EN 61400-4-2013 en Wind turbines - Part 4 Design requirements for wind turbine gearboxes.pdf

1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationWind turbinesPart 4: Design requirements for wind turbine gearboxesBS EN 61400-4:2013National forewordThis British Standard is the UK implementation of EN 61400-4:2013. It is ide

2、ntical to IEC 61400-4:2012. It supersedes BS ISO 81400-4:2005,which is withdrawn.The UK participation in its preparation was entrusted by Technical Committee PEL/88, Wind turbines, to Panel PEL/88/-/4, Wind turbine gearboxes (JWG 1).A list of organizations represented on this committee can be obtain

3、ed on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. The British Standards Institution 2013.Published by BSI Standards Limited 2013.ISBN 978 0 580 69337 3ICS 21.200; 27.180Compliance

4、 with a British Standard cannot confer immunity from legal obligations.This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 April 2013.Amendments issued since publicationDate Text affectedBRITISH STANDARDBS EN 61400-4:2013EUROPEAN STANDARD EN 6

5、1400-4 NORME EUROPENNE EUROPISCHE NORM March 2013CENELEC European Committee for Electrotechnical StandardizationComit Europen de Normalisation ElectrotechniqueEuropisches Komitee fr Elektrotechnische Normung Management Centre: Avenue Marnix 17, B - 1000 Brussels 2013 CENELEC - All rights of exploita

6、tion 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 desbotes de vitesses pour oliennes (C

7、EI 61400-4:2012) Windenergieanlagen - Teil 4: Auslegungsanforderungen fr Getriebe von Windenergieanlagen(IEC 61400-4:2012) This European Standard was approved by CENELEC on 2013-01-08. CENELEC members are bound to complywith the CEN/CENELEC Internal Regulations which stipulate the conditions for giv

8、ing this European Standardthe status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained onapplication to the CEN-CENELEC Management Centre or to any CENELEC member. This European Standard exists in three o

9、fficial versions (English, French, German). A version in any otherlanguage made by translation under the responsibility of a CENELEC member into its own language and notifiedto the CEN-CENELEC Management Centre has the same status as the official versions. CENELEC members are the national electrotec

10、hnical 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, Sl

11、ovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. BS EN 61400-4:2013EN 61400-4:2013 Foreword The text of document 88/438/FDIS, future edition 1 of IEC 61400-4, prepared by IEC/TC 88 “Windturbines“ and ISO/TC 60 “Gears“ was submitted to the IEC-CENELEC parallel vote and app

12、roved byCENELEC as EN 61400-4:2013. The following dates are fixed: latest date by which the document has to be implemented at national level bypublication of an identical national standard or by endorsement (dop) 2013-10-08 latest date by which the national standards conflicting with the document ha

13、ve 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 ofpatent rights. CENELEC and/or CEN shall not be held responsible for identifying any or all such patentrights. Endorsement notice The text of the International Sta

14、ndard IEC 61400-4:2012 was approved by CENELEC as a EuropeanStandard 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. BS E

15、N 61400-4:2013EN 61400-4:2013 Annex ZA (normative) Normative references to international publicationswith 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 reference

16、s, 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/HDapplies. Publication Year Title EN/HD Y

17、ear 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 windturbines EN 61400-3 - IEC/TS 61400-13 2001 Wind turbine generator systems - Part

18、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 andrating life - - ISO 683 series Heat-treatable steels, a

19、lloy steels and free-cutting steels - - ISO 1328-1 - Cylindrical gears - ISO system of accuracy - Part 1: Definitions and allowable values ofdeviations relevant to corresponding flanks ofgear teeth - - ISO 4287 - Geometrical Product Specifications (GPS) -Surface texture: Profile method - Terms, defi

20、nitions and surface texture parameters EN ISO 4287 - ISO 4288 - Geometrical Product Specifications (GPS) -Surface texture: Profile method - Rules and procedures for the assessment of surfacetexture EN ISO 4288 - ISO 4406 - Hydraulic fluid power - Fluids - Method forcoding the level of contamination

21、by solidparticles - - ISO 5725-2 - Accuracy (trueness and precision) ofmeasurement methods and results - Part 2: Basic method for the determination ofrepeatability and reproducibility of a standardmeasurement method - - ISO 6336 series Calculation of load capacity of spur and helicalgears - - ISO 63

