CN112577649B - Wind power gear box bearing stress testing method - Google Patents
Wind power gear box bearing stress testing method Download PDFInfo
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- CN112577649B CN112577649B CN202011445680.XA CN202011445680A CN112577649B CN 112577649 B CN112577649 B CN 112577649B CN 202011445680 A CN202011445680 A CN 202011445680A CN 112577649 B CN112577649 B CN 112577649B
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- 238000000034 method Methods 0.000 title claims abstract description 41
- 238000009662 stress testing Methods 0.000 title claims description 16
- 238000012360 testing method Methods 0.000 claims abstract description 15
- 238000013461 design Methods 0.000 claims description 13
- 238000004590 computer program Methods 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims 1
- 238000013480 data collection Methods 0.000 abstract 1
- 238000004364 calculation method Methods 0.000 description 7
- 239000011888 foil Substances 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000010720 hydraulic oil Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 238000013522 software testing Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0009—Force sensors associated with a bearing
- G01L5/0019—Force sensors associated with a bearing by using strain gages, piezoelectric, piezo-resistive or other ohmic-resistance based sensors
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/04—Bearings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
Abstract
The invention discloses a method for testing the bearing stress of a wind power gear box. Then, pressure is applied to the cantilever through a force application device, and meanwhile strain data and stress data of the cantilever are collected through a data collection device. And determining the corresponding relation between the strain and the stress of each side of the cantilever by combining the strain data and the stress data. And secondly, restoring the whole wind power equipment to a normal use state, acquiring real-time strain data of the cantilever in the actual use process of the gear box, and respectively calculating the stress of the left cantilever and the stress of the right cantilever according to the corresponding relation between the strain and the stress. And finally, calculating the torque arm resultant force of the gearbox according to the stress at the left cantilever and the right cantilever, and equivalently calculating the actual stress value of the gearbox bearing according to the torque arm resultant force. Therefore, the stress of the front bearing of the planet carrier of the gear box can be measured in the wind field without disassembling the gear box, and the device is convenient to operate and can be repeatedly used.
Description
Technical Field
The invention relates to the technical field of bearing supporting devices of testing machines, in particular to a method for testing stress of a bearing of a wind power gearbox.
Background
The wind power gear box is an important mechanical part of the wind generating set, cantilevers are arranged on two sides of the gear box, and the cantilevers can be installed on the wind power elastic support through elastic supporting parts to fix the gear box. In the use process of the existing gear box in a wind field, the phenomenon of rolling ball stripping occurs when the actual service time of a front bearing of a planet carrier of the gear box of a specific unit is less than 5 years, and the design life of the bearing is far shorter than 20 years. Through analysis of bearing failure reasons, the bearing is subjected to additional stress, so that the bearing is subjected to overlarge stress and fails in advance. The conventional method for calculating the bearing stress is to perform three-dimensional modeling by adopting the assembly position relation of parts related to the bearing and apply load to perform theoretical calculation, and the theoretical calculation value of the bearing stress is obtained by the checking mode and meets the design requirement.
However, the actual use process of the bearing is influenced by factors such as assembly and hoisting, and the actual stress of the bearing is different from the theoretical calculated value to a certain extent. In order to verify whether the stress of the bearing meets the design requirement in the use process, the actual stress value of the bearing needs to be calculated. And because planet carrier front bearing installs inside the gear box, if adopt conventional direct measurement mode to measure the back, need disassemble whole gear box, just can take out installation test sensor, be not convenient for operate in the wind field.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a method for testing the bearing stress of a wind power gear box, which is characterized in that the additional stress at a cantilever of the gear box in the using process is calculated through wind field testing and then is equivalent to the bearing stress calculation of the gear box, so that the actual stress value of the bearing is calculated, the operation is convenient, and the method can be repeatedly used.
The specific technical scheme is as follows:
in a first aspect, a wind turbine gearbox bearing stress testing method is provided, which includes:
disassembling the elastic supporting parts between the cantilevers and the elastic supports on two sides of the gear box, installing force application equipment between the cantilevers and the elastic supports, and arranging data acquisition equipment;
applying acting forces with different sizes to the cantilevers through the force application equipment, and simultaneously acquiring stress data and strain data of the cantilevers at two sides through the data acquisition equipment;
determining the corresponding relation between the cantilever strain and the stress according to the corresponding stress data and the strain data;
acquiring real-time strain data of cantilevers on two sides of a gear box in the using process through data acquisition equipment;
and calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain data, and equivalently calculating the actual stress value of the bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and the design parameters of the gearbox.
