Advanced Bearing Solutions For The Wind Industry
Advanced Bearing Solutions For The Wind Industry
WIND INDUSTRY 3
A GLOBAL PARTNER AND SOLUTIONS PROVIDER
As a leading manufacturer of rolling bearings, linear technology components and steering systems, NSK NSK has a long tradition in patent applications for machine parts. In our worldwide research centers, we
can be found on almost every continent – with production facilities, sales offices and technology centers not only concentrate on the development of new technologies, but also on the continual improvement
– providing our customers with responsive decision-making channels, effective logistics and local service. of quality based on the integrated technology platform of tribology, material technology, numerical
simulation and mechatronics.
TRIBOLOGY:
Improving Performance by Optimizing Friction. Tribology is the study of friction and wear
of contact surfaces in relative motion, such as rotating parts that endure enormous forces
with a thin oil film. Severe operating conditions are optimized through lubrication and surface
Europe treatments developed by NSK, resulting in superior performance for applications requiring low
friction, high-speed rotation, quiet operation or enhanced durability.
Asia
MATERIALS:
CORE TECHNOLOGIES
Oceania Superior Performance for Any Application. Materials research and development affects
nearly every aspect of product performance. Through careful selection of material
The Americas Africa composition, heat treatment and use of alternative materials, NSK enables optimization of
application performance. This may be through improvements in product function, endurance,
and reliability or through improvements in production and process cost efficiency.
NUMERICAL SIMULATION:
Turning Blind Risk Into Trusted Reliability. In the past, accuracy and reliability in product
development were achieved with experience-based design and longer testing periods. NSK’s
simulation technology allows for virtual validation to accelerate design and production.
Extreme conditions or innovative designs that defy previous expectations can also be
THE NSK COMPANY: evaluated and analyzed.
process stage.
4 WIND INDUSTRY 5
EVERY SOLUTION CALLS FOR THE RIGHT PRODUCTS
Whether for the main drive stage or accessories, our broad range of rolling bearing products deliver
reliable and sustainable operating life for a wide variety of applications.
3 GENERATOR
2 YAW DRIVE
4
3 5 PITCH DRIVE
MAIN ROTOR
SHAFT
MAIN GEARBOX
5
GENERATOR
PITCH / YAW
4 GEARBOX
MAIN ROTOR SHAFT MAIN GEARBOX GENERATOR PITCH AND YAW GEARBOX
The rotor induces high axial and radial loads in the main A variety of gearbox arrangements have been implemented Generators primarily use deep groove ball bearings and Yaw gearboxes turn the nacelle into the wind or away from it.
bearings, which occur both statically and dynamically. Given for wind turbines in recent years. Megawatt-class systems cylindrical roller bearings. Transmission of electrical current Pitch gearboxes are required for rotor blade adjustment. Deep
such loads as these, high bearing stiffness is indispensable. often combine planet gear stage(s) with multiple parallel gear can damage the rolling bearings and shorten their service groove ball bearings, cylindrical roller bearings, spherical roller
Spherical roller bearings used in the 3 point drivetrains, or stages. Deep groove ball bearings, spherical roller bearings, life. In order to avoid this damage, the use of insulated rolling bearings and tapered roller bearings are typically installed in
cylindrical and tapered roller bearings used in the modular cylindrical roller bearings, tapered roller bearings and bearings should be considered. NSK offers coated rolling these gearboxes.
drivetrain, are particularly well-suited for this application. four-point contact ball bearings are used, depending on the bearings where an insulating coating has been applied to the
location of the bearing. outer rings.
6 WIND INDUSTRY 7
MAIN SHAFT BEARINGS
8 WIND INDUSTRY 9
MAIN GEARBOX BEARINGS
HIGH-SPEED
4 INTERMEDIATE SHAFT
HIGH-SPEED SHAFT
NSKHPS CYLINDRICAL ROLLER BEARINGS, EM CAGE
5
CONDUIT TUBE › Bearing life increased as much as 2x compared to conventional designs
6
› As much as 23% higher basic load rating
› High strength and maximum rigidity for high loads and high speeds PERMISSIBLE MISALIGNMENT
Cr LIFE
› Higher permissible misalignment
22XXE, 23XXE 2XXE, 3XXE
10 WIND INDUSTRY 11
FOUR-POINT CONTACT BALL BEARINGS TAPERED ROLLER BEARINGS, DUPLEX
Four-point ball bearings are designed with a 35° contact Duplex tapered roller bearing arrangements feature two
angle and an inner ring that is split radially into two pieces. single row bearings and an outer ring spacer, as equivalent
Cage is machined brass. Their design allows one bearing to
singles or as a major/minor set. They can accommodate
sustain significant axial loads in either direction with high
capacity. They are capable of accommodating pure axial heavy radial loads and axial loads in both directions.
loads or combined loads where the axial load is higher. Available with Super-TF long-life steel or AWS-TF long-life
Available with Super-TF long-life steel and black oxide steel specialized to prevent white structure flaking. Also
coating. available with black oxide coating.
