CN201779247U - Gearbox off-line cleaning system - Google Patents

Abstract

The gearbox off-line cleaning system consists of a fuel tank unit, a flushing unit and an electric control unit. The flushing unit includes the first three-way rotary valve, the main pump, the second three-way rotary valve, the first three-way rotary valve, the main pump, the second The three-way rotary valves are connected in series to form a circuit, and at the same time, the working circuit is connected between the first three-way rotary valve and the second three-way rotary valve, and the working circuit is connected to the gear box; the series circuit of the main pump is provided with a magnetic filter, The main filter, the flowmeter, and the magnetic filter are located in the upstream pipeline of the main pump, and the main filter is located in the downstream pipeline of the main pump, and are connected in parallel with the cleanliness detector at both ends of the main filter. The utility model can realize the storage, heating and circulation filtering of the gear box flushing fluid, filling of the gear box flushing fluid, selection of flushing flow, gear box flushing, online cleanliness detection, and efficient oil pumping.

Description

Gearbox offline cleaning system

technical field

The utility model relates to a gear box cleaning device, specifically an off-line cleaning system for a gear box.

Background technique

The gearbox is used to match the speed and transmit torque between the prime mover and the working machine. Therefore, the normal operation of the gearbox affects the normal operation of the entire system. The main lubrication part (main oil system) of the wind turbine is the speed-increasing gearbox. According to the survey data, the oil system fails or even shuts down during use. 80% of them are related to oil pollution. Contaminated oil will cause failures of the speed-up gearbox, such as bearing and gear wear, grinding, frequent equipment maintenance, oil decline, etc. These problems directly affect the working efficiency and service life of the wind turbine. And it leads to excessive energy consumption and an increase in later maintenance costs. The cleanliness of the gearbox is an important indicator of the gearbox. For example, the standard of the wind power industry (about the cleanliness of gear lubricating oil): ANSI/AGMA/AWEA 6006-A03, which is jointly formulated by the American Standards Committee, the Gearbox Manufacturers Association and the Wind Energy Association, and is currently used by many wind turbine manufacturers and Referenced and adopted by the owner. It stipulates that the cleanliness level of the gearbox when it leaves the factory needs to meet the ISO**/14/11 standard, and it needs to meet the ISO 17/15/12 standard during operation. At present, domestic gearbox manufacturers pay attention to the cleanliness of the product processing and assembly process while introducing foreign advanced technology, and urgently need the market to provide efficient and fast gearbox internal cleanliness equipment.

Various possible causes of poor gearbox cleanliness:

(1) The cleanliness of the lubricating oil used in the gearbox is poor. This is the direct cause of poor cleanliness. The main consequences: when the gearbox starts to run, the lubricating oil enters the lubrication pipeline and is distributed to each lubrication point (usually the gear meshing area and the bearing area), and the impurities in it also reach the meshing area and the bearing, thereby affecting the their useful life.

(2) The iron filings generated during the machining of parts have not been cleaned up. On the one hand, the workers in the next process did not clean up the iron filings of the parts due to carelessness, resulting in defects such as pits or scratches on the surface of the parts; on the other hand, the iron filings existing in certain positions are not easy to clean, such as Iron filings in the oil hole (see Figure 1) These iron filings will be brought into the working area through the lubricating oil after the gearbox works, causing damage to the parts.

(3) The oil circuit after pickling is processed by welding and the like. Welding is not allowed after the oil circuit is pickled, otherwise the impurities generated by welding will enter the pipeline and enter the gearbox with the circulation of lubricating oil.

(4) Post-processing of certain parts is carried out on the assembled finished product.

(5) After the parts are cleaned, do not pay attention to preservation and place them randomly. Impurities such as dust enter the important surface of the part and affect the fit size.

(6) Paint cannot withstand high temperature. When the gearbox is running under high temperature conditions, the paint on the inner wall of the gearbox cannot withstand the high temperature, and the paint peels off and falls into the lubricating oil; the peeling paint on the outer wall of the gearbox affects the appearance.