With reference to the first aspect, in a first implementation manner of the first aspect, the elastic support members between the cantilevers on the two sides of the gear box and the elastic supports are sequentially detached in sequence.
With reference to the first aspect, in a second enablement manner of the first aspect, the force application device includes a hydraulic pump and a hydraulic jack disposed between the cantilever and the resilient support and connected to the hydraulic pump.
With reference to the second implementable manner of the first aspect, in a third implementable manner of the first aspect, the data acquisition device includes:
the strain devices are respectively used for sensing strain signals of the cantilevers at the two sides;
the pressure transmitter is used for detecting a pressure signal of the hydraulic pump;
and the data acquisition terminal is used for acquiring the strain signal and the pressure signal and respectively determining stress data and strain data of the cantilever according to the strain signal and the pressure signal.
With reference to the third implementable manner of the first aspect, in a fourth implementable manner of the first aspect, the strain device includes 2 resistive strain gauges, and the 2 resistive strain gauges are respectively adhered to the cantilevers on both sides and are in signal connection with the data acquisition terminal.
With reference to the third implementable manner of the first aspect, in a fifth implementable manner of the first aspect, the strain device includes 2 groups of strain gauge groups, the 2 groups of strain gauge groups are respectively adhered to the cantilevers on both sides, each group of strain gauge group includes 4 resistance strain gauges, and all the resistance strain gauges constitute a full-bridge test circuit and are in signal connection with the data acquisition terminal.
In a second aspect, a method for testing the bearing stress of a wind turbine gearbox is provided, which includes:
strain data under different stress conditions when cantilevers on two sides of a gear box are in a free state are collected;
determining the corresponding relation between the cantilever strain and stress according to all strain data;
detecting real-time strain of cantilevers on two sides of a gear box in the using process;
and calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain, and equivalently calculating the actual stress value of the bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and the design parameters of the gearbox.
With reference to the second aspect, in a first implementation manner of the second aspect, the corresponding relationship is determined by using a curve fitting method based on strain data corresponding to the cantilever.
With reference to the second aspect, in a second implementable manner of the second aspect, the equivalently calculating an actual stress value of the gearbox bearing according to the real-time stress data of the cantilevers at the two sides includes:
calculating resultant force data of the torsion arm of the gearbox according to real-time stress data of the cantilevers at the two sides;
and equivalently calculating the actual stress value according to the resultant force data and the design parameters of the gearbox.
In a third aspect, a storage medium is provided, which stores a computer program, and when the computer program runs, the wind turbine gearbox bearing stress testing method according to claim 7 is implemented.
Has the advantages that: the stress of the front bearing of the planet carrier of the gear box can be measured in a wind field, and the device is convenient to operate and can be repeatedly used. When the early damage of the bearing is found in the inspection process of the gear box, the gear box can be subjected to leveling test again by adopting the test method, and the additional stress at the cantilever is reduced, so that the additional stress of the bearing in front of the planet carrier is reduced, the running state of the bearing is improved, and the service life is prolonged.
Drawings
In order to more clearly illustrate the embodiments of the present invention, the drawings, which are required to be used in the embodiments, will be briefly described below. In all the drawings, the elements or parts are not necessarily drawn to actual scale.
FIG. 1 is a flow chart of a testing method according to an embodiment of the present invention;
FIG. 2 is a system block diagram of a data acquisition device;
FIG. 3 is a schematic structural diagram of a strain device according to an embodiment of the present invention;
fig. 4 is a flowchart of a testing method according to an embodiment of the present invention.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and therefore are only examples, and the protection scope of the present invention is not limited thereby.
In a first embodiment, a flow chart of a wind turbine gearbox bearing stress testing method shown in fig. 1 is provided, where the testing method includes:
step 2, applying acting forces with different sizes to the cantilevers through force application equipment, and simultaneously acquiring stress data and strain data of the cantilevers on two sides through data acquisition equipment;
step 3, determining the corresponding relation between the cantilever strain and the stress according to the corresponding stress data and the strain data;
step 4, acquiring real-time strain data of cantilevers on two sides of a gear box in the using process through data acquisition equipment;
and 5, calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain data, and equivalently calculating the actual stress value of the bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and the design parameters of the gearbox.
