WO2024088267A1

WO2024088267A1 - Remote vibration testing system for gearbox of wind generator set

Info

Publication number: WO2024088267A1
Application number: PCT/CN2023/126273
Authority: WO
Inventors: 李宁; 徐浩; 严家祥; 李钢强
Original assignee: 中车山东风电有限公司
Priority date: 2022-10-26
Filing date: 2023-10-24
Publication date: 2024-05-02
Also published as: CN115387970A; CN115387970B

Abstract

The present invention belongs to the technical field of generator set testing. Provided is a remote vibration testing system for a gearbox of a wind generator set. The system comprises a sensor group, a data collection instrument, an industrial control computer, a wireless router, a portable computer and a wind generator set, wherein hydraulic elastic supports are arranged at two sides of the wind generator set and are used for adjusting supporting pressure for torque arms of the wind generator set; the sensor group is used for collecting a vibration acceleration signal and a rotation speed signal of the wind generator set, transmitting same to the data collection instrument, and transmitting same to the industrial control computer after the data collection instrument performs signal processing on same; the industrial control computer performs processing and analysis on vibration data by means of vibration testing and analysis software; and the portable computer operates the vibration testing and analysis software by means of remote software, so as to perform processing and analysis on the vibration data. By means of the present invention, vibration test data of a gearbox can be remotely collected in real time when a wind generator set operates, and the influence of different elastic supporting pressures on the vibration of the gearbox is acquired by means of data analysis.

Description

A remote vibration test system for wind turbine gearbox

The present invention claims the priority of the Chinese patent application filed with the Chinese Patent Office on October 26, 2022, with application number 202211314396.8 and invention name “A remote vibration test system for the gearbox of a wind turbine generator set”, the entire contents of which are incorporated by reference into the present invention.

Technical Field

The invention relates to the technical field of generator set testing, and more particularly to a remote vibration testing system for a gearbox of a wind generator set.

Background technique

Wind turbines are located in remote areas with complex environmental conditions and variable working conditions. The gearbox is the main mechanical component for transmitting power. The existence of its internal rotating mechanism, the excitation generated by the shaft rotation and gear meshing, etc., causes vibration on the box body, which is one of the main excitation sources of wind turbine vibration. In order to reduce the impact of the gearbox housing vibration on the entire transmission chain, the elastic support structure is used to block the transmission of vibration energy and set appropriate damping to attenuate the vibration of the housing itself, thereby controlling the vibration transmission of the gearbox within the specified range and extending the service life of the wind turbine.

At present, there are three different elastic support methods according to the layout of the fan transmission chain: bearing type, stacked spring type and hydraulic type. The design of elastic support is generally based on the load of the fan to calculate the strength and stiffness to ensure that the elastic support has sufficient strength and stiffness, but the elastic support manufacturer will not consider the impact of the elastic support stiffness and strength on the gearbox or even the entire transmission chain, so it is necessary to study the impact of the elastic support on the gearbox vibration.

However, there are few studies on the effect of wind turbine elastic support on gearbox vibration, and most of them remain at During the theoretical analysis stage, although the influence of elastic support on the dynamic load characteristics of the wind turbine was studied from the perspective of simulation calculation, it was not possible to collect and analyze the gearbox vibration signal under different elastic support pressures from the perspective of wind field test vibration data.

Summary of the invention

In view of the problems existing in the prior art, the purpose of the present invention is to provide a remote vibration testing system for the gearbox of a wind turbine generator set, which realizes the remote and real-time collection of gearbox vibration test data when the wind turbine generator set is running, and ultimately obtains the influence of different elastic support pressures on the gearbox vibration through data analysis.

