SIST EN 61400-4:2013
(Main)Wind turbines - Part 4: Design requirements for wind turbine gearboxes
Wind turbines - Part 4: Design requirements for wind turbine gearboxes
This part of the IEC 61400 series is applicable to enclosed speed increasing gearboxes for horizontal axis wind turbine drivetrains with a power rating in excess of 500 kW. This standard applies to wind turbines installed onshore or offshore. This International Standard provides guidance on the analysis of the wind turbine loads in relation to the design of the gear and gearbox elements. The gearing elements covered by this standard include such gears as spur, helical or double helical and their combinations in parallel and epicyclic arrangements in the main power path. This standard does not apply to power take off gears (PTO). The standard is based on gearbox designs using rolling element bearings. Use of plain bearings is permissible under this standard, but the use and rating of them is not covered. Also included is guidance on the engineering of shafts, shaft hub interfaces, bearings and the gear case structure in the development of a fully integrated design that meets the rigours of the operating conditions. Lubrication of the transmission is covered along with prototype and production testing. Finally, guidance is provided on the operation and maintenance of the gearbox.
Windenergieanlagen - Teil 4: Auslegungsanforderungen für Getriebe von Windenergieanlagen
Eoliennes - Partie 4: Exigences de conception des boîtes de vitesses pour éoliennes
IEC 61400-4:2012 s'applique aux boîtes de vitesses sous carter pour trains d'entraînement d'éolienne à axe horizontal dont la puissance nominale dépasse 500 kW. Elle s'applique aux éoliennes installés sur terre et en mer. La présente Norme internationale donne des recommandations sur l'analyse des charges d'éolienne en tenant compte de la conception des éléments d'engrenage et de boîte de vitesses. Les éléments d'engrènement couverts par cette norme comprennent les engrenages à dentures droite, hélicoïdale simple ou double et leurs combinaisons dans des configurations parallèles et épicycloïdales dans le trajet de puissance principal. Cette norme ne s'applique pas aux engrenages de prise de force (PTO). Elle repose sur les conceptions de boîte de vitesses utilisant des roulements à éléments roulants. Des roulements simples peuvent être utilisés dans le cadre de cette norme, mais leur utilisation et leur étalonnage ne sont pas traités. Cette norme inclut également des recommandations relatives à l'ingénierie des arbres, des interfaces de moyeu d'arbre, des roulements et de la structure du carter des engrenages durant le développement d'une conception entièrement intégrée satisfaisant à des conditions de fonctionnement rigoureuses. La lubrification de la transmission est abordée ainsi que le prototype et les essais de production. Enfin, des recommandations sur l'exploitation et la maintenance de la boîte de vitesses sont données.
Vetrne turbine - 4. del: Konstrukcijske zahteve za menjalnike vetrnih turbin
Ta del skupine standardov IEC 61400 se uporablja za zaprte menjalnike, ki povečujejo hitrost, za prenosnike moči na vodoravni osi za vetrne turbine z nazivno močjo, ki je večja od 500 kW. Ta standard velja za vetrne turbine, ki so nameščene na obali ali na morju. Ta mednarodni standard podaja navodila za analizo obremenitev vetrnih turbin glede na izdelavo sklopk in elementov menjalnikov. Elementi gonil v tem standardu vključujejo ravne, vijačne ali dvojne vijačne zobnike in njihove kombinacije v vzporednih in epicikličnih razporeditvah v glavni poti napajanja. Ta standard ne velja za sklopke za prenos moči (PTO). Ta standard je osnovan na menjalnikih, ki so izdelani z ležaji z vrtečimi deli. V skladu s tem standardom je dovoljena uporaba navadnih ležajev, vendar ta standard ne vključuje njihove uporabe in ocenjevanja. Vključene so tudi smernice za projektiranje jaškov, vmesnikov pesta jaška, ležajev in konstrukcijo škatle za sklopke. Te smernice se uporabljajo za razvoj integrirane zasnove, ki izpolnjuje stroge pogoje delovanja. Skupaj s preskušanjem prototipov in izdelovanja ta standard vključuje tudi mazanje menjalnika. Prav tako podaja smernice za delovanje in vzdrževanje menjalnikov.