Specifically, firstly, the resistance strain gauges (1) are pasted at the same positions of the left and right cantilevers of the gear box, and signals are connected into data acquisition equipment. Then, the fastening bolts of the elastic supports on the two sides are loosened, the elastic elements above and below the cantilevers on the two sides are disassembled, and meanwhile, strain initial values of the left cantilever and the right cantilever of the gear box in a free state are acquired through data acquisition equipment.
When the cantilever is in free state, can be in the hydraulic jack of the same specification model of both sides cantilever top installation, both sides are simultaneously through hydraulic jack to exert pressure to the cantilever, simultaneously, gather the strain value of cantilever about the gear box and the effort size that hydraulic jack applyed the cantilever, the atress data of cantilever promptly through data acquisition equipment. And generating strain data by combining the strain initial value and the strain value, wherein the corresponding relation of the strain and the stress of each side cantilever can be determined by the strain data and the stress data of each side cantilever.
And then, the hydraulic jack is removed, the elastic supporting elastic element is restored to be installed, and the fastening bolt is screwed down, so that the whole wind power equipment is restored to a normal use state. Then, real-time strain data of the cantilever in the actual use process of the gear box are acquired through data acquisition equipment, and the stress of the left cantilever and the stress of the right cantilever are respectively calculated according to the obtained corresponding relation between the strain and the stress. And according to a force synthetic vector rule, calculating the resultant force of the torsion arm of the gearbox through the stress at the left cantilever and the right cantilever, and enabling the resultant force of the torsion arm to be equivalent to the stress calculation of a gearbox bearing, so that the actual stress value of the bearing is calculated. Therefore, the stress of the front bearing of the planet carrier of the gear box can be measured in the wind field without disassembling the gear box, and the gear box is convenient to operate and can be repeatedly used.
In this embodiment, it is preferable that the elastic supporting members between the cantilevers and the elastic supports on both sides of the gear box are sequentially detached in order. The upper and lower elastic elements of the left and right cantilevers cannot be removed simultaneously to avoid the gear case from overturning
In this embodiment, preferably, the force application device includes a hydraulic pump and a hydraulic jack, and the hydraulic jack is placed between the cantilever and the elastic support and connected with the hydraulic pump. Hydraulic oil can be injected into the hydraulic jack through the hydraulic pump, so that the hydraulic jack applies pressure to the cantilever.
In this embodiment, preferably, as shown in fig. 2, the data acquisition device includes:
the strain devices are respectively used for sensing strain signals of the cantilevers at the two sides;
the pressure transmitter is used for detecting a pressure signal of the hydraulic pump;
and the data acquisition terminal is used for acquiring the strain signal and the pressure signal and respectively determining stress data and strain data of the cantilever according to the strain signal and the pressure signal.
Particularly, the strain devices can be respectively arranged on the cantilevers on the two sides, and the data acquisition terminal can detect the strain of the cantilever in a free state, a stress state and a normal use state through the strain devices. The data acquisition terminal can detect the pressure data of the hydraulic pump through the pressure transmitter and determine the stress data of the cantilever according to the preset corresponding relation between the pressure data of the hydraulic pump and the pressure value of the hydraulic jack.
In this embodiment, preferably, the strain device includes 2 resistance-type strain gauges, and the 2 resistance-type strain gauges are respectively adhered to the cantilevers on two sides and are in signal connection with the data acquisition terminal. The resistance-type strain gauge can be adhered to the surface of the cantilever, and the strain of the cantilever is conveniently sensed.
The second embodiment and the second embodiment are substantially the same as the first embodiment, and the main differences are as follows: the strain device comprises 2 groups of strain gauge groups, wherein the 2 groups of strain gauge groups are respectively adhered to cantilevers on two sides, each group of strain gauge group comprises 4 resistance strain gauges 1, and all the resistance strain gauges 1 form a full-bridge test circuit and are connected with the data acquisition terminal through signals. The full-bridge test circuit can be constituteed to 4 resistance-type foil gauges, and wherein 2 resistance-type foil gauges 1 are as the work piece, and 2 resistance-type foil gauges 1 can be as the compensator in addition, so can reach fine anti-interference effect, improve sensitivity to software testing. Also, in order to save installation space, 2 resistance strain gauges 1 may be arranged on the same substrate 2 as shown in fig. 3.
