In the field of renewable energy, wind power plants play an essential role in CO2-free energy generation. These power plants consist of wind turbines encompassing large gearboxes that operate around the clock to convert wind energy into electrical energy. However, these critical components face constant challenges due to ever-changing weather conditions, subject to fluctuating loads and stresses. This constant stress can lead to wear and tear, resulting in costly, unscheduled maintenance and operational downtime.
A research team at the Institute of Machine Elements (IMA) at the University of Stuttgart has now developed an innovative system that recognises damaged gears in gearboxes and simultaneously relieves them so that the overall performance of the system is not impaired. Dr Martin Dazer and his research team have developed an advanced monitoring and control system specifically designed for large gearboxes, particularly those used in wind turbines. This innovative system represents a significant advance in predictive maintenance and operational efficiency.
The core of this innovation lies in the ability to detect damage in gearboxes and to carry out targeted relief measures without compromising the overall performance of the system. In this way, the remaining service life of these critical components is significantly extended. Perhaps most importantly, it addresses one of the most pressing issues in the wind energy sector: the need for expensive unscheduled maintenance.
At the core of the system's functionality is its capacity to detect and respond to material fatigue, a pervasive issue in gear design. Of particular concern is the phenomenon known as 'pitting' on tooth flanks, which can occur in case-hardened gears commonly used in wind turbines. Pitting typically affects individual teeth and, if left unchecked, can lead to catastrophic failure of the entire gear system.
The control strategy employed by this system is both sophisticated and adaptive. It utilizes sensors to monitor the topography of gear surfaces continuously. When these sensors detect a predefined rate of change indicative of damage, the system springs into action. It automatically adjusts the turbine settings to reduce the load specifically on the affected tooth, all while maintaining the overall performance of the system.
This targeted approach to load management represents a significant advancement over traditional maintenance strategies. By allowing the gearbox to continue functioning efficiently even when damage is detected, the system minimizes downtime and extends the operational life of the equipment. This not only reduces maintenance costs but also increases the overall reliability and efficiency of wind turbines.
The potential impact of this technology extends beyond the wind energy sector. Any industry relying on large gearboxes could benefit from this innovative approach to predictive maintenance and performance optimization. Recognizing the broad applicability and significance of this invention, patents have been filed and granted both in Europe (EP 3604803 B1) and the United States (US 11,506,280 B2), securing the innovation's place in the technological landscape.
Technologie-Lizenz-Büro (TLB) GmbH is actively supporting the patent management and the commercialization of this pioneering technology, offering manufacturers the opportunity to get a license for this system. This collaboration ensures that the benefits of this research can be realized across various industries, potentially revolutionizing how we approach the maintenance and operation of large-scale mechanical systems.
For those interested in exploring the potential of this technology for their operations, further information is available through TLB's Innovation Manager, Monjur Islam.
