applied

sciences
Article
Design of a Mechanical Power Circulation Test Rig
for a Wind Turbine Gearbox
Geun-Ho Lee 1 , Young-Jun Park 2,3, * , Ju-Seok Nam 4 , Joo-Young Oh 5 and Jeong-Gil Kim 6, *
1 Department of Smart Industrial Machinery, Korea Institute of Machinery & Materials, 156, Gajeongbuk-ro,
Yuseong-gu, Daejeon 34103, Korea; ghlee762@kimm.re.kr
2 Department of Biosystems and Biomaterials Science and Engineering, Seoul National University,
1 Gwanak-ro, Gwanak-gu, Seoul 08826, Korea
3 Research Institute of Agriculture and Life Sciences, Seoul National University, 1 Gwanak-ro, Gwanak-gu,
Seoul 08826, Korea
4 Department of Biosystems Engineering, Kangwon National University, 1 Kangwondaehak-gil, Chuncheon,
Gangwon-do 24341, Korea; njsg1218@kangwon.ac.kr
5 Safety System R&D Group, Korea Institute of Industrial Technology, 15 Jisiksaneop-ro, Hayang-eup,
Gyeongsan, Gyeongsangbuk-do 38408, Korea; jyoh@kitech.re.kr
6 Smart Agricultural Machinery R&D Group, Korea Institute of Industrial Technology,
119 Jipyeongseonsandan 3-gil, Baeksan-myeon, Gimje, Jeollabuk-do 54325, Korea
* Correspondence: yjpark95@snu.ac.kr (Y.-J.P.); kjg14@kitech.re.kr (J.-G.K.)




Received: 25 March 2020; Accepted: 30 April 2020; Published: 7 May 2020


Abstract: We developed a mechanical power circulation test rig for a wind turbine gearbox with a
power rating of 5.8 MW or less. The test rig consists of an electric motor, two auxiliary gearboxes,
a torque-applying device, lubrication systems, cooling systems, and control systems. The torque
generating device consists of a planetary gearbox and a hydraulic control system and is used to
apply the desired torque to the test gearbox. The hydraulic control system applies the torque on
the ring gear of the planetary gearbox. The gears and bearings of the two auxiliary gearboxes and
planetary gearboxes met the design criteria for a safety factor of over 1.2 and a bearing life of 30,000 h.
In addition, the master and slave gearboxes were connected to the test rig to verify whether the
torque-applying device had applied variable torque in real-time during the test. The device was only
able to induce a variable torque of up to 45.2 kN-m due to the limitation of the rated torque of the
master and slave gearboxes. The test rig can test not only efficiency, vibration, and noise but also
durability and overloading.

Keywords: hydraulic control system; power circulation test rig; torque-applying device; wind
turbine gearbox

1. Introduction
A wind turbine drivetrain transfers mechanical energy from the rotor to the generator. It consists
of main shaft, main bearing, a gearbox, and other components. Wind turbine gearboxes (WTGBs) that
transfer input power (low speed and high torque) from a rotor to a generator (high speed and low
torque) are expensive and generally recognized as a component with the highest failure rate among all
other components in the drivetrain. Additionally, because WTGBs are installed in the narrow space of
a nacelle, repair in the case of failure is costly and time-consuming. The design of a drivetrain influence
not only the performance of the wind turbine but also durability. The service life of a wind turbine
can be maintained at or extend beyond 20 years by reducing the failure rate of its drivetrain. The first
step to reducing the failure rate is to investigate the performance of the WTGB (i.e., efficiency, noise,

Appl. Sci. 2020, 10, 3240; doi:10.3390/app10093240 www.mdpi.com/journal/applsci

 Appl. Sci. 2020, 10, x FOR PEER REVIEW 2 of 16
Appl. Sci. 2020, 10, 3240 2 of 16

the performance of the WTGB (i.e., efficiency, noise, vibration, and durability). The reliability of a
WTGB, measured in terms of performance and durability, can be evaluated through laboratory tests
vibration, and durability). The reliability of a WTGB, measured in terms of performance and durability,
[1,2].
can be evaluated through laboratory tests [1,2].
The test rig for WTGBs can be categorized into electrical and mechanical power circulation
The test rig for WTGBs can be categorized into electrical and mechanical power circulation types,
types, as shown in Figure 1 [3,4]. The major difference between the two test rigs is the type of power
as shown in Figure 1 [3,4]. The major difference between the two test rigs is the type of power that is
that is circulated through the system. In the case of electrical power circulation, an electric motor
circulated through the system. In the case of electrical power circulation, an electric motor drives the
drives the input shaft of the test gearbox. Its output shaft is coupled to a generator that feeds the
input shaft of the test gearbox. Its output shaft is coupled to a generator that feeds the power back
power back to the grid. In this way, the total energy consumption is significantly reduced [4].
to the grid. In this way, the total energy consumption is significantly reduced [4]. However, in this
However, in this type, when components such as motor, generator, and inverter are being selected,
type, when components such as motor, generator, and inverter are being selected, the total power
the total power required for the test, including the gearbox driving power, and the losses that occur
required for the test, including the gearbox driving power, and the losses that occur at the gear/bearing
at the gear/bearing must be considered. Because large and expensive motors, generators, and
must be considered. Because large and expensive motors, generators, and inverters are required to test
inverters are required to test large gearboxes, the initial cost of the test is high. Nevertheless, the
large gearboxes, the initial cost of the test is high. Nevertheless, the advantages of this type include
advantages of this type include high accuracy and ease of torque control, and the test rig
high accuracy is
configuration and ease compared
simple of torque control, and the test
to the mechanical rig configuration
power circulation testisrig.
simple compared to the
mechanical power circulation test rig.

(a)

(b)
Figure1.1.Power
Figure Power circulation
circulation testforrig
test rig for aturbine
a wind wind gearbox
turbine (WTGB).
gearbox (a) Electrical(a)
(WTGB). Electrical
type. type. type.
(b) Mechanical (b)
Mechanical type.
In the case of mechanical power circulation type, input and output shafts of two gearboxes with
In the
identical case
gear of mechanical
ratios powertocirculation
are connected each othertype, input and output
by intermediate shaftsshafts
and of two gearboxes
gearboxes, witha
building
identical gear
closed-loop. ratios are connected
A torque-applying to each
device can be other by intermediate
included in the power shafts
loop.and
Thegearboxes,
applied torquebuildingloadsa
closed-loop.
both gearboxes. A An
torque-applying
external motordevice
is used can be included
to rotate in thewhich,
the system, powerinloop. The applied
steady-state, must torque loads
compensate
bothfor
only gearboxes. An external
the total power motor
loss of the is used
system. to rotate
Therefore, the system,
its power rating iswhich,
muchin lowersteady-state, must
than that which
compensate only for the total power loss of the system. Therefore, its power rating
actually loads the gears. The degree of power circulation is controlled by the torque, which is applied is much lower
than
by thethat which actually
torque-applying loads and
device the gears. The degree
the motor speed. Theof power circulation
advantage of thisis test
controlled
rig is the bysignificantly
the torque,
which isinstallation
reduced applied by cost
the torque-applying
because it does not device and the
require motor speed.
a generator Thedriving
and the advantage motor of this
onlytest rig isto
needs
the significantly reduced installation cost because it does not require a generator
be rated accordingly to the total power loss [4]. The disadvantage, however, is that the test rig becomes and the driving
motor only
complex dueneeds
to theto be ratedofaccordingly
addition to the total
auxiliary devices (e.g.,power loss [4]. The
shaft, gearbox) disadvantage,
to form the mechanical however,
closedis
that the
loop. test rig becomes
Furthermore, complex due
the conventional testtorigthe
foraddition
a WTGBof auxiliary
that devices (e.g.,
uses mechanical power shaft, gearbox)uses
circulation to
form the mechanical closed loop. Furthermore, the conventional test rig for a
an actuator installed in the torque arm of the gearbox to apply torque to its closed loop. In other words, WTGB that uses
mechanical
because power circulationdevice
the torque-applying uses an is actuator
installedinstalled
on the test in the torqueifarm
gearbox, the of theorgearbox
size shape oftothe applytest
torque to its closed loop. In other words, because the torque-applying device is
gearbox is changed, the test rig should also be changed. Each mechanical power circulation test rig is installed on the test
Appl. Sci. 2020, 10, 3240 3 of 16

