SpectraQuest Inc.,: Wind Turbine Drivetrain Diagnostics Simulator

An Ideal Apparatus for Wind Turbine Reliability Studies

SpectraQuest’s Wind Turbine Drivetrain Diagnosis Simulator (WTDS) has been designed to simulate wind turbine drivetrains for experimental and educational purposes. The drivetrain consists of a 1 stage planetary gearbox, a 2 stage parallel shaft gearbox with rolling bearings, a bearing loader, and a programmable magnetic brake. All elements of the WTDS have been designed to maximize the number of drivetrain configurations to investigate gearbox dynamics and acoustic behavior, health monitoring, vibration based diagnostic techniques, lubricant conditioning or wear particle analysis. It is robust enough to handle heady loads and spacious enough for easy gear placement, setup, and installation of monitoring devices. The two-stage parallel shaft gearbox can be configured as to reduce or increase the gear ratio. The planetary gear train, sun, planet and ring gears, the carrier, and bearings are all easily accessible.

Flexible Drivetrain Fault Diagnostics

The effect faults like surface wear, crack tooth, chipped tooth and missing tooth can be demonstrated on either spur gears or helical gears. Rolling element bearing faults like inner race, outer race, ball damage can also be incorporated. Adjustable clearance to study backlash is possible: increasing the amount of backlash is without major consequence (other than increased noise and rotational play), and reducing backlash can result in binding and/or excessive operating temperatures. Drivetrain misalignment can also be introduced intentionally in the WTDS. Any of these faults can be added to the drivetrain one at a time, or simultaneously to study fault interactions. Both torsional and radial loadings can be applied to study damage signature or propagation in gears and/or bearings: the torsional load is applied via a 3 HP variable frequency AC drive with a programmable, user-defined speed profiles; and the radial load is applied to a shaft in the parallel gearbox. With the programmable magnetic brake, rapid load fluctuation can be applied to simulate real life loading conditions experienced by wind turbines.

Features

1-stage planetary gearbox and 2-stage oil-lubricated parallel shaft gearbox.
Gears can slide along the shafts to alter system stiffness and make room for additional devices.
Adaptable to spur or helical gears.
Intentionally damaged or worn gearing can be fitted to study the effects on vibration signature.
Alterable backlash by replacing bearing mounting hubs to provide the desired clearance.
Modular design makes the introduction of faulted bearing and/or faulted gears an easy task.
Wind turbine simulator consisting of a tower, three blades with PC programmable variable blade pitch system, direct coupled system to connect blades to gearbox brake-end or chain driven system to connect blades
Multiple mounting locations provided for installation of various transducers.
Develop diagnosis techniques and advanced signal processing methods.
Torsional and radial variable speed loading
PC controlled magnetic brake connected directly to output shaft to provide loading

The WTDS is Heavy-Duty and Easily Configurable

The WTDS design enables changing gearbox and bearing components quickly and easily. The unit is adaptable to install either rolling element bearings or oil-impregnated sleeve bearings with either spur or helical gears. The modular design makes the introduction of faulted bearing and/or faulted gears an easy task. Multiple mounting locations are provided for installation of transducers. The motor, gearboxes, brake are mounted on a half inch aluminum plate with stiffeners and vibration isolators to minimize environmental vibration.Gears can slide along the shafts to alter system stiffness and make room for additional devices.Adaptable to spur or helical gears.Intentionally damaged or worn gearing can be fitted to study the effects on vibration signature.Alterable backlash by replacing bearing mounting hubs to provide the desired clearance.Modular design makes the introduction of faulted bearing and/or faulted gears an easy task.Wind turbine simulator consisting of a tower, three blades with PC programmable variable blade pitch system, direct coupled system to connect blades to gearbox brake-end or chain driven system to connect bladesMultiple mounting locations provided for installation of various transducers.Develop diagnosis techniques and advanced signal processing methods.Torsional and radial variable speed loadingPC controlled magnetic brake connected directly to output shaft to provide loading