General Information
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Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Vetrne turbine - 4. del: Konstrukcijske zahteve za menjalnike vetrnih turbinWindenergieanlagen - Teil 4: Auslegungsanforderungen für Getriebe von WindenergieanlagenEoliennes - Partie 4: Exigences de conception des boîtes de vitesses pour éoliennesWind turbines - Part 4: Design requirements for wind turbine gearboxes27.180Sistemi turbin na veter in drugi alternativni viri energijeWind turbine systems and other alternative sources of energyICS:Ta slovenski standard je istoveten z:EN 61400-4:2013SIST EN 61400-4:2013en01-junij-2013SIST EN 61400-4:2013SLOVENSKI
STANDARD
SIST EN 61400-4:2013
EUROPEAN STANDARD EN 61400-4 NORME EUROPÉENNE
EUROPÄISCHE NORM March 2013
CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung
Management Centre: Avenue Marnix 17, B - 1000 Brussels
© 2013 CENELEC -
All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 61400-4:2013 E
ICS 27.180
English version
Wind turbines -
Part 4: Design requirements for wind turbine gearboxes (IEC 61400-4:2012)
Eoliennes -
Partie 4: Exigences de conception des boîtes de vitesses pour éoliennes (CEI 61400-4:2012)
Windenergieanlagen -
Teil 4: Auslegungsanforderungen für Getriebe von Windenergieanlagen (IEC 61400-4:2012)
This European Standard was approved by CENELEC on 2013-01-08. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
SIST EN 61400-4:2013
EN 61400-4:2013 - 2 -
Foreword The text of document 88/438/FDIS, future edition 1 of IEC 61400-4, prepared by IEC/TC 88 "Wind turbines" and ISO/TC 60 "Gears" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as EN 61400-4:2013.
The following dates are fixed: • latest date by which the document has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2013-10-08 • latest date by which the national standards conflicting with the document have to be withdrawn (dow) 2016-01-08
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CENELEC [and/or CEN] shall not be held responsible for identifying any or all such patent rights.
Endorsement notice The text of the International Standard IEC 61400-4:2012 was approved by CENELEC as a European Standard without any modification. In the official version, for Bibliography, the following notes have to be added for the standards indicated: ISO/IEC 17025 NOTE
Harmonized as EN ISO/IEC 17025. ISO 2160 NOTE
Harmonized as EN ISO 2160. SIST EN 61400-4:2013
- 3 - EN 61400-4:2013
Annex ZA
(normative)
Normative references to international publications with their corresponding European publications
The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
NOTE
When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD applies.
Publication Year Title EN/HD Year
IEC 60050 series International electrotechnical vocabulary - -
IEC 61400-1 2005 Wind turbines -
Part 1: Design requirements EN 61400-1 2005
IEC 61400-3 - Wind turbines -
Part 3: Design requirements for offshore wind turbines EN 61400-3 -
IEC/TS 61400-13 2001 Wind turbine generator systems -
Part 13: Measurement of mechanical loads - -
IEC 61400-22 2010 Wind turbines -
Part 22: Conformity testing and certification EN 61400-22 2011
ISO 76 - Rolling bearings - Static load ratings
- -
ISO 281 2007 Rolling bearings - Dynamic load ratings and rating life - -
ISO 683 series Heat-treatable steels, alloy steels and free-cutting steels
- -
ISO 1328-1 - Cylindrical gears - ISO system of accuracy -
Part 1: Definitions and allowable values of deviations relevant to corresponding flanks of gear teeth - -
ISO 4287 - Geometrical Product Specifications (GPS) - Surface texture: Profile method - Terms, definitions and surface texture parameters EN ISO 4287 -
