Calculating loads and life-time reduction of wind turbine gearbox and generator bearings due to shaft misalignment

During the last two decades, wind turbine industries have faced high failure rates, downtimes and costly repairs. Gearbox and generator have contributed to this, especially, because their high speed shaft bearings have often failed. In this article, an analytical method is proposed to calculate the reaction loads of flexible connecting couplings installed between wind turbine gearbox and generator. Reaction loads are determined from joint kinematics and metal disk pack deformations as well as axial and angular shaft misalignment. The calculations are executed for both flexible connecting couplings and a universal joint shaft and applied to the gearbox high speed shaft. The performance of flexible connecting couplings and universal joint shaft is compared with respect to the bearing loads and life-time of the gearbox high speed shaft. It is shown that the early, unplanned bearing failures of gearbox and generator high speed
shaft can often be attributed to the flexible connecting couplings installed between gearbox and generator.