Wind turbines are increasingly deployed at larger scales and in harsher operating environments, leading to greater structural complexity, stronger load variability, and higher maintenance demands across both drivetrain and structural components. Reported field data indicate that gearboxes and bearings account for approximately 30–40% of total turbine downtime, while blade-related failures contribute roughly 20–25% of reported failure events, primarily through fatigue, delamination, leading-edge erosion, and lightning-induced defects. In parallel, large-scale and offshore turbines show increasing susceptibility to tower fatigue cracking, corrosion-assisted degradation, and flange joint bolt-preload loss under cyclic and environmental loading. This review provides a comprehensive applied-engineering synthesis of failure mechanisms, reliability challenges, and monitoring strategies for major wind turbine components, including gearboxes, bearings, blades, towers, and flange joints. A wide range of condition monitoring, structural health monitoring (SHM), and prognostics and health management (PHM) approaches is critically examined, including vibration analysis, acoustic emission, ultrasonic inspection, infrared thermography, impedance-based sensing, electromagnetic methods, machine vision, SCADA-based diagnostics, and artificial-intelligence-assisted fault classification. The review compares these techniques in terms of detectable damage types, spatial coverage, sensitivity, deployment practicality, and limitations under real operating conditions. In addition, statistical reliability methods and data-driven models are discussed to interpret failure trends and uncertainty. Recent AI-based studies have reported fault classification accuracies exceeding 90% under controlled or semi-controlled conditions; however, their field reliability remains constrained by data imbalance, domain shift, limited labeled failure datasets, model interpretability, and insufficient validation under realistic turbine operating environments. The main contribution of this review is an integrated applied synthesis that connects drivetrain and structural failure mechanisms with measurable monitoring indicators, diagnostic technologies, AI-enabled PHM limitations, and predictive-maintenance decision needs. The paper provides practical guidance for monitoring design, early fault detection, predictive maintenance, and long-term reliability improvement in next-generation wind turbine systems.
Ali et al. (Tue,) studied this question.
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