Wind farms are quickly becoming a major source of renewable, economic and ecological energy. Significant improvements have been made in the efficiency and power of wind turbines by research and development within the last twenty years. In the early Nineties, the average power of a turbine was approximately 250 kW. Today, due to further developments the produced power of 2.5-5 Megawatts has become standard. GG Friction Antidote in combination with highly developed lubrication systems contribute to safety, improve reliability and reduce maintenance costs of wind turbines.

Wind turbines and their components are exposed to high loads. The constantly changing high loads, vibrations and varying operating conditions require tough equipment. Add to those the external factors such as humidity and extreme temperature variations, and components will really suffer. Wind turbine maintenance is an arduous task and performed only at long intervals, which makes trouble-free operation even harder to accomplish. Selecting the right lubricant is therefore paramount – for initial lubrication of a component as well as for relubrication during operation.

After all, it is the lubricant that has to ensure reliable operation of each machine element. Both fluids (oils) and consistent lubricants (greases) are used in wind power plants. The main lubrication points are the main gearbox, the nacelle yaw gears, the main and generator bearings, the blade pitch mechanism and the yaw system. The lubricants used are required to offer reliable performance over a long service life over a wide temperature range as well as resist high load. For operators, these characteristics mean long relubrication intervals for greases and long lubricant life for oils.

Generator Bearing

Varying conditions from icy cold to extremely hot, unpredictable vibrations and shock loads require extraordinary bearing lubricants to assure low friction and long term performance. Advanced lubrication technology enables maintenance free operation.

Yaw Bearing

High static load and unpredictable wind conditions result in high vibration levels under load within the bearing roller and raceway contact. Consequently micro pitting occurs and can develop severe false brinelling if not protected with adequate lubricants.

Main Gear

Humidity, temperature variations, high speeds and unpredictable load conditions are demanding parameters for gear lubrication. Lubricants with extreme shear resistance, excellent adhesion properties and high load carrying capacities are required to cope with such an environment.

Main Bearing

The main shaft bearings experience large load variations and even shock loads due to unpredictable wind and weather conditions. High humidity levels require excellent corrosion protection capabilities. During standby of the rotor blades high levels of micro vibrations take place. Consequently, the lubricant is required to protect the bearing under high dynamic loading as well as under quasi-static condition in a harsh environment.

Pitch Bearing

Most of the time the pitch bearings do not rotate around their own axis but spinning around the

central rotor axis. High centrifugal forces in combination with shock loads and high vibration levels require lubricants that can operate under increased gravity and cope with false brinelling.

Pitch/Yaw Gear

Open gears have always been a challenge for lubrication, in particular when they are exposed to high static loads as well as increased gravity (pitch gears). Lubrication under such conditions requires higher levels of adhesion and lubricity.

Pitch/ Yaw Drive

Gears operating mostly in mixed friction conditions require special solutions. Semi liquid lubricants significantly reduce friction and wear. The thickener matrix contributes to better corrosion protection of all components.

Have you ever considered how lubricants can influence your operating costs? The lubricant itself constitutes only a minor investment, but its effects can be tremendous.

Use high-performance oils for enclosed gears operating under extreme loads

As wind generators get ever larger, the power density in wind turbine gears is increasing, causing higher stress on the gears. Experience has shown that the conventional gear oils available on the market today often fail to meet taxing requirements in terms of wear protection for rolling bearings, micropitting resistance, foam and residue formation, and viscosity stability.

Besides an oil‘s viscosity, it is the additives that protect components reliably against micropitting and scuffing damage, hence enabling longer gear life. Micropitting is a form of wear occurring on highly loaded gears, especially in the contact area subject to mixed friction and negative specific sliding. Material near the surface is plastically deformed, and micro-cracks form. To the naked eye, the damaged tooth flank area looks greyish. When sufficiently magnified, minute spalling and pores become visible. The principal causes of micropitting are high load, low gear speed, as this leads to reduced lubricant film thickness, unfavorable tooth geometry leading to high local loads on the tooth flank, roughness of the tooth flank and the wrong lubricant in use.

