CONTENTS CONTENTS

Contents

1 - Abstract 5

2 - Acknowledgments 6

3 - Introduction 7
3.1 ERASMUS Placements Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.1 Background and Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.2 Business areas facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.3 Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.4 Achievements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.5 Wind Gears Key numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.6 Industrial Gears key numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.7 Moventas Briefly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Allocation and daily procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 - Placement Tasks 15
4.1 Initial steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Practical Tasks / Simulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 Housing Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Procedures and Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.2 Internship Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Web page Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.3 Inspection Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Initial approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Initial results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.4 Bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3
CONTENTS CONTENTS

Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.5 Gear Testing Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Modified components seeking optimization . . . . . . . . . . . . . . . . . . . 29
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Load Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Comparison of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Frame results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Welded bases results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Screws results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contact tool results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.6 Planet Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Trainings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.1 Femfat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.2 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.3 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Tampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Jyväskylä . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Copenhagen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5 - Conclusions and future work 71

5.1 Main achievements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.2 Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.3 Future Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4
1 - ABSTRACT

1 - Abstract

A practical placement taking part in a European Company, integrated in the studies plan,
with full recognition before graduating, is nowadays possible through the New ERASMUS
Programme - LLP (Lifelong Learning Programme) Placements.

This report focuses on the activities and achievements during the period of the placement.
This placement corresponds to the final project equivalence in MIEM (Integrated Master in
Mechanical Engineering) Degree, specialization in Structural Engineering and Machine Design,
contributing 30 ECTS (European Credits Transfer System), provided at UP (University of Porto).

5
2 - ACKNOWLEDGMENTS

2 - Acknowledgments

The author would like to thank Petri Lahtinen, Group Manager in Technical analysis of Struc-
tural components, from Moventas, in the role of a coordinator to this placement for providing
timely inputs based on his experience in the domain of wind gears.

Further more, the author would like to acknowledge Paulo Tavares de Castro and Jorge Seabra,
from FEUP - Engineering Faculty of Porto University, for enabling this placement and for pro-
viding constant support and follow-up.

In addition, the author would like to acknowledge the team spirit shown by the colleagues at
Moventas namely Petri, Teemu and Ismo for their valuable time and contributions.

The author would to mention the importance of European ERASMUS programme, which has
provided a remarkable change in the European educational scenario.

I would like also to thank my family and friends for their understanding and comradeship through-
out this placement period.

Finally, special thanks to Merie Joseph for the report review.

6
3 - INTRODUCTION

3 - Introduction

3.1 ERASMUS Placements Program

The framework of ERASMUS (European Community Action Scheme for the Mobility of
University Students ) was established in 1987 and is a major part of the European Union Lifelong
Learning Programme (LLP) period from 2007 to 2013. It is the operational framework for
the European Commission’s initiatives in higher education. The recently created ERASMUS
placements, differs from the ERASMUS Studies in that it is a type of placement combined with
a specified time period in an enterprise or organization in European, EFTA/EEE and Turkey
countries, with a view to help individuals to adapt to the requirements of the European labor
market, acquiring specific skills and improve understanding of the economic and social culture
of the country concerned while acquiring the work experience. The period may be supported,
as appropriate, by preparatory or refresher courses in the host language or working language.
Host organizations for student placements may be enterprizes, training centers, research centers
or other organizations.
The characteristics of the individual placements are:

• Full recognition is provided by the home higher education institution for the period spent
abroad.

• It is necessary to have a Training Agreement for the student, regarding the programme
of the placement period; this agreement must be endorsed by the home higher education
institution and the host organization.

• The period of placement is covered by a placement contract endorsed by the higher edu-
cation institution sending the student, the consortium sending the student (if applicable),
the host organization and the beneficiary.

In a company environment, this program provides work experience, enabling the use of
knowledge, tools, procedures, that in this specific situation, were acquired trough the MIEM
subjects,projects,work-groups,professors at FEUP. It also allows to achieve maturity and per-
sonal growth,in a different environment as a result of applied work experience.

7
3 - INTRODUCTION 3.2. APPLICATION

3.2 Application

The author had experience of undertaking ERASMUS studies in Hungary in Spring semester
2007. After receiving the confirmation from the department of cooperation at FEUP about the
eligibility of the placement program, in November 2007, several countries were considered for the
placement program.

The country of placement was finalized as Finland because of previously established network
relationships.
After many applications, to companies like Outokumpu, Wärtsilä, Aker Yards, Ruukki, re-
sponse to take part in this challenging Programme, was sent by Moventas . The placement works
as a Final Project Equivalence in MIEM ( Integrated Master in Mechanical Engineering) Degree,
the final part of the studies plan, summing 30 ECTS ( European Credits Transfer System).
The report states the practical work placement, structured by date, performed at Moventas
Wind Oy, Jyväskylä , FINLAND in the framework of ERASMUS LLP - Placements pro-
gramme.

3.3 Company

3.3.1 Background and Present

Moventas, earlier Metso Drives, is one of the leading experts in mechanical power transmis-
sion. The company designs, manufactures and markets power transmission solutions and services
for process and energy industries. Moventas operates in a rapidly growing market. The com-
pany’s e 207 million sales revenue grew by 25 % in 2006, and grew by more than a third in 2007,
Figure 3.1. Moventas aims to double its sales by 2010 through organic growth.

Figure 3.1: Numbers of 2007 - MOVENTAS

8
3 - INTRODUCTION 3.3.2 Business areas facts

With its headquarters in Jyväskylä, Finland, the company has more than a century of en-
gineering experience. Well-known company names namely, Metso Drives, Santasalo and Valmet
are among the predecessors of Moventas, Figure 3.2. Having this solid background, the company
nowadays deals with both Wind (WG) and Industrial gears (IG). Today the company has nine lo-
cations globally, in Finland, Sweden, Germany, Canada, the United States and Singapore. With
its dedicated 24/7 service commitment, the company intends to further strengthen its global
reach to bring it closer to its customers.