In order to achieve the above object, the present invention is implemented through the following technical solutions:

A remote vibration test system for a wind turbine gearbox includes: a sensor group, a data acquisition instrument, an industrial control computer, a wireless router, a portable computer and a wind turbine;

The data of the data acquisition instrument are respectively connected with the data of the sensor group and the industrial control computer, the industrial control computer is connected with the data of the wireless router, and the wireless router is connected with the data of the portable computer through the wireless network; hydraulic elastic supports are arranged on both sides of the wind turbine generator set for adjusting the torque arm support pressure of the wind turbine generator set; the sensor group is installed in the wind turbine generator set for collecting vibration acceleration signals and speed signals, transmitting them to the data acquisition instrument, and transmitting them to the industrial control computer after signal processing by the data acquisition instrument, and vibration test analysis software is deployed on the industrial control computer, and the industrial control computer processes and analyzes the vibration data through the vibration test analysis software, and the portable computer operates the vibration test analysis software through remote software to realize the remote collection of vibration test data of the gearbox of the wind turbine generator set, and the vibration data is processed and analyzed after the data is collected.

Furthermore, the wind turbine generator set includes: a wind rotor, a main shaft, a gear box and a generator. The gear box is provided with a planet carrier of a first-stage planet, a first-stage planet sun gear, a planet carrier of a second-stage planet, a second-stage planet sun gear, a high-speed parallel axis large gear shaft, and a high-speed parallel axis small gear shaft; the wind rotor is connected to the main shaft, and the main shaft is connected to the first-stage planet. The first-stage planetary sun gear is connected to the planetary carrier of the first-stage planet, the first-stage planetary sun gear is installed on the planetary carrier of the first-stage planet, the first-stage planetary sun gear is connected to the planetary carrier of the second-stage planet, the second-stage planetary sun gear is installed on the planetary carrier of the second-stage planet, the second-stage planetary sun gear is connected to the high-speed parallel shaft large gear shaft, the large gear on the high-speed parallel shaft large gear shaft is meshed with the small gear on the high-speed parallel shaft small gear shaft for transmission, and the high-speed parallel shaft small gear shaft is connected to the generator; torque arms are provided on both sides of the gearbox, and the hydraulic elastic support is installed on both sides of the gearbox through the torque arm, which is used to balance the torque load transmitted from the main shaft to the gearbox, so that the vibration of the gearbox is carried out within the range of the pre-compression amount of the hydraulic elastic support.

Furthermore, the sensor group includes: a first-level planetary radial low-frequency acceleration sensor, a second-level planetary radial low-frequency acceleration sensor, a high-speed parallel axis radial general frequency acceleration sensor, a high-speed parallel axis axial general frequency acceleration sensor and a photoelectric speed sensor; the first-level planetary radial low-frequency acceleration sensor is installed in the radial direction of the first-level planet, and the second-level planetary radial low-frequency acceleration sensor is installed in the radial direction of the second-level planet, for collecting planetary-level vibration acceleration signals; the high-speed parallel axis radial general frequency acceleration sensor is installed in the radial direction of the high-speed parallel axis downwind bearing in the gear box, and the high-speed parallel axis axial general frequency acceleration sensor is installed in the axial direction of the high-speed parallel axis downwind bearing in the gear box, for collecting high-speed parallel axis vibration acceleration signals; the photoelectric speed sensor is installed on the high-speed parallel axis pinion shaft for collecting the speed signal of the high-speed parallel axis pinion shaft.

Furthermore, the hydraulic elastic support includes an upper elastic body and a lower elastic body respectively arranged in a closed cavity, the upper elastic body and the lower elastic body are arranged from top to bottom, and one end of the torque arm is installed between the upper elastic body and the lower elastic body; the upper elastic body and the lower elastic body both adopt vibration-damping pads with a metal frame structure.

Furthermore, the system further comprises a first hydraulic oil pipe and a second hydraulic oil pipe, wherein the upper elastic body of the hydraulic elastic support on one side of the wind generator set is connected to the lower elastic body of the hydraulic elastic support on the other side of the wind generator set through the first hydraulic oil pipe, and the lower elastic body of the hydraulic elastic support on one side of the wind generator set is connected to the lower elastic body of the hydraulic elastic support on the other side of the wind generator set through the second hydraulic oil pipe. The hydraulic oil pipe is connected to the upper elastic body of the hydraulic elastic support on the other side of the wind turbine generator set.

