Method for accelerated testing of wind turbine gearbox bearings based on frictional energy in the rolling contact

This paper investigates a method for a novel accelerated test procedure for rolling bearings in wind turbine gearboxes. Established test procedures e. g. highly accelerated lifetime tests (HALT) mainly reflect fatigue damage and not slip-induced damage patterns (e.g. smearing). A commonly used criterion to rate the severity of an operating point regarding slip-induced damage is the frictional energy. Frictional energy is introduced into the rolling contact as soon as there is a significant combination of simultaneously occurring slip and pressure. Up to now only critical thresholds for this criterion that must not be exceeded have been identified on small-scale component test rigs. However, the permissible amount and duration of overshoots of the critical threshold that lead to damage in the actual application are not understood yet. Therefore, the aim is to conduct tests on full-size test rigs in which frictional energy is applied until slip-induced damage occurs. In order to perform these tests in a reasonable time, it is essential to accelerate the test procedures. Thus, this paper introduces a method for accelerated test procedures based on frictional energy in the rolling contact. The requirement is that the same cumulated frictional energy as in field operation is applied in a shorter time on the test rig. A further requirement is that the frictional power in the accelerated test procedure never exceeds the maximum frictional power occurring in the field. This paper shows the theoretical background regarding frictional energy and the transfer to the test procedure.