Method and system for estimating life of a gearbox

1. A gearbox life estimation system comprising:

at least one sensor for obtaining field operational data related to loading of a gearbox from a gearbox component; and

a processor configured for receiving signals representative of the field operational data from the at least one sensor, for providing calculated operational load data for estimating life of the gearbox, the processor further configured to compute an excitation force to obtain an individual component load due to operational conditions,

wherein the field operational data represents operating parameters obtained while the gearbox is under operation.

2. The system of claim 1 wherein the gearbox component comprises at least one of a gearbox main shaft, bearing, or tooth.

3. The system of claim 1 wherein the field operational data comprises at least one of crow bar operations, number of start-ups, wind gusts, load sequences, low voltage ride throughs, grid mismatches, trips, oil quality, and component level faults.

4. The system of claim 1 wherein the processor is configured to obtain an individual component load due to excitation force, wherein the excitation force is calculated based on load unbalances due to faults.

5. The system of claim 4 wherein the processor is configured to calculate a total individual component load that is a summation of the individual component load due to excitation force and an individual component load due to operational conditions.

6. A gearbox life estimation system comprising:

at least one sensor configured for obtaining field operational data related to loading of a gearbox from gearbox components; and

a processor configured for receiving signals representative of the field operational data from the at least one sensor, and configured to provide an individual component load due to operational conditions for each of the gearbox components, the processor further configured to obtain an individual component load due to excitation force, wherein the excitation force is calculated based on load unbalances on the gearbox components due to faults.

7. The system of claim 6 wherein the processor is configured to calculate a total individual component load that is a summation of the individual component load due to excitation force and the individual component load due to operational conditions.

8. A method for estimating remaining life of a gearbox, the method comprising:

receiving signals representative of field operational data related to gearbox loading;

obtaining calculated operational load data for gearbox components based on the field operational data;

computing an individual component load due to operational conditions from excitation force generated due to faults; and

providing an estimate of remaining life of the gearbox using a combination of design data and the calculated operational load data.

9. The method of claim 8 wherein the providing the estimate of remaining life is performed in real time.

10. The method of claim 8 further comprising calculating excitation force due to load unbalance on the gearbox.

11. The method of claim 10 further comprising calculating an individual component load due to the excitation force.

12. The method of claim 11 further comprising calculating a total individual component load that is a summation of the individual component due to operational conditions and the individual component load due to the excitation force.

13. The method of claim 8 further comprising using the estimate of remaining life of the gearbox for predicting an incipient failure of the gearbox.