CN117847194A - Wind power gear box lubrication cooling system and control method - Google Patents
Wind power gear box lubrication cooling system and control method Download PDFInfo
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- CN117847194A CN117847194A CN202311868956.9A CN202311868956A CN117847194A CN 117847194 A CN117847194 A CN 117847194A CN 202311868956 A CN202311868956 A CN 202311868956A CN 117847194 A CN117847194 A CN 117847194A
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- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000001816 cooling Methods 0.000 title claims abstract description 37
- 238000005461 lubrication Methods 0.000 title claims abstract description 27
- 230000001360 synchronised effect Effects 0.000 claims abstract description 87
- 230000001276 controlling effect Effects 0.000 claims description 18
- 238000001914 filtration Methods 0.000 claims description 14
- 230000001105 regulatory effect Effects 0.000 claims description 10
- 230000008901 benefit Effects 0.000 abstract description 4
- 239000003921 oil Substances 0.000 description 143
- 230000008569 process Effects 0.000 description 22
- 239000010687 lubricating oil Substances 0.000 description 20
- 230000008859 change Effects 0.000 description 10
- 230000017525 heat dissipation Effects 0.000 description 9
- 230000033228 biological regulation Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 230000006698 induction Effects 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 101100408352 Drosophila melanogaster Plc21C gene Proteins 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000012208 gear oil Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000001050 lubricating effect Effects 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000010792 warming Methods 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000010729 system oil Substances 0.000 description 1
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H57/00—General details of gearing
- F16H57/04—Features relating to lubrication or cooling or heating
- F16H57/0412—Cooling or heating; Control of temperature
- F16H57/0413—Controlled cooling or heating of lubricant; Temperature control therefor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H57/00—General details of gearing
- F16H57/04—Features relating to lubrication or cooling or heating
- F16H57/0402—Cleaning of lubricants, e.g. filters or magnets
- F16H57/0404—Lubricant filters
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H57/00—General details of gearing
- F16H57/04—Features relating to lubrication or cooling or heating
- F16H57/0412—Cooling or heating; Control of temperature
- F16H57/0415—Air cooling or ventilation; Heat exchangers; Thermal insulations
- F16H57/0416—Air cooling or ventilation
-
- 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
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Motor Or Generator Cooling System (AREA)
Abstract
The invention relates to a lubrication and cooling system and a control method for a wind power gear box, wherein the method comprises the following steps: s1, acquiring the oil temperature of a gear box, judging whether the oil temperature of the gear box is lower than a low-temperature starting threshold value, if so, stopping the fan for protection, and otherwise, executing S2; s2, controlling the rotating speed of a permanent magnet synchronous motor connected with the gear pump to be in a first rotating speed interval, and executing S3 if the oil pool temperature of the gear box is greater than an oil pool temperature threshold value triggering the termination of warm-up; otherwise, continuing to warm up, performing current PID control on the load current of the permanent magnet synchronous motor, and then executing S3; s3, after the warming-up is stopped, PID control is carried out on the rotating speed of the permanent magnet synchronous motor; s4, acquiring the oil temperature of the distributor inlet, performing PID control on the oil temperature of the distributor inlet, and controlling the rotating speed of a variable frequency motor in the cooling assembly; and repeating the steps to lubricate and cool. Compared with the prior art, the invention has the advantages of low-temperature start, high reliability of a gearbox cooling system and the like.
Description
Technical Field
The invention relates to the technical field of lubrication and cooling of wind power gearboxes, in particular to a lubrication and cooling system and a control method of a wind power gearbox.
Background
For the wind generating set, when facing cold conditions, the over-temperature alarming phenomenon such as high oil temperature of the gear box can occur successively. When the fan works, the oil temperature of the gear box is fast reduced, the viscosity of the radiator rapidly rises when meeting cold gear oil, the heat exchanger can be blocked, and the radiator is easy to fail. In addition, the instantaneous pressure is also very high when the low-temperature starts, and the instantaneous pressure impact can bring negative effects to the motor pump, and the motor pump is easy to overload, so that the failure rate of the lubrication system is increased. In addition, in the low-temperature start-up process, the viscosity of gear oil is high, an oil pump cannot be started, and when the gears and the bearings in the gear box are in low-speed idle-load warm-up under the oil-free state, the bearings and tooth surfaces are easy to generate dry friction to damage.
Disclosure of Invention
The invention aims to provide a lubrication cooling system and a control method for a wind power gear box, which are used for reducing damage to an oil pump and the gear box when the wind power system is started at low temperature.
