The replacement frequency of wind yaw system is influenced by various factors:
1、 Equipment quality and design factors
Component quality
The quality of key components in the yaw system, such as yaw motors, yaw reducers, yaw bearings, etc., has a crucial impact on their service life and replacement frequency. For example, high-quality yaw bearings are made of high-quality steel and undergo precise machining and heat treatment processes, resulting in high wear resistance and fatigue strength. Such bearings may be able to operate normally for 10-15 years or even longer, while bearings with poor quality may experience severe wear and decreased accuracy within 5-7 years and require replacement.
The quality of the yaw motor is also crucial. The windings of high-quality motors are made of high-purity copper material with good insulation performance, and the motor has a high protection level, which can effectively prevent dust, moisture, etc. from entering the interior of the motor. This type of motor can be used for a long time under normal operating conditions, usually around 8-12 years before it may need to be replaced. Low quality motors may malfunction within 3-5 years due to winding short circuits, insulation aging, and other issues.
Rationality of system design
The design of the yaw system plays an important role in its reliability and replacement frequency. For example, a well-designed lubrication system can extend the service life of yaw components. If good grease lubrication channels and automatic lubrication devices are considered in the design, it can ensure that components such as yaw bearings and gears receive sufficient lubrication during operation, reducing wear. However, an improperly designed lubrication system may result in uneven distribution of grease, accelerate component wear, and increase replacement frequency.
The control strategy design of the yaw system is also important. Advanced control strategies can make yaw movements more precise and stable, reducing damage to components caused by impact and vibration. For example, by using intelligent yaw control algorithms, the yaw speed and angle can be adjusted reasonably according to the frequency and amplitude of wind direction changes, avoiding excessive damage to the system caused by frequent rapid yaw actions.
2、 Operating environment factors
climatic conditions
Wind speed and direction changes: In areas where wind speed changes frequently and wind direction is unstable, the number of actions of the yaw system will increase. For example, in coastal windward areas or valleys with complex terrain, the wind direction may change frequently in a short period of time, which requires the yaw system to work frequently to adjust the orientation of the wind turbine. Such high-frequency actions will accelerate the wear of components such as yaw motors, reducers, and bearings, which may shorten the replacement cycle to about 5-7 years. In areas with relatively stable wind direction, the yaw system has relatively less movement, and the service life of components may be extended to 10-12 years.
Temperature and humidity: Extreme temperature conditions can affect the performance of yaw system components. In cold environments, the viscosity of lubricating grease increases and its fluidity deteriorates, resulting in poor lubrication and increased friction between components. In high-temperature environments, components may experience additional stress due to thermal expansion, affecting their fitting accuracy. High humidity environments may cause rusting and corrosion of components, especially for metal parts that are not well protected. For example, in humid coastal areas or mountainous regions, yaw bearings may need to be replaced in 7-9 years due to corrosion.
Sand and salt spray environment: In areas with high levels of sand and dust, sand and dust are prone to enter the yaw system, causing wear and tear on components such as yaw bearings and gears. For example, in wind farms on the edge of deserts, sand and dust may block lubrication channels and exacerbate component wear. In coastal areas, the salt in salt spray is corrosive and can cause corrosion to the metal components of the yaw system, such as the housing of the yaw motor and the outer ring of the yaw bearing. In this environment, the components of the yaw system may need to be replaced in about 6-8 years.
geographical conditions
The geographical location and terrain of wind farms can also affect the frequency of yaw system replacement. If the wind farm is located in a mountainous area, due to the complex terrain, unstable airflow, and constantly changing wind directions, the yaw system needs to operate frequently to adapt to the changes in wind direction. Meanwhile, the transportation and maintenance conditions in mountainous areas are relatively poor, which may lead to delayed component replacement and further affect the service life of the system. Wind farms located in plain areas have relatively stable airflow, favorable geographical conditions for maintenance and transportation, and relatively low frequency of yaw system replacement.
3、 Maintenance factors
Quality and frequency of regular maintenance
Regular maintenance of the yaw system can effectively extend its service life. For example, according to the manufacturer’s recommendations, regularly (such as every six months) replenishing grease and cleaning the yaw bearings can ensure good lubrication and heat dissipation of the bearings. Regular inspection of the yaw motor, including measurement of insulation resistance of the motor winding, vibration detection of the motor, etc., can timely detect potential faults and handle them. If high-quality regular maintenance can be strictly implemented, the replacement cycle of the yaw system can be extended, for example, from the normal 8-10 years to 10-12 years.
On the contrary, if maintenance is not carried out for a long time or the maintenance quality is poor, such as not cleaning the dust and debris in the yaw system in a timely manner, and not regularly checking the wear of components, the yaw system may gradually accumulate and be damaged prematurely due to small problems. For example, if the yaw gear is not cleaned for a long time and the tooth surface wear intensifies, it may need to be replaced in 5-7 years.
Timeliness of fault maintenance
Timely maintenance is crucial when the yaw system malfunctions. For example, if abnormal noise is found in the yaw motor, stopping the machine in time for inspection and replacing damaged motor components can prevent the fault from further expanding and protect other related components. If the malfunction cannot be repaired in a timely manner, it may lead to a chain reaction, causing more components to be damaged and increasing the frequency of overall replacement.