CN220523255U - Gear box and gear box fault damage simulation experiment device - Google Patents

Abstract

The utility model provides a gear box and a gear box fault damage simulation experiment device, and relates to the technical field of gear box fault damage simulation. The gear box is used for fault damage simulation; the gearbox is formed by assembling a plurality of box body modules; the two adjacent box body modules are detachably connected; the gearbox further includes a fault damage module for replacing one or more of the plurality of box modules; the fault damage module for replacement is detachably connected with the adjacent box module. Like this, wholly split into a plurality of box modules with the gear box, when carrying out fault simulation, can be directly with the box module of trouble damage module to relevant position department replace, no longer need frequently dismantle inside gear and the gear shaft of box module to reduce the part wearing and tearing that cause because of changing the piece, improve trouble damage simulation's efficiency and accuracy. Meanwhile, the gearbox is simple and convenient to disassemble and assemble, and the efficiency of fault damage simulation can be improved.

Description

Gear box and gear box fault damage simulation experiment device

Technical Field

The utility model relates to the technical field of fault damage simulation of gearboxes, in particular to a gearbox and a fault damage simulation experiment device for the gearbox.

Background

At present, fossil fuels still take the dominant role in a global energy system, but fossil raw materials are non-renewable resources, and excessive use can cause two problems of aggravation of environmental pollution and exhaustion of energy resources, so that new energy is actively searched, the method becomes the only way for changing the current situation, and pollution-free and renewable energy sources such as wind energy and water energy become the primary choice. With the progress of technology, the wind power industry is rapidly developed, the running load is continuously increased, more people recognize the superiority of the wind power generation system, and the development of wind power generation technology is focused on all countries in the world. The investment on wind power projects is increased in all places in China, and wind power stations are built vigorously.

The gear box is a main component for realizing transmission, speed increasing and energy transmission in the wind turbine, and the running state of the gear box has direct influence on the power generation efficiency of the wind turbine. According to statistics, the occurrence frequency of faults of the gear box in the wind turbine generator is higher, the occurrence frequency of faults of the gear box is gradually increased along with the increase of global installed capacity, the types of faults are various, and serious safety problems are often induced. With the increase of the running load of the gear box and the severe working environment, the installation position and other factors affect the gear box of the wind turbine generator, so that the gear box of the wind turbine generator is not easy to disassemble and assemble, and the wind turbine generator can bring great influence to the wind turbine generator once the wind turbine generator breaks down. The gearbox is used as a key component for transmitting energy of the wind turbine, has high failure rate, long maintenance time and high cost, and has very important significance for state monitoring. Therefore, in the use process of the wind turbine, a worker usually reduces the failure rate of the wind turbine by carrying out state monitoring, failure analysis and failure diagnosis on the gear box, reduces the maintenance time and cost of equipment, improves the safety and reliability, and improves the running efficiency of the wind turbine.

Simulating the failure mechanism and critical component failure of a gearbox is essential to understanding the operational condition and failure prediction of the gearbox. The importance and urgency of fault simulation and diagnosis of gearboxes has become increasingly significant. However, the existing gearbox is troublesome to disassemble and assemble, the upper cover of the gearbox is required to be opened, then the parts in the gearbox are frequently disassembled and assembled to simulate fault damage, other box bodies and gear train structures are easily damaged in the disassembling and assembling process, and fault damage simulation and diagnosis results are inaccurate.

Disclosure of Invention

The utility model aims to provide a gear box and a gear box fault damage simulation experiment device, which are used for solving the problems that the gear box in the prior art is troublesome to assemble and disassemble during fault damage simulation and inaccurate in fault damage simulation and diagnosis results.

In order to achieve the above object, according to a first aspect of the present utility model, there is provided a gear box for fault damage simulation; the gearbox is formed by assembling a plurality of box body modules; the two adjacent box body modules are detachably connected; the gearbox further includes a fault damage module for replacing one or more of the plurality of box modules; the fault damage module for replacement is detachably connected with the adjacent box module.

Further, the fault damage module comprises a plurality of fault damage modules with different fault damages at different positions, and one or more of the fault damage modules can be selected to replace the corresponding box body module; the fault damage module for replacement conforms to the box shape of the box module being replaced.

Further, two adjacent box modules are detachably connected through bolts; the fault damage module for replacement is detachably connected with the adjacent box body module through bolts.

Further, each box module is provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each box module is meshed with the gears in the adjacent box modules.

Further, each housing module also includes bearings and sleeves coupled to the gear shafts, bearing seals and bearing caps mated to the bearings, and housings for enclosure and support.