Figure 3.2: Moventas History

3.3.2 Business areas facts

Wind Gears

After-market sales is a growing area. Wind-power generation is growing rapidly at an

annual growth rate of over 20 %. As one of the global leaders in the manufacture of wind-
turbine gears, Moventas is benefiting from the increased need for energy, the need to reduce
carbon-dioxide emissions, and the improved competitiveness of wind power as a result of
technological advances. The wind-turbine gear business is also enjoying a widening of cus-
tomer demand both in existing markets and in new regions, as even more customers seek
to rely on renewable energy resources, like India, China and Italy. After-market sales for
wind-turbines is one of the fastest-growing areas for Moventas and clearly one of its busi-
ness advantages. Turbines are often sited offshore or in remote locations, so minimizing
unscheduled maintenance is important.

9
3 - INTRODUCTION 3.3.2 Business areas facts

Monitoring

Monitoring the performance and condition of key components, such as the mechanical
power-transmission systems, which are at the heart of a wind turbine, is vital to ensure
that wind-turbines maintain high levels of reliability. Moventas has launched a sophisticated
condition-management system, that not only monitors the turbine’s operation, but also
provides the operator with an early warning of potential risk factors before actual damage
is done. The system can be integrated into new turbine designs or fitted to machines already
in operation.

Proactive lifecycle approach

The gears Life Cycle takes in account all aspects and consequences, Figure 3.3.

Figure 3.3: Proactive lifecycle

Industrial Gears

Moventas has a strong position in the process industry also. It is the leading supplier of
mechanical drives for the pulp and paper industry and one of the leading players in the
growing mining and minerals sector. The most promising growth prospects in Moventas
industrial-gear business are in service and maintenance programmes covering the entire
lifespan of equipment. Moventas has been keen to adopt a life-cycle approach which plays
an important role in creating top-class customer satisfaction. First-time installations in the
mining and minerals sector are also growing strongly. In particular, demand for servicing
and renewal of machinery is on the increase in the wood-processing industry

10
3 - INTRODUCTION 3.3.3 Expansion

3.3.3 Expansion

In response to growing market demand, the company has begun a substantial investment
programme totalling e100 million. Part of the visionary growth strategy is to expand production
capacity in Finland which will create approximately 100 new jobs this year and roughly the same
number again over the next few years with an extensive investment programme . Presently Moven-
tas employs about 1200 individuals, Figure 3.4. The first project in the investment programme
has now been completed, with the opening of an expanded facility for wind-turbine production in
Jyväskylä, Finland in March. A new construction project aimed at further increasing production
capacity for wind-turbine gears in Jyväskylä has already started. The Karkkila plant in Southern
Finland, which concentrates on industrial gears, will increase its large gear-manufacturing and
assembly capacity. The full additional capacity will come on stream in 2009.

Figure 3.4: Company Worldwide

3.3.4 Achievements

• Installed base for more than 8,000 units

• First wind turbine gears delivered in 1980

• Wind turbine main gears for the major wind turbine manufacturers

• Innovative technology for wind turbine gears up to multi MW class

• Uncompromising reliability

• Life cycle gear service support , Figure 3.3.

11
3 - INTRODUCTION 3.3.5 Wind Gears Key numbers

3.3.5 Wind Gears Key numbers

The section of Wind Gears, represents nowadays more than 50 % of the business, Figures 3.5
and 3.6.

Figure 3.5: Wind gears 2007 facts

Figure 3.6: Wind gears Sales/employes

3.3.6 Industrial Gears key numbers

The section of Industrial Gears, represented worldwide, offers solutions for all high demand
industries, Figures 3.7,3.8.

Figure 3.7: Industrial gears 2007 facts

12
3 - INTRODUCTION 3.3.7 Moventas Briefly

Figure 3.8: Industrial gears Sales/employes

3.3.7 Moventas Briefly

Figure 3.9: Moventas Key facts

13
3 - INTRODUCTION 3.4. ALLOCATION AND DAILY PROCEDURES

3.4 Allocation and daily procedures

The department where the placement took place is the department of Research and Design,
integrated part of Moventas Wind Oy division. It is organized in different sub-sections; Struc-
tural (Fatigue [2], Eigen frequencies, Classification, . . . ), Modeling, Lubrication, Gears [8], ,
Documentation , with respective responsibilities.
The placement specifically was held in the Structural analysis subsection, which is responsible
for research, analysis and certification of all Wind Energy products.
At the Structural section, the work-tools consist of a Cluster - Fujitsu Celsius 2 processor -
Books, Internet, Applications and respective Help [1], [3], manuals [2], [10], [13]; and guide-
lines, [11]. Software licenses are limited.
The working schedule is flexible, consisting of average 37,5 hours a week. For security and prac-
tical reasons, for crossing the doors, magnetic keys are used, and this is the also the support to
store data such as working hours and vacations period. Periodical meetings are held at the de-
partment. Archive and backup of information is an important issue, existing a network drive and
Tape support ( 20-50 Gb). The organization of the space is open, easing contacts , suggestions
and permanent follow-up. There is a help desk for all kinds of software and hardware problems.

The main aspects concerning this section are :

• Team of Structural Analysis included in the Research and Design division.Stress and dy-
namic analysis performed

• Usage of numerous compulsory softwares, Table 3.1, and procedures for full structural
analysis.

• Frequent training, meetings and dynamic environment.