designed to test WTGB of a certain specification. That is, there is no universal test rig that can test
all WTGBs.
Arun et al. surveyed published papers on the construction and procedure of a test rig for
noise, vibration, lubrication, cleanliness, and efficiency tests, using various test rigs of the two types.
In addition, Aren et al. introduced a new compact test rig developed. This system is similar to the
electrical power circulation-type test rig. The input of the gearbox is driven by a motor, and the
output is torque induced into the gearbox by a pump. The torque can be changed during the test
by adjusting the flow rate and pressure of the pump [5]. Mihailidis et al. introduced electrical and
mechanical power circulation type test rigs. A method for applying torque to the mechanical power
circulation-type test rig and a torque-applying device similar to a rotary actuator was introduced.
This device was equipped with a two-stage planetary gear train and a motor, which was installed on the
standard Forschungsstelle fur Zahnrader und Getriebebau of the Technical University Munich (FZG)
back-to-back test rig. They also demonstrated that the test torque and rotation speed could be varied.
However, they did not include the test results of their torque-applying device. It was also described as
a method applicable to small mechanical power circulation-type test rigs [4]. Jung et al. introduced a
failure analysis and test evaluation process for analyzing and evaluating the performance of a torque
generator. The rig for the evaluation was of the electrical power circulation type, and the input was
an electric motor while the output was a powder brake [6]. Krull introduced the general process
requirements for the simulation, test rig, testing, and verification of WTGBs. The paper describes the
purpose of the gearbox test (assuming design factors, noise, vibration, temperature) [7]. Musial et al.
introduced a 2.5-MW electrical power circulation-type test rig, which is installed in NREL(National
Renewable Energy Laboratory) [3]. The test rig was designed with the components and operational
characteristics of a real wind turbine drivetrain. The test rig was equipped to apply a non-torque load
to the main shaft connected to the gearbox by using a bearing and an actuator.
Previous studies have described the configuration of test rig, test procedures according to gearbox
test items and how to apply torque by using powder brakes, pumps or rotary actuators. However,
previous studies introduced a method of applying torque to an electric or mechanical power circulation
test rig for small gearboxes, and in the case of a mechanical power circulation test rig, there was no
device capable of applying variable torque during the test. In addition, in most studies for MW class
large gearbox tests, an electric power circulation test rig was used, and no mechanical power circulation
test rig capable of controlling variable torque during the test could be found.
In this study, we developed a mechanical power circulation test rig that can test gearboxes up to
5.8 MW. The rig is equipped with a variable torque-applying device with a planetary gearbox and
linear actuators. The performance of the test rig, as well as the variable torque-applying device, was
validated. A resonance analysis was performed on the test rig by changing the rotational speed of
the motor.

2. Characteristics of the General Mechanical Power Circulation Test Rig

The FZG back-to-back test rig is shown in Figure 2, and its working principle is shown in Figure 3.
The gears of the two gearboxes have equal teeth numbers and consequently, the same gear ratio.
The slow shafts are connected by an intermediate torque measuring shaft. The fast shafts are connected
by a load flange coupling that permits both ends to rotate relative to each other. When the rig is
terminated and the coupling bolts are loose, one flange can be fixed, while the required test torque
can be applied to the other by a lever and weights. The bolts are then tightened, prohibiting the
relative motion of the coupling flanges and storing the applied torque in the system. The flanges of
the torque-measuring flange rotate in the opposite directions according to the torsional deformation
of an intermediate shaft, thus proving the readout of the test torque. The flange of the load coupling
can now be released, and the test rig can be started. The power that the gearboxes transmit is equal to
the product of the applied torque and the rotational speed. The driving motor only has to supply the
power losses. This feature not only saves energy but also allows for the determination of the efficiency
Appl.Sci.
Appl.
Appl. Sci.2020,
Sci. 2020,10,
2020, 10,xxxFOR
10, FORPEER
FOR PEERREVIEW
PEER REVIEW
REVIEW 444of
of16
of 16
16

onlySci.
Appl.
only has
has to10,
2020,
to supply the power
3240 the
supply power losses.
losses. This
This feature
feature not
not only
only saves
saves energy
energy but
but also
also allows
allows
only has to supply the power losses. This feature not only saves energy but also allows for for
for the
4 ofthe
16
the
determination of
determination
determination of the
of the efficiency
the efficiency of
efficiency of one
of one gearbox.
one gearbox. Provided
gearbox. Provided that
Provided that both
that both gearboxes
both gearboxes are
gearboxes are identical,
are identical, it
identical, itit can
can be
can be
be
assumed
assumed
assumed that
that they
they
that they have
have
have the the
the same
same power
power loss.
loss. Since
Since no
no other
other sources
sources of
of significant
significant power
power loss
loss are
are
of one gearbox. Provided thatsame power loss.
both gearboxes areSince no other
identical, it cansources of significant
be assumed that theypower
have the loss are
same
present in
present
present in the
in the power
the power loop,
power loop, the
loop, the power
the power loss
power loss of
loss of aaa single
of single gearbox
single gearbox can
gearbox can be
can be easily
be easily obtained
easily obtained by
obtained by dividing
by dividing the
dividing the
the
power loss. Since no other sources of significant power loss are present in the power loop, the power
total power
total
total power loss
power loss by
loss by two
by two [5].
two [5].
[5].
loss of a single gearbox can be easily obtained by dividing the total power loss by two [5].

Figure2.2.
Figure
Figure
Figure 2.Forschungsstelle
2. Forschungsstellefur
Forschungsstelle
Forschungsstelle furZahnrader
fur
fur Zahnraderund
Zahnrader
Zahnrader undGetriebebau
und
und Getriebebau(FZG)
Getriebebau
Getriebebau (FZG)mechanical
(FZG)
(FZG) mechanicalpower
mechanical
mechanical powercirculation
power circulationgear
circulation gear
gear
test rig [5]. test
test rig
rig [5].
[5].
test rig [5].

Figure3.
Figure
Figure
Figure 3.Layout
3.
3. Layoutof
Layout
Layout ofthe
of
of theFZG
the
the FZGgear
FZG
FZG geartest
gear
gear testrig
test
test rig[4].
rig
rig [4].
[4].
[4].

