Abstract
There are a considerable number of fatigue damage estimation theories and fatigue life prediction of
mechanical components. The most popular one is Palmgren-Minor (P-M) theory. This theory has been used in
the standards for selecting the bearing –as a component subject to fatigue loading- and for expecting the
bearings lives. In Wind Turbine Gearboxes (WTGs), the bearings were selected to be without maintenance for
20 to 25 years; however, in real service life, the bearing suffer from premature failure within a life span of
quite less than the design life (1 to 5 years). A new applicable methodology and a procedure of calculation for
damage estimation due to fatigue loading and predicting the life has been suggested and tested. Results of 20
rolling and sliding tests which conducted under severe contact loading are used to test this method. The
suggested method depends on calculating the number of operating cycles under a specific contact loading
level to an equivalent number of loading cycles under the average loading level. This method depends on the
area under the S-N curve without any correction or loading factors and can be used to predict the WTG
bearings failure to manage the maintenance because the current life prediction standards have very high
percentages of error (> 400%). The reliability of this approach can be further verified by utilizing actual
operational data from Supervisory Control and Data Acquisition (SCADA), used for overseeing wind turbine
operations. Additional examinations are necessary to confirm the dependability of this novel method.
mechanical components. The most popular one is Palmgren-Minor (P-M) theory. This theory has been used in
the standards for selecting the bearing –as a component subject to fatigue loading- and for expecting the
bearings lives. In Wind Turbine Gearboxes (WTGs), the bearings were selected to be without maintenance for
20 to 25 years; however, in real service life, the bearing suffer from premature failure within a life span of
quite less than the design life (1 to 5 years). A new applicable methodology and a procedure of calculation for
damage estimation due to fatigue loading and predicting the life has been suggested and tested. Results of 20
rolling and sliding tests which conducted under severe contact loading are used to test this method. The
suggested method depends on calculating the number of operating cycles under a specific contact loading
level to an equivalent number of loading cycles under the average loading level. This method depends on the
area under the S-N curve without any correction or loading factors and can be used to predict the WTG
bearings failure to manage the maintenance because the current life prediction standards have very high
percentages of error (> 400%). The reliability of this approach can be further verified by utilizing actual
operational data from Supervisory Control and Data Acquisition (SCADA), used for overseeing wind turbine
operations. Additional examinations are necessary to confirm the dependability of this novel method.