22、36-1 2006 Calculation of load capacity of spur and helicalgears - Part 1: Basic principles, introduction andgeneral influence factors - - BS EN 61400-4:2013EN 61400-4:2013 Publication Year Title EN/HD Year ISO 6336-2 2006 Calculation of load capacity of spur and helicalgears - Part 2: Calculation of

23、 surface durability(pitting) - - ISO 6336-3 2006 Calculation of load capacity of spur and helicalgears - Part 3: Calculation of tooth bending strength - - ISO 6336-5 2003 Calculation of load capacity of spur and helicalgears - Part 5: Strength and quality of materials - - ISO 6336-6 2006 Calculation

24、 of load capacity of spur and helicalgears - Part 6: Calculation of service life undervariable load - - ISO/TR 10064-3 - Code of inspection practice - Part 3: Recommendations relative to gearblanks, shaft centre distance and parallelism of axes - - ISO 12925-1 - Lubricants, industrial oils and relat

25、ed products(class L) - Family C (Gears) - Part 1: Specifications for lubricants forenclosed gear systems - - ISO/TR 13593 - Enclosed gear drives for industrialapplications - - ISO/TR 13989-1 - Calculation of scuffing load capacity ofcylindrical, bevel and hypoid gears - Part 1: Flash temperature met

26、hod Hide details - - ISO/TR 13989-2 - Calculation of scuffing load capacity ofcylindrical, bevel and hypoid gears - Part 2: Integral temperature method - - ISO 14104 - Gears - Surface temper etch inspection aftergrinding - - ISO 14635-1 2000 Gears - FZG test procedures - Part 1: FZG test method A/8,

27、3/90 for relativescuffing 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 themodified reference rating life for universallyloaded bearings - - AGMA 9005 - Indu

28、strial Gear Lubrication - - ANSI/AGMA 925-A02 - Effect of lubrication on gear surface distress - - ANSI/AGMA 6001-E10 - Design and selection of components forenclosed gear drives - - ANSI/AGMA 6123 - Design manual for enclosed epicyclic geardrives - - ASTM E1049-85 - Standard practices for cycle cou

29、nting infatigue analysis - - DIN 471 - Circlips (retaining rings) for shafts: Normaltype and heavy type - - BS EN 61400-4:2013EN 61400-4:2013 Publication Year Title EN/HD Year DIN 472 - Circlips (retaining rings) for bores: Normaltype and heavy type - - DIN 743 2000 Shafts and axles, calculations of

30、 loadcapacity, Parts 1,2, 3 - - DIN 3990-4 - Calculation of load capacity of cylindricalgears: calculation of scuffing load capacity - - DIN 6885-2 - Parallel Key Geometries - - DIN 6892 - Mitnehmerverbindungen ohne Anzug Passfedern Berechnung und Gestaltung - - DIN 7190 - Interference fits Calculat

31、ion 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 BS EN 61400-4:201361400-4 IEC:2012(E) CONTENTS INTRODUCTION . 9 1 Scope 10

32、 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 p

33、rocess . 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

34、 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 Env

35、ironmental 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.

36、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 BS EN 61400-4:201361400-4 IEC:2012(E) 7.3.2 Bearing reliability considerations . . 38 7.3.3 Bearing steel quality requirements 39 7.3.4 General design considerations . 39 7.3

37、.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.

38、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 test

39、s 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 mon

40、itoring . 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 Identif

41、ying 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 BS EN 61400-4:201361400-4 IEC:2012(E) 8.3.2 Component testing 74 8.3.3 Workshop testing of a prototype gearbox .

42、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 sy

43、stem 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 maintenan

44、ce 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 requirem

45、ents . 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)

46、 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 c

47、alculation 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 char

48、t 25 Figure 5 Examples of bearing selection criteria 39 BS EN 61400-4:201361400-4 IEC:2012(E) Figure 6 Blind bearing assembly . . 45 Figure 7 Definition of section factor npl,of a notched component . 56 Figure 8 Idealized elastic plastic stress-strain curve . 57 Figure 9 Synthetic S/N curve (adapted

49、 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