ISO 4288 - Geometrical Product Specifications (GPS) - Surface texture: Profile method - Rules and procedures for the assessment of surface texture EN ISO 4288 -
ISO 4406 - Hydraulic fluid power - Fluids - Method for coding the level of contamination by solid particles - -
ISO 5725-2 - Accuracy (trueness and precision) of measurement methods and results -
Part 2: Basic method for the determination of repeatability and reproducibility of a standard measurement method - -
ISO 6336 series Calculation of load capacity of spur and helical gears
- -
ISO 6336-1 2006 Calculation of load capacity of spur and helical gears -
Part 1: Basic principles, introduction and general influence factors - -
SIST EN 61400-4:2013
EN 61400-4:2013 - 4 -
Publication Year Title EN/HD Year
ISO 6336-2 2006 Calculation of load capacity of spur and helical gears -
Part 2: Calculation of surface durability (pitting)
- -
ISO 6336-3 2006 Calculation of load capacity of spur and helical gears -
Part 3: Calculation of tooth bending strength
- -
ISO 6336-5 2003 Calculation of load capacity of spur and helical gears -
Part 5: Strength and quality of materials - -
ISO 6336-6 2006 Calculation of load capacity of spur and helical gears -
Part 6: Calculation of service life under variable load - -
ISO/TR 10064-3 - Code of inspection practice -
Part 3: Recommendations relative to gear blanks, shaft centre distance and parallelism of axes - -
ISO 12925-1 - Lubricants, industrial oils and related products (class L) - Family C (Gears) -
Part 1: Specifications for lubricants for enclosed gear systems - -
ISO/TR 13593 - Enclosed gear drives for industrial applications - -
ISO/TR 13989-1 - Calculation of scuffing load capacity of cylindrical, bevel and hypoid gears -
Part 1: Flash temperature method Hide details
- -
ISO/TR 13989-2 - Calculation of scuffing load capacity of cylindrical, bevel and hypoid gears -
Part 2: Integral temperature method - -
ISO 14104 - Gears - Surface temper etch inspection after grinding - -
ISO 14635-1 2000 Gears - FZG test procedures -
Part 1: FZG test method A/8,3/90 for relative scuffing load-carrying capacity of oils - -
ISO 15243 2004 Rolling bearings - Damage and failures - Terms, characteristics and causes - -
ISO/TS 16281 2008 Rolling bearings - Methods for calculating the modified reference rating life for universally loaded bearings - -
AGMA 9005 - Industrial Gear Lubrication - -
ANSI/AGMA 925-A02 - Effect of lubrication on gear surface distress - -
ANSI/AGMA 6001-E10 - Design and selection of components for enclosed gear drives - -
ANSI/AGMA 6123 - Design manual for enclosed epicyclic gear drives - -
ASTM E1049-85 - Standard practices for cycle counting in fatigue analysis - -
DIN 471 - Circlips (retaining rings) for shafts: Normal type and heavy type - -
SIST EN 61400-4:2013
- 5 - EN 61400-4:2013
Publication Year Title EN/HD Year
DIN 472 - Circlips (retaining rings) for bores: Normal type and heavy type - -
DIN 743 2000 Shafts and axles, calculations of load capacity, Parts 1,2, 3 - -
DIN 3990-4 - Calculation of load capacity of cylindrical gears: calculation of scuffing load capacity - -
DIN 6885-2 - Parallel Key Geometries - -
DIN 6892 - Mitnehmerverbindungen ohne Anzug – Passfedern – Berechnung und Gestaltung - -
DIN 7190 - Interference fits – Calculation and design rules - -
DIN 51517-3 - Lubricants: Lubricating oils –
Part 3: Lubricating oils CLP; Minimum requirements - -
- - Founding - Ultrasonic examination -
Part 3: Spheroidal graphite cast iron castings EN 12680-3 2003
SIST EN 61400-4:2013
SIST EN 61400-4:2013
IEC 61400-4 Edition 1.0 2012-12 INTERNATIONAL STANDARD Wind turbines –
Part 4: Design requirements for wind turbine gearboxes
INTERNATIONAL ELECTROTECHNICAL COMMISSION XG ICS 27.180 PRICE CODE ISBN 978-2-83220-506-8
