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D. J. Lekou , F. Mouzakis Centre for Renewable Energy Sources (CRES)

Fused Acoustic Emission & Vibration Techniques for Health Monitoring of Wind Turbine Gearboxes and Bearings. D. J. Lekou , F. Mouzakis Centre for Renewable Energy Sources (CRES). A. A. Anastassopoulos, D. Kourousis Envirocoustics S. A. Drive Train. Main Shaft Gearbox High speed shaft

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D. J. Lekou , F. Mouzakis Centre for Renewable Energy Sources (CRES)

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  1. Fused Acoustic Emission & VibrationTechniques for Health Monitoring of Wind Turbine Gearboxes and Bearings D. J. Lekou, F. Mouzakis Centre for Renewable Energy Sources (CRES) A. A. Anastassopoulos, D. Kourousis Envirocoustics S. A. European Wind Energy Conference 2009 16 – 19 March, Marseille, France

  2. Drive Train • Main Shaft • Gearbox • High speed shaft • Respective bearings European Wind Energy Conference 2009, Marseille, France

  3. Drive Train Component Failures • Roller Bearings • Ring & Roller cracks • Wearing, Spalling, Brinelling & Fluting • Gear Elements • Tooth cracking, Micro-pitting • Abrasion & Spalling • Shafts • Cracks & Imbalances European Wind Energy Conference 2009, Marseille, France

  4. Condition Monitoring • Vibration measurements • Wind Turbine Operation Measurements • Complemented by: • Oil analysis • Debris monitoring • Temperature monitoring • Visual Inspections (incl. Bore-scope) European Wind Energy Conference 2009, Marseille, France

  5. Vibration analysis - Classification • Low Frequency (0 – 20 kHz) • Monitoring of total oscillatory motion • FFT, Spectrum analysis • Medium Frequency (20 – 100 kHz) • Detection of waves @ the speed of sound • HFE, “Stress wave”, “Spike Energy”, etc. • High Frequency ( >100 kHz) • Detection of transient elastic waves • Acoustic Emission European Wind Energy Conference 2009, Marseille, France

  6. Vibration analysis – Low Frequency • Low Frequency (0 – 20 kHz) • Monitoring of total oscillatory motion • FFT, Spectrum analysis • Medium Frequency (20 – 100 kHz) • Detection of waves @ the speed of sound • HFE, “Stress wave”, “Spike Energy”, etc. • High Frequency ( >100 kHz) • Detection of transient elastic waves • Acoustic Emission European Wind Energy Conference 2009, Marseille, France

  7. Vibration analysis – Medium Frequency • Low Frequency (0 – 20 kHz) • Monitoring of total oscillatory motion • FFT, Spectrum analysis • Medium Frequency (20 – 100 kHz) • Detection of waves @ the speed of sound • HFE, “Stress wave”, “Spike Energy”, etc. • High Frequency ( >100 kHz) • Detection of transient elastic waves • Acoustic Emission European Wind Energy Conference 2009, Marseille, France

  8. Vibration analysis – High Frequency • Low Frequency (0 – 20 kHz) • Monitoring of total oscillatory motion • FFT, Spectrum analysis • Medium Frequency (20 – 100 kHz) • Detection of waves @ the speed of sound • HFE, “Stress wave”, “Spike Energy”, etc. • High Frequency ( >100 kHz) • Detection of transient elastic waves • Acoustic Emission European Wind Energy Conference 2009, Marseille, France

  9. Acoustic Emission • Detection of transient events • Due to rapid release of energy • Localized Source European Wind Energy Conference 2009, Marseille, France

  10. Acoustic Emission Signal & Features • Continuous type • Time-Driven Data • RMS • ASL • Absolute Energy • Burst type • AE Hit • Descriptors e.g. • Amplitude • Counts • Energy European Wind Energy Conference 2009, Marseille, France

  11. Experimental Set-Up • Measuring Loads & Vibrations • Wind Inflow parameters • Wind Turbine Operational Parameters • Mechanical Loads on Drive – Train • Vibration & Displacement on Gearbox • Acoustic Emission System • PAC PCI-2 18-bit A/D card • CH1: R30a (100kHz – 400kHz) • CH2: PICO (200kHz – 750kHz) European Wind Energy Conference 2009, Marseille, France

  12. Experimental Set-up details European Wind Energy Conference 2009, Marseille, France

  13. Indicative Results – Simulated source V S Magnitude kHz European Wind Energy Conference 2009, Marseille, France

  14. Indicative Results – Operational AE Hit V S Magnitude kHz European Wind Energy Conference 2009, Marseille, France

  15. Indicative results – AE & Vibration 2ms European Wind Energy Conference 2009, Marseille, France

  16. Indicative Results – Time-driven data ASL Absolute Energy Power (kW) European Wind Energy Conference 2009, Marseille, France Time (s)

  17. Indicative results – e.g. ASL vs POWER European Wind Energy Conference 2009, Marseille, France

  18. Conclusions - Discussion • Footprint of normal operation • Capturing Time-driven data • Capturing Transient events • Simulation of failure upper limit • Different characteristics from “normal” • Both methods have limitations • Combination of methods preferred European Wind Energy Conference 2009, Marseille, France

  19. Future Work • Footprint of failures • Introduction of failures • Use of Pulser Simulator • Increase data base • Application on other Wind Turbine Types European Wind Energy Conference 2009, Marseille, France

  20. Thank you for your attention • Acknowledgements • Partially supported by the European Regional Development Fund and the Greek Secretariat for R & D through AKMON • Part of the work was performed within the EC co-funded project PROTEST (212825) European Wind Energy Conference 2009, Marseille, France

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