The aim of the invention can be achieved by the following technical scheme:
a lubrication cooling system of a wind power gear box comprises a gear box, a distributor, a gear pump, a temperature sensor, a permanent magnet synchronous motor, a heat exchanger, a current sensor, a filtering component and a PLC controller,
the distributor is arranged on the gear box, the gear box is connected with an oil suction pipe of the gear pump, the gear pump is rigidly connected with the permanent magnet synchronous motor through a spline pair, an oil outlet of the gear pump is connected with an oil inlet of an oil inlet valve block of the filtering component, an oil outlet of an oil outlet valve block of the filtering component is connected with an oil inlet of the heat exchanger, and an oil outlet of the heat exchanger is connected with the gear box distributor, wherein the heat exchanger comprises an axial flow fan and a variable frequency fan motor;
the PLC is connected with a variable frequency driving unit which is connected with a variable frequency fan motor and a permanent magnet synchronous motor.
Further, a current sensor is arranged on the permanent magnet synchronous motor, and temperature sensors are arranged at the bottoms of the distributor and the oil pool of the gear box.
Further, a safety valve is arranged in the oil inlet valve block of the filter assembly and is connected with the gear box through an overflow pipe.
Further, a temperature control valve is arranged in an oil outlet valve block of the filter assembly, and the output of the temperature control valve is respectively connected with an oil inlet of the heat exchanger and a gear box distributor.
A lubrication and cooling control method for a wind power gear box is based on the system and comprises the following steps:
s1, acquiring the oil temperature of a gear box, judging whether the oil temperature of the gear box is lower than a low-temperature starting threshold value, if so, stopping the fan for protection, and otherwise, executing S2;
s2, controlling the rotating speed of a permanent magnet synchronous motor connected with the gear pump to be in a first rotating speed interval, controlling the gear pump to absorb oil from the gear box by the permanent magnet synchronous motor, simultaneously carrying out warming-up, obtaining load current of the permanent magnet synchronous motor and oil pool temperature of the gear box, stopping warming-up if the oil pool temperature of the gear box is greater than an oil pool temperature threshold value triggering the termination of warming-up, and executing S3; if the oil sump temperature of the gear box is not greater than the oil sump temperature threshold triggering the termination of the warm-up, continuing the warm-up, and performing current PID control on the load current of the permanent magnet synchronous motor until the condition that the oil sump temperature of the gear box is greater than the oil sump temperature threshold triggering the termination of the warm-up is met, and then executing S3, wherein the given current of the current PID control is the rated current of the gear pump;
s3, after the warming-up is stopped, the rotating speed of the permanent magnet synchronous motor is obtained, PID control is carried out on the rotating speed of the permanent magnet synchronous motor, and the given rotating speed of the rotating speed PID control is the rated rotating speed;
s4, filtering and cooling the oil sucked by the gear pump, entering a gear box distributor, acquiring the oil temperature at the inlet of the gear box distributor, performing PID control on the oil temperature at the inlet of the gear box distributor, controlling the rotating speed of a variable frequency motor in a cooling assembly, and regulating the rotating speed of a fan;
and repeating the steps to lubricate and cool.
Further, the specific steps of controlling the rotating speed of the permanent magnet synchronous motor connected with the gear pump in the first rotating speed interval are as follows:
the rotating speed of the permanent magnet synchronous motor connected with the gear pump is controlled to be within 0-1500 rpm.
Further, the specific steps of carrying out current PID control on the load current of the permanent magnet synchronous motor are as follows:
and (3) taking the difference between the given current and the load current of the permanent magnet synchronous motor, inputting the obtained difference into a PID controller, outputting a control signal to a PLC (programmable logic controller), and outputting a current adjusting signal to the permanent magnet synchronous motor by the PLC to adjust the load current of the permanent magnet synchronous motor.
Further, the PLC outputs a current adjusting signal to the permanent magnet synchronous motor, and the specific steps of adjusting the load current of the permanent magnet synchronous motor are as follows:
the PLC outputs a current adjusting signal to the permanent magnet synchronous motor, adjusts the rotating speed and torque of the permanent magnet synchronous motor and adjusts the load current of the permanent magnet synchronous motor.
Further, the specific step of PID control on the oil temperature at the inlet of the gear box distributor is as follows:
and (3) taking the difference between the temperature set value of the distributor and the oil temperature at the inlet of the distributor of the gearbox to obtain a temperature deviation value, inputting the temperature deviation value into a PID controller, outputting a control signal to a PLC (programmable logic controller) by the PID controller, outputting a temperature regulating signal to a variable frequency motor by the PLC controller, and regulating the rotating speed of a fan connected with the variable frequency motor.
Further, the PLC controller outputs a temperature adjusting signal to the variable frequency motor, and the specific steps of adjusting the rotating speed of the fan connected with the variable frequency motor are as follows:
the PLC controller outputs a temperature adjusting signal to the variable frequency motor, adjusts the rotating speed of the variable frequency motor, and adjusts the rotating speed of the fan based on the variable frequency motor.
