Reliability analysis and prediction of wind turbine gearboxes

This paper presents a reliability analysis model of wind turbine gearboxes by developing a generic gearbox configuration and modular structure. It encapsulates all the reliability critical components within the gearbox subsystem in a wind turbine. Reliability block diagrams of gearbox modules and components have been established by using Relex Reliability Analysis software. Failure rates of the critical components are estimated by applying existing industrial standards and datasheets for general mechanical applications. Results of failure rates and reliability of three generic gearbox configurations have been obtained. To improve the reliability prediction of wind turbine gearbox, an advanced prediction model based on failure modes and load carrying capability of individual components under operational conditions has been discussed. This research has highlighted the importance of validation of the reliability prediction models using available field failure data, which could be only possible through collaborations of wind farm owners, WT manufacturers, gearbox manufacturers, and bearing manufacturers.