Fatigue Analysis Design Approach, Manufacturing and Implementation of a 500 kW Wind Turbine Main Load Frame

Ahmet Selim Pehlivan, Mahmut Faruk Aksit and Kemalettin Erbatur
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Ahmet Selim Pehlivan: Department of Mechatronics Engineering, Faculty of Engineering and Natural Sciences, Sabanci University, 34956 Istanbul, Turkey
Mahmut Faruk Aksit: Department of Mechatronics Engineering, Faculty of Engineering and Natural Sciences, Sabanci University, 34956 Istanbul, Turkey
Kemalettin Erbatur: Department of Mechatronics Engineering, Faculty of Engineering and Natural Sciences, Sabanci University, 34956 Istanbul, Turkey

Energies, 2021, vol. 14, issue 12, 1-15

Abstract: The main load frame of a wind turbine is the primary mount for all nacelle equipment and is used as the principal load transmitter. This frame should have a reliable fatigue safety rating because it is a load-bearing component. In this work, the fatigue life design, manufacturing and implementation process for the main load frame of a 500 kW wind turbine are studied. The weight of the main load frame and static safety factors are preserved while the cyclic life of the bedplate is kept infinite. Modified Goodman theory is applied to achieve an effective fatigue design using a commercial finite element software package. Analytical calculations are carried out to obtain the safety factors of the bedplate and dynamic strength of the materials. A finite element approach is employed to perform stress analysis. Stress oscillations are established for both welded and cast parts of the hybrid bedplate, and the maximum and minimum stress values are established. Fatigue safety factors are calculated via fatigue analysis iterations. The obtained safety factors are adequate from the perspective of commonly accepted fatigue safety standards. Welding and casting techniques are applied together for manufacturing of the frame. On-site testing indicates that the wind turbine does not show any signs of fatigue. Rupture, cracks, and abrupt accelerometer reading variations are not observed.

Keywords: wind energy; wind turbine; main load frame; fatigue; Goodman; bedplate; finite element (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2021
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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