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BEARINGS & LINEAR MOTION


Schaeffler engineers use cutting-edge software to calculate and simulate a wind turbine drive train incorporating hydrodynamic plain bearings in its gearbox


Schaeffler explains how it uses closed loop engineering to


develop solutions that meet the demands of the wind


technology industry


DEVELOPMENT OF WIND TURBINES


DRIVING THE O


ptimised bearing design is fundamental to maximising wind turbine reliability and cost-effectiveness in operation. Schaeffler,


however, leverages closed loop engineering to play a key role that goes far beyond the provision of bearing solutions for on- and offshore wind. This approach, explained Bernd Endres, vice


president Regional Business Unit Wind at Schaeffler, enables the company to play a decisive role in further developing wind turbines and making them more cost-effective and efficient. He said: “As the term ‘closed loop’ suggests, the insights gained through simulation, testing and measurement are fed back into the product development process.” Schaeffler’s closed loop engineering approach


therefore starts with state-of-the-art calculation and simulation programs. These are specialised multi-body simulation programs that generate highly realistic dynamic models of individual rolling bearings, adjacent structures and even entire drive trains. The simulations use machine learning and cloud computing to optimise both the mechanics and the dynamics of wind turbine bearings. In addition to classic rolling bearings, Schaeffler can run calculations and simulations for the new hydrodynamic plain bearings that it developed for wind turbine gearboxes and that are now in series production.


BEARING TESTING Following this, to ensure reliability, Schaeffler subjects its wind turbine bearing systems to comprehensive testing. Its ‘Astraios’ test bench is used for large-size bearings to gain important insights into the loads and moments affecting wind turbine drive trains. The result is that new products can be tested under realistic conditions. In fact, the world’s most powerful test facility


for wind turbine main bearings is currently being built in Lindø, Denmark, in cooperation with LORC (Lindø Offshore Renewables Center) and R&D Test Systems. The facility should be ready to run its first test


programs by the end of 2025. Schaeffler played a major part in defining the specifications of the test facility and will use it to test its main shaft bearings in cooperation with turbine OEMs.


IN THE FIELD The third step in Schaeffler’s closed loop


engineering approach, alongside simulation and testing, is monitoring prototype turbines in field measurement campaigns. The results of these measurements are then used either to validate the original design parameters from the simulation process or to initiate further optimisations. The focus here is on the drive train, particularly the main shaft bearing system, as this is where all the forces exerted on the turbine add up. These early, design-phase measures, enable Schaeffler to minimise system failures and the associated costs while maximising system robustness. The closed loop approach also means that Schaeffler undertakes its bearing optimisation work in partnership with its customers. In this way, Schaeffler is helping to lower the levelised cost of electricity and drive the expansion of renewable energies.


Schaeffler


T: 0121 313 5830 www.schaeffler.co.uk/en/


WHITE PAPER COVERS THE MOUNTING AND DISMOUNTING OF ROLLING BEARINGS


Schaeffler has produced a new white paper that provides all you need to know about the correct preparation, installation and removal of rolling bearings, and how to ensure machine shafts are properly aligned. The company’s ten point checklist for safe mounting work will


help you avoid premature bearing failures in the future: • Protect your workspace and the rolling bearing from dust, dirt, and moisture. • Use drawings to familiarise yourself with the design. • Make sure that your bearing matches the specifications on the drawing.


• Check the housing bore and the shaft seat for dimensional, shape and positional accuracy, as well as cleanliness. • Ensure that the mounting of the bearing rings on the shaft or in the housing bore cannot be impaired by edges. A slip angle of 10˚ to 15˚ is helpful. • Wipe off any corrosion protection on the seat and contact surfaces. • Apply a very thin layer of suitable mounting paste to the cylindrical seating surfaces of the bearing rings.


• Do not cool the bearings. Condensation can lead to corrosion in the bearings and bearing seats. • After installation, apply a suitable lubricant to the rolling bearings. • Check the bearing to make sure it’s working properly. The white paper can be downloaded here: https://medias.schaeffler.co.uk/en/whitepaper/mounting-and-alignment


SEPTEMBER 2024 DESIGN SOLUTIONS 41


FEATURE


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