Longer gear life due to adjusted and constant viscosity ratings

The performance a lubricating oil offers are substantially influenced by its additive package and its viscosity. Gear life can be optimized by using synthetic gear oils showing a better viscosity-temperature behavior. Viscosity is of primary importance when selecting gear oils, as it significantly determines the formation of a lubricant film. Increasing viscosity results in thicker lubricant films, thus improving the antiwear and damping properties as well as scuffing load capacity. Viscosity decreases with increasing temperature and rises with increasing load. If the viscosity is too high, increased churning and squeezing losses can result in excessive heat, especially at elevated peripheral speeds. If the viscosity is too low, mixed friction conditions prevail and will result in increased wear. A high viscosity index makes for easier start-up at low outside temperatures, reduces power loss to a minimum and ensures the formation of a load-carrying lubricant fi lm also at high temperatures.

What‘s good for gears needs to be good for rolling bearings

Gear damage is frequently associated with damaged rolling bearings. This is why lubricant manufacturers are required to prove that their products are not only suitable for the lubrication of gears, but also for the bearings in the gearbox. Consequently, the revised standard DIN 51517 part 3 contains the FE8 rolling bearing test developed by bearing manufacturer FAG. The FE8 test serves to determine the wear characteristics of a gear oil and forms the basis of estimating the effect a gear oil has on rolling bearing life.

Oil compatibility with radial shaft elastomer seals

Many complaints regarding gears are raised because of oil leakage. As conventional gear oils are frequently not sufficiently compatible with the seal elastomers, the sealing function can suffer and leakage occurs.

High micropitting resistance helps prevent premature fatigue damage

Highly loaded gears are susceptible to scuffing and micropitting. High pressure and temperature occurring in the mesh zone can cause tooth damage and consequently lead to premature gear failure. The risk of scuffing or micropitting damage is particularly high with less-than-perfect tooth profiles and surfaces, or where shock loads, vibration, high surface pressures or high sliding friction occur. Micropitting changes the shape of the tooth flank, which may affect the mesh dynamics and the gear‘s noise characteristics. The cracks associated with micropitting may propagate, resulting in actual gear pitting. In field applications, micropitting formation is often reported even though industrial gear oils with a high micropitting load capacity are used.

Unearth the benefits of GG Friction Antidote – An investment that pays off and your benefits at a glance:

Innovative tribological solutions are our passion. We’re proud to offer unmatched friction reduction for a better environment and a quick return on your investment. Through personal contact and consultation, we offer reliable service, support and help our clients to be successful in all industries and markets.

Profitability:

Switching over to a high-performance lubricant pays off although purchasing costs may seem higher at first, less maintenance and longer vehicles/machinery parts lifecycle may already mean less strain on your budget in the short to medium term.

Continuous production processes and predictable maintenance intervals reduce production losses to a minimum. Consistently high lubricant quality ensures continuous, maintenance-free long-term lubrication for high plant availability. Continuous supply of fresh GG Friction Antidote treated lubricant to the lubrication points keeps friction low and reduces energy costs.

Safety:

Longer lubrication intervals reduce the frequency of maintenance work and the need for your staff to work in danger zones. Lubrication systems can therefore considerably reduce occupational safety risks in work areas that are difficult to access.

Reliability:

GG Friction Antidote treated lubricants ensure reliable, clean and precise lubrication around the clock. Plant availability is ensured by continuous friction reduction of the application. Lubrication with GG Friction Antidote treated lubricants help to prevent significant rolling bearing failures.

Need a good ROI? How about 3,900%?

It may sound too outrageous to be true, but the Institute of Mechanical Engineers estimates every $1,000 spent on proper lubrication yields $40,000 in savings.

INSTANT ROI FOR OPTIMIZING YOUR LUBRICATION REGIMEN

How many kilometers do you travel monthly?

How many hours do you clock monthly?

How many litres of fuel do you consume monthly?

What’s the cost of fuel to you monthly?

How many kilometers or hours do you run per oil change?

How many litres of oil do you consume per oil change?

What’s the cost of oil to you monthly?

What’s the cost of oil filters per oil change to you?

What’s the cost of grease to you monthly?

What’s the cost of fuel filters per oil change to you?

What’s the cost of air filters per oil change to you?

What’s the average frequency of vehicle/machinery replacement to you?

What’s the cost of vehicle/machinery replacement to you?

Would you like to lower your operating costs, improve uptime and increase your company’s profits?

Let’s do the math together … Learn more >>

The information in this literature is intended to provide education and knowledge to a reader with technical experience for the possible application of GG Friction Antidote.  It constitutes neither an assurance of your vehicle/machinery optimization nor does it release the user from the obligation of performing preliminary tests with GG Friction Antidote. We recommend contacting our technical consulting staff to discuss your specific application. We can offer you services and solutions for your heavy machinery and equipment.

Locate A GG Friction Antidote Dealer