Volume 2 2017
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www.bearingworld.org Journal Volume 2_2017 Editors: G. Poll _ A. Grunau _ B. Hagemann Industrial Research and Science in Dialogue with Practical Application Proceedings 2016 Technical Sponsor Forschungsvereinigung Antriebstechnik e.V. Lyoner Straße 18 60528 Frankfurt www.fva-net.de Organiser FVA GmbH Lyoner Straße 18 Published by 60528 Frankfurt ISBN 978-3-8163-0705-1 www.fva-service.de VDMA Verlag www.bearingworld.org 160061_09 FVA_BW_Pro_Umschlag_final.indd 1 23.11.16 14:24 Imprint Bearing World Journal Volume 2, December 2017 Published by: Forschungsvereinigung Antriebstechnik e.V. Lyoner Straße 18 60528 Frankfurt am Main Germany www.fva-net.de © 2017 VDMA Verlag GmbH Lyoner Straße 18 60528 Frankfurt am Main Germany www.vdma-verlag.com All rights reserved, particularly the right of duplication and disclosure, as well as translation. No part of the work may be reproduced in any form (print, photocopy, microfilm or any other method) without written consent from the publisher or saved, processed, duplicated or disclosed. PDF-ISSN 2566-4794 Volume 2_2017 Dear reader, Globalisation of industry increasingly requires international networking of research and development work. With BEARING WORLD, the German Research Association for Drive Technology, FVA, has initiated an international dialogue in which researchers and developers from universities and bearing manufacturers come together with users and experts from the industry. The first international Bearing World Conference, initiated and organised by FVA, took place in April 2016. More than 200 experts from 11 countries met in Hanover to share the latest research findings in the world of bearings. With Bearing World Journal, our aim is to continue this exchange among international experts by regularly publishing high-quality scientific reports related to rolling and plain bearings. We want to offer the international research community a new international publication platform for cutting-edge research in the field of bearings. The high quality of Bearing World Journal is ensured by the peer review process, which is carried out by the Bearing World Scientific Board. We would like to thank all of the authors for their interesting contributions to the Bearing World Journal. _ Prof. Dr.-Ing. Gerhard Poll, Initiator, Head of international Scientific Board _ Dr.-Ing. Arbogast Grunau, President of the FVA Management Board _ Bernhard Hagemann, Editor-in-chief Please send the paper you intend to publish in the next issue of the Bearing World Journal via e-mail as Word document to FVA ([email protected]). In addition please attach a PDF document. Bearing World Scientific Board Scott Bair, Georgia Institute of Technology, USA Prof. Harry Bhadeshia, University of Cambrigde, Great Britain Prof. Stefan Björklund, KTH Royal Institute of Technology, Stockholm, Sweden Prof. Benyebka Bou-Said, Institut National Des Sciences Appliquées (INSA) Lyon, France Prof. Ludger Deters, TU Magdeburg, Germany Prof. Duncan Dowson, University of Leeds, Great Britain Prof. Rob Dwyer-Joyce, University of Sheffield, Great Britain Prof. Michel Fillon, Université de Poitiers, France Prof. Sergei Glavastkih, KTH Royal Institute of Technology, Stockholm, Sweden Prof. Irina Goryacheva, Russian Academy of Sciences, Russia Prof. Feng Guo, Qingdao Technological University, China Prof. Martin Hartl, Brno University of Technology, Czech Republic Prof. Stathis Ioannides, Imperial College London, Great Britain Prof. Georg Jacobs, RWTH Aachen University, Germany Prof. Motohiro Kaneta, Brno University of Technology, Czech Republic Prof. Michael M. Khonsari, Louisiana State University, USA Prof. Ivan Krupka, Brno University of Technology, Czech Republic Prof. Roland Larsson, Luleå University of Technology, Sweden Prof. Antonius Lubrecht, Institut National Des Sciences Appliquées (INSA) Lyon, France Prof. Piet Lugt, SKF Nieuwegin; University of Twente, Enschede, Netherlands Prof. Jianbin Luo, State Key Laboratory of Tribology, Tsinghua University, China Prof. Guillermo Morales-Espejel, INSA Lyon, France Prof. Anne Neville, University of Leeds, Great Britain Prof. Hiroyuki Ohta, Nagaoka University of Technology, Japan Prof. Gerhard Poll, Leibniz University Hanover, Germany Prof. Martin Priest, University of Bradford, Great Britain Prof. Farshid Sadeghi, Purdue University, Lafayette, Indiana, USA Prof. Richard Salant, Georgia Institute of Technology, USA Prof. Bernd Sauer, TU Kaiserslautern, Germany Prof. Ian Sherrington, University of Central Lancashire, Great Britain Prof. Hugh Spikes, Imperial College London, Great Britain Prof. Gwidon Stachowiak, Curtin University Australia, Australia Prof. Kees Venner, University of Twente, Enschede, Netherlands Prof. Philippe Vergne, Institut National Des Sciences Appliquées (INSA) Lyon, France Prof. Fabrice Ville, Institut National Des Sciences Appliquées (INSA) Lyon, France Prof. Sandro Wartzack, Friedrich-Alexander-University Erlangen-Nürnberg, Germany Prof. John A. Williams, University of Cambridge, Great Britain Prof. Hans-Werner Zoch, IWT Stiftung Institut für Werkstofftechnik, Bremen, Germany Contents Analysis of planetary bearing and gear loads of a wind turbine main gearbox on a 4 MW system test bench ............................................................................................... 