CN110678648B - 风力发电设备 - Google Patents

风力发电设备 Download PDF

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CN110678648B
CN110678648B CN201880033842.3A CN201880033842A CN110678648B CN 110678648 B CN110678648 B CN 110678648B CN 201880033842 A CN201880033842 A CN 201880033842A CN 110678648 B CN110678648 B CN 110678648B
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shaft
wind power
power plant
layer
sliding
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CN110678648A (zh
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G·哈格尔
J·S·赫茨尔
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Miba Gleitlager Austria GmbH
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D15/00—Transmission of mechanical power
    • C—CHEMISTRY; METALLURGY
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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Abstract

本发明涉及一种风力发电设备传动装置(8)，包括至少一个支承在轴(15)上的齿轮(12)，为此，在所述齿轮(12)与轴(15)之间设有滑动层(20)，所述滑动层(20)通过热喷涂方法直接喷涂到轴(15)上，或者在中间设有至少一个另外的层(21)的情况下喷涂到所述另外的层(21)上，所述另外的层(21)通过热喷涂方法被喷涂到轴(15)上，所述滑动层(20)由如下喷涂材料制成，所述喷涂材料选自包括铝基合金、铋基合金、银基合金、铜基合金的组，在轴(15)上通过热喷涂方法喷涂两个沿轴向彼此间隔开距离设置的滑动层(20)，从而在这两个滑动层之间构成空隙(23)，空隙通过连接管线与周围大气连接，所述连接管线在所述轴(15)中延伸。

Description

风力发电设备
技术领域
本发明涉及一种风力发电设备传动装置、尤其是行星齿轮传动装置，包括至少一个支承在轴上的齿轮，为此，在所述齿轮与轴之间设有滑动层。
此外，本发明涉及一种具有转子和发电机的风力发电设备，其中，在转子和发电机之间设有风力发电设备传动装置、尤其是行星齿轮传动装置，该风力发电设备传动装置与转子和发电机作用连接。
此外，本发明涉及一种用于制造用于风力发电设备传动装置、尤其是行星齿轮传动装置的轴的方法。
背景技术
例如由DE 10260132 A1已知的，用于发电的风力发电设备的行星齿轮传动装置用于将风力发电设备转子的相对低的转速转换成发电机转子的较高的转速。通常，在这种行星齿轮传动装置中，如这也在DE 10260132 A1中所述的那样，将滚动轴承用作用于行星齿轮的支承元件。但现有技术、如EP 1544504 A2或AT 509624 A1也描述了将滑动轴承用作支承元件。作为滑动轴承在此通常使用滑动轴承衬套，该滑动轴承衬套被热缩到轴上或压入行星齿轮中。在维护或磨损的情况下更换这种滑动轴承是耗费的并且因此成本密集的。
