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Copyright of Tribologie und Schmierungstechnik is the property of Narr Francke Attempto Verlag GmbH & Co.KG and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Wind energy is an important renewable energy source. Rotor main bearings are critical components of wind turbines since a faulty main bearing leads to downtime and high repair costs. Operational expenditures amount to 32% of wind energy costs. The use of plain bearings as main bearings can potentially reduce these costs. Plain bearings with segmented sliding elements can be repaired up-tower without dismantling the drivetrain, as damaged segments can be exchanged individually. One such segmented plain bearing design is the conical plain bearing design called FlexPad. For the FlexPad, proof of concept was achieved for the 1 MW range during previous studies. Modern wind turbines—especially for offshore deployment—have increased in size significantly compared with their predecessors. The goal of current studies is to transfer the FlexPad design towards a main bearing unit at a market relevant scale of 8.5 MW. In this work, the identified scaling challenges are presented. A FlexPad model scaled to the 8.5 MW range is presented to illustrate the challenges. The bearing load components, such as radial forces and torque, increase on different scales with increasing rotor size leading to changed load characteristics with increasing size. Increased rotor weight and bearing diameters result in an increase in the breakaway torque required to start turbine rotation. This breakaway torque can exceed the torque generated by the turbine at starting wind speeds. The generally increased loads necessitate stiffer sliding segments leading to the increased weight of the segments, which hampers the ability to easily exchange segments. [ABSTRACT FROM AUTHOR]

Wind turbine drivetrains can be subjected to highly dynamic loading conditions caused by grid faults, power converter faults and dynamic wind excitations. These loading conditions can cause additional wear and possibly damage their components. Some of the most critical components in the mechanical drivetrain are its bearings. High-speed shaft bearings are especially prone to failure. Smearing is one possible damage pattern for these bearings. Previous studies observed a highly increased smearing risk caused by generator-induced torque excitations. In contrast, this study focuses on rotor-induced torque excitations and investigates the resulting smearing risk. The goal is to ascertain the general damage potential stemming from rotor-induced excitations for high-speed shaft bearings regarding smearing. To this end, a detailed bearing model was integrated into a validated multibody simulation of a research nacelle which was operated on a test bench. A smearing criterion was used to evaluate the smearing risk. Multiple sinusoidal rotor-induced torque excitations were investigated. The resulting smearing risk is highly dependent on the excitation amplitude and frequency, with higher amplitudes resulting in a greater smearing risk. Regarding frequency, only excitations with frequencies close to the system's first torsional eigenfrequency result in a significantly increased smearing risk. In general, the determined amplitudes and frequencies of rotor-induced torque excitations, necessary to cause a significant increase in smearing risk, are unlikely to occur in the field and therefore are of lesser importance to the high-speed shaft bearings than generator-induced torque excitations. [ABSTRACT FROM AUTHOR]