CN113821957A - Brake caliper modeling method for wind turbine generator main frame calculation - Google Patents
Brake caliper modeling method for wind turbine generator main frame calculation Download PDFInfo
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Abstract
The invention provides a brake caliper modeling method for wind turbine main frame calculation, which comprises the following steps: respectively constructing a brake caliper body, an upper friction plate and a lower friction plate three-dimensional model and assembling to construct a brake caliper simplified three-dimensional model; elastic units are respectively constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body so as to equivalently simulate the pre-pressure of a brake caliper piston cylinder to the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body. According to the invention, the elastic unit is used for equivalently simulating the pre-pressure of the piston cylinder of the brake caliper on the friction plate, so that the real working state of the brake caliper with the friction plate moving up and down is effectively simulated, the defects in the prior art in the yaw system modeling are overcome, the detail modeling mode of the brake caliper is perfected, and the correct mode of load transmission in the yaw system is established, so that the finite element result is more reliable and credible in the calculation of the main rack of the wind turbine generator.
Description
Technical Field
The invention relates to the technical field of wind power generation, in particular to a brake caliper modeling method for calculation of a main frame of a wind turbine generator.
Background
The main frame is one of important parts in the wind generating set, the stress level of the main frame directly influences the safety of the whole machine, and the calculation of the stress of the main frame is carried out based on finite elements. The finite element model of the main frame comprises a main frame, a main shaft, a torque arm, a bearing seat, a yaw motor, a yaw bearing, a brake disc, brake calipers, a tower cylinder, an elastic support, a gearbox torque arm and the like. The brake caliper is used as an important component of a wind turbine generator yaw system, and how to correctly establish a model of the brake caliper in finite element modeling is a crucial factor in main frame calculation. The brake caliper is characterized in that a disc spring or a hydraulic device in a piston cylinder of the brake caliper provides pre-pressure to act on a lower cushion block, the lower cushion block acts on a brake disc, and the torsional motion of the main frame is resisted through the friction force between the lower cushion block and the brake disc, so that the braking effect is achieved. The former modeling mode usually ignores the pre-pressure of a piston cylinder, directly binds and connects a friction cushion block with a brake disc, or simulates the braking effect of a brake caliper in a mode that the brake caliper is coupled to the center of the brake disc to establish a torsional elastic unit, but the mode usually ignores the real working state of the brake caliper, causes the error of yaw torque distribution, further causes the incorrect load transmission, and influences the correctness and the accuracy of the calculation of a main frame.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the brake caliper modeling method for the calculation of the main frame of the wind turbine generator, which aims to solve the technical problems that the existing modeling mode ignores the pre-pressure of a piston cylinder, causes the error of yaw torque distribution, further causes the incorrect load transfer, and influences the correctness and the accuracy of the calculation of the main frame.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a brake caliper modeling method for wind turbine main frame calculation comprises the following steps:
respectively constructing a brake caliper body, an upper friction plate and a lower friction plate three-dimensional model;
constructing a simplified three-dimensional model of the brake caliper based on the assembly of the brake caliper body, the upper friction plate and the lower friction plate;
elastic units are respectively constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body so as to equivalently simulate the pre-pressure of a brake caliper piston cylinder to the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body.
Optionally, the step of constructing an elastic unit to equivalently simulate pre-pressure of a brake caliper piston cylinder to the friction plate and simulate a sliding connection relationship between the friction plate and the brake caliper body between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body respectively comprises:
the number of the elastic units corresponds to the number of the brake caliper piston cylinders one to one, the arrangement positions of the elastic units correspond to the arrangement positions of the brake caliper piston cylinders one to one, and the pre-pressure of the elastic units is the maximum jacking force of the piston cylinders.
Optionally, the pre-pressure of the elastic unit is the maximum jacking force F of the piston cylinder, and the following formula is adopted:
wherein d represents the diameter of the piston cylinder and p represents the piston pressure of the piston cylinder.
Optionally, the step of constructing an elastic unit to equivalently simulate pre-pressure of a brake caliper piston cylinder to the friction plate and simulate a sliding connection relationship between the friction plate and the brake caliper body between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body respectively comprises:
respectively coupling all piston cylinders and upper friction plates which are positioned at the upper part of the brake caliper to respective middle points by a mode of establishing coupling points, and establishing a first elastic unit between the two coupling points;
all piston cylinders and lower friction plates which are positioned at the lower part of the brake caliper are respectively coupled to respective middle points by a mode of establishing coupling points, and a second elastic unit is established between the two coupling points.
Optionally, a first constraint unit is further constructed between the upper friction plate and the upper part of the brake caliper to simulate the sliding connection relationship between the upper friction plate and the brake caliper body; and a second constraint unit is also constructed between the lower friction plate and the lower part of the brake caliper to simulate the sliding connection relationship between the lower friction plate and the brake caliper body.
Optionally, the first elastic unit and the second elastic unit are both linear spring units.
Optionally, the method further comprises: and establishing standard contact between the friction plate and the brake disc, wherein the friction coefficient is set based on the technical protocol of the brake caliper.