Further, the plurality of box modules includes a planet wheel box module, an input axle box module, an intermediate axle box module, and an output axle box module: the planetary gear box module comprises a first box body, an annular gear, a main shaft, a planetary carrier, a planetary gear and a sun gear, wherein the annular gear is fixedly arranged in the first box body, the main shaft and the annular gear are coaxially arranged, the main shaft is connected with the planetary carrier, the planetary gear is rotatably arranged on the planetary carrier, the planetary gear is simultaneously meshed with the annular gear and the sun gear, and the sun gear and the main shaft are coaxially arranged; the input shaft box module comprises a second box body, an input shaft and a first gear; the first gear is connected with the input shaft, and the first gear and the input shaft can jointly rotate relative to the second box body; after assembly, the input shaft extends into the first box body to be connected with the sun gear; the intermediate axle box module comprises a third box body, an intermediate axle, a second gear and a third gear; the second gear and the third gear are connected with the intermediate shaft and are arranged at intervals; the intermediate shaft, the second gear and the third gear can jointly rotate relative to the third box body; after assembly, the second gear is meshed with the first gear; the number of teeth of the second gear is smaller than that of the first gear; the output axle box module comprises a fourth box body, an output shaft and a fourth gear; the fourth gear is connected with the output shaft, and the fourth gear and the output shaft can jointly rotate relative to the fourth box body; after assembly, the fourth gear is meshed with the third gear; the number of teeth of the fourth gear is smaller than the number of teeth of the third gear.

Further, the plurality of box modules includes a planet wheel box module, an input axle box module, an intermediate axle box module, and an output axle box module: the planetary gear box module comprises a first box body, an annular gear, a main shaft, a planetary carrier and planetary gears, wherein the annular gear is fixedly arranged in the first box body, the main shaft and the annular gear are coaxially arranged, the main shaft is connected with the planetary carrier, the planetary gears are rotatably arranged on the planetary carrier, and the planetary gears are meshed with the annular gear; the input shaft box module comprises a second box body, an input shaft, a sun gear and a first gear; the sun gear and the first gear are connected with the input shaft, and the sun gear, the first gear and the input shaft can jointly rotate relative to the second box body; after assembly, the sun wheel stretches into the first box body to be meshed with the planet wheel; the intermediate axle box module comprises a third box body, an intermediate axle, a second gear and a third gear; the second gear and the third gear are connected with the intermediate shaft, and the second gear, the third gear and the intermediate shaft can jointly rotate relative to the third box body; after assembly, the second gear is meshed with the first gear; the number of teeth of the second gear is smaller than that of the first gear; the output axle box module comprises a fourth box body, an output shaft and a fourth gear; the fourth gear is connected with the output shaft, and the fourth gear and the output shaft can jointly rotate relative to the fourth box body; after assembly, the fourth gear is meshed with the third gear; the number of teeth of the fourth gear is smaller than the number of teeth of the third gear.

Further, the plurality of case modules includes: a lower case module; a plurality of upper case modules are commonly placed on the lower case module; each upper box body module is detachably connected with the lower box body module respectively; the two adjacent upper box body modules are detachably connected; the fault damage module is used for replacing one or more of the plurality of upper box modules; the fault damage module for replacement is detachably connected with the upper box body module adjacent to the fault damage module.

Further, each upper box module is provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each upper box module is meshed with the gears in the upper box modules adjacent to the gears; the gear box is a wind power gear box in the wind turbine generator; the number of teeth of the driving gear is larger than that of the driven gear in the two gears meshed with each other.

According to a second aspect of the present utility model, there is provided a gearbox fault damage simulation experiment device, characterized in that the gearbox fault damage simulation experiment device comprises the gearbox described above.

By applying the technical scheme of the utility model, the whole gearbox is split into a plurality of box modules, and when fault simulation is carried out, the box modules at corresponding positions can be directly replaced by the fault damage modules, and gears and gear shafts in the box modules are not required to be frequently disassembled, so that part abrasion caused by replacement is reduced, and the efficiency and accuracy of fault damage simulation are improved. Meanwhile, the gearbox is simple and convenient to disassemble and assemble, and the efficiency of fault damage simulation can be improved.

Compared with the prior art, the application has the beneficial effects that:

this application is when the analog gear case carries out spare part change, directly dismantles gear case shafting and last box module that corresponds, and current majority technique is to open the epaxial trouble part of end cover and dismantles one by one, and the time consumption is long, and when the epaxial part of dismouting, causes the damage to the spare part easily, and this application can effectively reduce this kind of damage, and changes the module and less than changing epaxial single part time spent. Compared with the prior art, the device has the advantages of convenience in replacing parts, effective reduction in replacing part abrasion, accuracy in diagnosis and high efficiency, and the structure is easy to popularize in the field of fault simulation of the gearbox.