发明内容
本发明的任务在于提供一种易于维护的用于风力发电设备传动装置的滑动轴承解决方案。
所述任务借助开头提到的风力发电设备传动装置来解决，其中，所述滑动层通过热喷涂方法直接喷涂在轴上，或者在中间设有至少一个另外的层的情况下喷涂到该中间层上，其中，所述滑动层由如下喷涂材料制成，所述喷涂材料选自包括铝基合金、铋基合金、银基合金、铜基合金的组。
此外，所述任务通过开头提到的风力发电设备来解决，其中，风力发电设备传动装置根据本发明构造。
此外，本发明的任务通过开头提到的方法来解决，该方法包括下述步骤：提供轴并且由喷涂材料通过热喷涂方法将滑动层直接喷涂到轴上或在施加至少一个另外的层之后喷涂到所述另外的层上，其中，所述另外的层通过热喷涂方法被喷涂到轴上，其中，所述滑动层由如下喷涂材料制成，所述喷涂材料选自包括铝基合金、铋基合金、银基合金、铜基合金的组，其中，在所述轴上通过热喷涂方法喷涂两个沿轴向彼此间隔开距离设置的滑动层，从而在这两个滑动层之间构成空隙，其中，所述空隙通过连接管线与周围大气连接，所述连接管线在所述轴中延伸。所述另外的层可以是金属中间层。
在此有利的是，通过喷涂的滑动层可简化对滑动轴承的维护，因为因此可通过轴的相对易于实现的拆卸的来接近滑动轴承。这甚至可在风力发电设备的塔架上完成，由此可节省时间并因此节省成本。此外，与滑动轴承衬套相比，喷涂的滑动层的优点在于可避免滑动轴承由于蠕变和松弛效应的位置损失。滑动层的热喷涂的优点在于，轴即使在涂层过程中也不受到或几乎不受到热负荷。另外，颗粒在撞击轴时变平，从而它们可在齿轮的旋转运动方向上定向，从而润滑的层组分可通过在圆周方向上更长的路径更好地实现其润滑效果。
根据风力发电设备传动装置的一种实施变型方案可规定，滑动层由选自包括铝基合金、铋基合金、银基合金、铜基合金的组的材料制成，或所述滑动层包括所述材料。尤其是这些耐磨且在摩擦学上特别有效的材料在具有高功率密度且不使用负载平衡技术、如所谓的“柔性销解决方案”的紧凑型风力发电设备传动装置中已证明是特别有利的。此外，这些合金相对易于通过热喷涂方法处理。
也可在滑动层上设置聚合物基的磨合层，以便因此能实现在滑动层的磨合期间使滑动轴承工作表面更好地适应配合面，其中，另外有利的是，该磨合层也改善了滑动轴承本身的摩擦学性能。在此有利的是，该聚合物基的磨合层可通过喷雾方法来施加，即以与热喷涂方法具有一定相似性的方法来施加。因此可简化涂层的轴的制造。
根据风力发电设备传动装置的另一种实施变型方案可规定，在轴上通过热喷涂方法喷涂两个沿轴向彼此间隔开距离设置的滑动层，从而在这两个滑动层之间构成空隙，其中，所述空隙通过连接管线与周围大气连接，所述连接管线在所述轴中延伸。通过这两个滑动层之间的间隔在它们之间形成空隙，该空隙可用于经由轴供应油，从而可实现滑动层的更好的润滑。在此有利的是，该空隙可通过热喷涂方法简单且无需机械加工地制成。
在滑动层中可掺入硬颗粒和/或软相颗粒。在此有利的是，这些颗粒可借助热喷涂方法简单地一起处理，因此其掺入到滑动层中不是问题，而这例如基于熔融金属冶金中的熔析则可能构成问题。在此有利的是，也可借助颗粒简单地调节滑动层组织的粒度。因此，可简单地调节粗晶粒组织形态，从而减少沿晶界的扩散过程并且因此与之相关的失效机理、如晶界蠕变或合金元素含量的减少，由此可实现滑动轴承更长的运行。
硬颗粒优选地选自包括金属氧化物、金属氮化物、金属碳化物、金属硼化物、金属硅化物的组。优选使用熔点较高的硬质陶瓷颗粒。从而可更好地避免硬颗粒由于扩散现象而变粗，由此可借助热喷涂方法改善滑动层的某些希望的摩擦学特性的可调节性。