Compared with the prior art, the invention has the following beneficial effects:
(1) According to the method, the permanent magnet synchronous motor is controlled to run at a low rotation speed and a high torque in a first rotation speed interval and is warmed up, when the temperature of lubricating oil is increased and the temperature of the lubricating oil does not reach a threshold value, constant power control is carried out on the motor, the problem that the current of a motor pump is not overloaded when the lubricating oil pump is fed into a gear box for lubricating in the idling warming-up process of a wind driven generator earlier can be solved, when the temperature of the lubricating oil rises to a proper threshold value, the warming-up is finished, the rotation speed can be directly increased, the constant rotation speed of the motor is operated, more lubricating oil is provided, the control method for the variable speed soft start can meet the condition that the oil pump is started under the condition that the oil temperature is very low, dry friction of a sliding bearing gear box is avoided, the low temperature adaptability of the sliding bearing gear box is increased, meanwhile, the load current of the permanent magnet synchronous motor is prevented from being overloaded in the monitoring starting process, the constant rotation speed operation maintains the oil pressure continuously and stably, the problems that the oil pump is lost temporarily and the wind power system is frequently tripped in the low temperature switching process of the traditional design motor are avoided, the failure rate of the running of the oil pump motor is reduced when the oil temperature is excessively low in the running process of the wind power system is avoided, and the reliability of the wind power system is improved.
(2) The variable frequency motor is adopted to carry out PID control on the oil temperature at the inlet of the gear box distributor, a constant value of the temperature at the inlet of the gear box can be realized, the rotating speed of the cooling assembly can be flexibly regulated according to the change of the ambient temperature and the real-time heat load loss of the gear box in the running process of the wind driven generator, the fan of the cooling assembly can be operated in a stepless speed regulation mode, the flexible regulation of the air inlet quantity of the radiator is realized, the self-adaptive matching between the heating value and the heat dissipation capacity is realized, and the problem that the cooling fan is too fast in condensation of lubricating oil due to too low ambient temperature in low temperature seasons and the gear box is overtemperature due to the blockage of the radiator is avoided.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a system block diagram of the present invention;
FIG. 3 is a block diagram of the PID control of oil temperature according to the present invention;
in the figure, a fan motor 1, an axial flow fan 2, a plate-fin heat exchanger 3, a first bypass valve 4, a temperature control valve 5, a filter assembly 6, a double-precision filter element 7, a second bypass valve 8, a check valve 9, an air-permeable line 10, a safety valve 11, a one-way valve 12, a mechanical pump 13, a gear pump 14, a permanent magnet synchronous motor 15, a current sensor 16, a gear box 17, an oil pool temperature sensor 18, a distributor temperature sensor 19, a distributor 20, a PLC (programmable logic controller) 21, a power supply module 22 and a variable frequency driving unit 23.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The present embodiment is implemented on the premise of the technical scheme of the present invention, and a detailed implementation manner and a specific operation process are given, but the protection scope of the present invention is not limited to the following examples.
The existing wind generating set can successively generate overtemperature alarm phenomena such as high oil temperature of a gear box in winter. Mainly, only the influence of the high-temperature environment on the heat dissipation of the radiator is considered in design, and the influence of the low-temperature environment on the radiator is ignored. The viscosity of the gear oil of the radiator is rapidly and violently increased when the radiator encounters cold, so that the heat exchanger is blocked, and the high-temperature fault of the gearbox with poor heat dissipation under the low-temperature condition is prominent in winter; in addition, the existing radiator is a fan driven by a double-speed motor, the fan motor is frequently started and stopped, the impact moment is large, in addition, the double-speed asynchronous motor cannot meet the requirement of starting an oil pump motor to lubricate a gear box under the condition that the oil temperature viscosity of the gear box is high in a low-temperature starting working condition, the rated power of the motor is generally required to be increased to meet the low-temperature starting requirement, and the motor performance is wasted; the low-speed starting is carried out, the pressure at the moment of starting is also high, the motor pump is negatively influenced by the instant pressure impact, the failure rate of a lubricating system is increased, and particularly, the problems of abnormal damage of a coupling and running of the motor occur to the oil pump motor; in the low-temperature start-up process, the oil temperature and the viscosity are high, an oil pump cannot be started, gears and bearings in the gear box are in an oil-free state and are in low-speed no-load warm-up, and dry friction is easy to occur on the bearings and tooth surfaces to cause damage; in the high-low speed switching process of the double-speed motor, the problem that the lubricating oil pressure is temporarily lost exists, and serious negative effects are easily caused on a sliding bearing gear box.
Based on the above problems, the invention firstly provides a lubrication and cooling system of a wind power gear box, and the structure diagram of the system is shown in fig. 2. The whole system comprises an air-cooled heat exchanger component, an oil pump component, a safety valve 11, a filtering component 6, a temperature control valve 5, a current sensor 16, an oil pool temperature sensor 18, a distributor temperature sensor 19, a variable frequency driving unit 23, an in-cabinet PLC (programmable logic controller) 21 and a power supply module 22. The oil pool temperature sensor 18 is used to acquire the oil temperature of the gear box 17. The distributor temperature sensor 19 at the inlet of the gearbox is used for acquiring the oil temperature at the inlet of the distributor 20 of the gearbox, and is used for monitoring the temperature of the lubricating oil after cooling through a radiator, and is used as a feedback parameter of closed-loop control. The air-cooled heat exchanger assembly comprises a variable frequency fan motor 1, an axial flow fan 2, a plate-fin heat exchanger 3 and a first bypass valve 4. The oil pump assembly includes a gear box 17 and a gear pump 14. The power supply module 22 is used for supplying power to the variable frequency drive unit 23.