Bearing Location: High-Speed Intermediate Shaft Bearing Location: High-Speed Intermediate Shaft
High-Speed Shaft High-Speed Shaft
Low-Speed Intermediate Shaft
NSK Deep Groove Ball Bearings are designed to deliver Single row tapered roller bearings have high radial and axial
unsurpassed performance for a wide variety of applications. rigidity, and are capable of taking high radial loads and
Precision high-grade balls and super-finished raceways moment loads as well as axial loads in one direction. NSK
provide smooth and quiet operation. For low to medium offers a range of large size, dimensionally specialized single
radial loads and smaller axial loads in both directions. row tapered roller bearings for main gearbox applications in
Advanced lubricant technology and sealing designs ensure both metric and inch configurations. Available with Super-TF
optimum performance and reliability. Available in NSKHPS long-life steel and black oxide coating.
series with pressed steel cage or machined brass cage.
Bearing Location: Planetary Carrier
Bearing Location: Conduit Tube
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GENERATOR BEARINGS ADVANCED SOLUTIONS – NSK TOUGH STEEL
CERAMIC COATED INSULATING BEARINGS The valuation of a wind turbine includes one major maintenance cycle during its 20-year life
expectancy. As such, the need for improved durability in bearing performance is a critical
NSK ceramic coated bearings provide superior insulation
consideration to achieve the greatest reliability and total cost performance – even in uniquely
properties to prevent electrical erosion or arcing in bearings
used in turbine generators. An optimized alumina-based demanding operating conditions. In response, NSK has applied our Tough Steel technology to
ceramic material combined with a blend of additives is used develop bearing solutions that set a new standard for long service life.
to coat the outer ring, offering a high resistance to the flow
of electrical current. The coating is tough and durable when
impacted on its corner surfaces, and possesses excellent heat
dissipation properties. Boundary dimensions are identical to
a standard bearing, enabling easy replacement without need
for modifications.
Application Generator
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SUPER TF AND AWS-TF BEARINGS
In its quest for longer bearing service life, NSK has spent many years analyzing the mechanisms of AWS-TF AND WHITE STRUCTURE FLAKING
fatigue in bearings and researching and developing materials, heat treatment processes and operating
Hydrogen embrittlement is a prevailing bearing failure
conditions. The range of approaches to achieving longer service life taken by our research team are 1.0
mode found in wind turbine applications. It is a process by
shown in Fig. 1. The technology incorporated in our AWS-TF and Super-TF Bearings is designed to 0.8 which hydrogen penetrates into the bearing steel, causing
maximize service life under conditions where bearings are subject to hydrogen induced embrittlement it to weaken. Hydrogen itself is generated by typical
0.6
tribomechanical and tribochemical events occurring to the
and contamination induced surface-originating flaking.
R/C VALUE
0.4
bearing lubricant during operation of the wind turbine. White
structure forms below the surface of the bearing, and this
0.2 change to the microstructure results in the formation of
SUPER-TF AND SURFACE-ORIGINATING FLAKING cracks that will extend to the surface of the bearing under
0
GOAL : LONGER SERVICE LIFE 0 10 20 30 40 50 60 stress concentration during operation. Cracks propagate
Bearings can be required to operate under conditions RETAINED AUSTENITE LEVEL % under the load of each passing roller, leading to flaking and
PROBLEM
CLEAN ENVIRONMENTS CONTAMINATED ENVIRONMENTS where lubrication is easily contaminated. Metal particles ultimately bearing failure.
FIG. 2 RELATIONSHIP OF R/C VALUE TO RETAINED AUSTENITE LEVEL
SUBSURFACE- SURFACE-ORIGINATING WHITE STRUCTURE or casting sand in the lubricant create dents in the rolling
ORIGINATING FLAKING FLAKING FLAKING / CRACKING
contact surfaces, and stress concentrated around these With our AWS-TF bearings, NSK has countered white structure
dents eventually leads to cracking and to surface-originating flaking by applying the technology of Tough Steel long-life
400
flaking. The ability to reduce the concentration of stress materials. White structure flaking tends to be generated
MATERIAL MATERIAL MATERIAL SUPER-TF BEARING
around the shoulders of surface dents is directly related to 300
when hydrogen becomes concentrated at stress points.
REDUCTION OF OPTIMIZED INCREASED
achieving longer service life from the bearing. NSK optimizes additional chromium content in our bearing
NUMBER
NON-METALLIC COMPOSITION CHROMIUM
INCLUSIONS
200 steel composition to significantly decrease the diffusion
APPROACHES HEAT TREATMENT
NSK research and development of material properties rate of hydrogen and delay microstructural change,
100
TOUGHNESS
has revealed that a high level of retained austenite is thereby increasing resistance to white structure flaking.