软相颗粒可选自包括石墨、六方氮化硼、金属硫化物、如MoS2、WS2等的组。在此有利的是，尤其是氮化硼是反应惰性的并且不会在喷涂中被氧化。石墨虽然在喷涂时会部分燃烧，但氧化物并未掺入层中，而是以气态形式挥发。硫化物也可显著改善滑动层的自润滑性能。
根据该方法的一种实施变型方案可规定，硬颗粒和/或软颗粒在喷涂过程中保持固体形式。因此这些颗粒在喷涂滑动层的过程中不会熔化，从而可降低喷涂过程中意外相变的风险。另外，因此可更好地避免这些颗粒的粒度变化。因此可定义地调节滑动层的合金的上述组织粒度。
热喷涂方法优选可选自包括火焰喷涂、等离子喷涂、冷气喷涂、激光喷涂的组，因为这些方法相对易于实施。
附图说明
为了更好地理解本发明，参考下述附图更详细地阐述本发明。在此以高度简化示意图示出：
图1以侧视图示出风力发电设备；
图2以侧视剖面图示出行星齿轮传动装置形式的风力发电设备；
图3以侧视剖面图示出风力发电设备传动装置的局部；
图4以侧视剖面图示出风力发电设备传动装置的一种实施变型方案的局部。
具体实施方式
首先要指出，在不同的实施方式中相同部件使用同一附图标记或相同构件名称，其中，在全部说明书中包含的公开内容可以按意义转到具有相同附图标记或相同构件名称的部件上。同样，在说明中选择的位置说明如上面、下面、侧面等涉及直接描述以及所示附图并且在位置改变时按意义转到新的位置。
图1示出风力发电设备1。该风力发电设备1原则上相应于现有技术，即它包括塔架2，在塔架上在中间连接风向跟踪装置3的情况下设有机舱4，在机舱前端设有具有转子叶片6的转子5并且在其后端设有发电机7。在转子5与发电机7、即详细未示出的发电机的转子之间设有风力发电设备传动装置8，该风力发电设备传动装置在一侧与转子5连接并且在另一侧与发电机7的转子连接。风力发电设备传动装置8用于相对于转子增加转子的转速。最后在塔架2的底部还设有网络接口9。
由于这些部件原则上由风力发电设备1的现有技术已知，因此在这方面参见相关文献。但应注意，风力发电设备1不必限于图1所示的类型。
图2以侧视剖面图示出单级行星齿轮传动装置形式的风力发电设备传动装置8。
风力发电设备传动装置8包括太阳轮10，该太阳轮与通向发电机转子的轴11抗扭连接。太阳轮10被多个、如两个、优选三个或四个以行星齿轮形式的齿轮12包围。太阳轮10和齿轮12具有彼此啮合的端面齿部13、14，其中，这些端面齿部13、14在图1中用叉号表示。齿轮12支承在轴15(行星销)上。这些轴15插入轴架16(行星架)的孔中。在齿轮12上设有齿圈17，该齿圈在内表面上也至少部分地具有齿部18，该齿部与齿轮12的端面齿部14啮合。齿圈17与风力发电设备1的转子5的转子轴19抗扭连接(图1)。端面齿部13、14或齿部18可构造为直齿或斜齿。
由于这种行星齿轮传动装置原则上也已经由现有技术已知，因此在此不再赘述。但应指出，不仅行星齿轮传动装置的单级构造形式是可能的，而且多级、如两级或三级的构造形式也是可能的。
应指出，在下文中对于齿轮12使用单数。但本发明当然也可用于这样的风力发电设备传动装置8的所有齿轮12。
图3以侧视剖面图示出风力发电设备传动装置8的齿轮12在轴15上的支承区域的局部。齿轮12通过滑动轴承支承在轴上。为此，在轴15与齿轮12之间设置滑动层20。滑动层20直接设置在轴15上并与该轴连接。为此将用于滑动层20的材料通过热喷涂方法施加到轴15上。
根据一种实施变型方案必要时可规定，在施加滑动层20之前，在轴15上施加至少一个另外的层21，如图3中的虚线所示。优选所述另外的层21也通过热喷涂方法被施加到轴15上。所述另外的层21例如可以是扩散阻挡层和/或增粘剂层和/或轴承金属层。滑动层20在该实施方式中直接施加到所述另外的层21上。
