Engineering Research Express, cilt.7, sa.1, 2025 (ESCI, Scopus)
The key thrust of this research work is to in-situ Analysis of the drop in Thermal Performance of wind turbine gearbox systems and global challenges and sustainable ideas detection of several failures that occur in the wind turbine gearbox with the help of the latest emerging sensors, and the source of the slave gearbox is a significant input for the master gearbox setup running at 1100 to 1150 rpm at generator side from Jan 2020 to Dec 2020. From the Experimental results, it is clearly understood that the majority of failures occurred due to irregular velocities ranging from 9 to 10 m s−1 at average velocities, and the kinematic viscosities of the oil exceed 400 μ resulting in heavy vibrations resulting in higher maintenance costs. The Master gearbox gives more Predominant results than the Slave gearbox; oil sump temperatures exceeding 85 °C result in poor active power generation falling below 100 Kw, and slave Gearbox oil sump temperatures are achieved at 100 °C; the Maximum temperature attained from the IMS Drive end-stage rate of 85 °C to 90 °C at lower speeds for master gearbox; Whereas slave gearbox temperatures are attained at 110 °C. The average temperature attained from the HSS stage of the Gearbox coupled with the generator is 90 °C, causing heavy vibration frequencies ranging from decibels causing tooth pitting failures for the master gearbox and for the slave gearbox. Average temperatures were attained by 120 °C.