Warning! Make sure that you obtained this publication from an authorized distributor. SIST EN 61400-4:2013 colourinside
– 2 – 61400-4 © IEC:2012(E)
CONTENTS FOREWORD . 7 INTRODUCTION . 9 1 Scope . 10 2 Normative references . 10 3 Terms, definitions and conventions . 12 3.1 Terms and definitions . 12 3.2 Conventions . 15 4 Symbols, abbreviations and units . 17 4.1 Symbols and units . 17 4.2 Abbreviations . 21 5 Design for reliability . 23 5.1 Design lifetime and reliability . 23 5.2 Design process . 24 5.3 Documentation . 26 5.4 Quality plan . 26 6 Drivetrain operating conditions and loads . 27 6.1 Drivetrain description . 27 6.1.1 General . 27 6.1.2 Interface definition . 27 6.1.3 Specified requirements across interfaces. 28 6.2 Deriving drivetrain loads . 28 6.2.1 Wind turbine load simulation model . 28 6.2.2 Wind turbine load calculations . 29 6.2.3 Reliability of load assumptions . 29 6.3 Results from wind turbine load calculations . 29 6.3.1 General . 29 6.3.2 Time series . 30 6.3.3 Fatigue load . 30 6.3.4 Extreme loads . 31 6.4 Operating conditions . 31 6.4.1 General . 31 6.4.2 Environmental conditions . 31 6.4.3 Operating strategies . 32 6.5 Drivetrain analysis . 32 7 Gearbox design, rating, and manufacturing requirements . 32 7.1 Gearbox cooling . 32 7.2 Gears . 33 7.2.1 Gear reliability considerations. 33 7.2.2 Gear rating . 33 7.2.3 Load factors . 34 7.2.4 Gear materials . 36 7.2.5 Subsurface initiated fatigue . 37 7.2.6 Gear accuracy . 37 7.2.7 Gear manufacturing . 37 7.3 Bearings . 38 7.3.1 General . 38 SIST EN 61400-4:2013
61400-4 © IEC:2012(E) – 3 –
7.3.2 Bearing reliability considerations . 38 7.3.3 Bearing steel quality requirements . 39 7.3.4 General design considerations . 39 7.3.5 Bearing interface requirements . 42 7.3.6 Bearing design issues. 43 7.3.7 Bearing lubrication . 46 7.3.8 Rating calculations . 47 7.4 Shafts, keys, housing joints, splines and fasteners . 50 7.4.1 Shafts . 50 7.4.2 Shaft-hub connections . 50 7.4.3 Flexible splines . 51 7.4.4 Shaft seals . 51 7.4.5 Fasteners . 51 7.4.6 Circlips (snap rings) . 52 7.5 Structural elements . 52 7.5.1 Introduction . 52 7.5.2 Reliability considerations . 53 7.5.3 Deflection analysis . 53 7.5.4 Strength verification. 53 7.5.5 Static strength assessment . 54 7.5.6 Fatigue strength assessment . 58 7.5.7 Material tests . 62 7.5.8 Documentation . 63 7.6 Lubrication . 63 7.6.1 General considerations . 63 7.6.2 Type of lubricant . 64 7.6.3 Lubricant characteristics . 65 7.6.4 Method of lubrication . 66 7.6.5 Oil quantity . 67 7.6.6 Operating temperatures . 68 7.6.7 Temperature control . 68 7.6.8 Lubricant condition monitoring . 69 7.6.9 Lubricant cleanliness . 69 7.6.10 Lubricant filter . 70 7.6.11 Ports . 71 7.6.12 Oil level indicator . 71 7.6.13 Magnetic plugs . 71 7.6.14 Breather . 72 7.6.15 Flow sensor . 72 7.6.16 Serviceability . 72 8 Design verification . 72 8.1 General . 72 8.2 Test planning . 72 8.2.1 Identifying test criteria . 72 8.2.2 New designs or substantive changes . 73 8.2.3 Overall test plan . 73 8.2.4 Specific test plans . 73 8.3 Workshop prototype testing . 74 8.3.1 General . 74 SIST EN 61400-4:2013
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8.3.2 Component testing . 74 8.3.3 Workshop testing of a prototype gearbox . 74 8.3.4 Lubrication system testing . 75 8.4 Field test . 75 8.4.1 General . 75 8.4.2 Validation of loads . 75 8.4.3 Type test of gearbox in wind turbine . 76 8.5 Production testing . 77 8.5.1 Acceptance testing . 77 8.5.2 Sound emission testing . 77 8.5.3 Vibration testing . 77 8.5.4 Lubrication system considerations . 77 8.5.5 System temperatures . 77 8.6 Robustness test . 77 8.7 Field lubricant temperature and cleanliness . 