Bearings keep on rolling with the wind

The design and selection of suitable rolling bearings for wind turbine rotor shafts and gearboxes is critical in order to ensure a long service life and to minimise maintenance costs, says Dr Steve Lacey, Engineering Manager at Schaeffler UK.

For more than 25 years, the Schaeffler Group has designed and produced bearings for wind turbines. Specialist engineers work closely with designers, manufacturers and operators of wind turbines to ensure that the optimum bearing arrangements are selected to meet the demanding operating requirements.   Bearing selection is backed up by detailed calculations using sophisticated software developed within the Schaeffler Group.

Wind turbines consist of a rotor that is attached to the nacelle, which sits at the top of a tower. Within the nacelle are the main rotor, gearbox, generator, controller and brake. A cover protects the components inside the nacelle. The entire nacelle pivots to align optimally with the wind in order to prevent extreme loads and allow cost effective operation.

Wind turbines are designed to last for approximately 20 years. Therefore, the extended bearing rating life calculations should yield values of between 120,000 and 170,000 hours. Due to their location, onshore on hills and slopes, or several kilometres offshore and large tower heights, it is also critical that wind turbines have long maintenance intervals.

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