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BS EN IEC 61400-4:2025 - TC Tracked Changes. Wind energy generation systems - Design requirements for wind turbine gearboxes, 2025
- A-30381079.pdf [Go to Page]
- undefined
- European foreword
- Endorsement notice
- Annex ZA (normative) Normative references to international publications with their corresponding European publications [Go to Page]
- CONTENTS
- FOREWORD
- INTRODUCTION
- 1 Scope
- 2 Normative references
- 3 Terms, definitions, abbreviated terms, units and conventions [Go to Page]
- 3.1 Terms and definitions
- 3.2 Abbreviated terms and units
- 3.3 Conventions [Go to Page]
- 3.3.1 Shaft designations – examples for typical wind turbine gearbox architecture
- Figures [Go to Page]
- Figure 1 – Shaft designation in 3-stage parallel shaft gearboxes
- Figure 2 – Shaft designation in 3-stage gearboxes with one planet stage
- 4 Design process [Go to Page]
- 4.1 General
- Figure 3 – Shaft designation in 3-stage gearboxes with two planet stages
- Figure 4 – Shaft designation in 4-stage gearboxes with three planet stages
- 4.2 Gearbox type
- Tables [Go to Page]
- Table 1 – Definition of a gearbox type
- 4.3 Design life, service life, and reliability
- 4.4 Component class and consequence of failure
- 4.5 Design process
- Figure 5 – Design process flow chart
- 5 Gearbox interfaces and loads [Go to Page]
- 5.1 General
- 5.2 Interfaces
- 5.3 Loads
- 5.4 Drivetrain dynamics [Go to Page]
- 5.4.1 General
- 5.4.2 Model requirements
- 5.4.3 Required analyses
- 5.4.4 Evaluation of excitability
- 5.4.5 Verification of dynamic behaviour in system environment
- 6 Design and rating requirements [Go to Page]
- 6.1 Gears [Go to Page]
- 6.1.1 Reliability considerations
- 6.1.2 Calculation of gear load capacity
- Table 2 – Minimum safety factors for pitting resistance and bending strength
- Figure 6 – Definition of planet gear rim thickness [Go to Page]
- 6.1.3 Load factors
- Table 3 – Mesh load factor for planetary stages [Go to Page]
- 6.1.4 Materials
- 6.1.5 Accuracy
- 6.1.6 Manufacturing
- Table 4 – Required gear accuracy
- 6.2 Rolling bearings [Go to Page]
- 6.2.1 Reliability considerations
- 6.2.2 Bearing selection
- Figure 7 – Examples of bearing selection criteria [Go to Page]
- 6.2.3 Materials
- 6.2.4 Interface requirements
- 6.2.5 Design considerations
- Table 5 – Typical temperature differences for calculation of operating clearance [Go to Page]
- 6.2.6 Bearing lubrication
- 6.2.7 Rating calculations
- Table 6 – Bearing lubricant temperature for calculation of viscosity ratio
- Table 7 – Guide values for maximum contact stress
- 6.3 Plain bearings [Go to Page]
- 6.3.1 Reliability considerations
- 6.3.2 Design load cases and associated risks
- Table 8 – Plain bearing risks coupled to operating conditions
- Figure 8 – Notional operational conditions and plain bearing risk regions [Go to Page]
- 6.3.4 Shaft and housing fits
- 6.3.5 Hydrodynamic lubrication regime
- 6.3.6 Lubricant regime analysis
- 6.3.7 Bearing requirements
- 6.4 Shafts, keys, housing joints, splines, and fasteners [Go to Page]
- 6.4.1 Shafts
- Table 9 – Minimum safety factors [Go to Page]
- 6.4.2 Shaft-hub connections
- 6.4.3 Shaft seals
- 6.4.4 Fasteners
- 6.4.5 Bolted joints
- 6.4.6 Circlips
- 6.5 Structural elements [Go to Page]
- 6.5.1 General
- 6.5.2 Interfaces, boundary conditions, and loads
- 6.6 Lubrication [Go to Page]
- 6.6.1 General
- 6.6.2 Lubricant performance characteristics
- 6.6.3 Lubricant viscosity
- 6.6.4 Method of lubrication and cooling