(7) The sealant falls into the box. When too much sealant is applied to the gear box surface or other joint surfaces, the sealant will squeeze into the box and enter the lubricating oil after the box or cover is closed.

Effects and consequences of cleanliness on gearboxes

(1) The impact on lubrication and pipeline accessories. In order to increase the oil injection pressure for lubrication, the diameter of the oil hole in the gearbox is generally relatively small. After circulation, the lubricating oil can easily take out the iron filings staying in the oil hole position shown in Figure 7, and add oil The impurities in the oil will gradually block the small oil hole, resulting in insufficient lubricating oil or failure to lubricate.

(2) The influence on gears and meshing. In the process of gear meshing, the lubricating oil will bring impurities to the meshing tooth surface, destroy the smoothness of the tooth surface, reduce the mechanical properties of the tooth surface, affect the stability of the transmission, make the tooth surface prone to pitting, gluing, wear and other failures, shorten its service life.

(3) The impact on the bearing. Under normal lubrication conditions, the bearing will form an oil film between the surfaces of the parts without direct contact, which can reduce the friction and wear inside the bearing, improve the performance of the bearing and prolong the service life. When the oil contains impurities, the impurities enter between the rolling elements of the bearing and the inner and outer rings, increasing the friction and causing the rolling elements to rotate poorly, especially under high-speed and heavy loads, which will cause the inner and outer rings and rolling elements to form pits, causing their spots Corrosion or other failure modes will affect the service life.

Current domestic gearbox cleaning methods and status quo

(1) Strictly control the cleaning of parts and the process after cleaning. Formulate a reasonable cleaning process, and the cleaning process of different products should be explored according to the actual production; the surrounding environment where the parts are placed after cleaning should be kept clean, and the correct method should be used for storage.

(2) Use professional cleaning devices at each stage of the assembly process to ensure cleanliness with equipment. For example, the assembly parts are cleaned with an ultrasonic cleaning machine, and the cleaning system is used for cleaning after the final assembly.

The first is a system that is guaranteed by the workers' sense of responsibility and cannot be reliably guaranteed. The second is to rely on equipment to ensure the cleanliness, which is the most reliable method to ensure the cleanliness of the gearbox. At present, because there is no professional gearbox washing system in the market, most manufacturers mainly use the following two methods to clean the gearbox after the final assembly:

1) Use the filter system that comes with the wind turbine gearbox to flush online. The principle is shown in Figure 5:

At present, some wind turbine gearboxes have their own online lubrication system, and a set of filter 12 is attached between the circulation pump 11 and the gearbox 13 . Equipped with oil storage tank, filling and pumping equipment, the gear box can be flushed by replacing the high-precision filter with this system. However, due to the function, flow rate, filter quantity and specification limitations of the built-in online lubrication system, this online flushing method is inefficient. In severe cases, the residual large particle pollutants (such as iron chips) in the gearbox will damage the oil pump of the online lubrication system , can not meet the mass production of gearboxes.

2) Use the thin oil station to flush off-line. The principle is shown in Figure 6:

The filling pump 22 injects the oil in the oil tank 21 of the thin oil station into the gear box through the filter 23, and the oil pump 24 pumps the oil in the oil tank of the gear box 25 back to the oil tank 21 of the oil station to flush the gear box. This flushing method has the following disadvantages:

Since the flushing cycle process has more thin oil station oil tanks than online flushing, if the same filter and flushing flow are used, the flushing efficiency is 3-5 times lower than the online flushing efficiency; the reason is that the volume of the thin oil station oil tank is 3-3 times larger than the gearbox itself. 5 times, the number of oil cycles per unit time is 3-5 times less.

It is difficult to match the flow rate of the oil well pump and the filling pump, and cannot maintain the liquid level of the lubricating oil of the gearbox. Manual intervention is often required, and the labor intensity of workers is high.

Utility model content

Based on the above problems, the utility model provides a gearbox off-line cleaning system specially used for gearbox flushing.