Table 3.1: Some Compulsory Software for simulation/structural analysis

Software
CatiaV5 Solidworks Miktex Linux(CentOS) Ansys(Classic/Workbench) FEMFat

14
4 - PLACEMENT TASKS

4 - Placement Tasks

4.1 Initial steps

The initial step was integration which involved understanding all processes, departments,
factory layout and internal activities, organization, guidelines, personnel. The tools for work,
mainly the workstation, software, literature and objectives were made available in the first weeks
by installing all the software required and by providing hardware and cables.
Meanwhile, some individual personal training with the support of the software help [1], [3], [13],
internet, colleagues and books, in softwares like Ansys Classic ( developing the basics previously
done during the MIEM course in subjects namely Mecânica das Estruturas II , Mecânica da
Fractura), Catia V5 tutorials , Network configurations and data exchange between computers
and Cluster ( 8 processors, for Heavy FEM calculations).
All internal section reports are made using LaTex2ε, [4], [5], [6], [7], [9],. Also the usage of
tools for e-mail, software for bills like SAP, reservations, internal mail between departments, and
others, were acquired.

15
4 - PLACEMENT TASKS 4.2. PRACTICAL TASKS / SIMULATIONS

Table 4.1: Sequential Tasks Plan

4.2 Practical Tasks / Simulations

The software required to perform all sort of different tasks, was not fully available initially.
When new tasks were required, new software was sequently added as soon as possible, so that
the tasks were naturally performed. After gaining experience and confidence, through both per-
sonal and interpersonal ways, the tasks could be developed more easily, more confidently and
autonomously. A brief review of the activities and tasks that took place during placement pe-
riod, can be seen in Table 4.1.

4.2.1 Housing Simplification

Description

The housing of a 2MW power wind turbine (Figure 4.1), that was modeled in Catia V5,
needed simplification and preparation for modal analysis in Ansys Workbench. The steps are
to deactivate, hide or even change sketches in Catia V5, so that the global model is suitable,
incorporating good sense, for eliminating possible problems of elements size and shape when
meshing. The materials and constraints of the structure need to be carefully assigned for the
future Modal analysis.

16
4 - PLACEMENT TASKS 4.2.1 Housing Simplification

Table 4.3: Cast Iron GJS250 Proprieties

Table 4.4: Cast Iron GJL400 Proprieties

Figure 4.2: Fixed supports applied in the moment-arm holes

18
4 - PLACEMENT TASKS 4.2.1 Housing Simplification

Comments

This task allowed the author contact with parts of gear and allowed to realize and see the
functional components, size and geometry of Wind Turbines. The Softwares Catia V5 and Ansys
Workbench , were initially explored ( March 2008 ). Later on, the Ansys capabilities in Eigen
frequencies, allowed to study the behavior of the structure for further considerations.

(a) 1st

(b) 2nd

Figure 4.3: Housing Eigen Frequencies - 1st and 2nd Natural Modes

19
4 - PLACEMENT TASKS 4.2.2 Internship Webpage

4.2.2 Internship Webpage

Description

The webpage concerning the Internship was created in April 2008 with TextoHtml and also
basic HTML Language. This webpage was continuously reanalyzed and modified structurally.
Improvements were also made later, adding suitable information and also correcting some errors.
(http://paginas.fe.up.pt/˜em03078/).

Figure 4.4: Aspects of Internship webpage

Web page Structure

The most suitable Webpage structure was found to be:

• Placement Info

• Updated Workplan

• Downloads of Documents

Comments

The Webpage creation, maintenance and design, gives an idea of the structure, data stor-
age and procedures in order to provide essential information with direct and clear basis on the
Internet.

20
4 - PLACEMENT TASKS 4.2.3 Inspection Covers

(a) Inspection cover in present production

(b) Initial geometry attempt leading to improvements

Figure 4.6: Inspection Covers - Geometry changes

Initial results

The initial results, trial attempt, leading to the right direction of objectives, observed the
change in the vibration mode from axial to bending, and the removal of the ribs,Figure 4.7. The
obtained values for 1st /fundamental Frequency can be seen on Table 4.5.

Table 4.5: Inspection covers initial improvement aiming a higher fundamental frequency

Inspection covers assembly details Weight (Kg) 1st Frequency - Fundamental (Hz) MODAL
Original 55 1703
Modified 55,9 2057

22
4 - PLACEMENT TASKS 4.2.3 Inspection Covers

(a) Present Production Inspection Covers - Axial Vibration mode

(b) Initial geometry attempt - bending vibration mode

Figure 4.7: Inspection covers improvement aiming higher 1st /fundamental frequency

23
4 - PLACEMENT TASKS 4.2.3 Inspection Covers

Figure 4.9: 1st /fundamental frequency - Results for Final optimum solution

Table 4.6: Results of the production-ready inspection covers

Part Fundamental Freq (Hz)

Inspection cover ready for casting 1979

Comments

The inspection cover resolution, led the author to deal closely with a practical application
using the knowledge and tool of frequency analysis. It shows the sort of problems, encountered
when the gears (multi-body drive-train) are under run. The experience gained in modeling
provided a necessary skill in a practical work environment for a mechanical engineer.

25
4 - PLACEMENT TASKS 4.2.4 Bearing cover

Approach

The modeling performed in Catia V5, allowed various options for changing the geometry. The
main design changes was the addition of ribs/stiffners due to limitation in the functional areas
(ex. bearings, shaft ,. . . ). After importing this CATParts to Ansys Workbench, the boundary
conditions were maintained and solved towards the solution sequentially. The mesh and fixed
support boundaries are displayed in Figure 4.12

(a) Bearing cover - Mesh

(b) Bearing cover - Fixed support

Figure 4.12: Geometry and Constrains of bearing cover : Final solution

27
4 - PLACEMENT TASKS 4.2.4 Bearing cover

Figure 4.13: 4th Natural Vibration Mode

Results

The values achieved for this purpose are presented in Table 4.7. The Mode shape for the 4th
Natural frequency is displayed in Figure 4.13.