Transducers and DAQ

The drivetrain is designed to accommodate different types of sensors easily. Accelerometers can be installed on the gearboxes and on the bearing housing to measure the vibrations in all three directions. A torque meter enables precise load measurement. The input and output shafts can be fitted with encoder or tachometer to measure the transmission error or for time synchronize averaging. Other transducers can also be installed per customers’ request. Data acquisition hardware and software are also available from Spectra Quest and ready to do time domain and frequency domain signal analysis.Gears can slide along the shafts to alter system stiffness and make room for additional devices.Adaptable to spur or helical gears.Intentionally damaged or worn gearing can be fitted to study the effects on vibration signature.Alterable backlash by replacing bearing mounting hubs to provide the desired clearance.Modular design makes the introduction of faulted bearing and/or faulted gears an easy task.Wind turbine simulator consisting of a tower, three blades with PC programmable variable blade pitch system, direct coupled system to connect blades to gearbox brake-end or chain driven system to connect bladesMultiple mounting locations provided for installation of various transducers.Develop diagnosis techniques and advanced signal processing methods.Torsional and radial variable speed loadingPC controlled magnetic brake connected directly to output shaft to provide loading

Electrical
Motor	3 Phase, 3 HP motor, pre-wired self-aligning mounting system for easy installation/removal
Drive	3 HP variable frequency AC drive with multi-featured front panel programmable controller
RPM range	0 to 5000 rpm variable speed
Tachometer	Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposes
Voltage	230 VAC, Three phase, 60/50 Hz
Mechanical
Shaft Diameter	1″ diameter; Turned, Ground, & Polished (TGP) steel
Planetary Gearbox	1-stage, 4.7:1 gear ratio planetary gear with 3 planet stage
Parallel Gearbox	2 stage, 2.5 maximum ratio per stage, spur or helical gears
Parallel Shaft Gearbox Bearing	Deep groove ball bearing or oil-impregnated bronze sleeve bearing
Bearing Loader	3000lb capacity with force transducer
Torque meter	Up to 20N.m with built-in 360 pulse encoder
Output shaft encoder	360 pulse per turn encoder
Magnetic Brake	1.5 to 32 lb.ft capacity heavy duty magnetic particle brake
Wind Turbine	Chain driven 3 blade, 6 feet span
Foundation	1/2″ (12.7 mm) die cast aluminum base, base stiffener and eight rubber isolators
Physical
Weight	Approximately 250 lb
Dimensions	L=56″ (142cm), W=76″ (190cm), H=96″ (220cm)

Basic Wind Turbine Drivetrain Diagnostics Simulator System includes:

3 HP Variable frequency AC drive with multi-featured front panel programmable controller, 220 VAC 1 phase supply
3 Phase 3 HP motor, pre-wired self-aligning mounting system for easy installation/removal
Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposes
1 stage planetary gearbox with 4.7:1 gear ratio, planetary gear with 3 planet stage
2 stage parallel shaft gearbox with three in-line parallel shafts configurable as single or two stage reduction/increaser
Four Spur Gears to obtain two gear mesh frequencies and three shaft speeds in parallel gearbox
Six rolling element bearings in parallel gearbox
Programmable Heavy duty magnetic brake(780lb-in) with power supply for gearbox loading
Wind turbine simulator consisting of a tower, three blades with PC programmable variable pitch system, direct coupled system to connect blades to gearbox brake-end or chain driven system to connect blades
Precision machined bearing housings at both ends of the gearbox with mountings for direct measurements of bearing vibration
Parallel gearbox oil level gauge
1/2″ die cast aluminum base, base stiffener and eight rubber isolators
Comprehensive operations manual

