Validating FEA models of complex generator and gearbox assemblies using experimental modal analysis

The continual advances in the capability of analysis by the finite element method allow manufacturers to achieve reliable predictions of the performance of complex customised machinery solutions. The simulation described relates to a large, high power, synchronous generator and close-coupled epicyclic gearbox assembly. The techniques employed allowed the computation of component stress levels, rotor lateral critical speeds, structural vibration modes and detailed alignment information which not only facilitated product performance optimisation, but also enabled a significant reduction in assembly hours. The modelling methods utilised are described, in conjunction with details of the product testing completed to confirm excellent correlation to the FEM predictions.