As shown in fig. 4, the flow chart of the wind turbine gearbox bearing stress testing method includes:
the method comprises the following steps of firstly, acquiring strain data of cantilevers on two sides of a gear box under different stress conditions when the cantilevers are in a free state;
determining the corresponding relation between the cantilever strain and stress through all strain data;
step three, detecting real-time strain of cantilevers at two sides of the gearbox in the using process;
and step four, calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain, and equivalently calculating the actual stress value of the bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and design parameters of the gearbox.
Specifically, first, the resistive strain gauges may be attached to the same positions on the left and right cantilevers of the gear box, and the signals may be transmitted to the data acquisition device. And loosening the fastening bolts of the elastic supports at two sides, dismantling the elastic elements above and below the cantilevers at two sides, and simultaneously acquiring strain initial values of the left cantilever and the right cantilever of the gear box in a free state through data acquisition equipment. When the cantilever is in a free state, hydraulic jacks with the same specification and model can be installed above the cantilevers on the two sides, and the two sides exert pressure on the cantilever through the hydraulic jacks simultaneously.
Meanwhile, the magnitude of the acting force applied to the cantilever by the hydraulic jack, namely the stress value of the cantilever, and the strain value of the left cantilever and the right cantilever of the gear box under the acting force can be acquired through data acquisition equipment. The data acquisition equipment can acquire stress values of a plurality of groups of cantilevers and strain values corresponding to the stress values to form strain data, and on the basis of the strain data, the corresponding relation between the cantilever strain and the stress can be determined through a curve fitting method.
Then, the corresponding relation of the strain and the stress of each side cantilever can be determined through the strain data and the stress data corresponding to each side cantilever.
And secondly, the hydraulic jack is removed, and the whole wind power gear box is restored to a normal use state. And real-time strain data at the cantilever in the actual use process of the gearbox are acquired through data acquisition equipment.
And finally, respectively calculating the stress at the left cantilever and the right cantilever based on the acquired real-time strain data and the obtained corresponding relation between the strain and the stress, calculating the resultant force of the torsion arm of the gearbox according to a resultant vector rule of the forces, and enabling the resultant force of the torsion arm to be equivalent to the stress calculation of the gearbox bearing, thereby calculating the actual stress value of the bearing.
In this embodiment, preferably, based on the strain data corresponding to the cantilever, a curve fitting method is used to determine the corresponding relationship between the strain and the stress of the cantilever. The data acquisition device can acquire the stress value of the cantilever and the strain value of the cantilever under the stress condition. Stress values of a plurality of groups of cantilevers and strain values corresponding to the stress values can be collected to form strain data, and on the basis of the strain data, the corresponding relation between the cantilever strain and the stress can be determined through a curve fitting method.
In this embodiment, the equivalently calculating the actual stress value of the gearbox bearing according to the real-time stress data of the cantilevers at the two sides includes:
calculating resultant force data of the torsion arm of the gearbox according to real-time stress data of the cantilevers at the two sides;
and equivalently calculating the actual stress value according to the resultant force data and the design parameters of the gearbox.
Specifically, first, the resultant force data F may be calculated using the following calculation formula:
F＝FL+FR；
wherein, FLFor real-time force values of the left cantilever, FRThe real-time stress value of the right cantilever is shown.
Then, the actual stress value NA may be calculated using the following calculation:
NA＝G×(L-L1)/L+F×(L-L2)/L；
wherein G is partial gravity of the gear box, L is the center distance between the front bearing and the rear bearing of the planet carrier, and L is1Is the distance from the center of the front bearing to the center of gravity of the gear box part, L2The distance from the center of the front bearing to the center of the torsion armThese parameters can all be directly obtained from the design parameters of the gearbox.
A storage medium stores a computer program, and when the computer program runs, the wind power gear box bearing stress testing method is realized.
The above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention, and they should be construed as being included in the following claims and description.
