Increase wind gearbox power density by means of IGS (Improved Gear Surface)

Increasing gearbox power density is a key factor in reducing the levelized cost of wind energy (LCOE). The tooth root and flank load carrying capacity of gears are strongly affected by surface conditions. Additional finishing methods such as shot peening (SP) and superfinishing (SF) significantly increase the gear load capacity, but these effects have not yet been adequately considered in the current ISO 6336 standard or in any other gear standards. Based on the experimental results, an estimation of the safety margin increase is calculated for a wind gearbox part. Additional fatigue tests are needed to confirm this increase.

Automated summary

Increasing gearbox power density is crucial for reducing the cost of wind energy. The load carrying capacity of gears is strongly influenced by surface conditions. Additional finishing methods such as shot peening and superfinishing can significantly enhance gear load capacity, yet these effects have not been adequately addressed in current standards.