The purpose of this utility model is to realize through the following technical solutions:

Gearbox off-line cleaning system, composed of oil tank unit, flushing unit and electric control unit,

The fuel tank unit includes an insulated oil tank, oil tank accessories, a circulating pump, and a filter. An electric heating device is installed inside the insulated oil tank, and the insulated oil tank, the circulating pump, and the filter form a single circulation loop.

The flushing unit includes a first three-way rotary valve, a main pump, and a second three-way rotary valve. The first three-way rotary valve, the main pump, and the second three-way rotary valve are connected in series to form a circuit. The second three-way rotary valve is connected to the working circuit, and the working circuit is connected to the gear box; a magnetic filter, a main filter, and a flow meter are arranged on the series circuit of the main pump, and the magnetic filter is located in the upstream pipeline of the main pump. The main filter is located in the downstream pipeline of the main pump, and is connected in parallel with the cleanliness detector at both ends of the main filter.

The magnetic filter is composed of multiple magnetic rods with a magnetic field strength of 600 gauss, which can absorb most of the metal particles in the oil and protect the normal operation of the pump.

The main pump is a screw pump driven by a variable frequency motor. The flushing flow can be set according to the gear boxes of different specifications, and the flow rate is 50-200L/Min continuously adjustable.

The main filter adopts three-stage filtration with filtration accuracy of 10u, 6u and 3u, β _3(c) = 200, β _6(c) = 200, β _10(c) = 200, 10 micron and 6 micron filters Dirt-holding capacity: 8.3mg/cm ² , 3-micron filter dirt-holding capacity: 8mg/cm ² , three-stage filtration improves filtration efficiency and dirt-holding capacity, thereby prolonging the effective working time of the flushing system and reducing the number of filter elements number of replacements.

Flowmeters are mainly used to measure system flow.

The cleanliness detector is an optional accessory, which can detect the cleanliness of the oil online and provide quantitative index data for the flushing results.

The electric control system is mainly controlled by Siemens S7-300 series PLC, which is composed of 1 main PLC and 1 ET200pro substation. The main PLC CPU adopts CPU315-2DP, communicates with ET200pro substation on the one hand, and communicates with the upper computer on the other hand through the Profibus-DP network.

The electric control system is equipped with a Siemens touch screen to realize the functions of parameter setting, status display and operation.

The circulating pump is controlled by a Siemens 440 series frequency converter, and the flow is adjusted through speed regulation.

The utility model can realize the storage, heating and circulation filtering of the gear box flushing fluid, filling of the gear box flushing fluid, selection of flushing flow, gear box flushing, online cleanliness detection, and efficient oil pumping.

Description of drawings

The utility model will be described in further detail below according to the accompanying drawings and embodiments.

Figure 1 is a structural diagram of the internal circulation mode of the gearbox offline cleaning system.

Fig. 2 is a structural diagram of the filling mode of the gearbox offline cleaning system.

Fig. 3 is a structural diagram of the flushing mode of the gearbox off-line cleaning system.

Fig. 4 is a structural diagram of the oil pumping mode of the gearbox off-line cleaning system.

Figure 5 is a schematic diagram of online flushing using the filter system of the wind turbine gearbox.

Fig. 6 is a schematic diagram of off-line flushing using a thin oil station.

Fig. 7 is a structural diagram of an oil hole to be cleaned.

Detailed ways

In this embodiment, as shown in Figure 1-7, the gearbox offline cleaning system consists of a fuel tank unit, a flushing unit and an electronic control unit,

The fuel tank unit includes an insulated oil tank 1, an oil tank accessory, a circulation pump 3, and a filter 4. An electric heating device 2 is arranged inside the insulated oil tank 1, and the insulated oil tank 1, the circulation pump 3, and the filter 4 form a single cycle circuit.