Drawings

The above, as well as additional purposes, features, and advantages of exemplary embodiments of the present utility model will become readily apparent from the following detailed description when read in conjunction with the accompanying drawings. In the drawings, wherein like or corresponding reference numerals indicate like or corresponding parts, there are shown by way of illustration, and not limitation, several embodiments of the utility model, in which:

FIG. 1 schematically illustrates an internal drive configuration of an assembled plurality of case modules of a gearbox of an alternative embodiment provided by the present utility model;

FIG. 2 schematically illustrates an internal drive configuration of an alternative embodiment of the gearbox of FIG. 1 with a plurality of case modules disassembled;

FIG. 3 schematically illustrates an internal transmission schematic of a fault damage module corresponding to one of the tank modules of FIG. 2;

FIG. 4 schematically illustrates an internal transmission architecture of the case module of FIG. 2 after replacement with the failure module of FIG. 3;

FIG. 5 schematically illustrates a multiple case module disassembled configuration of another alternative embodiment of the gearbox of FIG. 1;

fig. 6 shows an enlarged view at P in fig. 5;

FIG. 7 schematically illustrates a plurality of assembled structural schematic diagrams of a gearbox according to another alternative embodiment provided herein;

fig. 8 schematically shows a top view of fig. 7;

fig. 9 schematically shows a replacement flow chart for replacing a box module on an output shaft by using a fault damage module when the fault damage simulation experiment is performed by using the gearbox provided by the utility model.

Reference numerals illustrate:

1. a first case; 2. an inner gear ring; 3. a main shaft; 4. a planet carrier; 5. a planet wheel; 6. a sun gear; 7. a second case; 8. an input shaft; 9. a first gear; 10. a third case; 11. an intermediate shaft; 12. a second gear; 13. a third gear; 14. a fourth case; 15. an output shaft; 16. a fourth gear; 17. a bearing; 18. a lower box body; 19. a bolt; 191. bolt holes; 20. and a fault damage module.

Detailed Description

It should be noted that, in the case of no conflict, the embodiments and features in the embodiments may be combined with each other. The utility model will be described in detail below with reference to the drawings in connection with embodiments.

As shown in fig. 1 to 8, the gearbox provided by the application is used for fault damage simulation; the gearbox is formed by assembling a plurality of box body modules; the two adjacent box body modules are detachably connected; the gearbox further includes a fault damage module 20 for replacing one or more of the plurality of box modules; the fault damage module 20 for replacement is detachably connected with the adjacent box module.

Like this, wholly split into a plurality of box modules with the gear box, when carrying out fault simulation, can be directly with the box module of trouble damage module 20 to relevant position department replace, no longer need frequently dismantle inside gear and the gear shaft of box module to reduce the part wearing and tearing that cause because of changing the piece, improve trouble damage simulation's efficiency and accuracy. Meanwhile, the gearbox is simple and convenient to disassemble and assemble, and the efficiency of fault damage simulation can be improved.

Optionally, the fault damage module 20 includes a plurality of fault damage modules 20 with different fault damages at different positions, and one or more of the fault damage modules may be selected to replace the corresponding box module; the fault damage module 20 for replacement conforms to the box shape of the box module being replaced. Therefore, the gearbox provided by the application can simulate various fault injuries, so that a fault diagnosis database can be established, and data support is provided for monitoring the gearbox. The fault damage type of the fault damage module 20 can be set according to actual needs.

In an alternative embodiment shown in fig. 3, the input shaft box module is used as a replaced box module, and the fault damage module 20 is used to replace the input shaft box module in fig. 2, and the replacement is shown in fig. 4, so that vibration signals of the fault gear and the fault shaft system in fig. 4 can be obtained through analysis.

Alternatively, as shown in fig. 5 to 8, two adjacent tank modules are detachably connected by bolts 19; the fault damage module 20 for replacement is detachably connected with the adjacent box module through bolts 19. Thus, the bolt 19 is used for dismounting and connecting, so that the structure is simple and the operation is convenient.

Optionally, each box module is provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each box module is meshed with the gears in the adjacent box modules. In this way, gear transmission is achieved through gear engagement between adjacent housing modules.

By adjusting the number of teeth of the gears, speed-up transmission or speed-down transmission can be realized. When the gearbox provided by the application is used in a wind turbine, the gearbox is a speed increasing gearbox.

Optionally, each housing module further comprises a bearing 17 and sleeve coupled to the gear shaft, a bearing 17 seal and bearing 17 end cap cooperating with the bearing 17, and a housing for enclosing and supporting.

Optionally, as shown in fig. 5, the plurality of housing modules includes a planet wheel housing module, an input housing module, an intermediate housing module, and an output housing module: the planet gear box module comprises a first box body 1, an annular gear 2, a main shaft 3, a planet carrier 4, planet gears 5 and a sun gear 6, wherein the annular gear 2 is fixedly arranged in the first box body 1, the main shaft 3 and the annular gear 2 are coaxially arranged, the main shaft 3 is connected with the planet carrier 4, the planet gears 5 are rotatably arranged on the planet carrier 4, the planet gears 5 are simultaneously meshed with the annular gear 2 and the sun gear 6, and the sun gear 6 and the main shaft 3 are coaxially arranged; the input shaft box module comprises a second box 7, an input shaft 8 and a first gear 9; the first gear 9 is connected with the input shaft 8, and the first gear 9 and the input shaft 8 can jointly rotate relative to the second box 7; after assembly, an input shaft 8 extends into the first box body 1 and is connected with the sun gear 6; the intermediate axle box module comprises a third box 10, an intermediate axle 11, a second gear 12 and a third gear 13; the second gear 12 and the third gear 13 are connected with the intermediate shaft 11 and are arranged at intervals; the intermediate shaft 11, the second gear 12 and the third gear 13 are rotatable together with respect to the third casing 10; after assembly, the second gear 12 is meshed with the first gear 9; the number of teeth of the second gear 12 is smaller than that of the first gear 9; the output shaft box module comprises a fourth box 14, an output shaft 15 and a fourth gear 16; the fourth gear 16 is connected with the output shaft 15, and the fourth gear 16 and the output shaft 15 can jointly rotate relative to the fourth box 14; after assembly, the fourth gear 16 is meshed with the third gear 13; the number of teeth of the fourth gear 16 is smaller than the number of teeth of the third gear 13. In this embodiment, the internal transmission structure of the assembled plurality of housing modules is shown in fig. 1.