Table 4.7: Bearing cover modifications achieving a higher 4th frequency

Cover details Weight (Kg) 4th Mesh Frequency (Hz)

Original 57.6 1502,8
Modified 65.2 1743

Comments

The best result was obtained when adding stiffeners in the exterior face. This was considered
because of the location and functionality, which did not allow a wide area of maneuverability,
resulting in adding stiffeners in the exterior face instead of interior face for solving the eigen
frequency resonance problem.
Functional details, such as forced lubrication pointing out the flow proprieties were also taken in
account.

28
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.15: Original Model

Figure 4.16: Modified Model

Figure 4.17: New concept model

Procedure

The Original cut section submodel/structure, constructed from the whole gear testing struc-
ture, was analyzed first,so that reference results could be obtained for the most important parts
like: welded frame, welded bases and housing. The material is considered as structural steel for
all components, Table 4.8.

30
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Table 4.10: Description of screws/bolts for Original and Modified

Screws Size Number screws Pretension (N) Details

M30 6 3e5 Housing to Platform
M16 4 3000 Spacers to Keljo VB dock-lock ( LONG )
M16 8 3000 Frame to Keljo VB dock-lock ( SHORT )

NEW CONCEPT
Since is New concept version is substantially different, the analysis was done with some differ-
ent aspects. In the New concept. cut structure, some components were completely removed and
there were changes in several components. The welded plates are different, the screws are only
6xM16, the holes housing, frame, spacers and welded plates are 17,5 mm diameter The screws
pre-tension and fixed support are repeated and also the contacts definition. The contacts are
kept the same, as others parameters moment, preload, and so on. The housing and the weld
frame holes were changed according to the screw’s size.
The location of screws is different Figure4.21 and Table 4.11.

Figure 4.21: Moment and Pre-tensions - New Concept

Table 4.11: Description of M16 screws/bolts for New concept

Screws Size Number screws Pretension (N) Details

M16 6 3e5 Housing to cylinder

33
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Comparison of Results

Stress and Strain Analysis for Housing The Ansys Workbench results are displayed in 2x
Auto (380x real).
The deformations, Figure 4.24, and Figure 4.25, for Original and Modified respectively, high-
light the maximum deformation in the housing and the much higher deformation in the screws
caused by the pre-tension.
The tension values, for this Original and Modified retrieve unrealistic results, reason why they
are not shown, thus the maximum stress is at the screws, 10X bigger than in the frame.

Figure 4.24: Total deformation Original

For the New concept, the Von Mises stresses, Figure 4.26, are very low, displaying the places
where the direct effect of the moment applied is visible.

The deformation of the elements can be noticed on the screw because of the magnification
and element characteristics.

In addiction, for the housing, the stress/strain values, due to screws elements distortion, are
not reliable and should not be taken in the analysis. However, the housing stresses are low and
acceptable.

35
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.25: Total deformation Modified

Figure 4.26: Von Mises - New concept

36
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.27: ORIGINAL - Frame stress (Von Mises)- maximum near bolt head

Frame results

Stress Analysis

Original :
The welding locations in the frame (top and bottom faces) were simulated with bonded contact.
The pretension inflicts stresses on this weldings. However, the high pretension of the screws
leads to maximum stress in a very localized area around the holes. The frame verifies almost no
changes when moment is applied, Figure 4.27.

Modified :
In the modified structure, the behavior is the same, so that from the Original to the Modified
structure we jump from 20 MPa to 30 MPa in surface areas near holes, which is still a reasonable
value, Figure 4.28.

New concept:
In this substantially changed structure, the behavior is the same, but from the Original or Modi-
fied to this one, the realistic results come to surface. There is a reduction of stresses, because the
pretension of M16 screws is 10x smaller (leads from 20/30 MPa originally to 5 MPa ) in surface
areas near holes, Figure 4.29.

37
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.28: MODIFIED - Frame stress (Von Mises)- maximum near bolt head

Figure 4.29: NEW CONCEPT - Frame stress (Von Mises)- maximum near bolt head

38
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Deformation Analysis

The deformation results of the frame behavior, Original and Modified, inflicted by the bolts
pre-tension, followed by a moment, retrieve the expected traction side/compression side, which
effectively brings notice to the bigger displacements, Figures 4.30, 4.31.
The main differences occur in the holes location and edges.

Figure 4.30: Original Total deformation of frame

For the New Concept, the loads are in a different level with lower magnitude, resulting in
deformations which are three times smaller.

39
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.31: Modified Total deformation of frame

Figure 4.32: New concept Total deformation of frame

40
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Welded bases results

Since there were high pre-tensions, stresses were analyzed in parts with direct connections
with the bolts. The welding locations between the frame and weld bases, simulated with bonded
contact, have to be taken in account that are not very close to reality, as said before, because
in real welding situation only the edges are welded while in simulation the entire surface on the
plane is selected and by consequence simulated as welded. The pretension of the screws inflict
the maximum stress in the opening located below the part. The contact areas of pressure in
this component caused by the M30 Screw, are located here, Figures 4.33, 4.34. Furthermore, for
different geometries of holes (opposing original/Modified versus New Concept), the stresses are
much smaller in the New concept, Figure 4.35

Figure 4.33: ORIGINAL - welded region stresses

41
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Figure 4.34: MODIFIED - welded region stresses

Figure 4.35: NEW CONCEPT - welded region stresses

42
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Screws results

The results for the screws are provided in the tables given below, without any important
differences between the original, modified and New concept sub structures, concerning the ad-
justment and variation of working load, Tables 4.14, 4.15 and 4.16.