Furthermore, both the upper elastic body and the lower elastic body are vibration-damping pads made of metal rubber vulcanizate.

Furthermore, the system also includes a 4G network card, which is installed in the wireless router to connect to the industrial control computer and provide a wireless network signal.

Furthermore, the data acquisition instrument has 16 built-in 24-bit AD acquisition channels for receiving vibration and speed signals transmitted by the sensor group and connected to the industrial control computer through the Ethernet port.

Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention provides a remote vibration test system for the gearbox of a wind turbine generator set, in which the vibration signal collected by the sensor group is transmitted to the data acquisition instrument, and then transmitted to the industrial control computer after signal processing by the data acquisition instrument, and the vibration test analysis software is deployed on the industrial control computer, and the 4G network card is inserted into the wireless router to provide network signals for the industrial control computer. The portable computer operates the vibration test analysis software through remote software to realize the remote collection of the gearbox vibration test data, and performs remote post-processing and analysis on the vibration data after the data is collected. Engineers perform time domain analysis, frequency domain analysis, inverse spectrum analysis, envelope spectrum analysis and time-frequency domain analysis through the vibration test analysis software, and finally obtain the influence of different elastic support pressures on the gearbox vibration.

It can be seen that compared with the prior art, the present invention has outstanding substantive features and significant progress, and the beneficial effects of its implementation are also obvious.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

FIG. 1 is a system structure diagram of a specific implementation mode of the present invention.

FIG. 2 is a schematic structural diagram of a wind turbine generator set according to a specific embodiment of the present invention.

FIG. 3 is a schematic structural diagram of a hydraulic elastic support according to a specific embodiment of the present invention.

Explanation of the reference numerals: 1. wind wheel, 2. main shaft, 3. planet carrier of the first-stage planet, 4. first-stage planet sun gear, 5. planet carrier of the second-stage planet, 6. second-stage planet sun gear, 7. high-speed parallel axis large gear shaft, 8. high-speed parallel axis small gear shaft, 9. generator, 10. torque arm, 11. hydraulic elastic support, 12. first-stage planet radial low-frequency acceleration sensor, 13. second-stage planet radial low-frequency acceleration sensor, 14. high-speed parallel axis radial general frequency acceleration sensor, 15. high-speed parallel axis axial general frequency acceleration sensor, 16. photoelectric speed sensor, 17. upper elastic body, 18. lower elastic body, 19. first hydraulic oil pipe, 20. second hydraulic oil pipe, 21. gear box.

Detailed ways

The specific implementation of the present invention is described below with reference to the accompanying drawings.

A remote vibration test system for a wind turbine gearbox as shown in FIG1 includes: a sensor group, a data acquisition instrument, an industrial control computer, a wireless router, a 4G network card, a portable computer and a wind turbine.

The data acquisition instrument is connected to the sensor group and the industrial control computer respectively, the industrial control computer is connected to the wireless router, and the wireless router is connected to the portable computer through the wireless network. The 4G network card is installed in the wireless router to connect to the industrial control computer and provide wireless network signals. The data acquisition instrument has 16 built-in 24-bit AD acquisition channels to receive the vibration and speed signals transmitted by the sensor group and connect to the industrial control computer through the Ethernet port.

Hydraulic elastic supports are provided on both sides of the wind turbine generator set to adjust the torque arm support pressure on the wind turbine generator set;

The sensor group is installed in the wind turbine generator set to collect vibration acceleration signals and speed signals. The vibration data is transmitted to the data acquisition instrument, and then transmitted to the industrial control computer after signal processing by the data acquisition instrument. The industrial control computer is equipped with vibration test analysis software. The industrial control computer processes and analyzes the vibration data through the vibration test analysis software. The portable computer operates the vibration test analysis software through remote software to realize the remote collection of the vibration test data of the gearbox of the wind turbine generator set. After the data is collected, the vibration data is processed and analyzed.