When the wind drives the impeller to rotate, the main shaft 3 is driven to rotate, and the main shaft 3 is rigidly connected with the planet carrier 4, so that the planet carrier 4 is driven to rotate, and the planet wheel 5 is connected with the planet carrier 4, so that the planet wheel 5 revolves around the sun wheel 6 while rotating, and the revolution and the rotation of the planet wheel 5 drive the sun wheel 6 to rotate, so that the planet wheel 5 and the sun wheel 6 are meshed to complete primary speed increasing. The rotation of the sun gear 6 drives the large gear driven by the first-stage fixed shaft on the same shaft to rotate, and the large gear is meshed with the small gear, so that the second-stage speed increasing is completed. The pinion driven by the first-stage fixed shaft drives the large gear driven by the second-stage fixed shaft on the same shaft to rotate, and the large gear is meshed with the pinion to finish three-stage speed increasing.

Optionally, as shown in fig. 2, the plurality of housing modules includes a planet wheel housing module, an input housing module, an intermediate housing module, and an output housing module: the planetary gear box module comprises a first box body 1, an annular gear 2, a main shaft 3, a planetary carrier 4 and planetary gears 5, wherein the annular gear 2 is fixedly arranged in the first box body 1, the main shaft 3 and the annular gear 2 are coaxially arranged, the main shaft 3 is connected with the planetary carrier 4, the planetary gears 5 are rotatably arranged on the planetary carrier 4, and the planetary gears 5 are meshed with the annular gear 2; the input shaft box module comprises a second box 7, an input shaft 8, a sun gear 6 and a first gear 9; the sun gear 6 and the first gear 9 are connected with the input shaft 8, and the sun gear 6, the first gear 9 and the input shaft 8 can jointly rotate relative to the second box body 7; after assembly, the sun gear 6 stretches into the first box body 1 to be meshed with the planet gears 5; the intermediate axle box module comprises a third box 10, an intermediate axle 11, a second gear 12 and a third gear 13; the second gear 12 and the third gear 13 are connected with the intermediate shaft 11, and the second gear 12, the third gear 13 and the intermediate shaft 11 can jointly rotate relative to the third box body 10; after assembly, the second gear 12 is meshed with the first gear 9; the number of teeth of the second gear 12 is smaller than that of the first gear 9; the output shaft box module comprises a fourth box 14, an output shaft 15 and a fourth gear 16; the fourth gear 16 is connected with the output shaft 15, and the fourth gear 16 and the output shaft 15 can jointly rotate relative to the fourth box 14; after assembly, the fourth gear 16 is meshed with the third gear 13; the number of teeth of the fourth gear 16 is smaller than the number of teeth of the third gear 13. The embodiment shown in fig. 2 differs from the embodiment shown in fig. 5 in that the sun gear 6 is divided differently. In the embodiment shown in fig. 2, the internal transmission structure of the assembled plurality of box modules is shown in fig. 1, and the three-stage speed increasing process is identical to that of the embodiment shown in fig. 5, and will not be repeated.

Alternatively, the division may be performed in other ways, for example, the ring gear 2, the main shaft 3, the carrier 4, the planetary gears 5, the input shaft 8, the sun gear 6 and the first gear 9 are divided into one case module, the intermediate shaft 11, the second gear 12 and the third gear 13 are divided into one case module, and the output shaft 15 and the fourth gear 16 are divided into one case module.

Alternatively, as shown in fig. 7 and 8, the plurality of case modules includes: a lower case 18 module; a plurality of upper housing modules, co-located on the lower housing 18 modules; each upper box module is detachably connected with the lower box 18 module respectively; the two adjacent upper box body modules are detachably connected; the fault damage module 20 is used to replace one or more of the plurality of upper case modules; the fault damage module 20 for replacement is detachably connected with the upper case module adjacent thereto. Therefore, the lower box 18 module is utilized for positioning and limiting, when the upper box module is replaced, the rest upper box modules cannot move, so that gears can be guaranteed to be accurately meshed, and replacement abrasion is reduced.

Optionally, each upper box module is provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each upper box module is meshed with the gears in the upper box modules adjacent to the gears. In this way, the speed increase or the speed reduction is realized through the gear transmission among the upper box body modules.