滑动层20是金属层，尤其是由金属合金制成或包含金属合金。材料优选可选自包括铝基合金、铋基合金、银基合金、铜基合金的组。但也可使用其它合金、如铟基合金、铅基合金或高度含铅的CuPb基合金。但优选使用无铅合金。无铅合金是指这样的合金，其最大含铅比例相应于此类合金中常见杂质的比例。
所述另外的层21例如可包括铝基合金、锡基合金、铜基合金、CuPb基合金，AlSn基合金、AlZn基合金、AlSi基合金、AlSnSi基合金、CuAl基合金、CuSn基合金、CuZn基合金、CuSnZn基合金、CuZnSn基合金、CuBi基合金和AlBi基合金、由Al、Ni、Co、Sn等制成的纯金属层，前提是所述另外的层21的成分与滑动层20的成分不同。
根据另一种实施变型可规定，在滑动层20上设有磨合层22，该磨合层在此情况下构成径向外层并且与齿轮12滑动接触。磨合层22例如可以是纯金属层、如锡。但磨合层22优选是聚合物基的磨合层22。作为聚合物尤其是使用聚酰亚胺或聚酰胺酰亚胺。此外，磨合层也可包含一定比例的固体润滑剂、如MoS2和/或石墨。磨合层22中聚合物的重量百分比可介于40％至80％之间。其余部分是固体润滑剂的重量百分比。
此外，可将硬颗粒和/或软相颗粒掺入滑动层20中。硬颗粒可选自包括金属氧化物、如MgO、TiO2、ZrO2、Al2O3、金属氮化物、金属碳化物、如SiC、WC、B4C、金属硼化物、金属硅化物的组。软相颗粒可选自石墨、六方氮化硼、金属硫化物。
应指出，硬颗粒的硬度大于其所埋入的滑动层20的基质的硬度。相反，软相颗粒的硬度低于其所埋入的滑动层20的基质的硬度。
滑动层20上的硬颗粒和/或软相颗粒的重量百分比可选自3％至25％、尤其是5％至20％的范围。
根据另一种实施变型方案，软相颗粒和/或硬相颗粒的平均粒度可介于1μm至100μm之间、优选5μm至20μm之间。
在图4中以纵剖视图示出风力发电设备传动装置8的另一种实施变型方案的局部。与风力发电设备传动装置8的上述实施变型方案不同，在本实施变型方案中通过热喷涂方法将两个沿轴向彼此间隔开距离地设置的滑动层20喷涂到轴15上。通过这两个滑动层20的轴向间隔而在它们之间形成空隙23。该空隙可用来供应润滑剂。如虚线所示，润滑剂供应在此可(仅)通过轴15进行。
为了在至少大致整个工作表面上更好地分配润滑剂，空隙7可通过至少一条连接管线与周围大气连接。优选地，该连接管线在轴15中延伸。
应指出，代替两个滑动层20也可在轴15上喷涂两个以上的滑动层20。
如已经提到的，滑动层20通过热喷涂方法被喷涂到轴15上。优选地，为此使用的喷涂方法选自包括火焰喷涂、如金属丝火焰喷涂或高速火焰喷涂、如HVOF(High-Velocity-Oxygen-Fuel高速氧气燃料)或HVAF(High-Velocity-Air-Fuel高速空气燃料)、等离子喷涂、冷气喷涂、激光喷涂的组。
根据一种实施变型方案可规定，使用一种包含硬颗粒和/或软相颗粒的喷涂材料，其中，在喷涂过程中硬颗粒和/或软相颗粒保持固体形式。为此选择一种熔点比硬颗粒和/或软相颗粒低的金属合金。
在将滑动层20或所述另外的层21喷涂到尤其是由钢制成的轴15上之前，优选对轴进行预处理。该预处理优选包括至少在待施加滑动层20或所述另外的层21的区域中使轴15的表面粗糙化。尤其是在该区域中对轴15喷丸。
此后，优选清洁轴15。
可以使用金属丝或粉末形式的喷涂材料。
滑动层20和/或所述另外的层21的喷涂也可在真空或保护气体气氛下进行。
在喷涂之后可对滑动层20和/或所述另外的层21进行后处理。
实施例示出可能的实施变型方案，在此应指出，各个实施变型方案的彼此组合也是可能的。
最后按规定要指出，为了更好地理解风力发电设备传动装置8或风力发电设备1，所述发电机传动装置或风力发电设备不一定按比例示出。
