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Collaborative optimization of meshing and lubrication for planetary gear-journal bearing integrated structure in high power density wind turbine drivetrains

Author

Listed:
  • Li, Hao
  • Tan, Jianjun
  • Fei, Wenjun
  • Zhu, Caichao
  • Sun, Yizhong
  • Sun, Zhangdong

Abstract

Replacing rolling bearings with journal bearings and integrating them with planetary gears can increase the torque density of wind turbine drivetrains. However, planetary gears are subjected to complex forces and moments from dynamic meshing of internal/external gear pairs, causing edge contact in journal bearings and feedback effects on gear meshing, leading to load bias and strong meshing-lubrication coupling. Considering the elastohydrodynamic (EHD) characteristics of planetary gear journal bearings (PGJB), the force-displacement compatibility equations between carrier pins and planetary gears are derived based on film force and thickness, establishing a rigid-flexible coupled tribo-dynamic model of wind turbine drivetrain. A surrogate model is used to reconstruct the mapping between modifications and system responses, and a multi-objective optimization model for gear and bearing modifications is established and solved using a genetic algorithm. The method's effectiveness is validated through comparisons before and after optimization and experimental tests. Results show that asymmetric deformation of carrier pins under dynamic meshing forces causes gear meshing load bias and PGJB edge contact, intensifying with increased input torque. After collaborative optimization, gear pair load bias and bearing edge contact are effectively reduced under all load conditions, significantly improving the load-sharing and vibration performance of the wind turbine gearbox.

Suggested Citation

  • Li, Hao & Tan, Jianjun & Fei, Wenjun & Zhu, Caichao & Sun, Yizhong & Sun, Zhangdong, 2025. "Collaborative optimization of meshing and lubrication for planetary gear-journal bearing integrated structure in high power density wind turbine drivetrains," Renewable Energy, Elsevier, vol. 255(C).
    • Handle: RePEc:eee:renene:v:255:y:2025:i:c:s0960148125014259
    DOI: 10.1016/j.renene.2025.123763
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    References listed on IDEAS

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    1. Zhu, Caichao & Xu, Xiangyang & Liu, Huaiju & Luo, Tianhong & Zhai, Hongfei, 2014. "Research on dynamical characteristics of wind turbine gearboxes with flexible pins," Renewable Energy, Elsevier, vol. 68(C), pages 724-732.
    2. Shields, Michael D. & Zhang, Jiaxin, 2016. "The generalization of Latin hypercube sampling," Reliability Engineering and System Safety, Elsevier, vol. 148(C), pages 96-108.
    3. Yin, Jiabao & Meng, Xianghui & Cheng, Shuai, 2025. "Enhancing wind turbine energy efficiency: Tribo-dynamics modeling and shape modification," Renewable and Sustainable Energy Reviews, Elsevier, vol. 208(C).
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