Research on Modular Design Method of Wind Turbine Gearbox

ABSTRACT The design of wind turbine gearboxes presents increasing challenges in balancing efficiency, reliability, and cost as turbines trend toward larger scales. Despite their critical role in power transmission, current modular design methodologies suffer from a lack of systematic mathematical modeling and inadequate leveraging of existing product data. Consequently, development cycles are protracted—often lasting 1–3 months—due to iterative calculations and cross‐disciplinary coordination, which can lead to project delays and client dissatisfaction. While prevailing optimization efforts, such as those based on the nondominated sorting genetic algorithm II (NSGA‐II) or on MATLAB‐based volume minimization, primarily address localized improvements (e.g., in gear profiles), they fall short of a holistic solution. To address these limitations, this paper proposes a novel modular classification framework that seamlessly integrates component functionality with digital modeling. This approach establishes rigorous mathematical–geometric relationships among components and enhances product databases to enable rapid data fitting between legacy and new designs. As a result, it facilitates immediate feasibility assessments during preliminary client consultations, significantly accelerates development timelines, and maximizes modular reuse rates, thereby optimizing both design efficiency and manufacturing resource utilization.