Innovative Future-Proof Testing Methods for Reliable Critical Components in Wind Turbines

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The future wind turbines will require flexible and economically affordable PDPs to obtain reliable and validated new concepts for bigger wind turbines or already installed turbines. One of the most critical components that have a high contribution to wind farms OpEx costs are the bearings (selected Case Studies 1 and 3 during INNTERESTING) and gearboxes (selected Case Study 2 during INNTERESTING). Since both components transfer high loads and have high failure rates, they are considered as critical components inside the wind turbine. Although the percentage of the total Capex cost of bearings (2% ) is not as high as other structures (e.g. blades 22% and gearbox 13%) , their role is not insignificant.However, the role of bearings and gears in the OpEx is higher due to the major impact of early. The fatigue requirements that must be assured for the lifetime is a key factor to reduce the negative effect of reparations. New wind energy key concepts and uses which are faster to commercialisation have been prioritised: INNTERESTING project aims to accelerate wind energy technology development and increase lifetime extension of wind turbine components by developing a disruptive methodology to demonstrate reliability of larger wind turbine critical components without the need of building larger test-benches in the future by overcoming size dependent issues during design process and testing. In this matter, INNTERESTING project pursues the development of innovative virtual and hybrid testing methods for prototype validation of pitch bearing and gearboxes components (Selected Study Cases Components). The new methodology will help saving time and money during the product development process (PDP) by integrating virtual testing and hybrid testing: including innovative non-physical and scaled/simplified physical testing. In comparison with current methodologies INNTERESTING will reduce considerable environmental and economic impacts, and improve social acceptance.