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12-10-2016

Design of wind turbine multistage gearbox

Our client is an electrical power generating company, specializing

in the production of electrical energy from renewable sources.
The company is considering expanding their wind farm capacity
with the establishment of a 140 MW wind farm in south-western
Victoria. For this facility the client has approached our
organization to undertake the detailed design of locally-made
gearboxes.
Major areas of investigation include the following:
- Overall layout of gearbox,
- Gear design, including materials and dimensions,
- Shafts, including stresses, fatigue life, deflections,
- Bearings, seals and lubricants,
- Gearbox housing design

Task for Engineers Pag 1 of 3

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12-10-2016

 Preliminary Design Data

Rotor Type = 3-Bladed, Horizontal Axis (5º Tilt)
Rotor Diameter = 62m
Rotor Mass = 34 400 Kg
Rotor Speed at Peak Output = 19.2 RPM / 12.8 RPM
Rotor Shaft Power (Peak) = 1530 kW / 295 kW
Generator Shaft Speed (Peak) = 1518 RPM / 1012 RPM
Generator Output Power (Peak) = 1300 kW / 250 kW
Generator Synchronous Speed = 1500 RPM / 1000 RPM
Generator Efficiency = 98%
Duty Cycle (Estimated) = High-Speed: 50%; Low Speed
38%; Off:12%
Cut-In Wind Speed = 3 m/s
Cut-Over Wind Speed = 7 m/s
Cut-Out Wind Speed = 25 m/s
Full Rated-Power Wind Speed = 15 m/s (approx)

Task for Engineers Pag 1 of 3

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12-10-2016

 Environmental Factors
The wind turbine will be operating in south-western India. The
graph below shows the power/speed characteristics of turbine
rotor (blade pitch control). The location of the wind turbine
requires us to consider environmental factors influences the
material choice and design of the gear box. Since the wind turbine
will likely be located in a costal area, we must take this into
account in our design our gearbox so that is resistant to corrosion..

The client requested that the following restraints were met:

1. Height- 2.2 meters
2. Weight- 3.3 meters
3. Length – 1.7 meters
4. Transmit power with gear ratio of - 1:79.06
5. Efficiency – 86%

Task for Engineers Pag 1 of 3