The distributor 20 is arranged on the gear box 17, the gear box 17 is connected with the gear pump 14, the gear pump 14 is connected with the permanent magnet synchronous motor 15, an oil outlet of the gear pump 14 is connected with an oil inlet of the filter assembly 6, an oil outlet of the filter assembly 6 is connected with an oil inlet of the heat exchanger, and an oil outlet of the heat exchanger is connected with the distributor 20, wherein the heat exchanger comprises the axial flow fan 2 and the variable frequency fan motor 1; the PLC controller 21 is connected with a variable frequency driving unit 23, and the variable frequency driving unit 23 is connected with the variable frequency fan motor 1 and the permanent magnet synchronous motor 15.
The permanent magnet synchronous motor 15 is provided with a current sensor 16, and the bottoms of the distributor 20 and the oil pool of the gear box 17 are provided with a distributor temperature sensor 19 and an oil pool temperature sensor 18. The oil inlet of the filter assembly 6 is also connected with a safety valve 11, and the safety valve 11 is connected with a gear box 17. A temperature control valve 5 is arranged in the oil outlet valve block of the filter assembly 6, and the output of the temperature control valve is respectively connected with the oil inlet of the heat exchanger and the gear box distributor 20. The thermostatic valve divides the oil into the heat exchanger and gearbox distributor 20, and when the oil pool temperature is higher than the action starting temperature of the thermostatic valve, the higher the temperature is, the larger the flow in the direction of the heat exchanger is until all the lubricating oil passes through the heat exchanger.
In the system shown in fig. 2, the gear pump 14 is controlled by the permanent magnet synchronous motor 15, oil enters the oil inlet valve block of the filter assembly 6 through the one-way valve 12, the one-way valve 12 is arranged at the inlet of the oil inlet valve block of the filter assembly 6, the safety valve 11 is simultaneously arranged in the oil inlet valve block, when the oil inlet pressure of the filter assembly is overlarge, the safety valve 11 is conducted, and the oil flows back to the gear box 17. When the oil pressure does not exceed the threshold value, the oil flows to the filter assembly 6. The filter assembly 6 is provided with a double-precision filter element 7 in a filter cartridge, a second bypass valve 8 is arranged beside the filter element, when the pressure difference of oil liquid before and after the filter element is overlarge, the second bypass valve 8 is conducted, only the filter element with coarse precision is passed, when the pressure of the oil liquid does not reach a pressure value, the oil liquid is subjected to fine filtration first and then coarse filtration, the oil inlet of the filter cartridge is provided with a check valve 9 (one-way valve), and the top of the filter cartridge is connected with the oil inlet of an oil inlet valve block of the filter cartridge through a pressure measuring joint by an air permeation line 10, so that the air accumulation in the filter cartridge is prevented. The check valve 9 prevents oil from flowing back into the gear pump 14. An oil outlet of the oil outlet valve block at the bottom of the filter cylinder is connected with an oil inlet of the plate-fin heat exchanger 3 and a gear box distributor 20, an axial flow fan 2 is arranged on the plate-fin heat exchanger 3, and the axial flow fan 2 is driven by a variable frequency fan motor 1. And a first bypass valve 4 is arranged on one side of the plate-fin heat exchanger 3, and when the oil pressure of an oil inlet of the plate-fin heat exchanger 3 is overlarge, the oil directly flows to an oil outlet of the heat exchanger through the first bypass valve 4. The oil outlet of the heat exchanger is connected to a distributor 20. The gear box 17 is also connected with a mechanical pump 13, the mechanical pump 13 is also connected with the check valve 12 and the filtering assembly 6, and the mechanical pump 13 can supply oil to the gear box 17 simultaneously with the gear pump 14. The thermostatic valve 5 can be used to regulate the flow through the oil inlet of the filter assembly 6 to which the heat exchanger is connected, i.e. to control the flow of lubricating oil through the plate fin heat exchanger 3.
In the system provided by the invention, the PLC 21 acquires information of the sensor and then sends a control signal to the variable frequency driving unit 23, and the variable frequency driving unit 23 controls the permanent magnet synchronous motor 15 and the variable frequency fan motor 1 to work.