Theclosed-loop
The
The
The closed-loopof
closed-loop
closed-loop ofthe
of
of thetest
the
the testrig
test
test rigis
rig
rig istorsion
is
is torsionloaded
torsion
torsion loadedso
loaded
loaded sothat
so
so thateach
that
that eachof
each
each ofits
of
of itssections,
its
its sections,being
sections,
sections, beingin
being
being intorsional
in
in torsional
torsional
torsional
equilibrium,has
equilibrium,
equilibrium,
equilibrium, hasequal
has
has equaland
equal
equal andopposite
and
and oppositetorques
opposite
opposite torquesat
torques
torques atits
at
at itstwo
its
its twoends.
two
two ends.If
ends.
ends. IfIfthe
If theapplied
the
the appliedtorque
applied
applied torqueand
torque
torque andthe
and
and therotation
the
the rotationat
rotation
rotation at
at
at
one
one
one end
end
end of
of
of aa
a closed-loop
closed-loop
closed-loop section
section
section are
are
are inin
in the
the
the same
same
same direction,
direction,
direction, then
then
then power
power
power
one end of a closed-loop section are in the same direction, then power will enter that section. If in the will
will
will enter
enter
enter that
that
that section.
section.
section. IfIf
If inin
in the
the
the
oppositedirection
opposite
opposite
opposite directionat
direction
direction atthe
at
at theother
the
the otherend,
other
other end,then
end,
end, thenpower
then
then powerwill
power
power willleave
will
will leavethe
leave
leave thesection.
the
the section.Since
section.
section. Sincethis
Since
Since thisapplies
this
this appliesto
applies
applies toall
to
to allloop
all
all loop
loop
loop
sections,power
sections,
sections,
sections, powerwill
power
power willcirculate
will
will circulatecontinuously
circulate
circulate continuously
continuously
continuously around
around
around
around the the
the
the closed-loop
closed-loop
closed-loop
closed-loop aindirection
in in
in aaa direction
direction
direction that
thatthat
that is determined
is determined
is
is determined
determined by
by
the
by the
the combination
combination
combination of of
of directions
directions of
directions of
torque
of torque
torqueand and
and rotation
rotation [8].
rotation [8].
Figure
[8]. Figure
4
Figure 4
shows
by the combination of directions of torque and rotation [8]. Figure 4 shows the scheme of power flow 4 shows
the
shows the
scheme
the scheme
of
scheme power of
of power
flow
power flow
with
flow
with circulation
with circulation
circulation
with circulation in aaa closed-loop
in a closed-loop
in
in closed-loop
closed-loop wherein
whereinwhereinPL_A and
wherein PPL_A
P PL_B
L_A
L_A and
and
and PPL_B
represent
P represent
the power
L_B represent
L_B represent thelosses
the
the power
power
power due losses
losses
losses due to
to friction
due
due tobetween
to friction
friction
friction
between
the gears and
between
between the gears
the
the gears
the
gears and the
bearings
and
and the
the bearings
inside
bearings
bearingsthe two inside
inside
inside the two
gearboxes.
the
the twoFrom
two gearboxes.
this scheme,
gearboxes.
gearboxes. Fromitthis
From
From this
this scheme,
is evident
scheme,
scheme, thatitit is
it is evident
is evident
gearbox
evident that
A that
has
that
gearbox
agearbox
heavier
gearbox A A has
load
A has a heavier
than gearbox
has aa heavier
heavier load load
B. than
load than gearbox
than gearbox
gearbox B. B.
B.

PPMM=
P ==PPL_A
L_A++PPL_B
L_B
M PL_A + PL_B

PPTT
P T

PPL_A
P L_A
L_A

PPTT---P
P PPL_A
L_A--PPL_B
L_B
T L_A - PL_B
PPL_B
P L_B
L_B

PPTT---P
P PPL_A
L_A
T L_A
BB
B AA
A

Figure
Figure 4.Scheme
Figure4.
Figure 4.
4. Schemeof
Scheme
Scheme ofpower
of
of powerflow
power
power flowin
flow
flow inpower
in
in powercirculation
power
power circulationtest
circulation
circulation testrig.
test
test rig.
rig.
rig.
Appl. Sci.
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This torque-applying clutch of the test rigs is simple and reliable, but it has a drawback; that is,
This torque-applying
the applied torque cannot be clutch of the test
controlled rigsthe
during is simple and reliable,
test. Therefore, but it torque
a variable has a drawback; that is,
test is impossible
the applied torque cannot be controlled
unless the test rig is terminated. during the test. Therefore, a variable torque test is impossible
unless the test rig is terminated.
3. Design of the Mechanical Power Circulation Test Rig
3. Design of the Mechanical Power Circulation Test Rig
3.1. Conceptual Design
3.1. Conceptual Design
The mechanical power circulation (or mechanical back-to-back type) rig has several gearboxes
The mechanical power circulation (or mechanical back-to-back type) rig has several gearboxes
connected in a closed-loop to circulate the torque loads. It is composed of an electric motor, two
connected in a closed-loop to circulate the torque loads. It is composed of an electric motor, two
auxiliary gearboxes (parallel gearboxes for torque circulation), a torque-applying device, lubrication
auxiliary gearboxes (parallel gearboxes for torque circulation), a torque-applying device, lubrication
systems, cooling systems, and control systems (Figure 5). The torque-applying device consists of a
systems, cooling systems, and control systems (Figure 5). The torque-applying device consists of a
planetary gearbox and a hydraulic control system. With this device, the desired torque can be
planetary gearbox and a hydraulic control system. With this device, the desired torque can be applied
applied to the test gearbox. The torque is applied to the ring gear of the planetary gear train by a
to the test gearbox. The torque is applied to the ring gear of the planetary gear train by a hydraulic
hydraulic control system that can be automatically controlled during the test. The applied torque
control system that can be automatically controlled during the test. The applied torque results from the
results from the difference of the rotation direction and the rate of the sun and ring gears. The
difference of the rotation direction and the rate of the sun and ring gears. The number of teeth of the
number of teeth of the gears is chosen such that, for a given rotation angle of the ring gear, the sun
gears is chosen such that, for a given rotation angle of the ring gear, the sun gears rotate in a different
gears rotate in a different direction and at different angles, resulting in torque. Load is applied in the
direction and at different angles, resulting in torque. Load is applied in the same manner as the
same manner as the planet carrier. The speed of the test gearbox is controlled by an electric motor,
planet carrier. The speed of the test gearbox is controlled by an electric motor, and the power supplied
and the power supplied from the motor covers the frictional loss of the test rig. Figure 6 shows the
from the motor covers the frictional loss of the test rig. Figure 6 shows the scheme of power flow
scheme of power flow with circulation in a closed loop. In this figure, PL_SG, PL_MG, PL_AG1, PL_AG2, and
with circulation in a closed loop. In this figure, PL_SG , PL_MG , PL_AG1 , PL_AG2 , and PL_TAG represent
PL_TAG represent the power losses due to friction between the gears and the bearings inside the three
the power losses due to friction between the gears and the bearings inside the three gearboxes and
gearboxes and two test gearboxes. From this scheme, it is evident that the slave gearbox is more
two test gearboxes. From this scheme, it is evident that the slave gearbox is more loaded than the
loaded than the master gearbox.
master gearbox.

