Down-Scaled Modeling of Wind Turbine Gearboxes
Purpose
Full-scale wind turbine gearbox testing is expensive and difficult to iterate quickly.
This work developed a structured down-scaling method to create compact gearbox models while preserving key design and dynamic characteristics required for engineering decisions.
Approach
The workflow separates scaling targets by function and constraint, then applies parameter scaling with iterative checks:
- Structural integrity targets (gear safety factors using ISO 6336)
- Dynamic targets (resonance distribution and drivetrain response)
- Practical design constraints for manufacturability and testability
A repeatable, step-by-step process was implemented to compute scale factors, update geometry and loading, and verify behavior at each iteration.
Key Results
- Reproduced safety factors and resonance trends with deviations around 5% across evaluated scales
- Reduced dependence on full-scale test infrastructure for early validation work
- Established a reusable method for scaling multi-stage gearbox concepts
Engineering Value
- Enables faster concept screening for drivetrain architectures
- Supports lower-cost validation planning and risk reduction
- Improves confidence when extrapolating scaled-test results to larger systems
Implementation
- Safety factor evaluation in KISSsoft (ISO 6336)
- Scaling and optimization logic in MATLAB
- Automated data exchange between MATLAB and KISSsoft via COM interface
- Modular object-oriented structure to support reuse across cases
Tools
MATLAB · KISSsoft · Simpack (context models) · COM automation