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<p>Wind energy is a&#xa0;crucial component of the global transition to renewable energy, and enhancing the performance, reliability, and cost-efficiency of wind turbines is key to their widespread adoption. One of the most important aspects of turbine reliability is the design of the main bearing system, which supports the drivetrain and experiences significant mechanical loads. This paper presents an in-depth analysis of the TRB-TRB (tapered roller bearings in O‑configuration) main bearing system, focusing on how variations in roller diameter, load angle, and bearing geometry affect load distribution, contact pressure, rating life, and overall cost efficiency.</p><p>Using Finite Element analysis from thyssenkrupp Rothe Erde, the study systematically examines a&#xa0;generic 6 MW onshore turbine drivetrain with roller diameters ranging from 60&#xa0;to 100 mm and load angles between 5 and 40°. The results demonstrate that optimized configurations significantly reduce manufacturing costs while maintaining technical integrity. These findings highlight the effectiveness of early-stage design optimization for achieving better cost efficiency, in line with the “Design-to-Cost” approach.</p><p>By combining technical simulation with economic analysis, the study provides a&#xa0;comprehensive framework for improving wind turbine main bearing systems. The insights from this research are particularly valuable for designing more efficient and cost-effective turbines, especially as turbines grow in size and capacity. Although the primary focus is on onshore wind turbines, the methods and findings could also be applied to offshore environments, where further research could explore the impact of harsher operational conditions on bearing performance.</p>

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Design-to-cost for TRB-TRB wind turbine main bearing systems

  • 期刊论文

  • 发表日期：

    2025年2月19日

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  • J. T. Terwey,
  • J. Mendelin

摘要

Wind energy is a crucial component of the global transition to renewable energy, and enhancing the performance, reliability, and cost-efficiency of wind turbines is key to their widespread adoption. One of the most important aspects of turbine reliability is the design of the main bearing system, which supports the drivetrain and experiences significant mechanical loads. This paper presents an in-depth analysis of the TRB-TRB (tapered roller bearings in O‑configuration) main bearing system, focusing on how variations in roller diameter, load angle, and bearing geometry affect load distribution, contact pressure, rating life, and overall cost efficiency.

Using Finite Element analysis from thyssenkrupp Rothe Erde, the study systematically examines a generic 6 MW onshore turbine drivetrain with roller diameters ranging from 60 to 100 mm and load angles between 5 and 40°. The results demonstrate that optimized configurations significantly reduce manufacturing costs while maintaining technical integrity. These findings highlight the effectiveness of early-stage design optimization for achieving better cost efficiency, in line with the “Design-to-Cost” approach.

By combining technical simulation with economic analysis, the study provides a comprehensive framework for improving wind turbine main bearing systems. The insights from this research are particularly valuable for designing more efficient and cost-effective turbines, especially as turbines grow in size and capacity. Although the primary focus is on onshore wind turbines, the methods and findings could also be applied to offshore environments, where further research could explore the impact of harsher operational conditions on bearing performance.