CARBURIZATION
an extremely effective means of maximizing the r/c 0
In rolling fatigue life tests conducted in hydrogen charged
CONTROL OF
HIGH PURITY
RETAINED AUSTENITE value around surface dents in the bearing material (see CARBIDE SIZE (MM) 0.2 0.4 0.6 0.8 1.0 1.2
environments, increasing chromium content proves to ensure
Fig. 2) - the greater the r/c value, the smaller the stress longer life performance.
concentration. TF technology in general is a unique heat FIG. 3 AVERAGE DIAMETER OF CARBIDE AND CARBONITRIDE
CONTAMINATION PARTICLES IN A SUPER-TF BEARING
RESISTANT BEARINGS treatment process developed by NSK to optimize the level of
retained austenite in bearing materials.
400
Z STEEL
However, austenite itself has a soft microstructure, reducing ORDINARY CARBURIZED
300 STEEL
MASS-PRODUCED
STEEL
the hardness of the bearing material. To meet the needs for
CARBONITRIDING
NUMBER
greater hardness with a higher level of retained austenite,
200
SUPER-TF BEARINGS AWS-TF BEARINGS
NSK adopts a technique to promote the uniform distribution
PRODUCTS &
SOLUTIONS and reduce the diameter of carbide and carbonitride 100
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BEARING FAILURE MODES
SURFACE-ORIGINATING FLAKING COMPARISON OF SERVICE LIFE WHITE ETCHING CRACKS / FLAKING COMPARISON OF SERVICE LIFE
1 2 3 1
SUJ2
1 2 1
SUJ2
debris H H H H
H H
0 0
dent cracking flaking hydrogen white
permeation and diffusion structure change
STF delivers 5 times the life of AWS-TF delivers 7 times the life of
Foreign debris Stress concentration Cracks propagate Hydrogen permeates White structure forms
contamination leads around debris dents under the load of each standard steel (SUJ2), while the bearing steel, below the surface of standard steel (SUJ2), while STF
to the formation of develop into cracks passing roller and AWS-TF delivers 3 times causing it to weaken the bearing delivers 4 times
dents develop into flaking
Crack formation begins along
the boundary of white structure
3 4 Cracks propagate under
the load of each passing roller
during repetitive stressing and develop into flaking
cracking flaking
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EXAMPLES: BEARING NOMENCLATURE
SPHERICAL ROLLER BEARING - 3 PT SUSPENSION CYLINDRICAL ROLLER BEARING, SINGLE ROW – HSIMS, HSS
240 spherical roller bearing, width series 4, diameter series 0 NU single row cylindrical roller bearing - 2 outer ring ribs,
CA high capacity internal design 23 dimension series (width series 2, diameter series 3)
g5 case hardened inner and outer rings (multiple options available) 26 bore diameter equals 130 mm (reference number x 5)
E4 lubrication groove and holes in outer ring /S/ black oxide coating
U303 special process control for wind turbine bearings C3 greater than normal radial internal clearance
STF NJ 28 /710 g5 M CCG338 U303 431 KH 57 55 SA +K CA640 U303 TAPERED ROLLER BEARING, SINGLE ROW - CARRIER SUPPORT
STF Super-TF long-life steel
431 bore diameter equals 431 - 431.999 mm R 431Z -3 /S/ E U303
NJ single row cylindrical roller bearing - 2 outer ring ribs,
KH double row tapered roller bearing
one inner ring rib R single row tapered roller bearing, special dimensions
57 outer diameter equals 570 - 579.999 mm
28 dimension series (width series 2, diameter series 8) 431Z bore diameter equals 431 - 431.999 mm
55 tolerance for inch bearing
/710 bore diameter equals 710 mm -3 serial number
SA special tolerance
g5 case hardened inner and outer rings (multiple options available) /S/ black oxide coating
+K outer ring spacer
M machined brass cage E notch in the outer ring
CA640 special axial clearance
CCG338 special radial internal clearance U303 special process control for wind turbine bearings
U303 special process control for wind turbine bearings
U303 special process control for wind turbine bearings
SA special tolerance
20 WIND INDUSTRY 21
CYLINDRICAL ROLLER BEARING, FULL COMPLEMENT –
PLANETARY CARRIER AND GEAR
FOUR POINT CONTACT BALL BEARING – HSIMS, HSS DEEP GROOVE BALL BEARING, CERAMIC COATED - GENERATOR
QJ four point contact ball bearing 63 deep groove ball bearing, diameter series 3
28 bore diameter equals 140 mm (reference number x 5) HD2 ceramic insulated coating on outer ring
E notch in the outer ring C3 greater than normal radial internal clearance
C3 greater than normal radial internal clearance X26 dimensional stabilizing treatment
U303 special process control for wind turbine bearings U303 special process control for wind turbine bearings
22
CAT. No.E1285 2018 A-2 Printed in Japan©NSK Ltd. First edition published in FEB. 2018