Table 4.14: Original bolts pretension results

Original bolts results

Behavior/Location Traction Compression Center

Bolt M30 M16 (Long) M16 (Short) M30 M16 (Long) M16 (Short) M30

Adjustment (mm) 0,8099 0,2202 0,0827 0,8084 0,2204 0,0827 0,8017

Max Work Load (N) 3e5 3,012e4 3,014e4 2,997e5 2,989e4 2,99e4 3,00e5

Table 4.15: Modified bolts pretension results

Modified bolts results

Behavior/Location Traction Compression Center

Bolt M30 M16 (Long) M16 (Short) M30 M16 (Long) M16 (Short) M30

Adjustment (mm) 0,8120 0,2161 0,0812 0,8015 0,2167 0,0811 0,801

Max Work Load (N) 3e5 3,013e4 3,012e4 2,997e5 2,989e4 2,986e4 3,00e5

Table 4.16: New concept bolts pretension results

New concept - M16 bolts

Location Pretension(N) Working Load(N) Difference(%) Adjustment(mm)

Traction 30000 30128 0,43 0,26996

Center 30000 30029 0,1 0,26888

Compression 30000 29866 0,45 0,26974

43
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Contact tool results

The contact tool was used to visualize the properties of the frictional contacts present, only
for original, modified . These are between the spacers/housing and cylinder/weld base , Figures
4.36 and 4.37, respectively. The sliding exists practically only due to the pretension of screws.
Note also the gap created by the parallel screws pretension (M30 and long M16), Figure 4.36. An-
alyzing the sequence in the contact, through the animation, because of the moment and bonded
contact simulating the welding, it is observed that there is penetration in the elements, caused
initially by the pre-tension, but afterwards by the pure moment applied.

44
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

(a) Gap Original structure

(b) Gap Modified structure

Figure 4.36: Contact tool results for the frictional contacts-GAP

45
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

(a) Status original structure

(b) Status modified structure

Figure 4.37: Contact tool results for the frictional contacts - STATUS

46
4 - PLACEMENT TASKS 4.2.5 Gear Testing Layout

Comments

The model evaluated, does not consider the bonded/welded regions properly, since the whole
welded area is bonded and it should only be evaluating the edges with proper geometry and
thickness of the type of welding.The moment applied would be more realistic if the whole housing
with bearing loads was available. Switching from Original to Modified, there is an effect of 50 %
higher stresses in the frame which is still low and acceptable (30 Mpa).
By removing components and/or material for saving weight, results show a direction to modify
the actual parts. Ansys results demonstrate that the moment applied, together with boundary
conditions and screws pretension, result in reasonably acceptable results for the New concept
structure, having almost no visible effect on stresses (5 MPa). The proposed changes, made for
saving weight, show some components can be removed. The usage of only M16 screws is suitable,
analyzing the details of the holes. The implementation of this New concept solution is strongly
recommended.

47
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

4.2.6 Planet Carrier

Description

A Planetary gears carrier, Figure 4.38 has to be optimized to achieve the reduction of weight.
It consists of a housing integrating four planetary gears which are in contact with an external ring
gear, Figure 4.39. The functional regions must be kept and the reduction must be done in regions
which will be highlighted in the FEM analysis in Ansys and Ansys Workbench. Subsequent
decisions will be made based on these results by the modeling team professionals.

Figure 4.38: Planetary Gearbox Assembly

Figure 4.39: Planet Carrier detail

48
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Procedure

Initially, 6 revisions were available, all with modifications to achieve mass reduction. The
list of revisions can be seen in Figure 4.40, pointing out that Revision 3 was not studied due
to numerous similarities comparing to Revision 4. The mesh has to be resized to achieve good
accuracy near fillets and areas with sudden geometry changes . The simulation is done by
analyzing the Planet Carrier as having the applied moment and four supports, simulating the
presence of the gear teeth contacts with ring gear.

(a) Revision 1 (b) Revision 2

(c) Revision 4 (d) Revision 5

(e) Revision 6 (f) Revision 7

Figure 4.40: Revisions for study

49
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Materials The supports for simulation have 10 % of Young Modulus (E) of the carrier’s cast
iron GJS-700. The structural steel material proprieties are applied for the pins which in reality
will hold 2 bearings each for each planetary gear. The materials are described in Tables 4.18 4.19
4.17.

Table 4.17: GJS-700 Cast iron material proprieties

GJS−700
Proprieties Value
Young’s Modulus 1,76e+005 Mpa
Poisson’s Ratio 0,275
Density 7, 2e − 0064kg/mm3
Thermal Expansion 1, 25e − 0051/◦ C

Table 4.18: Structural steel material proprieties

Structural steel
Proprieties Value
Young’s Modulus 2,e+005 MPa
Poisson’s Ratio 0,3
Density 7, 85e − 006kg/mm3
Thermal Expansion 1, 2e − 0051/◦ C
Tensile Yield Strength 250 MPa
Compressive Yield Strength 250, MPa
Tensile Ultimate Strength 460, MPa

Table 4.19: Supports material proprieties

Joustava
Proprieties Value
Young’s Modulus 17600 MPa
Poisson’s Ratio 0,3
Density 7, 2e − 006kg/mm3
Thermal Expansion 1, 25e − 0051/◦ C

50
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.43: Planet carrier constraints and moment load

Boundary conditions and Loads It is required to add displacement constraints because of

numerical errors. Even the smallest error would translate the model. The ”compression only”
supports are applied because bending must be allowed and translation along the moment axis (
yy axis , 2525 KNm). The fix support simulates the planetary gears.