Based on the system, the invention provides a wind power gear box lubrication and cooling control method, and a flow chart of the method is shown in fig. 1. The method comprises the following steps:
s1, acquiring the oil temperature of a gear box 17, judging whether the oil temperature of the gear box 17 is lower than a low-temperature starting threshold, if so, stopping the fan for protection, and otherwise, executing S2;
s2, controlling the rotating speed of the permanent magnet synchronous motor 15 connected with the gear pump 14 to be in a first rotating speed interval, controlling the gear pump 14 to absorb oil from the gear box 17 by the permanent magnet synchronous motor 15, simultaneously carrying out warming-up, obtaining load current of the permanent magnet synchronous motor 15 and oil pool temperature of the gear box 17, stopping warming-up if the oil pool temperature of the gear box 17 is greater than an oil pool temperature threshold value triggering the termination of warming-up, and executing S3; if the oil sump temperature of the gear case 17 is not greater than the oil sump temperature threshold triggering the termination of the warm-up, continuing the warm-up, and performing current PID control on the load current of the permanent magnet synchronous motor 15 until the condition that the oil sump temperature of the gear case 17 is greater than the oil sump temperature threshold triggering the termination of the warm-up is met, and then executing S3, wherein the given current of the current PID control is the rated current of the gear pump 14;
s3, after the warming-up is stopped, the rotating speed of the permanent magnet synchronous motor 15 is obtained, PID control is carried out on the rotating speed of the permanent magnet synchronous motor 15, and the given rotating speed of the rotating speed PID control is the rated rotating speed;
s4, filtering and cooling the oil sucked by the gear pump 14, entering a gear box distributor 20, acquiring the oil temperature at the inlet of the gear box distributor 20, performing PID control on the oil temperature at the inlet of the gear box distributor 20, controlling the rotating speed of a variable frequency fan motor 1 in a cooling assembly, and regulating the rotating speed of a fan;
and repeating the steps to lubricate and cool.
In the invention, a variable frequency driving unit 23 is adopted for controlling the variable frequency fan motor 1 and controlling the permanent magnet synchronous motor 15.
In the invention, the value range of the oil pool temperature threshold triggering the termination of the warm-up is 20-35 ℃. The low temperature start threshold value is in the range of-20 ℃ to-30 ℃. The oil sump temperature of the gearbox 17 and the oil temperature at the inlet of the gearbox distributor 20 are obtained based on temperature sensors. The oil temperature of the gearbox 17 is obtained based on a temperature sensor on the gearbox 17.
In S4, the oil entering the gear box distributor 20 will enter other components to be lubricated, and finally return to the gear box 17.
In S2, when the rotation speed of the permanent magnet synchronous motor 15 connected to the gear pump 14 is controlled to be within the first rotation speed interval, the permanent magnet synchronous motor 15 runs at a low rotation speed and a high torque.
The specific steps of current PID control on the load current of the permanent magnet synchronous motor 15 are as follows:
the given current and the load current of the permanent magnet synchronous motor 15 are subjected to difference, the obtained difference is input into a PID controller, the PID controller outputs a control signal to a PLC controller 21, the PLC controller 21 outputs a current adjusting signal to the permanent magnet synchronous motor 15, and the load current of the permanent magnet synchronous motor 15 is adjusted. At this time, the permanent magnet synchronous motor 15 runs with constant power, and the load current of the permanent magnet synchronous motor 15 is adjusted to be in the rated current of the gear pump 14, so that the excessive current of the gear pump can be prevented. In the process of constant power operation of the permanent magnet synchronous motor 15, the rotating speed of the permanent magnet synchronous motor 15 is always controlled in a first rotating speed interval.
S2-S4 are combined with a gear box oil supply system, the gear box 17 oil supply system adopts a PID closed-loop control mode, which is different from the traditional asynchronous induction double-speed motor, the oil pump motor adopts a permanent magnet synchronous motor 15, the low Wen Qiji working condition can realize low-rotation-speed and high-torque operation, a current sensor 16 is added in an oil pump power supply circuit, the current change of the motor is monitored in real time, the running state of the motor is monitored and recorded, an accurate current signal is provided for a PLC (programmable logic controller) 21, and the accurate control, speed regulation, frequency fixing and the like of the motor are realized; starting a lubrication system oil supply system in a low-temperature environment, feeding back the change of current in a low-temperature starting stage to a PLC module of a main control cabinet, adjusting the rotating speed and torque of a motor in real time based on a PLC set current value, realizing the requirement that an oil pump motor can still operate under high viscosity of lubricating oil, and realizing the early input of the lubricating oil pump to lubricate a gear box 17 in the idling (idle) warming-up process of a wind driven generator.
The specific steps of PID control on the rotation speed of the permanent magnet synchronous motor 15 are as follows:
the rotating speed of the permanent magnet synchronous motor 15 is obtained, the rotating speed is compared with the rated rotating speed of the permanent magnet synchronous motor 15, the comparison result is input into a PID controller, the rotating speed control signal of the PID controller is output to a PLC (programmable logic controller) 21, the PLC 21 outputs a rotating speed adjusting signal to the permanent magnet synchronous motor 15, and the permanent magnet synchronous motor 15 runs at a constant rotating speed. The constant rotation speed operation is used for providing stable oil quantity.
