Parametric Selection of Optimized Epicyclic Gearbox Layouts for Wind Power Plant Applications

The mechanical multiplier gearbox is one of the most important parts for wind power generation efficiency. Modern epicyclic gearboxes are compact, lightweight builds capable of high power ratings with coaxial input and output shafts. To achieve this, it is very important to select the proper internal gearbox layout and other relevant parameters in the early design stages as the wrong choices will result in a suboptimal solution. Parametric optimization was applied to select the optimal gearbox solution for a wind turbine application, while taking into account both two-carrier and three-carrier solutions. The large number of possible solutions has resulted in the development of the 2-SPEED software to conduct systematic analysis and comparison. The best five two-carrier solutions and the one best three-carrier solution have been selected from the solution pool, with the selection being based on the criteria of maximum efficiency, minimum weight, and minimal greater-ring diameter size. One optimal two-carrier solution was then selected from the five and compared to the three-carrier solution. Recommendations for the selection of either two-carrier and three-carrier gear train solutions according to the application demands have been deducted and provided. This will result in lighter, more efficient designs with smaller radial dimensions.