Structural simulation of yaw and pitch gearbox housing with roller bearing

The gearbox housing of a wind turbine plays a pivotal role in the functionality of yaw and pitch drives. Its strength is a crucial factor in the overall gearbox design, comprising components. Despite its significance, there lacks a well-defined design and validation procedure for gearbox housing, often relying on experiential design. Given the wind turbines’ extended lifespan, durability, reliability, cost-effectiveness, and rapid development time, a definitive design and validation procedure are imperative. Finite element simulation emerges as a faster and more effective tool for this purpose. Gearbox failure can result from manufacturing defects, inadequate lubrication, mishandling by end-users, and prolonged overloads – factors not adequately considered during the design phase. The study emphasizes the necessity of adhering to international standards (IEC16400 and DNV-GL2016) in validating and loading wind turbine components. Comprehensive analysis during the design stage is essential, particularly for the gearbox housing, as it is transmission forces, supports dynamic conditions, and influences structural rigidity. The paper outlines four approaches for developing virtual analysis models for yaw and pitch gearbox housings. Utilizing NX UG and NX Nastran, bearing and structural models were created to assess contact pressure, stress, and deformation of structural components. A new gearbox was developed to meet evolving demands, such as increased loads, turbine capacity, extended lifetime, and reduced weight. Virtual design evaluation proves to be an effective means of achieving these goals. Highlighting the importance of accurate load distribution modeling based on gearbox structure was done through this study which underscores the gearbox pinion’s role in transferring loads to critical bearings. developing a simplified bearing model is crucial for calculating maximum stress on gearbox structural members. The model aims to assess the housing’s strength concerning bearing-induced forces, emphasizing the need for proper models of bearing, stiffness, and force distribution to impact critical structural areas effectively.