The oil drawn by the gear pump 14 is filtered and cooled into the distributor 20 of the gearbox 17 and, when cooled, into the cooling assembly. S5, the specific steps of PID control on the oil temperature at the inlet of the distributor 20 of the gearbox 17 are as follows:
the temperature set value of the distributor 20 and the oil temperature at the inlet of the distributor 20 of the gearbox 17 are subjected to difference to obtain a temperature deviation value, the temperature deviation value is input into a PID controller 21, the PID controller 21 outputs a control signal to a variable frequency driving unit 23, the variable frequency driving unit 23 outputs a temperature adjustment signal to the variable frequency fan motor 1, and the rotating speed of the axial flow fan 2 connected with the variable frequency fan motor 1 is adjusted.
The cooling assembly consists of a variable frequency fan motor 1, an axial flow fan 2 and a plate-fin heat exchanger 3, and the cooling system motor adopts a permanent magnet synchronous or induction motor; the control of the cooling system of the gearbox 17 adopts a PID closed-loop control mode, the temperature of the distributor 20 at the inlet of the gearbox is acquired in real time, the target set temperature of the temperature sensor at the inlet of the gearbox is compared with the target set temperature of the temperature sensor at the inlet of the gearbox of the PLC 21, the rotating speed of the variable frequency motor is regulated by the variable frequency driver, the constant value of the temperature at the inlet of the gearbox can be realized, the rotating speed of the fan motor 1 can be flexibly regulated according to the change of the ambient temperature and the real-time heat load loss of the gearbox 17 in the running process of the wind driven generator, the flexible regulation of the air intake of a radiator is further realized, the self-adaptive matching of the heating value and the heat dissipation capacity is realized, the problems that the lubricating oil is condensed too fast due to the too low ambient temperature of a constant-speed heat dissipation fan in a low-temperature season of the fan and the overtemperature problem of the gearbox 17 is caused by the blockage of the radiator are avoided.
A block diagram of the PID control of the inlet oil temperature of the gearbox 17 is shown in fig. 3.
The fan motor 1 adopts a variable frequency motor, the principle of the variable frequency motor can adopt a permanent magnet synchronous motor or an induction motor, the rotating speed can be changed according to the change of the thermal load of the gear box 17 and the environmental temperature of the fan, and the variable frequency motor is changed into dynamic change, so that the heat dissipation capacity and the heat productivity are equal, the constant oil temperature of the gear box 17 is ensured, and the problems that the heat dissipation failure is caused by the blockage of a radiator in winter of the gear box 17, the oil temperature of the gear box 17 is high and the like are avoided; meanwhile, the problem that bearing running rings are caused by frequent start and stop of the double-speed fan motor and insulation failure of the motor can be avoided. The permanent magnet synchronous motor 15 is adopted in the oil pump motor, so that the requirement of starting the oil pump motor under the high viscosity of the sliding bearing gear box can be met, soft start and soft stop, stepless speed regulation and no impact can be realized, the energy-saving effect is good, and the problem of abnormal abrasion of the bearing caused by dry grinding of the sliding bearing in the low-temperature starting working condition of the idle warming (idle) gear box 17 of the wind turbine generator is avoided; by adopting the gear pump 14 to change speed and soft start and monitoring the load current of the permanent magnet synchronous motor 15 in the starting process, the system overload risk of the prior double-speed oil pump motor in low-temperature starting is avoided, the lubrication operation failure rate of the gear box 17 is reduced, and the operation reliability of the gear box 17 is improved.
The gear box 17 is directly shut down for protection when the oil temperature is below the low temperature start threshold of-30 c, and if not below the low temperature start threshold, the gear pump 14 is first attempted to start at a low speed (rotational speed of 0-1500 rpm). During the start of the gear pump 14 at a low speed, the rotational speed is gradually increased and warming up is performed.
Then judging whether the oil sump temperature of the gear box 17 is greater than an oil sump temperature threshold value triggering the termination of the warm-up, if so, stopping the warm-up, and executing the constant rotation speed control of S3; otherwise, the warm-up is continued, and at this time, the load current of the permanent magnet synchronous motor 15 is subjected to current PID control until the oil sump temperature of the gear case 17 is greater than the oil sump temperature threshold value triggering the warm-up termination, and then the constant rotation speed control of S3 is performed, wherein the given current of the current PID control is the rated current of the gear pump 14.
The lubricating oil supply in the low-temperature starting process can be improved as much as possible through the current PID control, and the negative influence on gears and bearings caused by the dry friction working condition in the warming-up process is reduced.
