant provides excellent protection for the bearings.

Viscosity refers to the ability of a lubricating oil to maintain its viscosity in a variety of high and low temperature environments. The operating environment of the fan is very bad. The day and night rotation, alternating heat and cold, the working environment of the fan is sometimes as low as minus 40 degrees Celsius, and sometimes up to 80 degrees Celsius. To determine if the lubricant can withstand dramatic changes in temperature, maintenance personnel can evaluate the viscosity index of the product. The viscosity index can be measured according to the ASTM D2270 standard, which reflects the resistance of the lubricating oil to temperature changes. Ironmaster Lubricants recommends that maintenance personnel should select products with a viscosity index of 160 or more.

Synthetic lubricants have a more pronounced viscosity temperature than mineral oil based lubricants and have excellent lubricity in many temperature environments. Therefore, synthetic lubricants are more commonly used in transmission oils.

Water resistance: avoid residual substances Given the working principle of wind turbines, it is impossible to completely separate the lubricant from the water. When the wind turbine blades rotate, the operating temperature of the gearbox will be as high as 95 degrees Celsius. When the blade stops rotating, the gearbox will gradually cool and absorb moisture or moisture from the air. When it begins to “breathe”, moisture enters the gearbox. When water enters the gearbox, it will dilute and decompose the lubricant, causing residue and damaging the gearbox. In order to prevent water resistance problems, a gear lubricant that does not easily retain moisture should be used. At the same time, it is even better if the lubricant can provide adequate protection for the device with a small amount of moisture. The water resistance of the lubricant can be evaluated by ASTM D1401, which measures the ability of the lubricant to remove moisture and is measured in time (minutes). Maintenance personnel should use lubricants with a score of “15 minutes” or less.

Viscosity characteristics: high performance synthetic lubricants superior performance Wind turbines are often subjected to harsh working conditions. From morning to night, from hot summer to cold winter, wind turbines are exposed to operating temperatures as low as minus 40 degrees Celsius and as high as 80 degrees Celsius. In order for a wind turbine to operate normally under such a large temperature difference, it is necessary for the lubricating oil to have superior viscosity characteristics. The Ironmaster Laboratory used ASTM D2270 to determine the viscosity index and evaluated the ability of the lubricant to resist viscosity changes with temperature. Tests have shown that synthetic lubricants offer significant advantages in terms of viscosity characteristics compared to mineral oils, providing excellent lubrication over a wide temperature range. Maintenance personnel should use synthetic lubricant products during routine maintenance and recommend products with a viscosity index of “160” or higher.

Lubrication point: high grade lubricants prevent micropitting A plurality of lubrication points are distributed on one wind turbine. The gearbox is the core component of the wind turbine and the most difficult part to lubricate. As we all know, gearboxes are also the most expensive components on wind turbines. In general, replacing a 1.5 MW wind turbine gearbox costs more than $250,000. The gearbox is filled with synthetic lubricants at the factory to ensure normal operation of the fan for three years, while most gearboxes have a standard warranty of only one year. When the gearbox has passed the warranty period, the maintenance personnel need to choose the lubricant replacement at the right time, which is called “after-sales service oil”. Affected by various unpredictable winds and loads, the main gearbox is prone to micropitting (a type of surface fatigue that can create surface cracks, small pits, broken surfaces, until the gear breaks), thus requiring a suitable Gear lubricants to prevent this type of wear

Water resistance: The oil in the gearbox must not be mixed with moisture. However, due to the operating characteristics of the fan itself, it is almost impossible to completely separate the oil and water in the fan. When the blade is rotating, the gearbox operates at temperatures as high as 80 degrees Celsius, and when the blades stop rotating, the gearbox cools down and draws moisture or moisture from the air. Therefore, moisture will inevitably enter the gearbox

At this time, if you use gear oil with poor water resistance, it will cause sludge and hydrolysis. In order to prevent malfunction due to water, it is necessary to find a gear oil that is not easy to absorb water but also provides sufficient lubrication protection for the equipment in the presence of a small amount of water. The water resistance characteristics of the gear oil are measured by the ASTM D1401 standard test, which measures the oil-water separation ability of the oil. The test standard is expressed in terms of time (minutes). Ironmaster lubricants are recommended for maintenance personnel to select gear oils of 15 minutes or less.

Fan gearbox lubricants are one of the most challenging industrial lubrication applications in the modern industrial world, requiring cutting-edge technology to ensure quality. The Tieba Industrial Lubricant Division has invested heavily in the development of various lubricants and ensures that they are suitable for use in harsh working environments. In addition to product development, Tieba engineers believe that it is equally important to help the wind farm make the right choices. They continue to share their practical experience at work, aiming to help wind power plants gain valuable experience in selecting fan lubricants. This helps wind farms increase productivity, minimize downtime, and reduce maintenance and parts replacement costs.