The WTDS provides a basic setup for performing drivetrain experiments and for learning vibration signatures of gearbox and bearing malfunctions. However, a detailed investigation of particular and more advance vibration phenomena will require additional attachments and fixtures which are available through optional kits.
Bearing Fault Kit (G-BFK-1)
Learn waveform and spectra of classic bearing defects. Learn about signal processing issues such as averaging techniques, leakage, and spectral resolution on determining bearing faults. Perform experiments with increasing severity of defects. Determine why an ultra-high resolution spectrum is needed to diagnose a bearing fault when fault frequencies are located close to multiples rotational speed. Learn how a large signal can mask adjoining low amplitude signal due to spectra leakage. The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Planetary Gearbox Bearing Fault Kit (G-BFK-P)
Study bearing faults in planetary gearbox The kit consists of two different levels of inner race fault and two different levels of needle fault Perform experiments with increasing severity of defects. Determine why an ultra-high resolution spectrum is needed to diagnose a bearing fault when fault frequencies are located close to multiples rotational speed. Learn how a large signal can mask adjoining low amplitude signal due to spectra leakage. The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Radial Bearing Loader (G-RBL)
Investigate bearing radial loading effects. Understand bearing failure signature as a function of load and rotational speed. Compare vibration signature between loaded and unloaded bearings. Study outer race bearing fault signature as a function of load location. The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Defective spur gears (G-SDG)
Study the effect of damaged tooth in gearboxes. Apply phase demodulation signal analysis to detect gear damage. Investigate backlash between mating gears. The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Defective planetary gears (G-PDG)
Study the effect of damaged planetary gears. Apply phase demodulation signal analysis to detect gear damage. The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Eccentric Spur Gear (G-ESG)
Study the effects of eccentric spur gear. Measure the vibration signature of eccentric gears. The kit consists of one eccentric spur gear. The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Helical gears set (G-HG)
Study the helical gears parallel shaft gearbox. Compare vibration signature between spur and helical gears. The kit consists of four helical gears to replace standard spur gears in gearbox The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Defective helical gears (G-HDG)
Study the effect of damaged helical gears. Apply phase demodulation signal analysis to detect gear damage. The kit consists of one gear with chipped tooth and one gear with missing tooth,and one gear with surface defect Requires G-HG The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Torque transducer with built encoder on input shaft (G-TOR)
Measure the torque on the input shaft. Study torque variation through full rotation cycle. Track shaft position in signal analysis. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Shaft encoder (G-ENC)
Measure transmission error in the gearbox by comparing input and output rotation. The kit consists of one 360 pulse per revolution encoder and once per revolution index Track shaft position in signal analysis. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
PC Motor Control Kit (G-PCK)
Operate DDS from remote location. Pre-program speed acceleration, deceleration, and length of run to meet exact requirements. The kit consists of PC software, one interface module to motor drive and cables. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
PC Load Control Kit (G-PCLK)
Operate magnetic brake from remote location. Pre-program load profiles of run to meet exact requirements. The kit consists of PC software, one interface module to magnetic brake and cables. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
Radial Bearing Loader Force Transducer (G-RBFT)
Measure the radial load applied by the mechanically operated bearing loader. The kit consists of one transducer measuring radial force and one matching signal conditioner. The kit consists of PC software, one interface module to magnetic brake and cables. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder The kit consists of one mechanical bearing loader The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.

High Value Combination Packages

The WTDS is available in various high value combination packages.

Package # 1 :	Basic WTDS + Kits for in-depth studies of wind turbine drivetrain diagnostics
Package # 2 :	Basic WTDS + Kits in-depth studies of wind turbine drivetrain diagnostics with instrumentation
Package # 3 :	Basic WTDS + Kits in-depth studies of wind turbine drivetrain diagnostics with instrumentation plus torque transducer and encoders

Option kit		PKG 1	PKG 2	PKG 3
Parallel gearbox bearing fault kit	W-BFK-1	x	x	x
Planetary gearbox bearing fault kit	W-BFK-P	x	x	x
Defective spur gears	W-SDG	x	x	x
Eccentric spur gear	W-ESG	x	x	x
Helical gears set	W-HG	x	x	x
Defective helical gears	W-HDG	x	x	x
Defective planatary gears	W-PDG	x	x	x
PC motor control kit	W-PCMK		x	x
PC load control kit	W-PCLK		x	x
Radial bearing loader	W-RBL		x	x
Radial bearing loader force transducer (Requires G-RBL)	W-RBFT		x	x
Torque transducer with built encoder on input shaft	W-TOR			x
Shaft encoder	W-ENC			x

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Wind Turbine Drivetrain Diagnostics Simulator

An Ideal Apparatus for Wind Turbine Reliability Studies

Flexible Drivetrain Fault Diagnostics

Features

The WTDS is Heavy-Duty and Easily Configurable

Transducers and DAQ

Basic Wind Turbine Drivetrain Diagnostics Simulator System includes:

Bearing Fault Kit (G-BFK-1)

Planetary Gearbox Bearing Fault Kit (G-BFK-P)

Radial Bearing Loader (G-RBL)

Defective spur gears (G-SDG)

Defective planetary gears (G-PDG)

Eccentric Spur Gear (G-ESG)

Helical gears set (G-HG)

Defective helical gears (G-HDG)

Torque transducer with built encoder on input shaft (G-TOR)

Shaft encoder (G-ENC)

PC Motor Control Kit (G-PCK)

PC Load Control Kit (G-PCLK)

Radial Bearing Loader Force Transducer (G-RBFT)

High Value Combination Packages