Dynamic modeling and analysis of wind turbine gear-bearing coupling system considering tooth root crack and slicing coupling effect

Tooth root cracks would change the meshing stiffness excitation of the gears, increasing the vibration and noise of wind turbine gearbox. Currently, there is relatively little literature that focuses on the slicing coupling effect of cracked gears, leading to incomplete accuracy in solving the time-varying mesh stiffness (TVMS) of gears under cracked conditions, making it difficult to accurately reflect the impact of root crack excitations on the dynamic behavior of wind turbine gear-bearing coupled systems. In this work, The improved analytical calculation method is proposed for the TVMS and system vibration coupling solution of the cracked gear pair, considering the slicing coupling effect. The dynamic model of the wind turbine high-speed stage gear set is developed using the lumped parameter approach, and the rolling bearing is modeled using the Hertz contact theory. Then, the excitations of the gear-bearing coupling system are developed using an improved slicing method. Lastly, the dynamic model of the wind turbine gear-bearing coupling system that considers tooth root cracks and the slicing coupling effect is established and validated. The results indicate that The TVMS modification algorithm considering the slicing coupling effect can better depict the dynamic change of the gear meshing stiffness under the crack failure. Cracks could reduce the TVMS of the gear pair, neglecting the coupling effect between the sliced gear tooth gains the potential risks of overestimating the influence of the gear crack depth on the TVMS. In addition, Gear cracks excitation may alter the dynamic contact load amplitude of the bearing rolling elements, resulting in a tendency for the load-bearing area to decrease. Moreover, When the cracked teeth are involved in meshing, The decrease in mesh stiffness will result in a larger amplitude periodic shock response to the system vibration displacement and a sideband phenomenon near the mesh frequency, neglecting the coupling effect between the sliced gear tooth or simplifying the bearing to a linear support stiffness matrix gain the potential risks of underestimating the influence of the gear crack depth on the vibration displacement of the gear-bearing coupling system.