Special Interest Group Meeting: Precision Engineering for Sustainable Energy Systems


Tutorial: Gear metrology for Wind Energy Systems (WES)

Wednesday 13th October 2021
Time: 09:00 – 12:30 (CEST)

The tutors are Dr Martin Stein, Physikalisch-Technische Bundesanstalt, DE and Dr Rob Frazer, National Gear Metrology Lab, Newcastle University, UK

Gears and gearboxes are an important part of many wind energy systems. Small tolerances account for high demands on manufacturing metrology for such components with complex geometry.

This tutorial session will show attendees how we currently measure gears, discuss some limitations of these processes and introduce participants to some of the strategies that are being researched.

Tutorial programme:

  • Why do we measure gears?
  • What do we measure? – Gear geometry introduction
  • How do we measure gears?  Typical measuring machines and methods
  • What do we evaluate?  Classical gear evaluation parameters –with ISO 1328-1:2013.
  • What do we get wrong? Contributions to measurement uncertainty, traceability and classical calibration strategies for large gears
  • What is new and why do we need to improve measurement methods?
    • Full surface scanning with tactile and optical probes
    • Holistic evaluation of involute gears
    • Evaluation of harmonic content- (some candidate methods)
    • GPS compatible strategies- the challenges and some possible solutions
  • How do we use the holistic gear measurement data?  Interfacing measurement data with CAD/TCA models and Digital Twins.

Intended for:

This tutorial is aimed at technical staff, graduate and postgraduate engineers, post-doctoral researchers, operators and managers of wind energy systems responsible for purchasing, repairing or maintaining these facilities.

This training is part of the 19ENG07 Met4Wind project which has received funding from the EMPIR programme co-financed by the Participating States and from the European Union’s Horizon 2020 research and innovation programme.

Tutor Biographies

Rob Frazer

Rob Frazer received a BSc in Mechanical Engineering and PhD from Newcastle University.  He is a senior engineer with the Design Unit at Newcastle University and spent the last 35 years working with gears and gearboxes.  Rob leads gear measurement research at the UK’s National Gear Metrology Laboratory (NGML), is chair of British Standard Institute (BSI) gear committee, MCE-5 and a member of the ISO gear accuracy working group (ISO TC60 WG2).  He provides technical support to the British Gear Association’s (BGA) research committee, helps deliver its training programmes and teaches on Newcastle University’s MSc and MEng Mechanical Power Transmissions Module.

Martin Stein

Martin Stein has studied mathematics and physics at Leibniz University Hanover, Germany, and finished his PhD in 2012. He’s been heading the working group for gear and thread metrology at Physikalisch-Technische Bundesanstalt (PTB) since 2014. One of that group’s main research areas is metrology for large gears as used in wind energy systems. Martin Stein is an active member in national standardization bodies for gear metrology of the VDI/VDE and DIN.

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