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Developing high durability roller bearings to continuously improve the performance of wind turbine gearbox bearings

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IMX High-Durability Bearings Enhance Torque Power Density of Wind Turbine Gearboxes​ IMX high-durability bearings increase the torque power density of wind turbine gearboxes. By extending the rated bearing life, they reduce the size of bearings and gears by 25%. Meanwhile, improved reliability prevents early bearing failure.​ IMX has developed a new type of roller bearing for wind turbine gearboxes. This bearing achieves an industry-leading rated life, which can significantly reduce gearbox downtime and maintenance time.​ IMX’s high-durability wind turbine gearbox bearings rely on an optimized combination of custom-engineered steel and heat treatment processes, designed to enhance fatigue resistance and reliability. The optimized chemical heat treatment process improves the surface and subsurface performance of the bearings.​ David Vaes, Manager of IMX Wind Turbine Gearbox Management Center, said: “The heat treatment process enhances the surface material properties of bearing components, increases the material strength of both surface and subsurface, and effectively handles high-stress operating conditions during bearing operation. The performance of rolling bearings largely depends on raw material parameters such as microstructure, residual stress, and hardness.”​ This custom steel and heat treatment process offers several benefits: it extends the rated life of the bearings, which in turn reduces the bearing size under the same operating conditions; it improves the load-carrying capacity of new bearings to resist typical failure modes of gearbox bearings, such as early bearing failures caused by white etching cracks (WEC), micro-pitting, and wear.
 

 

  内部轴承台架测试和计算显示,与目前的行业标准相比,轴承寿命提高了5倍。此外,在内部轴承台架测试也证明,抗应力起源的WECs导致的早期失效能力提高了10倍。
  SKF高耐久性齿轮箱轴承带来的性能提高意味着轴承尺寸可以减小,有助于增加齿轮箱的扭矩功率密度。这对于*新一代的大兆瓦多*风电机组设计来说至关重要。
  在一个典型的6 MW风电齿轮箱行星*中, 通过使用SKF高耐久性齿轮箱轴承,在保持与行业标准轴承相同额定寿命下,可将行星轮轴承的尺寸减小多达25%,从而使行星齿轮的尺寸也相应减小。
  齿轮箱中的不同位置可以实现类似的尺寸缩减。在平行齿轮*,轴承尺寸的减小也将降低打滑擦伤相关类型损伤的风险。
  阻止典型故障模式的发生,有助于齿轮箱制造商、风机厂家和服务提供商提高产品可靠性,减少计划外的停机和维修成本。
  这些新特征有助于降低风能的能源均等化成本(LCoE),并支持风能行业成为未来能源结构的基石。

 

 

 

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