The flushing unit includes a first three-way rotary valve 5, a main pump 7, and a second three-way rotary valve 9. The first three-way rotary valve 5, the main pump 7, and the second three-way rotary valve 9 are connected in series to form a circuit. A working circuit is connected between the first three-way rotary valve 5 and the second three-way rotary valve 9, and the working circuit is connected to the gear box 11; a magnetic filter 6, a main filter 8, and a flow meter are arranged on the series circuit of the main pump 7 12. The magnetic filter 6 is located in the upstream pipeline of the main pump 7, and the main filter 8 is located in the downstream pipeline of the main pump 7, and the two ends of the main filter 8 are connected in parallel with the cleanliness detector 10.

The magnetic filter 6 is composed of a plurality of magnetic rods with a magnetic field strength of 600 gauss, which can absorb most of the metal particles in the oil and protect the normal operation of the pump.

The main pump 7 is a screw pump driven by a variable frequency motor. The flushing flow can be set according to the gear boxes of different specifications, and the flow rate is 50-200L/Min continuously adjustable.

The main filter 8 adopts three-stage filtration with filtration accuracy of 10u, 6u and 3u respectively, β _3(c) = 200, β _6(c) = 200, β _10(c) = 200, 10 micron and 6 micron The dirt-holding capacity of the filter is: 8.3mg/cm ² , and the dirt-holding capacity of the 3-micron filter is: 8mg/cm ² . The three-stage filtration improves the filtration efficiency and the dirt-holding capacity, thereby prolonging the effective working time of the flushing system and reducing the Filter replacement times.

The flow meter 12 is mainly used to measure the system flow.

The cleanliness detector 10 is an optional accessory, which can detect the cleanliness of the oil on-line and provide quantitative index data for the flushing results.

The electric control system 13 is mainly controlled by Siemens S7-300 series PLC, which is composed of one main PLC and one ET 200pro substation. The main PLC CPU adopts CPU315-2DP, communicates with ET200pro substation on the one hand, and communicates with the upper computer on the other hand through the Profibus-DP network.

The electronic control system 13 is equipped with a Siemens touch screen to realize functions such as parameter setting, status display and operation.

Circulation pump 3 is controlled by Siemens 440 series frequency converter, and flow regulation is realized through speed regulation.

The implementation of this patent can realize the internal circulation mode, filling mode, flushing mode and oil pumping mode by selecting the opening and closing of the valve ports of the first three-way rotary valve 5 and the second three-way rotary valve 9, as shown in Figures 1-4 shown.

The utility model can realize the storage, heating and circulation filtering of the gear box flushing fluid, filling of the gear box flushing fluid, selection of flushing flow, gear box flushing, online cleanliness detection, and efficient oil pumping.

Claims (7)

1. The gearbox offline cleaning system is composed of a fuel tank unit, a flushing unit and an electric control unit. It is characterized in that the flushing unit includes a first three-way rotary valve, a main pump, a second three-way rotary valve, and a first three-way rotary valve. , the main pump, and the second three-way rotary valve are connected in series to form a circuit, and at the same time, a working circuit is connected between the first three-way rotary valve and the second three-way rotary valve, and the working circuit is connected to the gear box. 2. The off-line cleaning system for gearboxes according to claim 1, wherein the fuel tank unit includes an insulated oil tank, an oil tank accessory, a circulation pump, and a filter, and the insulated oil tank, the circulation pump, and the filter form a single circulation loop . 3. The off-line cleaning system for gearboxes according to claim 2, characterized in that an electric heating device is provided inside the thermal insulation tank. 4. The gearbox off-line cleaning system according to claim 1, characterized in that a magnetic filter, a main filter and a flow meter are arranged on the series circuit of the main pump. 5. The gearbox off-line cleaning system according to claim 4, wherein the magnetic filter is located in the upstream pipeline of the main pump. 6. The gearbox off-line cleaning system according to claim 4, wherein the main filter is located in the downstream pipeline of the main pump. 7. The off-line cleaning system for gearboxes according to claim 6, characterized in that both ends of the main filter are connected in parallel with cleanliness detectors.

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