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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Ahmet Selim Pehlivan & Mahmut Faruk Aksit & Kemalettin Erbatur, 2021. "Fatigue Analysis Design Approach, Manufacturing and Implementation of a 500 kW Wind Turbine Main Load Frame," Energies, MDPI, vol. 14(12), pages 1-15, June.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:12:p:3581-:d:575955
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    References listed on IDEAS

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    1. Wang, Shuaishuai & Nejad, Amir R. & Bachynski, Erin E. & Moan, Torgeir, 2020. "Effects of bedplate flexibility on drivetrain dynamics: Case study of a 10 MW spar type floating wind turbine," Renewable Energy, Elsevier, vol. 161(C), pages 808-824.
    2. Hesam Mirzaei Rafsanjani & John Dalsgaard Sørensen, 2015. "Reliability Analysis of Fatigue Failure of Cast Components for Wind Turbines," Energies, MDPI, vol. 8(4), pages 1-16, April.
    3. Zhiyu Jiang & Weifei Hu & Wenbin Dong & Zhen Gao & Zhengru Ren, 2017. "Structural Reliability Analysis of Wind Turbines: A Review," Energies, MDPI, vol. 10(12), pages 1-25, December.
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    Cited by:

    1. Wei Li & Shinai Xu & Baiyun Qian & Xiaoxia Gao & Xiaoxun Zhu & Zeqi Shi & Wei Liu & Qiaoliang Hu, 2022. "Large-Scale Wind Turbine’s Load Characteristics Excited by the Wind and Grid in Complex Terrain: A Review," Sustainability, MDPI, vol. 14(24), pages 1-29, December.

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