Claims (9)
1. A wind power gear box bearing stress testing method is characterized by comprising the following steps:
disassembling the elastic supporting parts between the cantilevers and the elastic supports on two sides of the gear box, installing force application equipment between the cantilevers and the elastic supports, and arranging data acquisition equipment;
applying acting forces with different sizes to the cantilevers through force application equipment, and acquiring stress data and strain data of the cantilevers on two sides through data acquisition equipment, wherein the force application equipment comprises a hydraulic pump and a hydraulic jack;
determining the corresponding relation between the cantilever strain and the stress according to the corresponding stress data and the strain data;
acquiring real-time strain data of cantilevers on two sides of a gear box in the using process through data acquisition equipment;
calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain data, and equivalently calculating an actual stress value of a bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and design parameters of the gearbox;
the data acquisition device includes:
the strain device is used for sensing strain signals of the cantilevers on the two sides;
the pressure transmitter is used for detecting a pressure signal of the hydraulic pump;
and the data acquisition terminal is used for acquiring the strain signal and the pressure signal and respectively determining stress data and strain data of the cantilever according to the strain signal and the pressure signal.
2. The wind power gearbox bearing stress testing method according to claim 1, wherein the elastic supporting members between the cantilevers and the elastic supports on two sides of the gearbox are sequentially detached according to a sequence.
3. The wind power gearbox bearing stress testing method according to claim 1, wherein the hydraulic jack is placed between the cantilever and the elastic support and connected with the hydraulic pump.
4. The wind power gear box bearing stress testing method according to claim 1, wherein the strain device comprises 2 resistance-type strain gauges, and the 2 resistance-type strain gauges are respectively adhered to the cantilevers on two sides and are in signal connection with the data acquisition terminal.
5. The wind power gearbox bearing stress testing method according to claim 1, wherein the strain device comprises 2 groups of strain gauge groups, the 2 groups of strain gauge groups are respectively adhered to cantilevers on two sides, each group of strain gauge group comprises 4 resistance strain gauges, and all the resistance strain gauges form a full-bridge testing circuit and are in signal connection with the data acquisition terminal.
6. A wind power gear box bearing stress testing method is characterized by comprising the following steps:
loosening fastening bolts of elastic supports on two sides, dismantling elastic elements above and below cantilevers on the two sides, acquiring strain initial values of free states of left and right cantilevers of a gear box through data acquisition equipment, installing force application equipment with the same specification and model above the cantilevers on the two sides, and applying pressure to the cantilevers on the two sides through the force application equipment at the same time, wherein the force application equipment comprises a hydraulic pump and a hydraulic jack;
the data acquisition device includes:
the strain device is used for sensing strain signals of the cantilevers on the two sides;
the pressure transmitter is used for detecting a pressure signal of the hydraulic pump;
the data acquisition terminal is used for acquiring the strain signal and the pressure signal and respectively determining stress data and strain data of the cantilever according to the strain signal and the pressure signal;
determining the corresponding relation between the cantilever strain and stress according to the strain data;
detecting real-time strain of cantilevers on two sides of a gear box in the using process;
and calculating real-time stress data of the cantilevers according to the corresponding relation and the real-time strain, and equivalently calculating the actual stress value of the bearing of the gearbox according to the real-time stress data of the cantilevers at two sides and the design parameters of the gearbox.
7. The wind power gearbox bearing stress testing method of claim 6, wherein the correspondence is determined using a curve fitting method based on strain data corresponding to the cantilever.
8. The wind power gearbox bearing stress testing method according to claim 6, wherein the equivalently calculating the actual stress value of the gearbox bearing according to the real-time stress data of the cantilevers at the two sides comprises:
calculating resultant force data of the torsion arm of the gearbox according to real-time stress data of the cantilevers at the two sides;
and equivalently calculating the actual stress value according to the resultant force data and the design parameters of the gearbox.
9. A storage medium, characterized in that a computer program is stored, which when running implements the wind gearbox bearing stress testing method according to claim 6.
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| US20130269479A1 (en) * | 2012-04-11 | 2013-10-17 | General Electric Company | Gearbox and support apparatus for gearbox carrier |
| CN103177168A (en) * | 2013-04-24 | 2013-06-26 | 湖南大学 | Reverse engineering method of gear tooth surface friction factor |
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