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Design optimization of a wind turbine gear transmission based on fatigue reliability sensitivity

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Abstract

Fatigue failure of gear transmission is one of the key factors that restrict the performance and service life of wind turbines. One of the major concerns in gear transmission under random loading conditions is the disregard of dynamic fatigue reliability in conventional design methods. Various issues, such as overweight structure or insufficient fatigue reliability, require continuous improvements in the reliability-based design optimization (RBDO) methodology. In this work, a novel gear transmission optimization model based on dynamic fatigue reliability sensitivity is developed to predict the optimal structural parameters of a wind turbine gear transmission. In the model, the dynamic fatigue reliability of the gear transmission is evaluated based on stress-strength interference theory. Design variables are determined based on the reliability sensitivity and correlation coefficient of the initial design parameters. The optimal structural parameters with the minimum volume are identified using the genetic algorithm in consideration of the dynamic fatigue reliability constraints. Comparison of the initial and optimized structures shows that the volume decreases by 3.58% while ensuring fatigue reliability. This work provides new insights into the RBDO of transmission systems from the perspective of reliability sensitivity.

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Abbreviations

b :

Face width, mm

CA:

Convergence accuracy

C 0 :

Degradation factor

d 1 :

Diameter of the reference circle, mm

d(X 1, X 2):

Similarity degree between two design parameters

F t :

Tangential tooth load, N

g(t):

Dynamic fatigue reliability function

g 11 :

First tooth of the pinion gear in Stage II

g 81 :

Eighth tooth of the wheel gear in Stage II

g II1 :

Wheel gear in Stage II

g II2 :

Pinion gear in Stage II

g III1 :

Wheel gear in Stage III

g III2 :

Pinion gear in Stage III

i StgI :

Transmission ration of Stage I

i StgII :

Transmission ration of Stage II

i StgIII :

Transmission ration of Stage III

K a :

Application factor

K aβ :

Face load factor of bending stress calculation

Kfα :

Transverse load factor of bending stress calculation

K hβ :

Face load factor of contact stress calculation

K hα :

Transverse load factor of contact stress calculation

K v :

Dynamic factor

m n :

Normal module, mm

n :

Gear velocity

p Ii :

Planetary gear in Stage I

R(t):

Dynamic reliability, %

R f0 :

Initial bending fatigue reliability, %

R H0 :

Initial contact fatigue reliability, %

R SF :

Initial bending fatigue reliability determined by the safety factor, %

R SH :

Initial contact fatigue reliability determined by the safety factor, %

R ops :

Fatigue reliability of the optimized structure

R inis :

Fatigue reliability of the initial structure

R i (t):

Dynamic fatigue reliability of Stages II and III, %

R iH (t):

Dynamic contact fatigue reliability of Stages II and III, %

R iF (t):

Dynamic bending fatigue reliability of Stages II and III, %

R I(t):

Dynamic fatigue reliability of Stage I, %

R IFr (t):

Dynamic bending fatigue reliabilities of the ring gear, %

R IHr (t):

Dynamic contact fatigue reliabilities of the ring gear, %

R IFs (t):

Dynamic bending fatigue reliabilities of the sun gear, %

R IHs (t):

Dynamic contact fatigue reliabilities of the sun gear, %

R IFpi (t):

Dynamic bending fatigue reliabilities of the planetary gear, %

R IHpi (t):

Dynamic contact fatigue reliabilities of the planetary gear, %

sI :

Sun gear in Stage I

r(n):

Residual fatigue strength of the gear under n loading cycle numbers, N/mm2

r(0):

Initial fatigue strength of the gear without any damage

S max :

Equivalent peak load of the gear, N/mm2

S F :

Initial bending safety factor

S H :

Initial contact safety factor

rI :

Ring gear in Stage I

T 1 :

Sample torque for stress calculation

t :

Service time, year

u :

Gear ratio

V op :

Volume of the optimized structure, Vini Volume of the initial structure, m3

v :

Circumferential velocity, m/s

\({\overline X_1}\) :

Basic factor set

\({\overline X_2}\) :

Stress calculation factor set

\({\overline X_3}\) :

Fatigue strength calculation factor set

\(\overline X \) :

Initial design parameter set

\(\overline x \) :

Design variable set

Y Fa :

Tooth form factor

Y S a :

Dedendum stress concentration factor

Y ε :

Contact ratio factor of bending stress calculation

Y β :

Helix angle factor of bending stress calculation

Y ST :

Stress correction factor of bending fatigue strength calculation

Y NT :

Life factor of bending fatigue strength calculation

Y X :

Size factor of bending fatigue strength calculation

Z H :

Zone factor

Z E :

Elasticity factor

Zε :

Contact ratio factor of contact stress calculation

Z β :

Helix angle factor of contact stress calculation

Z NT :

Life factor of contact fatigue strength calculation

Z L :

Lubrication factor

Z v :

Velocity factor

Z R :

Roughness factor

Z W :

Work hardening factor

Z X :

Size factor of contact fatigue strength calculation

z 1 :

First tooth of the ring gear in Stage I

z 2 :

Second tooth of the ring gear in Stage I

z 5 :

Fifth tooth of the sun gear in Stage I

α t :

Calculation factor of the zone factor, αt = arctan(tanαn/cosβ)

β :

Helix angle, °

β(t):

Reliability index

β b :

Calculation factor of the zone factor, βb = arctan(tanβcosαt)

η :

Mutation probability

μ g(t) :

Mean value of dynamic fatigue reliability

ρ(X 1,X 2):

Correction coefficient between two design parameters

σF:

Bending stress of tooth root, N/mm2

σ Fst :

Maximum bending static strength, N/mm2

σ Fpst :

Maximum bending static allowable strength, N/mm2

σ Flim :

Allowable bending stress number, N/mm2

σ H :

Contact stress of tooth face, N/mm2

σ Hst :

Maximum contact static strength, N/mm2

σ Fst :

Maximum contact static allowable strength, N/mm2

σ Hlim :

Allowable contact stress number, N/mm2

σ g(t) :

Variance of dynamic fatigue reliability function

Φ(·):

Cumulative distribution function of the standard normal distribution

ϕ(·):

Probability density function of standard normal distribution ⊗ Kronecker product

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Acknowledgements

This work was financially supported by the National Natural Science Foundation of China (Grant No. U1864210).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing, 400044, China

    Genshen Liu, Huaiju Liu, Caichao Zhu & Tianyu Mao

  2. School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, 610500, China

    Gang Hu

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  1. Genshen Liu
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  2. Huaiju Liu
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Correspondence to Huaiju Liu.

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Liu, G., Liu, H., Zhu, C. et al. Design optimization of a wind turbine gear transmission based on fatigue reliability sensitivity. Front. Mech. Eng. 16, 61–79 (2021). https://doi.org/10.1007/s11465-020-0611-5

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