Electric
Motor

Slave Master
Gearbox Gearbox

(a)

(b)
Figure 5.
Figure 5. Layout
Layout of the
the developed
developed test
test rig.
rig. (a) Concept of the developed test rig (b)
(b) Configuration
Configuration of
of
the test
the test developed
developed rig.
rig.
Appl. Sci. 2020, 10, 3240 6 of 16
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Figure 6.
Figure 6. Scheme of the power flow
flow in
in the
the developed
developed test
test rig.
rig.

The
The test
testrig
rigwas
wasdesigned
designed based on the
based on size, capacity,
the size, and test
capacity, andrequirements of the WTGBs.
test requirements Figure 5
of the WTGBs.
shows the conceptual design and layout of the apparatus, and Table 1 lists the
Figure 5 shows the conceptual design and layout of the apparatus, and Table 1 lists the specificationsspecifications of the
WTGBs that canthat
of the WTGBs be tested
can beintested
the rig.inIn therig.
the case
Inofthe
a WTGB,
case of the rotational
a WTGB, thespeed of thespeed
rotational high-speed
of the
shaft is usually
high-speed shaft1100–2200
is usuallyrpm and therpm
1100–2200 rated rotational
and the ratedspeed of an speed
rotational electricofmotor is 1180
an electric rpm.isThus,
motor 1180
gear
rpm. Thus, gear ratios of the auxiliary gearboxes were selected such that all WTGBs of 5.8 MW be
ratios of the auxiliary gearboxes were selected such that all WTGBs of 5.8 MW or less could or
tested. In the
less could design In
be tested. of the
the mechanical
design of the power circulation
mechanical powertestcirculation
rig, if the slave and
test rig, if master
the slavegearboxes
and masterdo
not rotate atdothe
gearboxes notsame speed,
rotate at theadditional torques
same speed, will accumulate
additional torques will in the closed-loop,
accumulate andclosed-loop,
in the the test rig
could be damaged. Thus, this was considered for the gear ratio selection.
and the test rig could be damaged. Thus, this was considered for the gear ratio selection.

Table 1. Specifications
Table 1. Specifications of
of gearboxes
gearboxes that
that can
can be
be tested.
tested.

Classification
Classification SpecificationofofTest
Specification TestGearbox
Gearbox
Gearbox
Gearbox size
size Diameter:
Diameter: 4.3 m, Length:3.3
4.3 m, Length: 3.3mm
Max. power
Max. power 5800 kW
5800 kW
Max.
Max. torque
torque at at high-speed
high-speed shaft
shaft 50.2
50.2kN-m
kN-matat1100
1100rpm
rpm
Max.
Max. speed
speed at at high-speed
high-speed shaft
shaft 2200
2200rpm
rpmatat25.1
25.1kN-m
kN-m

A 3D model view and a photograph of the developed test rig are given in Appendix A.
A 3D model view and a photograph of the developed test rig are given in Appendix A.

3.2. Design
3.2. Design of
of Gearboxes
Gearboxes Used
Used in
in the
the Test
Test Rig
Rig
The gear
The gearratios
ratiosofof auxiliary
auxiliary gearbox
gearbox #1 (Figure
#1 (Figure 7), auxiliary
7), auxiliary gearboxgearbox #2 (Figure
#2 (Figure 8), torqued
8), and the and the
gearbox (Figure 9) were selected to meet the rated rotational speed required by the test the
torqued gearbox (Figure 9) were selected to meet the rated rotational speed required by test
WTGB.
WTGB. Furthermore,
Furthermore, the optimalthe size
optimal
of thesize of the
entire entirewas
gearbox gearbox was determined
determined by considering
by considering the size of the
the size
test
of the test gearbox. When the rotation speed of the electric motor was 1000 rpm,
gearbox. When the rotation speed of the electric motor was 1000 rpm, auxiliary gearbox #1 s shafts O auxiliary
0 gearbox1
#1′s O
and shafts ① at
2 rotated and ② rpm
1000 rotated
andat 1000O
shaft 3 rpm
rotated 2000③
andatshaft rotated
rpm. at 2000
Auxiliary rpm. Auxiliary
gearbox #20 s shaft gearbox
O4 rotated #2′s
at
shaft ④rpm,
285.714 rotated
shaftatO5285.714
rotatedrpm, shaft
at 1000 rpm,⑤androtated
shaftatO
6 1000 rpm,
rotated at and rpm.⑥
2000shaft Therotated
torqued atgearbox’s
2000 rpm.shaft
The
torqued
O gearbox’s shaft ⑦
7 rotated at 1000 rpm and shaft Orotated at 1000 rpm and shaft ⑧ rotated at 285.714 rpm.
8 rotated at 285.714 rpm. Therefore, the design was made such that Therefore, the
design
the test was made
gearbox suchbe
could that the test gearbox
connected to shaftscouldO
2 and beO 5connected
or shafts to
O3 shafts
and O 6②of and ⑤ or shafts
the auxiliary ③ and
gearboxes
⑥ of the auxiliary gearboxes according to the rotational speed
according to the rotational speed of the high-speed shaft of the test gearbox. of the high-speed shaft of the test
gearbox.

Figure 7. Layout of auxiliary gearbox #1.

#1′s shafts ① and ② rotated at 1000 rpm and shaft ③ rotated at 2000 rpm. Auxiliary gearbox #2′s
shaft ④ rotated at 285.714 rpm, shaft ⑤ rotated at 1000 rpm, and shaft ⑥ rotated at 2000 rpm. The
torqued gearbox’s shaft ⑦ rotated at 1000 rpm and shaft ⑧ rotated at 285.714 rpm. Therefore, the
design was made such that the test gearbox could be connected to shafts ② and ⑤ or shafts ③ and
⑥
Appl.ofSci.
the auxiliary
2020, 10, 3240 gearboxes according to the rotational speed of the high-speed shaft of the7 of
test
16
gearbox.

Appl.Sci.
Appl. Sci.2020,
2020,10,
10,x xFOR
FORPEER
PEERREVIEW
REVIEW 77of
of16
16
Figure 7.
Figure Layout of
7. Layout of auxiliary
auxiliary gearbox
gearbox #1.
#1.

Figure 8. Layout
Layout of
of auxiliary gearbox #2.
Figure 8. Layout of auxiliary gearbox #2.

