IEC 61400-4:2012
(Main)Wind turbines - Part 4: Design requirements for wind turbine gearboxes
Wind turbines - Part 4: Design requirements for wind turbine gearboxes
IEC 61400-4:2012 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. It 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. The standard is based on gearbox designs using rolling element bearings. 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.
Eoliennes - Partie 4: Exigences de conception des boîtes de vitesses des 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.
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IEC 61400-4
Edition 1.0 2012-12
INTERNATIONAL
STANDARD
colour
inside
Wind turbines –
Part 4: Design requirements for wind turbine gearboxes
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IEC 61400-4
Edition 1.0 2012-12
INTERNATIONAL
STANDARD
colour
inside
Wind turbines –
Part 4: Design requirements for wind turbine gearboxes
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
PRICE CODE
XG
ICS 27.180 ISBN 978-2-83220-506-8
– 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
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
– 4 – 61400-4 © IEC:2012(E)
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 .
...
IEC 61400-4 ®
Edition 1.0 2012-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Wind turbines –
Part 4: Design requirements for wind turbine gearboxes
Éoliennes –
Partie 4: Exigences de conception des boîtes de vitesses des éoliennes
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
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copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.
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Switzerland
About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.
About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigendum or an amendment might have been published.
IEC publications search - webstore.iec.ch/advsearchform Electropedia - www.electropedia.org
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variety of criteria (reference number, text, technical containing more than 22 000 terminological entries in English
committee,…). It also gives information on projects, replaced and French, with equivalent terms in 16 additional languages.
and withdrawn publications. Also known as the International Electrotechnical Vocabulary
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IEC 61400-4 ®
Edition 1.0 2012-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Wind turbines –
Part 4: Design requirements for wind turbine gearboxes
Éoliennes –
Partie 4: Exigences de conception des boîtes de vitesses des éoliennes
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 27.180 ISBN 978-2-8322-7835-2
– 2 – IEC 61400-4:2012 © IEC 2012
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
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 . 51
7.4.3 Flexible splines . 51
7.4.4 Shaft seals . 52
7.4.5 Fasteners . 52
7.4.6 Circlips (snap rings) . 53
7.5 Structural elements . 53
7.5.1 Introduction . 53
7.5.2 Reliability considerations . 53
7.5.3 Deflection analysis . 54
7.5.4 Strength verification. 54
7.5.5 Static strength assessment . 55
7.5.6 Fatigue strength assessment . 58
7.5.7 Material tests . 63
7.5.8 Documentation . 63
7.6 Lubrication . 64
7.6.1 General considerations . 64
7.6.2 Type of lubricant . 65
7.6.3 Lubricant characteristics . 65
7.6.4 Method of lubrication .
...
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