7 Liewen, C., RWTH Aachen University (DE) Influence of slip on the formation of White Etching Cracks on a two-disc test rig and a kinematic study on a full-scale bearing ..................................................................... 15 Guzmán, G., F., RWTH Aachen University (DE) An Experimental Study regarding Maintainability of a Rolling Bearing Arrangement Equipped with a Ring Lubricator for Oil Supply ................................................................... 25 Müller, M., Friedrich-Alexander-Universität Erlangen-Nürnberg (DE) Radially Preloaded Cylindrical Roller Bearings –Operating Performance and Optimized Preload .............................................................................................................. 35 Böttcher, R., Leibniz Universität Hannover (DE) Capacitances and Lubricant Film Thicknesses of Oil Lubricated Bearings ......................... 43 Furtmann, A., Leibniz Universitaet Hannover (DE) Modelling power losses of cylindrical roller bearings in an FZG gear test rig ...................... 49 Tu, M., KTH Royal Institute of Technology (SE) Boundary layers on bearing raceways subject to operating conditions with high risk of white etching cracks related premature rolling contact fatigue ........................................ 59 Lipinsky, D., Westfälische Wilhelms-Universität Münster (DE) 5 Analysis of planetary bearing and gear loads of a wind turbine main gearbox on a 4 MW system test bench C. Liewen1, G. Jacobs2, D. Bosse3 1 Center for Wind Power Drives, RWTH Aachen University, [email protected] 2 Center for Wind Power Drives, RWTH Aachen University, [email protected] 3 Center for Wind Power Drives, RWTH Aachen University, [email protected] Abstract – The majority of wind turbines (WT) worldwide have a main gearbox to increase their rotor speed [1]. With the exception of a few niche products, most gear concepts use planetary stages as the first gear stage, because of their advantages regarding power splitting, low construction volume and weight, as well as a high transmission ratio at high efficiency. Inside the planetary stage the high rotor torque of the wind turbines is distributed over several planets and reunited at the sun gear. The rolling bearings inside a WT gearbox are the cause of about two-thirds of all gearbox damages [2] [3]. A substantial share of the downtime resulting from these damages come from the planetary bearings [4]. To increase the WT reliability and to further optimize the design of the planetary bearings a better knowledge of the resulting local loads at the planetary bearing and at the surrounding components is required. It is the aim of this paper to show the impact of planetary gear loads on the local loads of an overdetermined multi-row (4 rows) planetary bearing of a 2.7 MW research nacelle through measurements on a 4 MW system test bench. Furthermore, the procedure of estimating gear and planetary bearing load distribution from measured data is presented. The comparison of a WT operation point with 100 % pure torque with an operation point with additional non-torque loads (NTL) leads to the conclusion that during gearbox development and prototype testing, unexpected and overlooked additional bearing row loading can occur. Keywords – wind turbine, system test bench, planetary bearing, load distribution, strain 1. Introduction 2. Test bench and device under test The majority of wind turbines (WT) worldwide have a main gearbox 2.1. 4 MW system test bench of the CWD to increase their rotor speed [1]. Thereby the size and cost of the re- quired generators can be reduced. Although gearbox damages are rel- The wind acting on a WT is characterized by gusts and turbulences and atively low compared to damages of other wind turbine components, is of a highly variable nature. Also the behavior of the electrical grid gearbox damages cause the longest downtimes [5]. Long downtimes at the point of common coupling (PCC) of a WT is not predictable. If result mainly from damages in which the complete gearbox has to be a WT and its components are to be investigated in field, this variable replaced for maintenance. The rolling bearings are the cause of about wind and