Analysis of Failures of High Speed Shaft Bearing System in a Wind Turbine

During the operation of wind turbines with gearbox of traditional configuration, consisting of one planetary stage and two helical stages high failure rate of high speed shaft bearings is observed. Such a high failures frequency is not reflected in the results of standard calculations of bearing durability. Most probably it can be attributed to atypical failure mechanism. The authors studied problems in 1.5 MW wind turbines of one of Polish wind farms. The analysis showed that the problems of high failure rate are commonly met all over the world and that the statistics for the analysed turbines were very similar. After the study of potential failure mechanism and its potential reasons, modification of the existing bearing system was proposed. Various options, with different bearing types were investigated. Different versions were examined for: expected durability increase, extent of necessary gearbox modifications and possibility to solve existing problems in operation.