The oil pump motor adopts the permanent magnet synchronous motor, is matched with the variable frequency driver, and is started in a rotating speed gradual change mode based on the temperature of the oil pool, so that the oil pump can be started at extremely low temperature earlier, the lubricating requirement in the idling (idling) warming-up process of the wind turbine generator can be met, the dry friction working condition in the previous warming-up process is avoided, and meanwhile, the risk of insufficient lubrication caused by short lubricating oil pressure loss due to the power failure of the motor in the high-low speed switching process is avoided; when the rotating speed of the motor is low, the efficiency is still maintained at a high level, and the energy consumption is reduced; and under the same rated power, the volume of the permanent magnet motor can be designed smaller, the motor structure is flexible, and the operation and maintenance are easier to replace. Compared with an asynchronous motor, the permanent magnet synchronous motor has the advantages that the power factor is larger, the efficiency is higher, the weight is lighter, the energy-saving benefit of the synchronous motor in the whole life cycle is much higher than that of the asynchronous motor, the energy consumption of an auxiliary motor of a fan is greatly reduced, and the rise of the component cost caused by variable frequency driving and the like can be completely counteracted; the permanent magnet motor rotor adopts the permanent magnet, does not have induced current, does not produce heat, compares induction asynchronous motor heat dissipation easier, can reliably operate under higher cabin temperature, and under equal power, permanent magnet synchronous motor weight is lighter, and power density is higher, and small in size occupies cabin space less, promotes the convenience that the later stage was moved and is kept in the maintenance and change, and its excellent energy efficiency performance greatly reduces fan power auxiliary power consumption simultaneously, and energy-saving benefit is obvious.
According to the invention, the cabin environmental control requirement is reduced, the special technical characteristics of low-temperature fans such as cabin heating and cabin heat preservation are not required to be added, the situation of high-limit power of the oil temperature of the development cabin in winter is solved, the heat dissipation requirement under the working condition of high wind and high temperature in summer is met, the problem of high-limit power of the oil temperature of the gearbox in winter is effectively solved, and the fan is stably operated under the extreme environment of minus 30 ℃.
The invention meets the requirements of high reliability of low-temperature starting and oil pump starting under the working condition of very low oil temperature, avoids dry friction of the sliding bearing gear box, increases the low-temperature adaptability of the sliding bearing gear box, can realize the adaptability matching requirements of an oil pump system under different working conditions, and improves the lubrication reliability; by adopting the continuous change of the variable speed soft start rotating speed of the electric pump and monitoring the load current of the permanent magnet synchronous motor in the starting process, the overload risk of the oil pump motor when the oil temperature is too low is avoided, the operation failure rate of the wind turbine generator is reduced, and the reliability of a gear box lubrication system is improved.
After the gear box is stopped for a long time under a low temperature working condition, the machine needs to be restarted, the temperature of an oil pool is close to minus 30 ℃, the viscosity of lubricating oil is very high, the double-speed motor cannot be started under such low temperature, after variable frequency control is adopted, soft start can be carried out based on the temperature of the oil pool, the characteristics of low speed and high torque of a permanent magnet synchronous motor can be utilized, the rotating speed of an oil pump motor can be gradually increased, when the temperature of the oil pump is high, the oil pump operates in a low-rotating speed and high torque mode, a certain amount of lubricating oil can be ensured to enter the gear box in the low temperature starting warming-up process, dry friction of tooth surfaces and bearings is avoided, when the temperature of the lubricating oil rises to a proper range, more lubricating oil can be directly increased, the problems of short oil pressure loss, frequent tripping of low temperature starting and the like in the high-low speed switching process of an old design motor are avoided.
Under the working condition of low-temperature strong wind, in the power generation process of the wind driven generator, the actual heat radiation capacity of the radiator far exceeds the heat productivity of the gearbox due to low air temperature, lubricating oil is cooled rapidly, and the heat balance of the gearbox is required to be maintained through frequent start-stop fans.
The foregoing describes in detail preferred embodiments of the present invention. It should be understood that numerous modifications and variations can be made in accordance with the concepts of the invention by one of ordinary skill in the art without undue burden. Therefore, all technical solutions which can be obtained by logic analysis, reasoning or limited experiments based on the prior art by the person skilled in the art according to the inventive concept shall be within the scope of protection defined by the claims.
Claims (10)
1. A lubrication and cooling system of a wind power gear box is characterized by comprising a gear box, a distributor, a gear pump, a temperature sensor, a permanent magnet synchronous motor, a heat exchanger, a current sensor, a filtering component and a PLC (programmable logic controller),
the distributor is arranged on the gear box, the gear box is connected with an oil suction pipe of the gear pump, the gear pump is rigidly connected with the permanent magnet synchronous motor through a spline pair, an oil outlet of the gear pump is connected with an oil inlet of an oil inlet valve block of the filtering component, an oil outlet of an oil outlet valve block of the filtering component is connected with an oil inlet of the heat exchanger, and an oil outlet of the heat exchanger is connected with the gear box distributor, wherein the heat exchanger comprises an axial flow fan and a variable frequency fan motor;
the PLC is connected with a variable frequency driving unit which is connected with a variable frequency fan motor and a permanent magnet synchronous motor.
2. The lubrication and cooling system of a wind power gear box according to claim 1, wherein a current sensor is arranged on the permanent magnet synchronous motor, and a temperature sensor is arranged at the bottom of the distributor and the oil pool of the gear box.
3. The lubrication and cooling system of a wind power gear box according to claim 1, wherein a safety valve is arranged in an oil inlet valve block of the filter assembly and is connected with the gear box through an overflow pipe.