77 8.8 Bearing specific validation . 78 8.8.1 Design reviews . 78 8.8.2 Prototype verification/validation . 78 8.9 Test documentation . 79 9 Operation, service and maintenance requirements . 79 9.1 Service and maintenance requirements . 79 9.2 Inspection requirements . 79 9.3 Commissioning and run-in . 79 9.4 Transport, handling and storage . 80 9.5 Repair . 80 9.6 Installation and exchange . 80 9.7 Condition monitoring . 80 9.8 Lubrication . 80 9.8.1 Oil type requirements . 80 9.8.2 Lubrication system. 80 9.8.3 Oil test and analysis . 81 9.9 Operations and maintenance documentation . 81 Annex A (informative)
Examples of drivetrain interfaces and loads specifications . 82 Annex B (informative)
Gearbox design and manufacturing considerations . 93 Annex C (informative)
Bearing design considerations . 96 Annex D (informative)
Considerations for gearbox structural elements . 122 Annex E (informative)
Recommendations for lubricant
performance in wind turbine gearboxes . 125 Annex F (informative)
Design verification documentation . 140 Annex G (informative)
Bearing calculation documentation . 143 Bibliography . 151
Figure 1 – Shaft designation in 3-stage parallel shaft gearboxes . 15 Figure 2 – Shaft designation in 3-stage gearboxes with one planet stage . 16 Figure 3 – Shaft designation in 3-stage gearboxes with two planet stages . 17 Figure 4 – Design process flow chart . 25 Figure 5 – Examples of bearing selection criteria . 39 SIST EN 61400-4:2013
61400-4 © IEC:2012(E) – 5 –
Figure 6 – Blind bearing assembly . 45 Figure 7 – Definition of section factor npl,σ of a notched component . 56 Figure 8 – Idealized elastic plastic stress-strain curve . 57 Figure 9 – Synthetic S/N curve (adapted from Haibach, 2006) . 60 Figure A.1 – Modular drivetrain . 82 Figure A.2 – Modular drivetrain with 3-point suspension . 83 Figure A.3 – Integrated drivetrain . 83 Figure A.4 – Reference system for modular drivetrain . 85 Figure A.5 – Rear view of drivetrain . 86 Figure A.6 – Reference system for modular drivetrain with 3-point suspension . 87 Figure A.7 – Reference system for integrated drivetrain . 88 Figure A.8 – Example of rainflow counting per DLC . 90 Figure A.9 – Example of load revolution distribution (LRD) . 91 Figure C.1 – Load bin reduction by lumping neighbouring load bins . 97 Figure C.2 – Consumed life index (CLI) . 99 Figure C.3 – Time share distribution . 99 Figure C.4 – Effects of clearance and preload on pressure
distribution in radial roller bearings (from Brandlein et al, 1999) . 102 Figure C.5 – Nomenclature for bearing curvature . 103 Figure C.6 – Stress distribution over the elliptical contact area . 105 Figure C.7 – Examples of locating and non-locating bearing arrangements . 114 Figure C.8 – Examples of locating bearing arrangements . 114 Figure C.9 – Examples of accommodation of axial displacements . 114 Figure C.10 – Examples of cross-locating bearing arrangements . 115 Figure C.11 – Examples of bearing arrangements with paired mounting . 115 Figure D.1 – Locations of failure for local (A) and global (B) failure . 123 Figure D.2 – Local and global failure for two different notch radii . 123 Figure D.3 – Haigh-diagram for evaluation of mean stress influence (Haibach, 2006) . 124 Figure E.1 – Viscosity requirements versus pitch line velocity . 126 Figure E.2 – Test apparatus for filterability evaluation . 134 Figure E.3 – Example for circuit design of combined filtration and cooling system . 138
Table 1 – Symbols used in the document . 18 Table 2 – Abbreviations . 21 Table 3 – Mesh load factor Kγ for planetary stages . 35 Table 4 – Required gear accuracy . 37 Table 5 – Temperature gradients for calculation of operating clearance . 4
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