Wind turbine gearbox manufacturers

The micro-pitting performance of wind turbine gear oil meets the requirements of Flender AG and Winergy and also meets the requirements of US Steel 224, AGMA9005-E02 and DIN51517 Part 3. At the same time, the compatibility of various types of seals and sealing materials is good. Suitable for wind power equipment gearboxes and plastic extrusion gearboxes. It can meet the lubrication needs of various types of closed gears, such as spur gears, worm gears, hypoid gears, etc. In addition to gearboxes for wind turbine equipment and plastic extrusion, it is also suitable for gearboxes in the steel industry, paper industry and other equipment. The Tieba wind turbine gear oil is compatible with mineral gear oils, but blending may reduce its performance. For best performance, it is recommended to thoroughly remove old oil and flush the gearbox. Do not mix with other gear oils to avoid affecting the performance of wind turbine gear oil.

The American Gear Manufacturers Association (AGMA) guidelines have stringent requirements for gear oil cleanliness in the main gearbox because keeping gear oil clean can significantly extend component life. The filter performance of gear oil refers to the ability of the gear oil to pass through the filter under actual operating conditions without blocking the filter. This filtration performance is often overlooked. Standard filtration performance tests generally only evaluate new, non-aqueous oils that indicate or do not indicate operating conditions. Large wind farms have proven that even if the filter is replaced at twice the replacement frequency recommended by the original equipment manufacturer, the total cost of ownership for a year will exceed $275,000.

It is also important to understand the effect of additives in the gear oil on filtration performance. Filtration performance is generally defined in microns. In many cases, a 2 to 3 micron Kidney Loop filter and a 5 micron primary filter are used to clean the gear oil and protect the components of the fan gearbox. It is also important to properly understand and treat micron-sized filter materials. Occasionally, the additive can be filtered from the gear oil or possibly separated from the gear oil, especially when the gear oil is mixed with water. In addition, the filtration performance of wet and dry gear oils is different.

The micro-pitting performance of wind turbine gear oil meets the requirements of Flender AG and Winergy and also meets the requirements of US Steel 224, AGMA9005-E02 and DIN51517 Part 3. At the same time, the compatibility of various types of seals and sealing materials is good. Suitable for wind power equipment gearboxes and plastic extrusion gearboxes. It can meet the lubrication needs of various types of closed gears, such as spur gears, worm gears, hypoid gears, etc. In addition to gearboxes for wind turbine equipment and plastic extrusion, it is also suitable for gearboxes in the steel industry, paper industry and other equipment. The Tieba wind turbine gear oil is compatible with mineral gear oils, but blending may reduce its performance. For best performance, it is recommended to thoroughly remove old oil and flush the gearbox. Do not mix with other gear oils to avoid affecting the performance of wind turbine gear oil.


Wind turbine gearbox manufacturers

In order to increase the efficiency of wind turbines, engineers hope to develop cost-effective solutions in combination with the best electronic and mechanical design. GEWindEnergy hopes to expand the production of wind turbine generators and decided to set up a key transmission assembly line at its GETransportation plant in Pennsylvania, USA. However, the equipment already in the factory does not have the ability to test the product.

The performance of the gearbox must be verified before the loading and installation of the wind turbine tower is completed. Calibration requires the gearbox to operate at full power at full speed to perform speed/torque testing and accurate data acquisition such as vibration, noise, lubricant temperature and gear meshing.

The problem is further complicated by the fact that the test gearbox needs to move quickly during the test. In addition, the test site is the main production site, which will cause noise interference between production and testing, while lacking power isolation or machine base to support the test equipment. The utility system also needs to be upgraded to provide a drive power of up to 1.5 mW.
After meeting the above requirements, an experienced GE technician is required to operate the test equipment, not a computer engineer. Therefore, computer-controlled data acquisition and control systems must be highly robust and user-friendly.

After-sales inspection of the 1.5mW transmission with the test platform enables the determination of vibration and acoustic characteristics while verifying that the output speed and load requirements meet specifications. The unit to be tested (UUT) is connected to a similar gearbox that operates in reverse to simulate the torque of the wind turbine. The entire test bench is driven and loaded by four GE traction engines and is controlled by LabVIEW.

Technical implementation:       
The most critical technical problem with the gearbox test bench is the simulation of 578,000 lb-ft, 18 rpm wind turbine inputs, which are the only devices that meet the conditions. Therefore, another identical gearbox (in the opposite direction of rotation) is used as the ideal speed/torque source. The test gearbox is connected to the input shaft of another fixedly mounted wind turbine gearbox. The 1.5 mW motor system drives the output shaft of the fixed gearbox to drive the tested gearbox to operate at a certain speed and torque. The 1.5 mW generator system is connected to the output shaft of the gearbox being tested to simulate a quantitative load.

 sogears manufacturing

The best service from our transmission drive expert to your inbox directly.

Get in Touch


ANo.5 Wanshoushan Road Yantai, Shandong, China

T+86 535 6330966

W+86 185 63806647

© 2020 Sogears. All Rights Reserved.