Fatigue Life Prediction of Main Bearings in Wind Turbines Under Random Wind Speeds

To address the complex operating conditions and challenging dynamic characteristics of bearings in the main shaft transmission system of wind turbines, this study investigates a specific wind turbine model. By comprehensively considering factors such as main shaft structure, cumulative damage, and stochastic wind loads, we adopt a modular analysis framework integrating the wind field, aerodynamics, the structural response, and fatigue life prediction to establish a method for predicting the fatigue life of main shaft bearings under stochastic wind conditions. To verify this method, the fixed-end main shaft bearing of a 4.5 MW wind turbine was selected as a case study. The research results show the following: (1) Increases in both average wind speed and turbulence intensity significantly shorten the fatigue life of the bearing. (2) Higher turbulence intensity amplifies the dispersion of the speed and load of rolling elements, thereby increasing the probability of extreme operating conditions and exerting an adverse impact on fatigue life. (3) The average wind speed has a significant influence on the overall fatigue life: within a specific range, the fatigue failure probability of the main bearing increases as the average wind speed decreases. (4) The impact of wind speed fluctuations on the hub center load is much greater than that caused by rotational speed changes. (5) In addition, the modular design method adopted in this study calculates that the fatigue life of the fixed-end bearing is 28.8 years, with an overall error of only 0.8 years compared to the 29.6-year fatigue life obtained using Romax simulation software. This research provides important theoretical references and engineering value for improving the operational reliability of wind turbines and enhancing the accuracy of bearing fatigue life prediction.