Reliability analysis of wind turbine gearboxes: past, progress and future prospects

Purpose As a clean and renewable energy source, wind energy will become one of the main sources of new energy supply in the future. Relying on the stable and strong wind resources at sea, wind energy has great potential to become the primary energy. As a critical part of the wind turbine, the gearbox of a wind turbine often bears a large external load. Especially at sea, due to the effects of ocean corrosion, waves and wind, the burden of the wind turbine gearbox is greater, which brings great challenges to its reliability analysis. This study aims to systematically review the reliability research in wind turbine gearboxes and guide future research directions and challenges. Design/methodology/approach This study systematically reviews some design requirements and reliability analysis methods for wind turbine gearboxes. Then, it summarizes previous studies on wind load uncertainty modeling methods, including the processing of wind measurement data and the summary of three different classifications of random wind speed prediction models. Finally, existing reliability analysis studies on two major parts of the gearbox are described and summarized. Findings First, the basic knowledge of wind turbine gearboxes and their reliability analysis is introduced. The requirements and reliability analysis methods of wind turbine gearboxes are explained. Then, the processing methods of wind measurement data and three different random wind speed prediction models are described in detail. Furthermore, existing reliability analysis studies on two common parts of wind turbine gearboxes, gears and bearings, are summarized and classified, including a summary of bearing failure modes. Finally, three possible future research directions for wind turbine gearbox reliability analysis are discussed, namely, reliability research under the influence of multiple factors on gears, damage indicators of bearing failure modes and quantitative evaluation criteria for the overall dynamic characteristics of offshore wind turbine gearboxes and a summary is also given. Originality/value This paper aims to systematically introduce the relevant contents of wind turbine gearboxes and their reliability analysis. The contents of wind speed data processing, predictive modeling and reliability analysis of major components are also comprehensively reviewed, including the classification and principle introduction of these contents.