- 6.6.5 Quantity of lubricant in the lubrication system
- 6.6.6 Operating temperatures
- 6.6.7 Temperature control
- 6.6.8 Lubricant condition monitoring
- 6.6.9 Lubricant filtration
- 6.6.10 Ports
- 6.6.11 Lubricant level indicator
- 6.6.12 Magnetic plugs
- 6.6.13 Breather port
- 6.6.14 Flow sensor
- 7 Design verification and design validation [Go to Page]
- 7.1 General
- 7.2 Design verification and validation plan
- 7.3 Failure mode categorization
- 7.4 Verification methods [Go to Page]
- 7.4.1 General
- 7.4.2 Testing
- Table 10 – Failure mode categorization [Go to Page]
- 7.4.3 Similarity
- 7.4.4 Simulation
- 7.5 Verification and validation matrix
- Table 11 – Verification and validation matrix
- 8 Manufacturing and quality assurance [Go to Page]
- 8.1 General
- 8.2 Quality plan [Go to Page]
- 8.2.1 General
- 8.2.2 Surface temper inspection of gears after grinding
- 8.2.3 Surface roughness inspection
- 8.3 Critical processes
- 8.4 Statistical process control
- 8.5 Factory acceptance testing [Go to Page]
- 8.5.1 Test objectives
- 8.5.2 Acceptance test plan
- 8.5.3 Factory test sequences
- 8.5.4 Acceptance measurements
- 8.6 Non-conforming components [Go to Page]
- 8.6.1 General
- 8.6.2 Grinding notches
- 9 Design for service and operation [Go to Page]
- 9.1 General
- 9.2 Service and operation design requirements
- 9.3 Service and operation documentation requirements
- 9.4 Safety
- Annex A (informative) Examples of drivetrain interfaces and loads specifications [Go to Page]
- A.1 General
- A.2 Common wind turbine drivetrain architectures [Go to Page]
- A.2.1 Non-integrated drivetrain with 4point suspension
- Figure A.1 – Non-integrated drivetrain with 4point suspension [Go to Page]
- A.2.2 Non-integrated drivetrain with 3point suspension
- A.2.3 Integrated drivetrain
- Figure A.2 – Non-integrated drivetrain with 3point suspension
- Figure A.3 – Rotor-side integration with rigid main shaft connection
- Figure A.4 – Rotor-side integration with flexible main shaft connection
- Figure A.5 – Generator-side integration with rotor support in generator
- Figure A.6 – Generator-side integration with rotor support in gearbox and generator
- Figure A.7 – Generator-side integration with rotor support in gearbox [Go to Page]
- A.2.4 Interfaces
- A.2.5 Coordinate system
- A.2.6 Interface descriptions
- Table A.1 – Analysis information at interfaces for non-integrated drivetrains [Go to Page]
- A.2.7 Engineering data at the interface
- A.3 Wind turbine load descriptions [Go to Page]
- A.3.1 Load description formats
- Table A.2 – Analysis information at interfaces for integrated drivetrain
- Table A.3 – Engineering data and design load descriptions [Go to Page]
- A.3.2 Rainflow matrices
- Table A.4 – Rainflow matrix example [Go to Page]
- A.3.3 Load revolution distribution
- Figure A.8 – Example of rainflow cycles per design load case [Go to Page]
- A.3.4 Extreme load descriptions
- Figure A.9 – Example of a load revolution distribution
- Table A.5 – Extreme load matrix example
- A.4 Wind turbine reference power and speed [Go to Page]
- A.4.1 General
- A.4.2 Wind turbine power control theory
- Figure A.10 – Wind turbine power control regions [Go to Page]
- A.4.3 Practicalities of power control
- Figure A.11 – Ideal power and speed control strategy
- Figure A.12 – Control strategy compared to actual response
- Annex B (informative) Dynamic gearbox model verification and validation [Go to Page]
- B.1 General
- B.2 Verification of drivetrain dynamics models
- B.3 Validation of drivetrain dynamics models
- Bibliography [Go to Page]
