Two reasons why gearboxes leak
October 29, 2012
Steven Bushong :
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Gearbox oil leaks present a special challenge in an outdoor green-power application. Unfortunately, they have been so prevalent, leaks are defined by their degree. Drips, leaks, seeps, and weeps all contribute to the costs of maintenance and to the environment in which we work, both in
nacelle and out.
The most common cause of gearbox oil leaks: excessive oil
Modern wind-turbine gear designs provide a necessary power-to-weight ratio. But relatively small housings alone lack the capacity to reject the heat generated in the process of converting low speed high-torque rotational energy from the rotor into energy for the generator. Summer heat, high humidity, and high altitude all reduce a system’s ability to cool.
These gearboxes have internal plumbing with orifices to control pressure and nozzles to deliver cool, clean oil to bearings and gear meshes. An integrated oil pump moves oil from the sump on the high-speed side, through a filter and a cooler as directed by the manifold block. The oil level in the gearbox is a delicate balance between enough oil to fill the entire lubrication circuit during operation and the lowest oil-sump level.