Figure 9. Layout
Figure9. Layout of torque application gearbox.
gearbox.
Figure 9. Layout of torque application gearbox.
InInthe
theauxiliary
auxiliarygearbox
gearbox design,
design, ifif thethe number
number of of gear
gear pairs
pairs is is small,
small, thethe center
center distance
distanceof ofone
one
gear In
pairthe auxiliary
will become gearbox
too design,
large, and if
the the number
gear’s pitch of gear
line pairs
velocity, is
gear pair will become too large, and the gear’s pitch line velocity, weight, and volume, balance, etc. small,
weight, the
and center
volume, distance of
balance, one
etc.
gear
may pair
mayyield will become
yielduncertainties. too
uncertainties. To large,
Toaddress and
addressthis,the gear’s
this, the pitch
the number
number of line velocity,
of gear
gear pairs
pairs wasweight, and
was increased. volume,
increased. Shaft balance,
Shaft design
designand etc.
and
may yield
bearing
bearing uncertainties.
selection
selection were To address
wereperformed
performed this,
based
based on the
on the number
thedesigned
designed ofgear
gear pairs
gearpair.
pair. Thewas
The increased.
torque
torque Shaft gearbox
application
application design
gearboxandisisa
bearing
planetary selection
geartrain were
withperformed
five planet based
gears. on the
Baseddesigned
on
a planetary geartrain with five planet gears. Based on the total size of the the gear
total pair.
size The
of thetorque application
gearbox, the gear ratio wasis
the gear gearbox
ratio was
adesigned
planetary
designed totogeartrain
be 3.5. with five planet gears. Based on the total size of the gearbox, the gear ratio was
be3.5.
designed
The
TheISOto
ISObestandard
3.5.
standard was
wasusedusedto toassess
assess the the gear
gear strength
strength [9] and bearing life life [10].
[10]. Detailed
Detailedresults
results
are The ISO
presented standard
in Appendixwas used
B. In to
theassess
results,
are presented in Appendix B. In the results, gear pairs the gear
gear strength
pairs with [9]
theand bearing
lowest safetylife [10].
factor Detailed
were
lowest safety factor were GP05 and GP05results
and
are
GP09
GP09presented
ofofthe in Appendix
theauxiliary
auxiliary gearboxesB. In (1.3212).
gearboxes the results,
(1.3212). Thegear pairswith
bearing withthe theshortest
the lowest life
shortest safety
life wasfactor
was BRG32
BRG32 were GP05
ofthe
of the and
torque
torque
GP09 of the gearbox
application
application auxiliary gearboxes
gearbox (30,683
(30,683 h). (1.3212).
h). The
The designedThe bearing
designed gear pairs withand theselected
shortest bearings
selected life was BRG32
bearings satisfied
satisfied ofthe torque
the design
design
application
criteria
criteriafor foragearbox
asafety
safety (30,683
factor
factor ath).at
of of The
least designed
1.2
least andand
1.2 agear
a bearing pairs
bearing ofand
life life of selected
30,000 h,bearings
h, respectively.
30,000 satisfied
respectively.Therefore, thethe
Therefore, design
three
the
criteria
gearboxes fordesigned
three gearboxes a safety factor
for theof
designed for at
testthe least
rig test 1.2
were and
wereadeemed
rigdeemed bearing
suitable life
forof
suitable 30,000
for testing
testing h, respectively.
WTGBs WTGBs
of 5.8 of
MW 5.8Therefore,
MW
or the
or less.
less.
three gearboxes designed for the test rig were deemed suitable for testing WTGBs of 5.8 MW or less.
3.3.
3.3.Hydraulic
HydraulicControl ControlSystem
SystemDesign
Design forfor Torque-Applying
Torque-Applying Device Device
3.3. Hydraulic
The Control System Design for Torque-Applying Device
Thesection
sectionisisbased
basedon onprevious
previousresearch
researchby by Kim
Kim et et al.
al. [11].
[11].
test
testrig
Thesection
The applies
rigis based torque
applies torque
on in
previousinaaclosed-loop
research bythrough
closed-loop through
Kim et al. aa separate
separate torque-applying
[11]. torque-applying device, device,which
which
consists
consists of
The test a planetary
of a rig
planetary gearbox
appliesgearbox
torque andand a hydraulic
in aaclosed-loop control
hydraulic control system, as shown
through a separate torque-applying in Figure 10.
Figure 10. The The hydraulic
hydraulic
device, which
control
controlsystem
consists system
of consists
consists
a planetary of aofcontroller,
gearbox and a ahydraulic
a controller, directional control
a directional
control valve, as
control
system, two
valve, relief
showntwovalves,
inrelief
Figurefour10.linear
valves, Thefouractuators,
linear
hydraulic
actuators,
control systema hydraulic
consistspump, an electric motor,
of a controller, and oilcontrol
a directional pressure lines.two
valve, The relief
directional
valves,control
four valve
linear
applies torque in the normal/reverse direction (A mode/B mode)
actuators, a hydraulic pump, an electric motor, and oil pressure lines. The directional control valveto the torque arms of the planetary
gearbox,
applies by changing
torque the direction of
in the normal/reverse flow supplied
direction (A mode/B frommode)the hydraulic pump.arms
to the torque A two-way valve is
of the planetary
used. Two relief valves are installed between the directional
gearbox, by changing the direction of flow supplied from the hydraulic pump. A two-way valve control valve and hydraulic pump,is
which control the pressure of the entire hydraulic control system.
used. Two relief valves are installed between the directional control valve and hydraulic pump,
Appl. Sci. 2020, 10, 3240 8 of 16

a hydraulic pump, an electric motor, and oil pressure lines. The directional control valve applies torque
in the normal/reverse direction (A mode/B mode) to the torque arms of the planetary gearbox, by
changing the direction of flow supplied from the hydraulic pump. A two-way valve is used. Two relief
valves are installed between the directional control valve and hydraulic pump, which control the
pressure of the entire hydraulic control system.
Appl. Sci. 2020, 10, x FOR PEER REVIEW 8 of 16

Figure 10. Hydraulic

Figure 10. circuitfor
Hydraulic circuit forcontrolling
controllingactuators
actuators [11].
[11].

The controller controls the movement of the four actuators by controlling the directional control
valve, relief valve, and electric motor. It can switch between A and B modes by controlling the
directional control valve and can vary the magnitude of the torque applied to the system by
controlling the proportional pressure control-type relief valve. Furthermore, the electric motor can
be stopped after the desired torque is applied to the torque-applying device, and the pressure of the
Appl. Sci. 2020, 10, 3240 9 of 16

The controller controls the movement of the four actuators by controlling the directional control
valve, relief valve, and electric motor. It can switch between A and B modes by controlling the
directional control valve and can vary the magnitude of the torque applied to the system by controlling
the proportional
Appl. pressure
Sci. 2020, 10, x FOR control-type relief valve. Furthermore, the electric motor can be stopped
PEER REVIEW 9 of 16
after the desired torque is applied to the torque-applying device, and the pressure of the actuators
is maintained
on/off control by theused
were pilot-operated
to control check valve. In
a directional this study,
control valvethe
andswitch control
an electric and on/off
motor, control
respectively.
were used to control
Additionally, a directional control
a PID (Proportional Integralvalve and an electric
Derivative) motor,
controller wasrespectively. Additionally,
used to regulate a PID
a proportional
(Proportional Integral Derivative)
pressure control-type relief valve.controller was used
The parametric to regulate
values of theaPID
proportional
controllerpressure control-type
were obtained by a
relief valve. The
trial-and-error parametric
method. values
Figure of theaPID
11 shows controller
block diagramwere obtained
of the feedbackby control
a trial-and-error
system tomethod.
control
Figure
the torque11 shows
of the atest
block
rig.diagram of the
A controller feedback
input of 50.2control
kN-m system
was set to
ascontrol the torque
the reference oftorque,
target the testand
rig.
A
thecontroller
hydraulicinput of 50.2
actuators kN-m
were was set
operated as the
until the reference target
target torque wastorque,
reachedand the hydraulic
using actuators
the feedback signal
were
from operated until the target torque was reached using the feedback signal from a torque meter.
a torque meter.

Figure 11.
Figure Feedback control
11. Feedback control system
system for
for torque
torque control.
control.