According to the technical scheme, the invention has the beneficial effects that:
the invention provides a brake caliper modeling method for wind turbine main frame calculation, which comprises the following steps: respectively constructing a brake caliper body, an upper friction plate and a lower friction plate three-dimensional model; constructing a simplified three-dimensional model of the brake caliper based on the assembly of the brake caliper body, the upper friction plate and the lower friction plate; elastic units are respectively constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body so as to equivalently simulate the pre-pressure of a brake caliper piston cylinder to the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body. According to the invention, the elastic unit is used for equivalently simulating the pre-pressure of the piston cylinder of the brake caliper on the friction plate, so that the real working state of the brake caliper with the friction plate moving up and down is effectively simulated, the defects in the prior art in the yaw system modeling are overcome, the detail modeling mode of the brake caliper is perfected, and the correct mode of load transmission in the yaw system is established, so that the finite element result is more reliable and credible in the calculation of the main rack of the wind turbine generator.
Drawings
In order to more clearly illustrate the detailed description of the invention or the technical solutions in the prior art, the drawings that are needed in the detailed description of the invention or the prior art will be briefly described below. Throughout the drawings, like elements or portions are generally identified by like reference numerals. In the drawings, elements or portions are not necessarily drawn to scale.
FIG. 1 is a flow chart of a brake caliper modeling method for wind turbine generator mainframe calculation;
FIG. 2 is a simplified model of a brake caliper;
FIG. 3 is a simplified model of another embodiment of a brake caliper;
in the figure: 1-friction plate, 2-elastic unit, 3-piston cylinder and 4-coupling point.
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.
Referring to fig. 1, the present invention provides a modeling method for a brake caliper for calculation of a main frame of a wind turbine generator, including the following steps:
s1, respectively constructing a brake caliper body, an upper friction plate and a lower friction plate three-dimensional model;
s2, assembling to construct a brake caliper simplified three-dimensional model based on the brake caliper body, the upper friction plate and the lower friction plate;
s3, elastic units are respectively arranged between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body, so that the pre-pressure of a brake caliper piston cylinder to the friction plate can be simulated equivalently, and the sliding connection relation between the friction plate and the brake caliper body can be simulated.
Aiming at the construction of the elastic unit, the application provides two construction methods of the elastic unit, which specifically comprise the following steps:
the method comprises the following steps:
the number of the elastic units corresponds to the number of the brake caliper piston cylinders one to one, the arrangement positions of the elastic units correspond to the arrangement positions of the brake caliper piston cylinders one to one, and the pre-pressure of the elastic units is the maximum jacking force of the piston cylinders. Wherein, the biggest jacking force F of piston cylinder adopts following formula:
wherein d represents the diameter of the piston cylinder and p represents the piston pressure of the piston cylinder.
The second method comprises the following steps:
all piston cylinders and upper friction plates which are positioned at the upper part of the brake caliper are respectively coupled to respective midpoints by establishing coupling points, and a first elastic unit and a first constraint unit are constructed between the two coupling points; all piston cylinders and lower friction plates which are positioned at the lower part of the brake caliper are respectively coupled to respective middle points by establishing coupling points, and a second elastic unit and a second constraint unit are established between the two coupling points. Wherein, the first elastic unit and the second elastic unit are both linear spring units.
As a further improvement to the above, the brake caliper modeling method further comprises: standard contact is established between the friction pads and the brake disc, and the friction coefficient is set based on the technical protocol of the brake caliper, so that load transfer can be simulated more accurately.
According to the invention, the brake caliper body, the upper friction plate and the lower friction plate are respectively constructed and assembled in a constraint relation, the prepressing force of a piston cylinder of the brake caliper to the friction plates is equivalently simulated by constructing the elastic unit, and the sliding connection relation between the friction plates and the brake caliper body is simulated, so that the real working state of the brake caliper with the friction plates moving up and down is effectively simulated, the defects of the prior art in establishing a yaw system modeling mode are overcome, the brake caliper detail modeling mode is perfected, and the correct mode of load transmission in the yaw system is established, so that the finite element result is more reliable and credible in the calculation of the main frame of the wind turbine generator.
