Gearbox Reliability Collaborative Gearbox 1 Failure Analysis Report: December 2010 - January 2011

Unintended gearbox failures have a significant impact on the cost of wind farm operations. In 2007, NREL initiated the Gearbox Reliability Collaborative (GRC). The project combines analysis, field testing, dynamometer testing, condition monitoring, and the development and population of a gearbox failure database in a multi-pronged approach to determine why wind turbine gearboxes do not achieve their expected design life. The collaborative of manufacturers, owners, researchers, and consultants focuses on gearbox testing and modeling and the development of a gearbox failure database. Collaborative members also investigate gearbox condition monitoring techniques. Data gained from the GRC will enable designers, developers, and manufacturers to improve gearbox designs and testing standards and create more robust modeling tools. GRC project essentials include the development of two identical, heavily instrumented representative gearbox designs. Knowledge gained from the field and dynamometer tests conducted on these gearboxes builds an understanding of how the selected loads and events translate into bearing and gear response. This report contains the analysis of the first gearbox design.