Four actuators
Four actuatorswere wereused
usedininthe thetorque-applying
torque-applying device.
device.If only twotwo
If only actuators
actuators werewere
usedused
(one each
(one
at the left and right lower sides of torque-applying device), the torque
each at the left and right lower sides of torque-applying device), the torque could not have been could not have been controlled
accurately accurately
controlled when applying whenitapplying
to the planetary
it to thegearbox
planetary duegearbox
to the difference
due to thebetweendifference thebetween
areas of thethe
actuator rods arising from the same operating pressures of the actuators.
areas of the actuator rods arising from the same operating pressures of the actuators. Thus, Thus, radial loads otherradial
than
the torque
loads otheract on the
than the torque
planetaryact gearbox. However,
on the planetary if four actuators
gearbox. However,are used,
if four torque can
actuators are be controlled
used, torque
accurately when it is applied to the planetary gearbox because the actuators
can be controlled accurately when it is applied to the planetary gearbox because the actuators are operated at the same
are
pressure. Thus, loads other than torque do not act on the planetary gearbox.
operated at the same pressure. Thus, loads other than torque do not act on the planetary gearbox.
The ring
The ring gear torque,TTload
gear torque, , which
, which
load is is applied
applied byby thethe hydraulic
hydraulic control
control system,
system, is expressed
is expressed as theas
the product of the input torque,
product of the input torque, Tin, of the T , of the sun gear and the gear ratio (i = Z r /Z
in sun gear and the gear ratio (i = Zr/Zs) of the planetary gearbox, s ) of the planetary
gearbox,
and the and
forcethe force
Fload Fload on
acting acting
the on the actuator
actuator is calculated
is calculated fromfrom radius
radius l2 and
l2 and factors sof
safetyfactor
safety of the
the
torque-applying device.
torque-applying device. The The pressure
pressure required
required by by the system can
the system be derived
can be derived from from thethe force
force acting
acting on on
the actuators and their cross-sectional areas. These relationships are expressed
the actuators and their cross-sectional areas. These relationships are expressed in Equations. (1)–(5). in Equations (1)–(5).
The
The torque-applying
torque-applying device device changes
changes the the linear motion, xxpp,, of
linear motion, of the
the actuator
actuator to to rotational
rotational motion,
motion, θ. θ.
Therefore, there are mechanical limits to the torque-applying device.
Therefore, there are mechanical limits to the torque-applying device. Equation (6) shows the Equation (6) shows the rotational
angle of the
rotational planetary
angle of the gearbox
planetary depending on the change
gearbox depending of stroke
on the changeofofthe actuator.
stroke of the actuator.
The structure and specifications of the torque-applying
The structure and specifications of the torque-applying device are shown in Figure device are shown in Figure
12 and12Table
and
Table 2, respectively.
2, respectively.
Tload = Tin ·i (1)
T
Fload = =load ·s∙ (1)
(2)
l2
Fα = Fγ , Fβ = Fδ (3)
= ∙ (2)
Fload = Fα + Fβ + Fγ + Fδ = 2(Fα + Fβ ) (4)
= , Fload = (3)
Psystem = (5)
π
 
4=× 2 × dpiston 2 + (dpiston 2 − drod 2 )
+ + + = 2( + (4)

= (5)
×2×( +( − ))
4

+ − +
= + − (6)
2 2
Appl. Sci. 2020, 10, 3240 10 of 16

  2 
 l1 2 + l2 2 − xp + lx 
π
θ = cos−1   + θ f −
 
2 2
(6)
 2l1 l2 
 2
Appl. Sci. 2020, 10, x FOR PEER REVIEW 10 of 16

Figure 12. Free-body diagram of the torque-applying device [11].

Table 2. Specifications
Table 2. Specifications of
of the
the torque-applying
torque-applying device.
device.
Parameters
Parameters Value
Value
Load torque acting
Load torque acting actuator
actuator (T)load)
(Tload 125
125kN-m
kN-m
Radius
Radius of the
of the torque-applying
torque-applying device(l
device(l 2 ) 2) 0.85
0.85mm
Length
Lengthfrom point
from A to
point A point B(l1B(l
to point ) 1) 1.227m
1.227 m
Length
Lengthfrom point
from B toB point
point C(lC(l
to point x ) x) 0.885m
0.885 m
Piston diameter
Piston of actuators
diameter of actuators 0.1m
0.1 m
Rod
Roddiameter of actuators
diameter of actuators 0.055m
0.055 m
Stroke of actuators
Stroke of actuators ±0.175mm
±0.175
Load torque acting actuator (Tload ) 125 kN-m
Load torque acting actuator (Tload) 125 kN-m

4. Experimental Analysis
4. Experimental Analysis

4.1. Evaluation of
4.1. Evaluation of Torque
Torque Range
Range
The
The available
availabletorque
torquerange
rangeofof
thethe
testtest
rigrig
waswas
investigated through
investigated a series
through of tests.
a series A torque
of tests. meter
A torque
was
meterinstalled on the point
was installed on theconnected to the high-speed
point connected shaft of the
to the high-speed 5.8-MW
shaft of thegearbox
5.8-MWshown
gearboxin Figure
shown13,
in
and a digital graduator was used to measure the rotational angle of ring gear of
Figure 13, and a digital graduator was used to measure the rotational angle of ring gear torque-applying device.
of
The hydraulic
torque-applying system was operated, and the rotational angle was recorded until the torque of the
device.
high-speed shaft reached its maximum value (50.2 kN-m). The maximum rotational angle was 10.5◦ in
all the 10 iterations of the test. This value is smaller than the angle of 23.8◦ , which is the rotational
angle of the ring gear when the stroke of the hydraulic cylinder in the torque-applying device is the
largest. Therefore, it can be concluded that the measurable torque range of the rig is enough to test
5.8-MW gearboxes.

Figure 13. Torque meter installed on the test rig.

 4.1. Evaluation of Torque Range
The available torque range of the test rig was investigated through a series of tests. A torque
meter was installed on the point connected to the high-speed shaft of the 5.8-MW gearbox shown in
Appl. Sci. 2020,
Figure 13,10,and
3240a digital graduator was used to measure the rotational angle of ring gear11of of 16
torque-applying device.

