In this study, a method to predict the contact friction coefficients at the rolling‐sliding contacts of isotropic superfinished and axially ground gear and bearing surfaces in wind turbine gearboxes is proposed. A two‐disc test rig was used to measure friction coefficient values within a slide‐to‐roll ratio range of −0.8 to 0.8, rolling velocities of 2 to 12 m/s, at oil temperatures of 50°C, 70°C, and 100°C and Hertzian contact pressures of 1.2, 1.6, and 2.0 GPa. A polyalphaolefin (PAO) International Standards Organization (ISO) viscosity grade (VG) 320 was the lubricant. Data from 90 individual friction coefficient tests were combined to develop two closed‐form friction coefficient formulae. A multivariable linear regression analysis was used to derive the regressed formulae. Using the developed regressed formulae, the predicted friction values follow the trend of measured values at all of the operating conditions. The results show that the regressed formulae are close to experimental friction coefficient values. The friction coefficient predictions confirm that the regressed formulae are capable of simulating contact friction values for the lubricated contact conditions considered.
A concept has been developed for a novel lightweight wheel structure intended for rotor and stator use in directdrive wind turbine generators. It uses a slanted spoke and rim architecture to provide maximum static structural performance with minimum weight. A unique attribute of the structure is its use of layered sheet steel elements to form the spokes and rim. Friction between layers establishes structural integrity. The interaction between layers and the resulting increase in damping normal to the stack offers improved dynamic performance. A static structural analysis of a full-scale stator wheel structure for an 8 MW permanent magnet machine demonstrates the structural effectiveness of the architecture. To understand vibration characteristics of the lightweight wheel structure, a quarterscale prototype was built and an experimental modal analysis was carried out to measure actual radial vibration responses. This data was used to verify a numerical model, and there was good agreement between measured and predicted behaviours. Finally, a modal analysis was carried out for the full-scale stator wheel structure. The dynamic performance of the wheel is acceptable for the stator of the 8 MW direct-drive permanent magnet synchronous generator embodiment.
A non-contact modal analysis method is implemented to estimate the structural damping ratios for four stacks of sheet-steel, each bound using a different method. The setup comprised the four subject stacks and, for comparison, two single homogeneous steel plates of the same length and width with thicknesses that approximated the layered stack heights. To carry out the modal analyses, each test item was hung to simulate a free-free boundary condition. A force and frequency adjustable impact hammer imparted transient vibration to each hanging test piece after which the local relative velocity for each one of an array of discrete target points across the entire length-to-width surface was measured using an optical transducer. Damping ratios were extracted from the frequency response curves using the half power bandwidth method. Comparing the results obtained for the layered sheet-steel stacks with those from the homogeneous steel plates showed that damping ratios and loss factors can be estimated using the proposed experimental technique. The consistent impacts and the elimination of test structure mass loading improves the accuracy of damping estimates. In comparison to the solid plates, the layered sheet-steel stacks were characterized by increased damping. The effect was most significant for the stack bound together by polymer rivets.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.