Contacts The contacts must be set as frictional between carrier and the pins, Figure 4.44,
because it’s the most important contact for the load, and more close to reality.
Since there are bearings in the planetary gears, the contact here is considered frictionless,
Figure 4.45.

52
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.44: Frictional Contacts

Figure 4.45: Frictionless contacts

53
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Results

The results were obtained using structural analysis, obeying the same constraints, mesh sizes
and contacts. The revisions are listed sequentially.

Revision 1

The Revision 1 can be admitted as reference to others. It gathers the main ideas and func-
tionalities required for the function in the wind gear train, that is, the model to modify.
There are secondary maximums in the ribs edges. The maximum occurs, as always, inside
the pin hole.

Figure 4.46: Minimum Principal Stress - revision 7

54
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.47: Maximum Principal Stress - CUT - revision 1

Figure 4.48: Pin cut - stresses - Revision 1

55
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Revision 2

The changes in this revision are mainly for the inside and outside fillets, attempting a new
concept and direction. There are secondary maximums on the edges of the ribs. The max-
imum occurs, as always, inside the pin hole.

Figure 4.49: Minimum Principal Stress - revision 7

56
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.50: Maximum Principal Stress - CUT - revision 2

Figure 4.51: Pin cut - stresses - Revision 2

57
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Revision 4

There is a change in the thickness of the housing in this case, so that the pin has to be
modified (shortened) the same amount of length 15 mm. The external area is substantially
changed in order to save weight. There are secondary maximums on the edges of the ribs.
The maximum occurs, as always, inside the pin hole.

Figure 4.52: Minimum Principal Stress - revision 7

58
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.53: Maximum Principal Stress - CUT - revision 4

Figure 4.54: Pin cut - stresses - Revision 4

59
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Revision 5

In this revision, a new approach was utilized, keeping edges and modeling a deep gap, keep-
ing structural stiffness and removing some material at the same time. There are secondary
maximums on the edges of the ribs. The maximum occurs, as always, inside the pin hole.

Figure 4.55: Minimum Principal Stress - revision 7

60
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.56: Maximum Principal Stress - CUT - revision 5

Figure 4.57: Pin cut - stresses - Revision 5

61
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Revision 6

The main modifications are the added chamfer in front and holes crossing the hole carrier.
There are secondary maximums on the edges of the ribs. The maximum occurs, as always,
inside the pin hole.

Figure 4.58: Minimum Principal Stress - revision 7

62
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.59: Maximum Principal Stress - CUT - revision 6

Figure 4.60: Pin cut - stresses - Revision 6

63
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Revision 7

The final revision tries to achieve the maximum advantage of an external rib between gears.
The minimum stress is in this case with reversed color scale and the elements are visible.
The maximum occurs, as always, inside the pin hole.

Figure 4.61: Minimum Principal Stress - revision 7

64
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.62: Maximum Principal Stress - CUT - revision 7

Figure 4.63: Pin cut - stresses - Revision 7

65
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Shape optimization The availability of shape finder module in Workbench, confirmed the
initial assumption, about where are the locations for material removal or modifications, Figure
4.64. The main visible area to remove is easy to understand analyzing the low material stresses.
The advantage is that some details like near the pin hole or outer surface, can be seen more easily
and action can be taken to remove material in those locations.

Figure 4.64: Shape optimization for Revision 1

Tangential deformation While observing the functionality of the gears, the deflection has to
be analyzed., Figure 4.65. Probes for displacement are positioned in the front and the back, with
the suitable coordinate system, Figures 4.66 and 4.67, measuring the tangential displacement, in
order to have an approximation.

66
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Figure 4.65: Deformation probes

Figure 4.66: Deformation probe 1

Figure 4.67: Deformation probe 2

67
4 - PLACEMENT TASKS 4.2.6 Planet Carrier

Table 4.20: Results for the Planet carrier

Comments

The results show an optimum achievable mass reduction of about 500 Kg. The maximum
stress value occurs, as always, inside the pin hole. Design modifications need to be done for lower-
ing the stresses in this spot. Different designs can now be taken into consideration. It is possible
to conclude that the recommended way of achieving this goal was correct. The achievement of
higher safety factors can be considered as a future research area.. The deformation achieves the
best result for Revision 7, concerning the weight goal, among new revisions. On the other side,
the deformation is much higher than the original planet carrier , Table 4.20 . Future work will
be done to solve this problem.

68
4 - PLACEMENT TASKS 4.3. TRAININGS

4.3 Trainings

Various trainings were attended during this placement. These trainings allowed the author to
learn and understand interaction of companies, formal procedures, control and selection of infor-
mation, importance of IT (Information§Technology) and HPC (High Performance Computing).

1. FEMFAT

2. SKF

3. ANSYS

4. Ricardo

5. MEDESO CAE User conference - Ansys

4.3.1 Femfat

A trainer from Austria was provided to Moventas facilities, in order to assure all the contents
for the training, transmitting theoretical background and practical utilization of the FEMFat
Software.

4.3.2 SKF

In this training, done in Lapland, the main topics were :

• Basic rating life

• ISO 281

• SKF AFC

• Galaxy

• SKF Bearing Beacon

• SKF ECS

4.3.3 Ansys

Tampere

A presentation and discussion were arranged at the facilities of a new licences supplier com-
pany - Process Flow, showcasing problems and requirements.