As shown in Figure 2, the wind turbine generator set includes: a wind wheel 1, a main shaft 2, a gear box 21 and a generator 9. The gear box 21 is provided with a planet carrier 3 of a first-level planet, a first-level planet sun gear 4, a planet carrier 5 of a second-level planet, a second-level planet sun gear 6, a high-speed parallel axis large gear shaft 7, and a high-speed parallel axis pinion shaft 8; the wind wheel 1 is connected to the main shaft 2, the main shaft 2 is connected to the planet carrier 3 of the first-level planet, the first-level planet sun gear 4 is installed on the planet carrier 3 of the first-level planet, the first-level planet sun gear 4 is connected to the planet carrier 5 of the second-level planet, the second-level planet sun gear 6 is installed on the planet carrier 5 of the second-level planet, the second-level planet sun gear 6 is connected to the high-speed parallel axis large gear shaft 7, the large gear on the high-speed parallel axis large gear shaft 7 is meshed with the small gear on the high-speed parallel axis small gear shaft 8 for transmission, and the high-speed parallel axis small gear shaft 8 is connected to the generator 9.

Torque arms 10 are provided on both sides of the gear box 21, and hydraulic elastic supports 11 are installed on both sides of the gear box 21 through the torque arms 10, which are used to balance the torque load transmitted from the main shaft to the gear box 21, so that the gear box 21 vibrates within the range of the pre-compression amount of the hydraulic elastic supports 11.

The sensor group includes: a first-stage planetary radial low-frequency acceleration sensor 12, a second-stage planetary radial low-frequency acceleration sensor 13, a high-speed parallel axis radial general-frequency acceleration sensor 14, a high-speed parallel axis axial general-frequency acceleration sensor 15 and a photoelectric speed sensor 16. The first-stage planetary radial low-frequency acceleration sensor 12 is installed in the radial direction of the first-stage planetary carrier 3, and the second-stage planetary radial low-frequency acceleration sensor 13 is installed in the radial direction of the second-stage planetary carrier 5, for collecting planetary vibration acceleration signals; the high-speed parallel axis radial general-frequency acceleration sensor 14 is installed in the radial direction of the high-speed parallel axis downwind bearing in the gear box 21. The high-speed parallel shaft axial general frequency acceleration sensor 15 is installed in the axial direction of the high-speed parallel shaft downwind bearing in the gear box 21, and is used to collect the high-speed parallel shaft vibration acceleration signal; the photoelectric speed sensor 16 is installed on the high-speed parallel shaft pinion shaft 8, and is used to collect the speed signal of the high-speed parallel shaft pinion shaft 8.

As an example, as shown in Figure 3, the hydraulic elastic support 11 includes an upper elastomer 17 and a lower elastomer 18 respectively arranged in a closed cavity, the upper elastomer 17 and the lower elastomer 18 are arranged from top to bottom, and one end of the torque arm 10 is installed between the upper elastomer 17 and the lower elastomer 18; the upper elastomer 17 and the lower elastomer 18 both adopt vibration-damping pads with a metal frame structure.

In addition, the two hydraulic elastic supports 11 are connected by a first hydraulic oil pipe 19 and a second hydraulic oil pipe 20. Among them, the upper elastic body 17 of the hydraulic elastic support 11 on one side of the wind turbine generator set is connected to the lower elastic body 18 of the hydraulic elastic support 11 on the other side of the wind turbine generator set through the first hydraulic oil pipe 19, and the lower elastic body 18 of the hydraulic elastic support 11 on one side of the wind turbine generator set is connected to the upper elastic body 17 of the hydraulic elastic support 11 on the other side of the wind turbine generator set through the second hydraulic oil pipe. When the gearbox 21 vibrates, the volume of the cavity of the hydraulic elastic support 11 changes due to external force, and the hydraulic pressure in the cavity flows, and the liquid flowing up and down generates damping, blocking and consuming the energy generated by the vibration, thereby achieving a vibration reduction effect; by adjusting the elastic support pressure, the vibration test data of the planetary stage and high-speed parallel axis of the gearbox that changes with the pressure are collected.