Optionally, the gearbox is a wind turbine gearbox in a wind turbine. With the increase of the running load of the gear box and the severe working environment, the installation position and other factors affect the gear box of the wind turbine generator, so that the gear box of the wind turbine generator is not easy to disassemble and assemble, and the wind turbine generator can bring great influence to the wind turbine generator once the wind turbine generator breaks down. Therefore, the wind power gear box provided by the application can set the corresponding fault damage module 20 aiming at the fault damage of the wind power gear box, so that the wind power gear box is favorable for fault analysis, the running state of the wind power plant gear box can be indirectly monitored through signals obtained through fault simulation experiments, unnecessary periodic inspection of staff can be reduced, active maintenance is realized, the service life of the wind power gear box is prolonged, the maintenance cost is reduced, fault data can be used as the basis for performance evaluation of the gear box and structural optimization of a transmission system, and the wind power gear box has important significance for further popularization of the wind power generation industry.

Alternatively, the number of teeth of the driving gear is larger than the number of teeth of the driven gear in the two gears meshed with each other. Thus, the speed can be increased after the gear transmission.

Optionally, the application still provides a gear box fault damage simulation experiment device, and gear box fault damage simulation experiment device includes foretell gear box.

Optionally, the gearbox fault damage simulation experiment device further comprises: the vibration signal collector is used for collecting the whole section of vibration signals in the running process of the gear box; and the fault analysis processor is used for carrying out time domain index analysis on the whole section of vibration signal to obtain a time domain diagram and a frequency domain diagram of the fault damage module 20. The vibration signal of the vibration sensor is analyzed by using an effective signal processing method, the fault characteristics of the gearbox are diagnosed, and the method is one of the common strategies for wind farm gearbox fault diagnosis. The time domain index has the advantages of accuracy, intuitiveness and high timeliness, so that the time domain index analysis can be carried out by using the whole section of vibration signal to monitor the running state of the gear box, and the fault early warning can be carried out by setting the size of the index threshold. The time domain diagram and the frequency domain diagram of the fault gear are obtained through analysis and processing of the vibration signals, and the functions of state monitoring and fault early warning of the gear box are achieved through analysis of the time domain diagram and the frequency domain diagram. Meanwhile, the fault characteristics of the gearbox are extracted by utilizing various methods, so that the fault characteristics can be highlighted.

The embodiment of the application provides a wind power gear box structure suitable for fault damage simulation, belongs to the field of fault simulation diagnosis, can simulate a plurality of faults and part damage types of a wind power gear box, provides convenience for research and verification of fault and damage characteristics of the wind power gear box for scientific researchers, and also provides basis for fault diagnosis of the wind power gear box. The wind power gearbox has the advantages that the integrated module can be integrally disassembled and assembled, and the wind power gearbox is simple and convenient and has higher efficiency. The gear box is divided into a plurality of independent integrated modules according to the gear shaft, each module is connected with the adjacent module through bolts 19, and the wind power gear box for fault and damage simulation is formed through assembly. The planetary wheel 5 of the gear box and the corresponding gear, bearing 17, sealing element, end cover, sleeve and box body for surrounding and supporting the planetary wheel are divided into an independent planetary shaft integrated module, the fixed shaft wheel train of the gear box is provided with a plurality of fixed gear shafts, and each gear shaft, the corresponding on-shaft gear, bearings 17 at two ends, bearing 17 sealing elements at two ends, end covers of bearings 17 at two ends, sleeve on the gear shaft and box body blocks for surrounding and supporting the sleeve are made into an independent fixed shaft integrated module. The parts with specific faults and damages are integrated into their corresponding planetary shaft integrated module and stationary shaft integrated module, i.e. the fault damage module 20 is formed. When the fault and damage of a certain part are required to be simulated, based on the wind power gear box for fault and damage simulation, the connecting bolts 19 between the integrated module corresponding to the part and the adjacent modules are removed, the integrated module with the specified fault and damage part is installed, the integrated module with the specified fault and damage part is well connected with the adjacent modules through the bolts 19, replacement of the integrated module with the specified fault and damage part can be completed, the box body and the shaft parts of the whole set of gear box do not need to be removed one by one, the axial positions and fastening states of other shafting are kept unchanged, and accurate meshing between gears is ensured.

In the wind turbine generator system, the gear box is difficult to disassemble and assemble, the operation load is gradually increased, and the working environment is bad, so that once the gear box breaks down, the whole wind turbine generator system is seriously affected, and therefore, the gear box is subjected to fault diagnosis, state real-time monitoring and fault prediction, and the method has important significance for safe operation of the wind turbine generator system. Compared with the construction of a fault simulation test bed, the development of the test in the actual wind power plant has larger limitation, and the test difficulty of full power is increased along with the continuous increase of the installed capacity of the fan, so that the wind power gearbox suitable for fault simulation is necessary. The existing fault diagnosis method can frequently disassemble parts on the gearbox to damage the box body and the gear train structure, so that fault simulation and diagnosis are inaccurate, and an axle surface is inevitably scratched when an axle disc is disassembled and assembled. According to the wind power gearbox, the wind power gearbox is assembled and disassembled in a modular mode, each gear shaft, the corresponding box body and the corresponding parts on the shafts are used as an integrated module, and when fault simulation is carried out, the quick replacement of the damaged parts of the fault to be tested is realized through the connecting bolts 19 between the integrated modules, so that the time for replacing the parts is saved, the abrasion of the parts caused by replacing the parts is reduced, and the efficiency and the accuracy of the fault damage simulation are improved. The method has the advantages of convenience in replacing the parts, effective reduction in abrasion of replacing the parts, accuracy in diagnosis and high efficiency, and is easy to popularize and apply.