The invention also provides a modeling method for the calculation of the main frame of the wind turbine generator, which comprises the following steps:
s11, acquiring a three-dimensional model for calculation of the main frame, wherein the model comprises the main frame, a main shaft, a torque arm, a bearing seat, a yaw motor, a yaw bearing, a brake disc, brake calipers, a tower, an elastic support, a gearbox torque arm and the like;
s21, assembling according to the geometric model of the step S11, simplifying the three-dimensional model of the brake caliper, and storing the three-dimensional model into a file type which can be identified by finite element software, wherein the simplified brake caliper model comprises the following steps: a brake caliper body, an upper friction plate and a lower friction plate, as shown in figure 2;
s31, each brake caliper is provided with 3 piston cylinders, the number of the piston cylinders is 6, and precompression of each piston cylinder to the brake disc, namely the jacking force F of the piston cylinders is obtained through calculation according to the diameter d and the pressure p of the piston cylinders of the brake calipers;
s41, the simplified brake caliper finite element model has two simplified methods:
the first method is that the number of piston cylinders of a piston cylinder of the brake caliper is simplified into a model of the equal piston cylinder, and the prepressing force of the piston cylinder on friction plates is simulated by applying elastic units, the prepressing force of each elastic unit is the maximum jacking force of the piston cylinder, and the friction plates and the cylinder wall adopt a frictionless contact mode;
a second method is to couple all the piston cylinders together and create a brake caliper model by creating a MPC184 (constraint unit) and an elastic unit in parallel, as shown in fig. 3. Specifically, the ansys (finite element analysis software) couples the piston cylinder and the friction plate to respective middle points by establishing a Remote point, and connects a combination 14 (linear elastic unit) unit and an MPC184 unit in parallel between the two coupling points to realize the effect of sliding the friction plate up and down along the cylinder wall and applying the elastic unit in the first method. Specifically, in abaqus (finite element analysis software), coupling can be established by establishing cuppling, and a translator (connector) is established between two coupling points to achieve the effect; the MPC184 and the COMBIN14 are connected in parallel, so that the number of grids is reduced, the nonlinear contact boundary is reduced, and the convergence efficiency of the finite element model during calculation is improved;
s51, gear meshing of a yaw pinion and a yaw bearing is simulated by a COMBIN39 (nonlinear elastic unit), main bearing rollers and yaw bearing rollers are simulated by a COMBIN39, and connection between a torsion arm and an elastic supporting seat is simulated by a bushing unit (the rigidity in different directions can be set);
s61, establishing standard contact between the friction plate and the brake disc, setting the friction coefficient according to the related technical protocol of the brake caliper, and binding and connecting the main frame and the bearing seat, the bearing seat and the main bearing, the main frame and the elastic support seat and the like;
s71, taking the load loading point as the center of the hub, and transmitting the load to the engine room by establishing a coupling mode between the center of the hub and the front end face of the main shaft;
and S81, submitting calculation.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; 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 (7)
1. A brake caliper modeling method for wind turbine main frame calculation is characterized by comprising the following steps:
respectively constructing a brake caliper body, an upper friction plate and a lower friction plate three-dimensional model;
constructing a simplified three-dimensional model of the brake caliper based on the assembly of the brake caliper body, the upper friction plate and the lower friction plate;
elastic units are respectively constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body so as to equivalently simulate the pre-pressure of a brake caliper piston cylinder to the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body.
2. The method for modeling the brake caliper for the calculation of the main rack of the wind turbine generator set according to claim 1, wherein an elastic unit is constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body to equivalently simulate the pre-pressure of a piston cylinder of the brake caliper on the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body, and the method comprises the following steps:
the number of the elastic units corresponds to the number of the brake caliper piston cylinders one to one, the arrangement positions of the elastic units correspond to the arrangement positions of the brake caliper piston cylinders one to one, and the pre-pressure of the elastic units is the maximum jacking force of the piston cylinders.
3. The method for modeling the brake caliper for the calculation of the main frame of the wind turbine generator according to claim 2, characterized in that the pre-pressure of the elastic unit is the maximum jacking force F of the piston cylinder, and the following formula is adopted:
wherein d represents the diameter of the piston cylinder and p represents the piston pressure of the piston cylinder.
4. The method for modeling the brake caliper for the calculation of the main rack of the wind turbine generator set according to claim 1, wherein an elastic unit is constructed between the upper friction plate and the top of the brake caliper body and between the lower friction plate and the bottom of the brake caliper body to equivalently simulate the pre-pressure of a piston cylinder of the brake caliper on the friction plate and simulate the sliding connection relationship between the friction plate and the brake caliper body, and the method comprises the following steps:
respectively coupling all piston cylinders and upper friction plates which are positioned at the upper part of the brake caliper to respective middle points by a mode of establishing coupling points, and establishing a first elastic unit between the two coupling points;
all piston cylinders and lower friction plates which are positioned at the lower part of the brake caliper are respectively coupled to respective middle points by a mode of establishing coupling points, and a second elastic unit is established between the two coupling points.
5. The brake caliper modeling method for wind turbine generator main frame calculation according to claim 4, characterized in that a first constraint unit is further constructed between the upper friction plate and the upper part of the brake caliper to simulate a sliding connection relationship between the upper friction plate and the brake caliper body; and a second constraint unit is also constructed between the lower friction plate and the lower part of the brake caliper to simulate the sliding connection relationship between the lower friction plate and the brake caliper body.
6. The method for modeling a brake caliper for wind turbine main frame calculation according to claim 4, wherein the first elastic unit and the second elastic unit are both linear spring units.
7. The brake caliper modeling method for wind turbine main frame calculation according to any one of claims 1-6, further comprising:
and establishing standard contact between the friction plate and the brake disc, wherein the friction coefficient is set based on the technical protocol of the brake caliper.
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