Appl. Sci. 2020, 10, x FOR PEER REVIEW 11 of 16

The hydraulic system was operated, and the rotational angle was recorded until the torque of
the high-speed shaft reached its maximum value (50.2 kN-m). The maximum rotational angle was
10.5° in all the 10 iterations of the test. This value is smaller than the angle of 23.8°, which is the
rotational angle of the ring gear when the stroke of the hydraulic cylinder in the torque-applying
device is the largest. Therefore, it can be concluded that the measurable torque range of the rig is
enough to test 5.8-MW gearboxes. Figure13.
Figure 13. Torque
Torque meter
meter installed
installed ononthe
thetest
testrig.
rig.
After performing the preliminary test of the variable torque-applying device, the master/slave
gearbox
Afterwas mounted the
performing on the test rig totest
preliminary verify thevariable
of the performance of the torque-applying
torque-applying device while
device, the master/slave
changingwas
gearbox themounted
torque according
on the test to rig the test conditions.
to verify the performance Figure of 14
the shows the resultsdevice
torque-applying of the test
while
performed
changing theby changing
torque the rotational
according to the test speed of theFigure
conditions. motor14and thethe
shows torque of of
results the
thetorque-applying
test performed
device
by according
changing to the test
the rotational conditions
speed after and
of the motor applying the master/slave
the torque gearbox. Figure
of the torque-applying device14a,b present
according to
thetest
the measured
conditions rotational speedsthe
after applying of master/slave
the output shaft of the
gearbox. master/slave
Figure 14a,b present gearbox, and Figure
the measured 14c,d
rotational
show the
speeds torques
of the outputof theofoutput
shaft shaft of the
the master/slave master/slave
gearbox, and Figure gearbox. At the
14c,d show the beginning
torques of theof output
the rig
verification
shaft test, the motor
of the master/slave rotation
gearbox. At the speed was increased,
beginning and the torque
of the rig verification of motor
test, the the torque-applying
rotation speed
device
was was changed.
increased, and theAt approximately
torque 750 rpm, thedevice
of the torque-applying rotational
wasspeed
changed. of the
At motor and the torque
approximately 750 rpm, of
the rotational
the torque-applying
speed ofdevice was and
the motor changed to their
the torque target
of the values. After device
torque-applying 40 minwas of testing
changed under the
to their
rated test
target conditions
values. After 40ofmin
the of
master/slave
testing under gearbox, the test
the rated test conditions
rig was stopped
of the while changing
master/slave the torque
gearbox, the
andrig
test rotational
was stoppedspeed. The changing
while test was not the performed
torque and until the maximum
rotational speed. Thetorque (50.2
test was notkN-m) of theuntil
performed test
rig maximum
the was reached due(50.2
torque to thekN-m)limitation
of the testof rig
thewasrated condition
reached due toofthe
thelimitation
master/slave
of thegearbox. It was
rated condition
confirmed
of that, until
the master/slave the rated
gearbox. torque
It was of 45.2that,
confirmed kN-m,untilthere was no
the rated problem
torque in kN-m,
of 45.2 performing the test
there was no
while sequentially
problem in performing changing
the testthe torque
while of the torque-applying
sequentially changing the device.
torque of the torque-applying device.

Figure 14. Test

Figure 14. Test result
result of
of rotational
rotational speed
speed and
and torque
torquechange
changefor
forthe
thetest
testrig
rigvalidation.
validation.
4.2. Resonance Analysis
4.2. Resonance Analysis
To confirm the occurrence of resonance in the developed test rig, a speed sweep test was
To confirm the occurrence of resonance in the developed test rig, a speed sweep test was
conducted. After accelerometers were installed on the test gearbox of the test rig, the acceleration
conducted. After accelerometers were installed on the test gearbox of the test rig, the acceleration
signals were measured as the rotational speed of the high-speed shaft was increased from 0 rpm to
signals were measured as the rotational speed of the high-speed shaft was increased from 0 rpm to
the maximum operating speed of 1100 rpm. Table 3 lists the specifications of the accelerometer and
the maximum operating speed of 1100 rpm. Table 3 lists the specifications of the accelerometer and
measurement equipment.
measurement equipment.

Table 3. Specifications of measurement and analysis equipment.

Equipment Specifications
16 ch. signal analyzer
Appl. Sci. 2020, 10, 3240 12 of 16

Table 3. Specifications of measurement and analysis equipment.

Equipment Specifications
16 ch. signal analyzer
Appl. Sci. 2020, 10, x FOR PEER REVIEW 50 to 25,600 line FFT 12 of 16
Signal analyzer 25 kHz input module
Generator and sampling module
Sensitivity: 100 ± 2% pC/m/s2
Accelerometers 25 kHz zoom processor
Freq. range:100
Sensitivity: 0.2–26,000 Hz 2
± 2% pC/m/s
Accelerometers
Freq.range:
Freq. range:0.3–40,000
0.2–26,000HzHz
Charge amplifier Freq.
Charge amplifier Max. input: 7 V (rms) Hz
range: 0.3–40,000
Max. input: 7 V (rms)
Frequency: 159.15 Hz
Frequency: 159.15 Hz
Acceleration:
Acceleration:1010m/sm/s2(rms)
2
(rms)
Calibration
Calibrationexciter
exciter Velocity: 10 mm/s (rms)
Velocity: 10 mm/s (rms)
Displacement:1010μm
Displacement: (rms)
µm(rms)

The measured
The measuredacceleration
accelerationsignals were
signals usedused
were to analyze the frequency
to analyze according
the frequency to the rotational
according to the
speed. Because the gear mesh frequencies of the first, second, and third stages of the test
rotational speed. Because the gear mesh frequencies of the first, second, and third stages of the test gearboxes
under the maximum
gearboxes under theoperational
maximumseed (1100 rpm)
operational were(1100
seed 19 Hz, 122 Hz,
rpm) were and19513 Hz,122
Hz, respectively,
Hz, and the513main
Hz,
acceleration component
respectively, in the operating
the main acceleration area wasinthe
component thegear mesh frequency,
operating area was and no resonant
the gear frequency
mesh frequency,
component
and appeared,
no resonant as shown
frequency in Figure
component 15. That as
appeared, is, shown
resonance did not15.
in Figure occur
Thatinis,
the operatingdid
resonance region
not
of the gearbox (0–1100 rpm). Thus, it was verified that the test rig had no problems when
occur in the operating region of the gearbox (0–1100 rpm). Thus, it was verified that the test rig had testing
theproblems
no gearbox. when testing the gearbox.

Figure
Figure 15.
15. Waterfall
Waterfall plot
plot for
for vibration
vibration of
of the
the developed
developed test
test rig.
rig.

5. Conclusions
5. Conclusions
In this
In this study,
study, aa mechanical
mechanicalpower
powercirculation
circulationtest
testrig
rigwas
wasdeveloped
developedtototest WTGBs
test WTGBs of of
5.85.8
MW MWor
less.
or TheThe
less. rig consists of an of
rig consists electric motor, motor,
an electric two auxiliary gearboxes,
two auxiliary a torque-applying
gearboxes, device, lubrication
a torque-applying device,
systems, cooling systems, and control systems. The torque-applying device
lubrication systems, cooling systems, and control systems. The torque-applying device consists consists of a simple
of a
planetary
simple gearboxgearbox
planetary and hydraulic control system
and hydraulic controland applies
system andtorque totorque
applies the testtogearbox.
the test The hydraulic
gearbox. The
control system
hydraulic controlconsists
systemofconsists
a controller, several valves,
of a controller, severalfour linearfour
valves, actuators, a hydraulic
linear actuators, a pump, an
hydraulic
electric motor, and oil pressure lines. It was designed to accurately control torque
pump, an electric motor, and oil pressure lines. It was designed to accurately control torque and and eliminate the
effect of loads
eliminate otherof
the effect than theother
loads torque.
than the torque.
The torque-applying device wasinstalled
The torque-applying device was installedoutside
outsidethethetest gearbox
test gearboxand developed
and developedto automate
to automatethe
controlling of applied torque. Therefore, compared with conventional mechanical
the controlling of applied torque. Therefore, compared with conventional mechanical power power circulation
test rigs, thetest
circulation developed
rigs, the test rig has test
developed the advantage
rig has the of being able
advantage ofto apply
being variable
able to applytorques in real-time
variable torques
during a test.
in real-time during a test.
For auxiliary gearboxes, components such as bearings and gears were designed to have an
adequate lifespan under the rated load condition of 5.8 MW. This was verified by comparing it with
the ISO standard. Furthermore, the speed sweep test results confirmed the absence of resonance in
the test gearbox in the operating region of 0–1100 rpm for the WTGB. Therefore, the developed test
rig can be used to test performance indicators, such as efficiency, vibration, and noise, as well as
durability and overload tests. Therefore, we believe that this rig can also be used in other large
multi-MW gearboxes applied for power plants, ships, etc.
Appl. Sci. 2020, 10, 3240 13 of 16

For auxiliary gearboxes, components such as bearings and gears were designed to have an
adequate lifespan under the rated load condition of 5.8 MW. This was verified by comparing it with the
ISO standard. Furthermore, the speed sweep test results confirmed the absence of resonance in the test
gearbox in the operating region of 0–1100 rpm for the WTGB. Therefore, the developed test rig can be
used to test performance indicators, such as efficiency, vibration, and noise, as well as durability and
overload tests. Therefore, we believe that this rig can also be used in other large multi-MW gearboxes
applied for power plants, ships, etc.

