This paper presents the state-of-the-art technologies and development trends of wind turbine drivetrains – the system that converts kinetic energy of the wind to electrical energy – in different stages of their life cycle: design, manufacturing, installation, operation, lifetime extension, decommissioning and recycling. Offshore development and digitalization are also a focal point in this study. Drivetrain in this context includes the whole power conversion system: main bearing, shafts, gearbox, generator and power converter. The main aim of this article is to review the drivetrain technology development as well as to identify future challenges and research gaps. The main challenges in drivetrain research identified in this paper include drivetrain dynamic responses in large or floating turbines, aerodynamic and farm control effects, use of rare-earth material in generators, improving reliability through prognostics, and use of advances in digitalization. These challenges illustrate the multidisciplinary aspect of wind turbine drivetrains, which emphasizes the need for more interdisciplinary research and collaboration.

High operations and maintenance costs for wind turbines reduce their overall cost effectiveness. One of the biggest drivers of maintenance cost is unscheduled maintenance due to unexpected failures. Continuous monitoring of wind turbine health using automated failure detection algorithms can improve turbine reliability and reduce maintenance costs by detecting failures before they reach a catastrophic stage and by eliminating unnecessary scheduled maintenance. A SCADA (Supervisory Control and Data Acquisition System) -data based condition monitoring system uses data already collected at the wind turbine controller. It is a cost-effective way to monitor wind turbines for early warning of failures and performance issues. In this paper, we describe our exploration of existing wind turbine SCADA data for development of fault detection and diagnostic techniques for wind turbines. We used a number of measurements to develop anomaly detection algorithms and investigated classification techniques using clustering algorithms and principal components analysis for capturing fault signatures. Anomalous signatures due to a reported gearbox failure are identified from a set of original measurements including rotor speeds and produced power.

The U.S. Department of Energy's Office of Scientific and Technical Information

Despite the wind industry's dramatic development during the past decade, it is still challenged by premature turbine subsystem/component failures, especially for turbines rated above 1 MW. Because a crane is needed for each replacement, gearboxes have been a focal point for improvement in reliability and availability. Condition monitoring (CM) is a technique that can help improve these factors, leading to reduced turbine operation and maintenance costs and, subsequently, lower cost of energy for wind power. Although technical benefits of CM for the wind industry are normally recognized, there is a lack of published information on the advantages and limitations of each CM technique confirmed by objective data from full-scale tests. This article presents first-hand oil and wear debris analysis results obtained through tests that were based on full-scale wind turbine gearboxes rated at 750 kW. The tests were conducted at the 2.5-MW dynamometer test facility at the National Wind Technology Center at the National Renewable Energy Laboratory. The gearboxes were tested in three conditions: run-in, healthy, and damaged. The investigated CM techniques include real-time oil condition and wear debris monitoring, both inline and online sensors, and offline oil sample and wear debris analysis, both onsite and offsite laboratories. The reported results and observations help increase wind industry awareness of the benefits and limitations of oil and debris analysis technologies and highlight the challenges in these technologies and other tribological fields for the Society of Tribologists and Lubrication Engineers and other organizations to help address, leading to extended gearbox service life.

The U.S. Department of Energy's Office of Scientific and Technical Information