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    Wind Turbine Gearbox Design Project PDF

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    risirarocks
    The document describes a wind turbine gearbox design project where students will work in groups to design the gearbox. The gearbox is required to increase the rotational speed from the turbine blades to the generator. It must use a compound reverted gear train with a ratio between 17:1 and 21:1. The design must minimize weight and size while withstanding typical and large loads over a 10-year life at 99% reliability.

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    Wind Turbine Gearbox Design Project PDF

    Uploaded by

    risirarocks
    1K views3 pages
    The document describes a wind turbine gearbox design project where students will work in groups to design the gearbox. The gearbox is required to increase the rotational speed from the turbine blades to the generator. It must use a compound reverted gear train with a ratio between 17:1 and 21:1. The design must minimize weight and size while withstanding typical and large loads over a 10-year life at 99% reliability.

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    Wind Turbine Gearbox Design Project.pdf

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    The document describes a wind turbine gearbox design project where students will work in groups to design the gearbox. The gearbox is required to increase the rotational speed from the turbine blades to the generator. It must use a compound reverted gear train with a ratio between 17:1 and 21:1. The design must minimize weight and size while withstanding typical and large loads over a 10-year life at 99% reliability.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views3 pages

    Wind Turbine Gearbox Design Project PDF

    Uploaded by

    risirarocks
    The document describes a wind turbine gearbox design project where students will work in groups to design the gearbox. The gearbox is required to increase the rotational speed from the turbine blades to the generator. It must use a compound reverted gear train with a ratio between 17:1 and 21:1. The design must minimize weight and size while withstanding typical and large loads over a 10-year life at 99% reliability.

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    Wind Turbine Gearbox Design Project

    Description
    You will work in groups of 5 on a group design project. You will need to submit a final design report as a group.
    A separate handout will be given detailing the requirements of the final design report.

    Background
    Wind turbines are becoming increasingly popular devices for converting wind energy into electricity. The
    concept is to mount airfoil shapes onto a rotor such that as the wind blows over the airfoils, the shaft is urged
    to turn. The shaft speed is usually much slower than is needed for efficient electricity generation, so a gear
    box is used to increase the speed between the turbine blades and the generator. In addition to these basic
    components, most wind turbine generators also include a means for feathering the airfoils in high winds to
    keep them from spinning too fast, and means for pointing the airfoils in the most advantageous direction
    (usually into the wind). Figure 1 shows a typical conceptual layout of one design for a wind turbine which
    consists of the following parts: a tower for support and lift, turbine blades to catch the wind, a gearbox for
    transmission, a generator to convert mechanical energy to electricity.

    Tail Generator Gearbox


    rudder

    Turbine
    blades

    Tower

    Figure 1. Wind turbine parts


    You are to design the gearbox for the wind turbine, which is supported by a 60 foot tall tower. Use a
    compound reverted gear train to increase the rotational speed from the input to the output. The diameter of
    the blades is 17 feet. The gearbox consists of spur gears, rolling element bearings, shafts, keys, and retaining
    rings.

    Specifications
    The following are design specifications for the gearbox:

    Weight and size Minimize


    Material You should select the materials for your design
    Gear train value Nominally 18:1; minimum ratio: 17:1; maximum ratio: 21:1
    Shaft arrangement The input and output shafts should be in line
    (Figure 2) Use a compound reverted gear train
    Input shaft: protruding 4inches out of front of gearbox
    Output shaft: protruding 2inches out of rear of gearbox
    Provide adequate key slots on the input and output shafts
    Show how various shaft attachments are connected to the shafts
    Weak link Design the keys as the weak link of the gearbox, i.e., if anything would fail, it
    would be the keys in order to protect other parts
    Load Typical load: 20mph wind and 200rpm blade rotational speed, this gives
    the following loading on the input shaft of the gearbox:
    Torque from the three blades: 38.6 ft-lbs
    Lateral load (weight of blades and hub, which are mounted directly
    on the input shaft of the gearbox): 260lbs
    Axial load (thrust from the three blades): 50.25lbs
    Large load: large wind can produce loads up to 3 times the typical loads.
    The turbine speed is, however constant at 200rpm since it is regulated
    by adjustable pitch blades.
    Life 10 years continuous operation
    Reliability 99% for all parts
    Factors of safety Keys and shafts: = 2, = 2
    Bearings: fatigue: n=1
    Bearings for static large load conditions: n=1
    Gears: fatigue safety of factors are n=1.2 for surface and n=1.5 for bending
    Other parts: yield and fatigue factors of safety of at least 2.

    4 inch long
    2 inch long
    input shaft
    output shaft

    Gearbox
    Connection to
    Connection to
    generator
    turbine blades

    Figure 2. gearbox
    Design Specification Check-Sheet

    Overall For each shaft

    Design specification Part drawings as needed (size, fillets,


    Layout/assembly drawing shoulders, key slots, retaining ring grooves,
    Function description etc)
    Overall size Material
    Overall weight Final design analysis (loads; FBDs, shear and
    moment diagrams; critical planes and
    points; stresses; deflections and rotations
    For each gear (within the recommended limits for
    bearings and gears); etc)
    Equivalent design loads
    Factors of safety (static and fatigue)
    Rotational speed
    Show how bearings and gears are attached
    Diametral pitch
    to the shafts
    Number of teeth
    Tooth Quality ( Q )
    v
    For each key
    Face width
    Rim effects (if any) to remove weight Part drawings as needed
    Material Type of key
    Attachment to shaft Size (length; width; height; etc)
    Final design analysis Keyway type and dimensions
    Factors of safety (bending and pitting) Factors of safety
    Show how the keys are used as the weak
    For each bearing links
    Design loads (equivalent loads) For each retaining ring
    Bearing selection (Type of bearing; Bore;
    OD; width; etc) Size (thickness; groove diameter; etc)
    Rating life in hours, and reliability Allowable axial thrust

    Optimization

    Minimize the weight and size of the design

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