When the system is running, first adjust the five working conditions of the hydraulic elastic support 11 pressure, namely: the first hydraulic oil pipe pressure value 0bar, the second hydraulic oil pipe pressure value 0bar; the first hydraulic oil pipe pressure value 60bar, the second hydraulic oil pipe pressure value 60bar; the first hydraulic oil pipe pressure value 0bar, the second hydraulic oil pipe pressure value 120bar; the first hydraulic oil pipe pressure value 120bar, the second hydraulic oil pipe pressure value 0bar; the first hydraulic oil pipe pressure value 120bar, the second hydraulic oil pipe pressure value 120bar; then the vibration signal collected by the sensor group is transmitted to the data acquisition instrument, and then transmitted to the industrial control computer after signal processing by the data acquisition instrument. The vibration test analysis software is deployed on the industrial control computer, and the 4G network card is inserted into the wireless router to provide network signals for the industrial control computer. The portable computer operates the vibration test analysis software through the remote software; finally, the remote collection of gearbox vibration test data is realized, and the vibration data is remotely post-processed and analyzed after the data is collected. The specific analysis process is as follows:

According to the VDI3834 standard, the time domain analysis is performed on the collected gearbox vibration data. The main parameter indicators include maximum value, mean, variance, waveform, pulse, margin, kurtosis and other indicators. The characteristics of the data can be reflected by these indicators. At the same time, they can be used to determine whether the vibration of the gearbox is out of limit during operation, and more intuitively reflect the early signal characteristics; frequency domain analysis, frequency domain analysis converts time domain signals into frequency domain signals through Fourier transform, calculates the speed frequency of the gearbox shaft system and the gear meshing frequency, analyzes the variation range of characteristic frequencies, and can determine the type, degree and occurrence location of the vibration signal; inverse spectrum analysis, the logarithmic spectrum of the vibration signal is Fourier transformed again to extract the frequency components contained in the signal spectrum. Periodic components, such as local faults in gears, will produce a large number of sideband frequency components; envelope spectrum analysis, the envelope spectrum is sensitive to signals related to impact force, and will extract weak signals submerged in background noise, extract periodic impact signals with small amplitude, and then perform spectrum analysis on the signal; time-frequency domain analysis, when the time domain and frequency domain indicators cannot effectively evaluate the nonlinear and non-stationary signals of the gearbox, the time-frequency domain analysis is used to achieve multi-scale analysis of the entire signal and local details, with good time-frequency resolution, and is used in gearbox characteristic frequency separation, weak signal extraction and early vibration signal evaluation. Through the above analysis, the influence of different elastic support pressures on the gearbox vibration is finally obtained.

In conjunction with the accompanying drawings and specific embodiments, the present invention will be further described. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art may make various changes or modifications to the present invention, and these equivalent forms also fall within the scope limited by the application.

Claims

A remote vibration test system for a gearbox of a wind turbine generator set, characterized in that it comprises: a sensor group, a data acquisition instrument, an industrial control computer, a wireless router, a portable computer and a wind turbine generator set;

The data of the data acquisition instrument is connected with the sensor group and the industrial control computer respectively, the industrial control computer is connected with the wireless router, and the wireless router is connected with the portable computer through the wireless network;

Hydraulic elastic supports are provided on both sides of the wind turbine generator set to adjust the torque arm support pressure on the wind turbine generator set;

The sensor group is installed in the wind turbine generator set to collect vibration acceleration signals and speed signals, transmit them to the data acquisition instrument, and transmit them to the industrial control computer after signal processing by the data acquisition instrument. The industrial control computer processes and analyzes the vibration data through the vibration test analysis software. The portable computer operates the vibration test analysis software through the remote software to realize the remote collection of the vibration test data of the gear box of the wind turbine generator set. After the data is collected, the vibration data is processed and analyzed.