附图标记列表
1 风力发电设备
2 塔架
3 风向跟踪装置
4 机舱
5 转子
6 转子叶片
7 发电机
8 风力发电设备传动装置
9 网络接口
10 太阳轮
11 轴
12 齿轮
13 端面齿部
14 端面齿部
15 轴
16 行星架
17 齿圈
18 齿部
19 转子轴
20 滑动层
21 层
22 磨合层
23 空隙

Claims (12)

1.一种风力发电设备传动装置(8)，包括至少一个支承在轴(15)上的齿轮(12)，为此，在所述齿轮(12)与轴(15)之间设有滑动层(20)，其特征在于，所述滑动层(20)通过热喷涂方法直接喷涂到轴(15)上，或者在中间设有至少一个另外的层(21)的情况下喷涂到所述另外的层(21)上，其中，所述另外的层(21)通过热喷涂方法被喷涂到轴(15)上，其中，所述滑动层(20)由如下喷涂材料制成，所述喷涂材料选自包括铝基合金、铋基合金、银基合金、铜基合金的组，其中，在所述轴(15)上通过热喷涂方法喷涂两个沿轴向彼此间隔开距离设置的滑动层(20)，从而在这两个滑动层(20)之间构成空隙(23)，其中，所述空隙(23)通过连接管线与周围大气连接，所述连接管线在所述轴(15)中延伸。
2.根据权利要求1所述的风力发电设备传动装置(8)，其特征在于，在所述滑动层(20)上设有聚合物基的磨合层。
3.根据权利要求1或2所述的风力发电设备传动装置(8)，其特征在于，在所述滑动层中掺入硬颗粒和/或软相颗粒。
4.根据权利要求3所述的风力发电设备传动装置(8)，其特征在于，所述硬颗粒选自包括金属氧化物、金属氮化物、金属碳化物、金属硼化物、金属硅化物的组，和/或所述软相颗粒选自包括石墨、六方氮化硼、金属硫化物的组。
5.根据权利要求1或2所述的风力发电设备传动装置(8)，其特征在于，所述风力发电设备传动装置(8)是行星齿轮传动装置。
6.一种风力发电设备(1)，所述风力发电设备具有转子(5)和发电机(7)，其中，在转子(5)与发电机(7)之间设有风力发电设备传动装置(8)，该风力发电设备传动装置与转子(5)和发电机(7)作用连接，其特征在于，所述风力发电设备传动装置(8)是根据权利要求1至5中任一项所述的风力发电设备传动装置(8)。
7.根据权利要求6所述的风力发电设备(1)，其特征在于，所述风力发电设备传动装置(8)是行星齿轮传动装置。
8.一种用于制造用于风力发电设备传动装置(8)的轴(15)的方法，包括下述步骤：
-提供轴(15)，
-由喷涂材料通过热喷涂方法将滑动层(20)直接喷涂到轴(15)上或在施加至少一个另外的层(21)之后喷涂到所述另外的层(21)上，其中，通过热喷涂方法将所述另外的层(21)喷涂到轴(15)上，其中，所述滑动层(20)由如下喷涂材料制成，所述喷涂材料选自包括铝基合金、铋基合金、银基合金、铜基合金的组，其中，在所述轴(15)上通过热喷涂方法喷涂两个沿轴向彼此间隔开距离设置的滑动层(20)，从而在这两个滑动层(20)之间构成空隙(23)，其中，将所述空隙(23)通过连接管线与周围大气连接，所述连接管线在所述轴(15)中延伸。
9.根据权利要求8的方法，其特征在于，使用包含硬颗粒和/或软相颗粒的喷涂材料，其中，所述硬颗粒和/或软相颗粒在喷涂期间保持固体形式。
10.根据权利要求8或9所述的方法，其特征在于，所述热喷涂方法选自包括火焰喷涂、等离子喷涂、冷气喷涂、激光喷涂的组。
11.根据权利要求8或9所述的方法，其特征在于，所述另外的层(21)是金属中间层。
12.根据权利要求8或9所述的方法，其特征在于，所述风力发电设备传动装置(8)是行星齿轮传动装置。
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