Introduction
Gear boxes of wind energy plants have to face high expectations with respect to its life span. Compliance with this requirement shall be achieved with an appropriate dimensioning next to establishing close tolerances. Unnecessarily high costs are caused by not required and too tight tolerances.

In order to determine the saving potential a recognised manufacturer of wind turbine gear boxes appointed a small team of experts from IndustrieHansa to carry out the tolerance analysis of a planetary gear.

Solutions: Completion of tolerance analyses under consideration of predefined boundary conditions for tolerancing of gear components.

Puncture points

• Development of a customer specific method for tolerance analyses of planetary gears
• Building up a 3 D simulation model considering part tolerances and deformation
• Monte Carlo simulation for calculation of dispersion of measured values to be expected
• Determine relevant parameters  
• Calculation of geometrical transmission ration of relevant parameters
• Tolerance analysis in assembly status as well as during complete motion sequence
• Differentiation between static and kinematic effects

Benefits
Next to the determination of tolerance related deviations of the functional sizes, purchased parts could be identified as tolerance critical influencing factors. In-house components showed tolerances which could be widened without loss of quality.

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