Mesh Load Factor Uncertainty Analysis in a 5-MW Wind Turbine Planetary Gearbox Affected by Inherent Manufacturing Errors

The current work focuses on the study of the uncertainty related to the manufacturing process of gears for 5-MW planetary transmissions aimed to the wind generator industry. With this objective, the Monte Carlo method is the employed tool to analyse the influence that selected manufacturing errors have in the performance of these planetary transmissions, more precisely in its mesh load factor. In more detail, the selected manufacturing errors are tangential pinhole position and tooth thickness errors, following the tolerances set by the DIN 3967. This study provides the probability distributions of mesh load factor values related to the size of the manufacturing errors in the transmission. Moreover, both kinds of errors are included together in numerous different planetary transmissions, and the probability distribution functions are also obtained for these. The results lead to relevant conclusions related to the influence of these errors in the performance of these transmissions and their durability and cost-effectiveness.