The wind turbine generator system gearbox fault simulation diagnosis method is used for simulating various fault models of the wind turbine generator system gearbox. The gear box is a main component for realizing transmission, speed increasing and energy transmission in the wind turbine, and the running state of the gear box has direct influence on the power generation efficiency of the wind turbine. As global installed capacity increases, the frequency of gear box failures increases as well, and the types of failures are varied, often inducing serious safety problems. Thus, simulating the failure mechanism and critical component failure of a gearbox is essential to understanding the operational condition and failure prediction of the gearbox.

In wind turbines, the gearbox is an important component of the drivetrain. The gearbox has severe working conditions, works under the complex working conditions of low speed, heavy load and alternating load for a long time, and simultaneously bears the impact of strong wind and the vibration of other parts and wind power in the engine room, so that the gearbox is extremely easy to break down, the gearbox is positioned in a narrow space on the top of the fan tower, the internal structure is complex, the coupling connection between the gearbox and other parts is firm, and once the fault occurs, the gearbox is difficult to maintain and replace. High maintenance costs can result once the fault is shut down.

The occurrence frequency of faults of the gear box in the wind turbine generator is high, so that the importance and urgency of fault simulation and diagnosis of the gear box become more and more remarkable. With the increase of the running load of the gear box and the severe working environment, the installation position and other factors affect the gear box of the wind turbine generator, so that the gear box of the wind turbine generator is not easy to disassemble and assemble, and the wind turbine generator can bring great influence to the wind turbine generator once the wind turbine generator breaks down. The staff reduces the failure rate of the wind turbine generator through carrying out state monitoring, failure analysis and failure diagnosis on the gear box, reduces the maintenance time and cost of equipment, improves the safety and reliability, and improves the running efficiency of the wind turbine generator. The gearbox is used as a key component for transmitting energy of the wind turbine, has high failure rate, long maintenance time and high cost, and has very important significance for state monitoring. Therefore, the gearbox provided by the application can simulate a plurality of fault types of the gearbox, provides convenience for scientific researchers in the research and verification process of a fault research method, and also provides a basis for fault diagnosis of the gearbox. The running state of the wind power plant gearbox can be indirectly monitored through signals obtained through fault simulation experiments, unnecessary periodic inspection of staff can be reduced, active maintenance is achieved, the service life of the wind power plant gearbox is prolonged, maintenance cost is reduced, fault data can be used as the basis for performance evaluation of the gearbox and structural optimization of a transmission system, and the method has important significance for further popularization of the wind power generation industry.

In the alternative embodiment shown in fig. 1 of the present application, the internal structure of the gear box is formed by a three-stage speed increasing mechanism, as shown in fig. 1, the diagram (a) is a planetary gear shafting in the gear box, including a main shaft 3, planetary gears 5, a planet carrier 4 and the like, three planetary gears 5 are located between an inner gear ring 2 and a sun gear 6, the planetary gears 5 are meshed with the sun gear 6 and the inner gear ring 2 simultaneously, so that the planetary gears 5 not only rotate but also revolve around the sun gear 6, and the power transmission of the planetary gears 5 completes the first-stage speed increasing of the gear box. Fig. (b) shows a fixed shafting comprising sun gear 6, first gear 9 and input shaft 8, wherein first gear 9 meshes with second gear 12 on intermediate shaft 11 in fig. (c) for a second step up. And the third gear 13 on the intermediate shaft 11 is meshed with the fourth gear 16 on the output shaft 15 in the figure (d), so that the third-stage speed increase is realized. The wind force promotes the blade rotation, and the speed increasing gear train in the gear box is the rotational speed to promote, reaches the generator rotational speed and promotes the generator and generate electricity, converts wind energy into electric energy.

The gear fault simulation test bed can be built through the gear box, fault vibration signals are collected, analyzed and processed in a laboratory, the purposes of experiment, analysis and establishment of a fault diagnosis database are achieved, and effective basis is provided for fault diagnosis of the gear box. According to the gear box, the bolts 19 between the adjacent box body modules of the gear box are loosened, the box body modules on the gear box are replaced to achieve the purpose of replacing gears and meshing different fault gears, and the purpose of fault diagnosis of the gears, the bearings 17, the box bodies and the like is achieved. If the relative positions of the other two modules are not required to be adjusted when the box modules on the intermediate shaft 11 are replaced, the fixed states of the other two shafting and the upper end cover are not changed, and only the intermediate shaft 11 and the corresponding upper end cover are required to be replaced integrally. And in the same way, only a single module is installed, and the disassembly and assembly process is simple. The box of the upper box module comprises an upper end cover.

