# Contact Load Measurement and Validation for Tapered Rollers in Wind Turbine Main Bearing

## TL;DR

This paper introduces a new method to measure contact loads in wind turbine bearings, improving reliability and performance through real-time strain data.

## Contribution

A novel strain–phase–load calculation method with real-time phase compensation for accurate contact load measurement in rotating rollers.

## Key findings

- The proposed bracket structure effectively captures strain signals without compromising roller stiffness.
- The strain–phase–load method enables real-time contact load acquisition with 95% accuracy.
- The method supports improved bearing reliability, fatigue life prediction, and structural optimization.

## Abstract

What are the main findings?
An analysis was conducted on the issue of roller inner bore measurement point sensitivity, and a bracket structure for strain measurement was proposed.A strain–phase–load calculation method considering the roller’s rotation phase was proposed.

An analysis was conducted on the issue of roller inner bore measurement point sensitivity, and a bracket structure for strain measurement was proposed.

A strain–phase–load calculation method considering the roller’s rotation phase was proposed.

What is the implication of the main finding?
This structure can effectively capture strain signals while ensuring the overall structural stiffness of the roller after drilling.This method enables real-time acquisition of contact load during roller rotation, which is of great significance for improving bearing operational reliability.

This structure can effectively capture strain signals while ensuring the overall structural stiffness of the roller after drilling.

This method enables real-time acquisition of contact load during roller rotation, which is of great significance for improving bearing operational reliability.

Addressing the need for contact load detection in wind turbine main bearings during service, a roller contact load measurement method is proposed. An analytical model characterizes the contact load-to-inner bore strain mapping relationship. To overcome the inherent low sensitivity of direct bore strain measurement, bore-to-measurement-point sensitivity analysis was optimized. Multiple structurally optimized sensor brackets were designed to enhance strain measurement sensitivity, and their performance was comparatively evaluated via simulation. To mitigate sensitivity fluctuations caused by roller rotation phase variations, a strain–phase–load calculation method incorporating real-time phase compensation was developed and verified through simulation analysis. A dedicated roller contact load testing system was constructed and experimental validation was conducted. Results demonstrate 95% accuracy in contact load acquisition. This method accurately obtains roller contact loads in wind turbine main bearings, proving crucial for studying bearing mechanical behavior, predicting fatigue life, optimizing structural design, and enhancing reliability.