FE-analytical slice model and verification test for load distribution analysis and optimization of planetary gear train in wind turbine

•Propose a new FE-analytical slice model for load distribution analysis of PGT.•Reveal the load distribution behavior with coupling effects of elasticity and errors.•Optimize the load distribution by tooth modification and in-phase eccentricity arrangement.•Conduct the load distribution simulation and test of PGT to verify the proposed model. Load distribution behavior of planetary gear train (PGT) is crucial for the contact and bending fatigue failure of wind turbine transmission system. With the increasing power of wind turbines, the load and failure rate of wind turbine become larger, which leads to the demand of accurate and efficient modeling, analysis and optimization for load distribution of PGT. In this paper, a new efficient and accurate FE-analytical slice model for load distribution analysis and optimization of PGT in wind turbine is proposed, which is explicitly formulated by the geometry slice model of external/internal gear contact, original FE-analytical slice model for local contact deformation, and efficient finite element (FE) model for global structural deformation. In the FE-analytical slice model, geometry errors are effectively descripted by discretizing gears into a series of slices, while gear tooth contact elasticity and structural elasticity are addressed by the FE-analytical method accurately and efficiently. Upon the proposed model, the load distribution behaviors of PGT with coupling effects of elasticity and errors are revealed and optimized by tooth modification and in-phase eccentricity arrangement strategy. The load distribution tests of PGT in wind turbine are conducted, verifying the proposed FE-analytical slice model which is significant to improve the load-bearing capacity and avoid the fatigue failure of wind turbine transmission system.