Research on contact characteristics and fatigue life of main shaft
bearings in wind turbines under flexible constraints
Abstract
A 1:1 scale test platform was constructed to accurately simulate the
working conditions and flexible constraints of wind turbine bearings.
The research focuses on the main bearing of a 4.5MW wind turbine, where
a finite element model of the main shaft system is established. The
impact of ring deformation, load conditions, and bearing geometric
parameters on the contact characteristics and fatigue life of the main
bearing were investigated under the flexible constraints imposed by a
hollow main shaft and thin-walled bearing housing. The results indicate
that in comparison to the rigid ring model, the fatigue life of the main
bearing is reduced in the case of the flexible ring model. Additionally,
the location of maximum stress occurrence has shifted towards the larger
end of the roller when compared to the rigid ring model. The contact
load in the primary load-carrying region of the main bearing increases
with radial load and tilting moment, while the contact load in the
non-load-carrying region exhibits an inverse relationship. The number of
carrying rollers increases with the increase of axial load, leading to a
decrease in the contact force of the bearing. However, once all the
rollers are loaded, the contact force increases proportionally with the
axial load. As the contact angle increases, the contact load of the
tapered roller bearing (TRB) decreases. As the radial clearance
increases in the positive direction, the contact stress of the bearing
increases and consequently leads to a decrease in fatigue life. The
fatigue life of the bearing can be increased by applying a negative
clearance or axial preload of approximately -0.5mm. The increase in
interference between the inner ring and the spindle leads to a reduction
in bearing contact stress, thereby enhancing its fatigue life.