Jyväskylä

Medeso Conference/Seminar was conducted for performing training and showcasing new prod-
ucts, clearing doubts, new softwares, meeting other colleagues from the sector.

69
4 - PLACEMENT TASKS 4.3.3 Ansys

Copenhagen

MEDESO CAE User conference: 26, 27 May 2008 Conference, with companies from all over
Scandinavia, sharing experience and applications, representing and establishing contacts.
This conference provided the author with the opportunity to have more theoretical background
and to absorb case studies in other companies namely:

• AlfaLaval

• Kanthal AB

• Grundfos

• SwereaSicomp

• XDIN

• Scania

• Siemens

• BAE Systems Bofors

• Validus Engineering

70
5 - CONCLUSIONS AND FUTURE WORK

5 - Conclusions and future work

5.1 Main achievements

This placement provided the author with an enriching personal and professional experience.
Since it was held in a company of extremely good environment, reputation, know-how and re-
sults through all existence, based on professionalism and excellence, numerous achievements and
experiences were possible.

The tasks performed allowed the author in understanding the problems that are faced in
practice, exploring softwares used in mechanical applications, learning new engineering contents,
such as contact analysis, mesh creation efficiency, developing problem questioning and method
of resolution, maturing skills and knowledge acquired previously.
From an engineering perspective, the usage of tools such as Ansys for FEM and Vibrations,
Femfat, for Fatigue, Catia V5 for Modeling were found to be extremely powerful and fast, while
analyzing huge amount of data, load cases and different geometries.
The tasks were performed as the primary present needs were discussed and settled in the struc-
tural analysis section. The optimization of components, structures is always an objective in mind.

It was sequently enjoyed the variety of challenges through out the placement in this organi-
zation. During the strong personal growth period the whole company has been able to improve
operations and utilize new capacity effectively, bringing even more challenges to future operations.
From a management perspective, the whole process of adapting to a new corporate environ-
ment, working in teams, cooperating between departments, and exposure to practical aspects of
running an enterprise helped in providing a sense of satisfaction for the author.
From a personal perspective, the author was glad to acquire the ability to adjust, accept
and adapt to a different culture in a new country, having a different language. In short,this
challenging role helped the author to develop soft and hard skills which are essential for an
international career.
Highlighting achievements from the placement, those can be summarized as follows:

1. The starting procedures were easily performed, and the integration was easy owing to the
cooperation and help of colleagues at Moventas.

2. The tasks performed required multiple skills in modeling and FEM based on discussion
with team members. The learning process was a step by step process,helping the author to
evolve professionally, socially and personally.

71
5 - CONCLUSIONS AND FUTURE WORK 5.2. IMPROVEMENTS

3. The tasks performed depended wholly on the dialogues between team elements and sections.
The specific areas dealt by the author did not have a resolution in advance and required
several trials and changes, experience and good sense in order to obtain results. This
provided the author with the unique opportunity of interaction with others to obtain best
results.

4. The placement made the author understand the importance of the role played by software,
information system and computational power in an enterprise.

Tasks were performed as per the current needs of the enterprise. The solutions provided by
the author were discussed and settled in the structural analysis section. The author has observed
that the optimization of components and structures is always an objective in the minds of Moven-
tas employees.

The main strengths in the organizational climate of the company can be described as follows:

• Moventas’s values and objectives are seen as worth aiming for

• Awareness of the objectives and values of the company

• Decisions concerning one’s own work can be made independently enough

5.2 Improvements

Computer administration plays a major role in the efficiency of an enterprise. The lack of
proper computer administration in a company leads rise to delay in effective problem resolutions
and difficulty in information sharing and access. In Moventas, efforts are being done to improve
the situation along with the growth of the company.

The main areas in need of development on the whole company level:

• Organization of work.

• Work in departments as well as decision-making are not regarded having the optimum
efficiency.

• Information flow (information flow between and inside the departments, high amount of
rumors).

• Induction into new tasks.

5.3 Future Work

The author was still under the placement at the date of report submission.
Present task is to study the 2D interaction between the pin and hole of planet carrier, as described
in section 4.2.6 , Page 48.

72
LIST OF FIGURES LIST OF FIGURES

List of Figures

3.1 Numbers of 2007 - MOVENTAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Moventas History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Proactive lifecycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Company Worldwide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Wind gears 2007 facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Wind gears Sales/employes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Industrial gears 2007 facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Industrial gears Sales/employes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Moventas Key facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Gears Housing after simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Fixed supports applied in the moment-arm holes . . . . . . . . . . . . . . . . . . . 18
4.3 Housing Eigen Frequencies - 1st and 2nd Natural Modes . . . . . . . . . . . . . . . 19
4.4 Aspects of Internship webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Wind turbine gear Assembly - Meshed - Inspection cover Location . . . . . . . . . 21
4.6 Inspection Covers - Geometry changes . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Inspection covers improvement aiming higher 1st /fundamental frequency . . . . . . 23
4.8 Mesh and contact for production-ready inspection covers . . . . . . . . . . . . . . . 24
4.9 1st /fundamental frequency - Results for Final optimum solution . . . . . . . . . . . 25
4.10 Wind turbine gear Assembly - Meshed - Bearing cover location . . . . . . . . . . . 26
4.11 Bearing cover in present production . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.12 Geometry and Constrains of bearing cover : Final solution . . . . . . . . . . . . . 27
4.13 4th Natural Vibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.14 Gears testing structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.15 Original Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.16 Modified Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.17 New concept model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.18 Gears testing ground support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.19 Location of the Bolts/screws analyzed for Original and Modified . . . . . . . . . 32
4.20 Moment and Pre-tensions - Original and Modified . . . . . . . . . . . . . . . . . . 32
4.21 Moment and Pre-tensions - New Concept . . . . . . . . . . . . . . . . . . . . . . . 33
4.22 Bolts pretension step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.23 Moment step graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.24 Total deformation Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.25 Total deformation Modified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.26 Von Mises - New concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