The wind turbine generator set comprises: a wind wheel, a main shaft, a gear box and a generator. The gear box is provided with a planet carrier of a first-level planet, a first-level planet sun gear, a planet carrier of a second-level planet, a second-level planet sun gear, a high-speed parallel axis large gear shaft and a high-speed parallel axis small gear shaft; the wind wheel is connected to the main shaft, the main shaft is connected to the planet carrier of the first-level planet, the first-level planet sun gear is mounted on the planet carrier of the first-level planet, the first-level planet sun gear is connected to the planet carrier of the second-level planet, the second-level planet sun gear is mounted on the planet carrier of the second-level planet, the second-level planet sun gear is connected to the high-speed parallel axis large gear shaft, the large gear on the high-speed parallel axis large gear shaft is meshed with the small gear on the high-speed parallel axis small gear shaft for transmission, and the high-speed parallel axis small gear shaft is connected to the generator;

Torque arms are provided on both sides of the gearbox. The hydraulic elastic supports are installed on both sides of the gearbox through the torque arms to balance the torque load transmitted from the main shaft to the gearbox, so that the gearbox vibration is pre-compressed by the hydraulic elastic supports. within the scope of quantity;

The sensor group includes: a first-level planetary radial low-frequency acceleration sensor, a second-level planetary radial low-frequency acceleration sensor, a high-speed parallel-axis radial general-frequency acceleration sensor, a high-speed parallel-axis axial general-frequency acceleration sensor and a photoelectric rotation speed sensor;

The first-stage planetary radial low-frequency acceleration sensor is installed in the radial direction of the first-stage planet.

The secondary planetary radial low-frequency acceleration sensor is installed in the radial direction of the secondary planet to collect planetary-level vibration acceleration signals;

The high-speed parallel shaft radial general frequency acceleration sensor is installed in the radial direction of the high-speed parallel shaft downwind bearing in the gear box, and the high-speed parallel shaft axial general frequency acceleration sensor is installed in the axial direction of the high-speed parallel shaft downwind bearing in the gear box, which is used to collect the high-speed parallel shaft vibration acceleration signal;

The photoelectric speed sensor is installed on the high-speed parallel shaft pinion shaft and is used to collect the speed signal of the high-speed parallel shaft pinion shaft.
According to claim 1, the remote vibration test system for the gearbox of a wind turbine generator set is characterized in that the hydraulic elastic support includes an upper elastic body and a lower elastic body respectively arranged in a closed cavity, the upper elastic body and the lower elastic body are arranged from top to bottom, and one end of the torque arm is installed between the upper elastic body and the lower elastic body; the upper elastic body and the lower elastic body both adopt vibration-damping pads with a metal frame structure.
According to claim 2, the remote vibration test system for the gearbox of a wind turbine generator set is characterized in that a first hydraulic oil pipe and a second hydraulic oil pipe are also provided on the hydraulic elastic support, and the upper elastic body of the hydraulic elastic support on one side of the wind turbine generator set is connected to the lower elastic body of the hydraulic elastic support on the other side of the wind turbine generator set through the first hydraulic oil pipe, and the lower elastic body of the hydraulic elastic support on one side of the wind turbine generator set is connected to the upper elastic body of the hydraulic elastic support on the other side of the wind turbine generator set through the second hydraulic oil pipe.
The remote vibration test system for the gearbox of a wind turbine generator set according to claim 3 is characterized in that The invention is that both the upper elastic body and the lower elastic body are vibration-damping pads made of metal rubber vulcanizate.
The remote vibration test system for a wind turbine gearbox according to claim 1 is characterized in that the system further comprises a 4G network card, which is installed in a wireless router and is used to connect to an industrial control computer and provide a wireless network signal.
The wind turbine gearbox remote vibration test system according to claim 1 is characterized in that the data acquisition instrument has built-in 16 24-bit AD acquisition channels for receiving vibration and speed signals transmitted by the sensor group and connected to the industrial control computer through an Ethernet port.