4. The lubrication and cooling system of a wind power gear box according to claim 1, wherein a temperature control valve is installed in an oil outlet valve block of the filtering assembly, and the output of the temperature control valve is connected with an oil inlet of the heat exchanger and the gear box distributor respectively.
5. A wind power gear box lubrication cooling control method, characterized in that the method is based on the wind power gear box lubrication cooling system according to any one of claims 1-4, the method comprising:
s1, acquiring the oil temperature of a gear box, judging whether the oil temperature of the gear box is lower than a low-temperature starting threshold value, if so, stopping the fan for protection, and otherwise, executing S2;
s2, controlling the rotating speed of a permanent magnet synchronous motor connected with the gear pump to be in a first rotating speed interval, controlling the gear pump to absorb oil from the gear box by the permanent magnet synchronous motor, simultaneously carrying out warming-up, obtaining load current of the permanent magnet synchronous motor and oil pool temperature of the gear box, stopping warming-up if the oil pool temperature of the gear box is greater than an oil pool temperature threshold value triggering the termination of warming-up, and executing S3; if the oil sump temperature of the gear box is not greater than the oil sump temperature threshold triggering the termination of the warm-up, continuing the warm-up, and performing current PID control on the load current of the permanent magnet synchronous motor until the condition that the oil sump temperature of the gear box is greater than the oil sump temperature threshold triggering the termination of the warm-up is met, and then executing S3, wherein the given current of the current PID control is the rated current of the gear pump;
s3, after the warming-up is stopped, the rotating speed of the permanent magnet synchronous motor is obtained, PID control is carried out on the rotating speed of the permanent magnet synchronous motor, and the given rotating speed of the rotating speed PID control is the rated rotating speed;
s4, filtering and cooling the oil sucked by the gear pump, entering a gear box distributor, acquiring the oil temperature at the inlet of the gear box distributor, performing PID control on the oil temperature at the inlet of the gear box distributor, controlling the rotating speed of a variable frequency motor in a cooling assembly, and regulating the rotating speed of a fan;
and repeating the steps to lubricate and cool.
6. The method for controlling lubrication and cooling of a wind power gear box according to claim 5, wherein the specific steps of controlling the rotation speed of a permanent magnet synchronous motor connected with a gear pump within a first rotation speed interval are as follows:
the rotating speed of the permanent magnet synchronous motor connected with the gear pump is controlled to be within 0-1500 rpm.
7. The method for controlling lubrication and cooling of a wind power gear box according to claim 5, wherein the specific steps of performing current PID control on the load current of the permanent magnet synchronous motor are as follows:
and (3) taking the difference between the given current and the load current of the permanent magnet synchronous motor, inputting the obtained difference into a PID controller, outputting a control signal to a PLC (programmable logic controller), and outputting a current adjusting signal to the permanent magnet synchronous motor by the PLC to adjust the load current of the permanent magnet synchronous motor.
8. The method for controlling lubrication and cooling of a wind power gear box according to claim 7, wherein the PLC controller outputs a current adjusting signal to the permanent magnet synchronous motor, and the specific step of adjusting the load current of the permanent magnet synchronous motor is:
the PLC outputs a current adjusting signal to the permanent magnet synchronous motor, adjusts the rotating speed and torque of the permanent magnet synchronous motor and adjusts the load current of the permanent magnet synchronous motor.
9. The method for controlling lubrication and cooling of a wind power gear box according to claim 5, wherein the specific step of performing PID control on the oil temperature at the inlet of the gear box distributor is as follows:
and (3) taking the difference between the temperature set value of the distributor and the oil temperature at the inlet of the distributor of the gearbox to obtain a temperature deviation value, inputting the temperature deviation value into a PID controller, outputting a control signal to a PLC (programmable logic controller) by the PID controller, outputting a temperature regulating signal to a variable frequency motor by the PLC controller, and regulating the rotating speed of a fan connected with the variable frequency motor.
10. The method for controlling lubrication and cooling of a wind power gear box according to claim 9, wherein the PLC controller outputs a temperature adjustment signal to the variable frequency motor, and the specific step of adjusting the rotation speed of a fan connected to the variable frequency motor is as follows:
the PLC controller outputs a temperature adjusting signal to the variable frequency motor, adjusts the rotating speed of the variable frequency motor, and adjusts the rotating speed of the fan based on the variable frequency motor.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN118375720A (en) * | 2024-06-25 | 2024-07-23 | 新乡市万和过滤技术股份公司 | Wind power gear box lubrication and filtration system and filtration process |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118375720A (en) * | 2024-06-25 | 2024-07-23 | 新乡市万和过滤技术股份公司 | Wind power gear box lubrication and filtration system and filtration process |
| CN118375720B (en) * | 2024-06-25 | 2024-08-23 | 新乡市万和过滤技术股份公司 | Wind power gear box lubrication and filtration system and filtration process |
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