As shown in fig. 7 and 8, the box, the shaft, the gear, the bearing 17, the end cover, the sealing ring and other devices in each upper box module keep the fixed position of the box connection still, and the box modules are replaced and disassembled. It is assumed that during fault simulation, the modules with different faults need to be replaced, the whole upper end cover is not required to be opened like a conventional gearbox, and the sealing device, the bearing 17, the gears and other parts are detached one by one.

The basic structure of the gearbox consists of a shaft, bearings 17, gears. If the gearbox as a whole is studied, the fault signal analyzed may be relatively single in performance, and the signal may be formed by a superposition of multiple causes. If the basic structures of the gear box are researched, for example, the constituent parts of the gear box are monitored respectively, and the position and the type of the fault can be effectively judged according to different vibration generated by the parts in the operation process.

The vibration signal of the vibration sensor is analyzed by using an effective signal processing method, the fault characteristics of the gearbox are diagnosed, and the method is one of the common strategies for wind farm gearbox fault diagnosis. The time domain index has the advantages of accuracy, intuitiveness and high timeliness, so that the time domain index analysis can be carried out by using the whole section of vibration signal to monitor the running state of the gear box, and the fault early warning can be carried out by setting the size of the index threshold. The time domain diagram and the frequency domain diagram of the fault gear are obtained through analysis and processing of the vibration signals, and the functions of state monitoring and fault early warning of the gear box are achieved through analysis of the time domain diagram and the frequency domain diagram. Meanwhile, various methods are utilized to extract the fault characteristics of the gear box, so that the fault characteristics are highlighted.

The fault of the parallel shaft gear in the shafting is tooth breaking through signal processing and fault feature extraction of the parallel shaft gear in fig. 3 and comparison with data in a fault database. When the fault module is known, the fault module is replaced, the input shaft box module corresponding to the input shaft box module in fig. 2 can be replaced in fig. 3, the fault gear box after the replacement in fig. 4 is obtained, the corresponding vibration signal can be obtained by analyzing the fault gear box, and then if the corresponding vibration signal is detected in practical application, the corresponding fault can be determined.

Fig. 5 is a block integrated structure diagram of the gear box, which is divided into a planetary gear box module, an input shaft box module, an intermediate shaft box module and an output shaft box module, and the modules are connected through bolts 19. In the embodiment of fig. 5, the position of the sun gear 6 is divided in the planetary gear module.

As shown in fig. 6, a bolt hole 191 is provided in one of the case modules, and a bolt 19 in the other case module is fitted with the bolt hole 191 to achieve the detachable connection.

The fault simulation diagnosis is carried out on the replaced module, the bolts 19 connected with the fault module in fig. 7 and 8 are required to be opened, the integrated fault shafting and the box body are integrally disassembled, the connection relation between the parts on the shaft and the upper end cover of the gear box is not required to be disassembled, the positions and the fixed states of other modules are kept unchanged, the box body module with the same appearance to be replaced is installed at the position where the module is originally disassembled, the bolts 19 are fastened, the accurate meshing of gears is ensured, the fault diagnosis is carried out on the replaced module by repeating the previous operation, and the fault type of the replaced module is determined.

Fig. 9 is a flowchart of the replacement of the case module on the gear case output shaft 15. If the output shaft box module needs to be replaced, only the bolts 19 of the upper box module and the bolts 19 connected with the lower box 18 module of the intermediate shaft 11 adjacent to the output shaft 15 are required to be loosened, the fixed mounting positions of the shafting of the output shaft 15 of the gearbox, including the shaft, the bearing 17, the gear, the sealing device and other parts, are kept unchanged, only the whole box module is disassembled, and the disassembling process is shorter. On the contrary, the installation of the replacement module only needs shorter assembly time, and the space device of the three shafts of the gear box has small transverse size and compact structure. The characteristics enable the application to have better engineering applicability.

The foregoing is merely illustrative of the present utility model, and the present utility model is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present utility model. Therefore, the protection scope of the present utility model shall be subject to the protection scope of the claims.

While exemplary embodiments of the present application are shown in the drawings, it should be understood that the present application may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. The technical means used in the examples are conventional means well known to those skilled in the art unless otherwise indicated.

It is noted that unless otherwise indicated, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this utility model belongs. Relational terms such as "first" and "second", and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "coupled," "connected," and the like are to be construed broadly and may be, for example, fixedly attached, detachably attached, or integrally formed; can be mechanically or electrically connected; either directly or indirectly via an intermediary. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising … …" does not exclude the presence of other like elements in a process, method, article or apparatus that comprises the element.