6. Patents
Geun-Ho Lee et al., (2011), KR Patent No. 10-1109540, Daejeon: Korean Intellectual Property Office.

Author Contributions: The co-author of this paper, Y.-J.P., contributed equally to the corresponding author.
Conceptualization, G.-H.L. and Y.-J.P.; Methodology, G.-H.L. and Y.-J.P.; Software, J.-Y.O.; Validation, J.-G.K.
and J.-S.N.; Formal Analysis, J.-Y.O.; Investigation, J.-S.N.; Resources, J.-Y.O.; Data Curation, J.-G.K.; Writing –
Original Draft Preparation, G.-H.L. and Y.-J.P.; Writing—Review & Editing, J.-G.K.; Visualization, G.-H.L. and
Y.-J.P.; Supervision, J.-G.K. All authors have read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Conflicts of Interest: The authors declare no conflict of interest.

Nomenclature
i Gear ratio of planetary gearbox (i = Zr /Zs )
Tin Sun gear torque of planetary gearbox
Tload Reaction torque of planetary gearbox
Fload Force acting on actuator
s Safety factor
dpiston Piston diameter of actuator
drod Rod diameter of actuator
PL_A(B) Power loss due to friction of gears and bearings in gearbox A (B)
Power loss due to friction between gears and bearings in slave gearbox,
PL_SG(MG, AG1, AG2, TAG)
master gearbox, auxiliary gearbox 1 and 2, and gearbox for torque application)
Power supplied to closed loop in motor (sum of power losses of gearboxes A
PM
and B)
PT Total power circulating in closed loop of test rig
Psystem System pressure
l1 Distance from center of planetary gearbox to connecting point of actuator
l2 Distance from center of planetary gearbox to center of torque arm
Xp Moving distance of actuator stroke
θf Angle from vertical line of actuator to line AB
Fα Force acting on actuator α
Fβ Force acting on actuator β
θ Rotation angle of planetary gearbox
Appl. Sci. 2020, 10, 3240 14 of 16

Appendix A
Appl. Sci. 2020, 10, x FOR PEER REVIEW 14 of 16

Figure A1.
Figure A1. 3D model view of the developed test
test rig.
rig.

Figure A2.
Figure A2. Picture of the
Picture of the developed
developed test
test rig.
rig.

Table A1. List and description of test rig components.

Index Item Description No. of Items
1 Electric motor 2.7 MW, 6P, 690 V, 60 Hz 1
2 Motor support Rig support 1
3 Auxiliary gearbox #1 for torque circulation Max. power: 5.8 MW 1
4 Auxiliary gearbox #1 support Rig support 1
5 Torque meter & speed sensor #1 up to 80 kN m, 3000 rpm 1
2 m × 4 m: 6 pieces
6 Bed plate 1
2 m × 5 m: 6 pieces
7 Slave gearbox Gearbox for speed reduction 1
8 Torque arm support for slave gearbox Rig support 2
9 Master gearbox Gearbox for test 1
10 Torque arm support for master gearbox Rig support 2
11 Torque meter & speed sensor #2 up to 80 kN m, 2000 rpm 1
12 Auxiliary gearbox #2 for torque circulation Max. power: 5.8 MW 1
13 Auxiliary gearbox #2 support Rig support 1
14 Planetary gearbox for automatic torque application Max. power: 5.8 MW 1
15 Hydraulic control system for automatic torque application No. of cylinder: 4 Cylinders are connected to ring gear 1
16 Universal joint - 2
17 Bearing block - 2
18 Manual torque-applying device Device for applying initial torque to closed-loop test rig 1
19 Bearing block support - 1

Appendix B

Table A2. List and description of test rig components.

Appl. Sci. 2020, 10, 3240 15 of 16

Table A1. List and description of test rig components.

Index Item Description No. of Items

1 Electric motor 2.7 MW, 6P, 690 V, 60 Hz 1
2 Motor support Rig support 1
Auxiliary gearbox #1 for torque
3 Max. power: 5.8 MW 1
circulation
4 Auxiliary gearbox #1 support Rig support 1
5 Torque meter & speed sensor #1 up to 80 kN m, 3000 rpm 1
2 m × 4 m: 6 pieces
6 Bed plate 1
2 m × 5 m: 6 pieces
7 Slave gearbox Gearbox for speed reduction 1
8 Torque arm support for slave gearbox Rig support 2
9 Master gearbox Gearbox for test 1
10 Torque arm support for master gearbox Rig support 2
11 Torque meter & speed sensor #2 up to 80 kN m, 2000 rpm 1
Auxiliary gearbox #2 for torque
12 Max. power: 5.8 MW 1
circulation
13 Auxiliary gearbox #2 support Rig support 1
Planetary gearbox for automatic torque
14 Max. power: 5.8 MW 1
application
Hydraulic control system for automatic No. of cylinder: 4 Cylinders are
15 1
torque application connected to ring gear
16 Universal joint - 2
17 Bearing block - 2
Device for applying initial torque
18 Manual torque-applying device 1
to closed-loop test rig
19 Bearing block support - 1

Appendix B

Table A2. List and description of test rig components.

Safety Factor
Gear Pair Number
Root Flank
GP01 2.5138 1.4416
GP02 1.7291 1.5737
GP03 1.6789 1.5678
GP04 1.7491 1.5978
GP05 1.7614 1.3212
GP06 2.5964 1.9290
GP07 2.5291 1.5736
GP08 3.5295 1.8712
GP09 2.5163 1.3212
GP10 3.0736 1.4849
GP01 2.5138 1.4416
GP02 1.7291 1.5737
GP03 1.6789 1.5678
GP04 1.7491 1.5978
GP05 1.7614 1.3212
GP06 2.5964 1.9290
GP07 2.5291 1.5736
GP08 3.5295 1.8712
GP09 2.5163 1.3212
Appl. Sci. 2020, 10, 3240 16 of 16

Table A3. Life of bearings for test rig gearboxes.

Bearing Number Life (h) Bearing Number Life (h)

BRG01 >175,200 BRG17 58,399
BRG02 >175,200 BRG18 168,390
BRG03 >175,200 BRG19 >175,200
BRG04 >175,200 BRG20 >175,200
BRG05 141,972 BRG21 >175,200
BRG06 >175,200 BRG22 >175,200
BRG07 38,119 BRG23 >175,200
BRG08 >175,200 BRG24 >175,200
BRG09 98,958 BRG25 164,203
BRG10 >175,200 BRG26 138,050
BRG11 >175,200 BRG27 34,025
BRG12 62,682 BRG28 >175,200
BRG13 >175,200 BRG29 >175,200
BRG14 105,243 BRG30 >175,200
BRG15 41,243 BRG31 38,547
BRG16 >175,200 BRG32 30,683

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