73
LIST OF FIGURES LIST OF FIGURES

4.27 ORIGINAL - Frame stress (Von Mises)- maximum near bolt head . . . . . . . . . 37
4.28 MODIFIED - Frame stress (Von Mises)- maximum near bolt head . . . . . . . . . 38
4.29 NEW CONCEPT - Frame stress (Von Mises)- maximum near bolt head . . . . . . 38
4.30 Original Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.31 Modified Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.32 New concept Total deformation of frame . . . . . . . . . . . . . . . . . . . . . . . 40
4.33 ORIGINAL - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.34 MODIFIED - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.35 NEW CONCEPT - welded region stresses . . . . . . . . . . . . . . . . . . . . . . . 42
4.36 Contact tool results for the frictional contacts-GAP . . . . . . . . . . . . . . . . . 45
4.37 Contact tool results for the frictional contacts - STATUS . . . . . . . . . . . . . . 46
4.38 Planetary Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.39 Planet Carrier detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.40 Revisions for study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.41 Planet Carrier - Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.42 Mesh - refinement locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.43 Planet carrier constraints and moment load . . . . . . . . . . . . . . . . . . . . . . 52
4.44 Frictional Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.45 Frictionless contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.46 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.47 Maximum Principal Stress - CUT - revision 1 . . . . . . . . . . . . . . . . . . . . . 55
4.48 Pin cut - stresses - Revision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.49 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.50 Maximum Principal Stress - CUT - revision 2 . . . . . . . . . . . . . . . . . . . . . 57
4.51 Pin cut - stresses - Revision 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.52 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.53 Maximum Principal Stress - CUT - revision 4 . . . . . . . . . . . . . . . . . . . . . 59
4.54 Pin cut - stresses - Revision 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.55 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.56 Maximum Principal Stress - CUT - revision 5 . . . . . . . . . . . . . . . . . . . . . 61
4.57 Pin cut - stresses - Revision 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.58 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.59 Maximum Principal Stress - CUT - revision 6 . . . . . . . . . . . . . . . . . . . . . 63
4.60 Pin cut - stresses - Revision 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.61 Minimum Principal Stress - revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.62 Maximum Principal Stress - CUT - revision 7 . . . . . . . . . . . . . . . . . . . . . 65
4.63 Pin cut - stresses - Revision 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.64 Shape optimization for Revision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.65 Deformation probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

74
LIST OF FIGURES LIST OF FIGURES

4.66 Deformation probe 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.67 Deformation probe 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

75
LIST OF TABLES LIST OF TABLES

List of Tables

3.1 Some Compulsory Software for simulation/structural analysis . . . . . . . . . . . . 14

4.1 Sequential Tasks Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 Structural Steel Proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Cast Iron GJS250 Proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Cast Iron GJL400 Proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Inspection covers initial improvement aiming a higher fundamental frequency . . . 22
4.6 Results of the production-ready inspection covers . . . . . . . . . . . . . . . . . . . 25
4.7 Bearing cover modifications achieving a higher 4th frequency . . . . . . . . . . . . 28
4.8 Structural Steel Proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.9 Friction proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.10 Description of screws/bolts for Original and Modified . . . . . . . . . . . . . . . . 33
4.11 Description of M16 screws/bolts for New concept . . . . . . . . . . . . . . . . . . . 33
4.12 Bolts pretension step table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.13 Moment step table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.14 Original bolts pretension results . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.15 Modified bolts pretension results . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.16 New concept bolts pretension results . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.17 GJS-700 Cast iron material proprieties . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.18 Structural steel material proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.19 Supports material proprieties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.20 Results for the Planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

76
REFERENCES REFERENCES

References

[1] ANSYS. Ansys CLASSIC and Ansys WORKBENCH - HTML Help.

[2] Dr. Joachim Bergmann. Synthetische für Eisenverkstoffe, 1999. Software SWL1999.

[3] CATIAV5Help. CATIA V5 HTML Help.

[4] TeX Community. TeX Help, How-to, Guides, Macros, Packages, Webpages.

[5] Victor Eijkhout. Tex by Topic. Addison-Wesley, 2nd edition, March 1992.

[6] Michel; Rahtz Sebastian Goossens. The LaTeX Web Companion. Addison-Wesley, 2nd
edition, December 1999.

[7] Donald Ervin Knuth. The Texbook. Addison-Wesley, 3rd edition, October 1990.

[8] S. Butterfield McNiff B., W.Musial. Improving wind turbine gearbox reliability. National
Renewable Energy Lab. 1617 Cole Blv. Golden, CO 80401-3393, May 2007. NREL.

[9] Tobias Oetiker. The not so short Introduction to LaTeX 2ε. 4.22 edition, June 2007.

c FEUP, Porto-
[10] José Dias Rodrigues. Apontamentos de Vibrações de Sistemas Mecânicos .
Portugal, 2nd edition, September 2007.

c Finland, December 2005.

[11] SFS. SFS Standards .

c
[12] PAKARINEN; Mauno; KUKKOLA; Teemu. Vibration Resonances in GE Wind Turbine .
MOVENTAS WIND OY, MARTINKATU, P.O. BOX 158, FIN-40101 JYVÄSKYLÄ , FIN-
LAND, April 2008.

c Medeso, Germany, 1st edition,

[13] Mr. Erke Wang. Efficient Contact Analysis with Ansys .
September 2006.

77