Claims (10)

1. A gearbox, wherein the gearbox is used for fault damage simulation;

the gearbox is formed by assembling a plurality of box body modules; the two adjacent box body modules are detachably connected;

the gearbox further includes a fault damage module for replacing one or more of the plurality of box modules; and the fault damage module for replacement is detachably connected with the adjacent box body module.

2. A gearbox according to claim 1, characterised in that,

the fault damage module comprises a plurality of fault damage modules which are positioned at different positions and have different fault damages, and one or more of the fault damage modules can be selected to replace the corresponding box body module;

the fault damage module for replacement conforms to the box shape of the box module being replaced.

3. A gearbox according to claim 1, characterised in that,

two adjacent box modules are detachably connected through bolts;

the fault damage module used for replacement is detachably connected with the adjacent box body module through bolts.

4. A gearbox according to claim 1, characterised in that,

each box module is internally provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each box module is meshed with the gears in the adjacent box modules.

5. A gearbox as set forth in claim 4, wherein,

each of the housing modules further includes a bearing and sleeve coupled to the gear shaft, a bearing seal and bearing end cap mated to the bearing, and a housing for enclosing and supporting.

6. The gearbox of claim 1, wherein the plurality of housing modules comprises a planet wheel housing module, an input housing module, an intermediate housing module, and an output housing module:

the planet wheel box module comprises a first box body, an annular gear, a main shaft, a planet carrier, a planet wheel and a sun wheel, wherein the annular gear is fixedly arranged in the first box body, the main shaft and the annular gear are coaxially arranged, the main shaft is connected with the planet carrier, the planet wheel is rotatably arranged on the planet carrier, the planet wheel is simultaneously meshed with the annular gear and the sun wheel, and the sun wheel and the main shaft are coaxially arranged;

the input shaft box module comprises a second box body, an input shaft and a first gear; the first gear is connected with the input shaft, and the first gear and the input shaft can jointly rotate relative to the second box body; after assembly, the input shaft extends into the first box body and is connected with the sun gear; the intermediate shaft box module comprises a third box body, an intermediate shaft, a second gear and a third gear; the second gear and the third gear are connected with the intermediate shaft and are arranged at intervals;

the intermediate shaft, the second gear and the third gear can jointly rotate relative to the third box body; after assembly, the second gear is meshed with the first gear; the number of teeth of the second gear is smaller than that of the first gear;

the output shaft box module comprises a fourth box body, an output shaft and a fourth gear; the fourth gear is connected with the output shaft, and the fourth gear and the output shaft can jointly rotate relative to the fourth box body; after assembly, the fourth gear is meshed with the third gear; the number of teeth of the fourth gear is smaller than that of the third gear.

7. The gearbox of claim 1, wherein the plurality of housing modules comprises a planet wheel housing module, an input housing module, an intermediate housing module, and an output housing module:

the planet gear box module comprises a first box body, an annular gear, a main shaft, a planet carrier and planet gears, wherein the annular gear is fixedly arranged in the first box body, the main shaft and the annular gear are coaxially arranged, the main shaft is connected with the planet carrier, the planet gears are rotatably arranged on the planet carrier, and the planet gears are meshed with the annular gear;

the input shaft box module comprises a second box body, an input shaft, a sun gear and a first gear; the sun gear and the first gear are connected with the input shaft, and the sun gear, the first gear and the input shaft can jointly rotate relative to the second box body; after assembly, the sun wheel stretches into the first box body to be meshed with the planet wheel;

the intermediate shaft box module comprises a third box body, an intermediate shaft, a second gear and a third gear; the second gear and the third gear are connected with the intermediate shaft, and the second gear, the third gear and the intermediate shaft can jointly rotate relative to the third box body; after assembly, the second gear is meshed with the first gear; the number of teeth of the second gear is smaller than that of the first gear;

the output shaft box module comprises a fourth box body, an output shaft and a fourth gear; the fourth gear is connected with the output shaft, and the fourth gear and the output shaft can jointly rotate relative to the fourth box body; after assembly, the fourth gear is meshed with the third gear; the number of teeth of the fourth gear is smaller than that of the third gear.

8. Gearbox according to claim 1 or 6 or 7, characterized in that,

the plurality of case modules includes:

a lower case module;

a plurality of upper case modules commonly placed on the lower case module; each upper box body module is detachably connected with the lower box body module respectively; the two adjacent upper box body modules are detachably connected;

the fault damage module is used for replacing one or more of the plurality of upper box modules; and the fault damage module for replacement is detachably connected with the upper box body module adjacent to the fault damage module.

9. A gearbox as claimed in claim 8, characterised in that,

each upper box body module is internally provided with at least one gear shaft, and each gear shaft is connected with at least one gear; after assembly, at least one gear in each upper box module is meshed with the gears in the upper box modules adjacent to the gears;

the gear box is a wind power gear box in the wind turbine generator;

the number of teeth of the driving gear is larger than that of the driven gear in the two gears meshed with each other.

10. A gearbox fault damage simulation experiment device, characterized in that the gearbox fault damage simulation experiment device comprises a gearbox according to any one of claims 1 to 9.