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wind turbine testing in the NREL dynamometer test bed.pdf

5MW风电齿轮增速箱设计 (一级行星轮系)【7张CAD图纸和说明书】

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关键词：: 5MW风电齿轮增速箱设计 (一级行星轮系)【7张CAD图纸和说明书】 mw 齿轮增速设计一级行星 cad 图纸以及说明书仿单

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摘要

风电产业的飞速发展促成了风电装备制造业的繁荣，风电齿轮箱作为风电机组的核心部件，倍受国内外风电相关行业和研究机构的关注。但由于国内风电齿轮箱的研究起步较晚，技术薄弱，特别是兆瓦级风电齿轮箱，主要依靠引进国外技术。因此，急需对兆瓦级风电齿轮箱进行自主开发研究，真正掌握风电齿轮箱设计制造技术，以实现风机国产化目标。

本文设计的是兆瓦级风力发电机组的齿轮箱，通过方案的选取，齿轮参数计算等对其配套的齿轮箱进行自主设计。

首先，确定齿轮箱的机械结构。选取一级行星派生型传动方案，通过计算，确定各级传动的齿轮参数。对行星齿轮传动进行受力分析，得出各级齿轮受力结果。依据标准进行静强度校核，结果符合安全要求。

最后，对齿轮传动系统进行了齿面接触应力计算，结果符合要求。

关键词：风力发电，风机齿轮箱，结构设计，

Abstract

The rapid development of wind power industry lead to the prosperity of wind power equipment manufacturing industry．As the core component of wind turbine，the gearbox is received much concern from related industries and research institution both at home and abroad．However, due to the domestic research of gearbox for wind turbine starts late，technology is weak，especially in the gearbox for MW wind turbine，which mainly relied on the introduction of foreign technology．Therefore，it is urgent need to carry out independent development and research on MW wind power gearbox，and truly master the design and manufacturing technology in order to achieve the goal of localization．

This paper takes the wind power。The independent design of the gearbox matching for the wind turbine has been carried out by selecting the transmission scheme and calculating the gear parameters。

Firstly, the mechanical structure of gearbox is determined．The two-stage derivation planetary transmission scheme is selected．The gear parameters of every stage transmission is calculated．，and the force analysis results is obtained．The static strength check of tooth surface contact is implemented according to related standard．The result shows that it is accord with safety requirements．

Secondly, the helical gear parametric model is established based on involutes curve equation and generation theory of spiral line by using the function of parametric modeling in Pro／E．

Then, the tooth surface contact stress of the gear transmission is calculated．

Key Words：the wind power ，Gearbox for Wind Turbine；Structure Design；Parametric Modeling

Abstract ii

1.引言 - 1 -

1.1课题来源 - 1 -

1.2国内外发展现状与趋势 - 2 -

1.2.1风力发电国内外发展现状 - 2 -

1.2.2风电齿轮箱的发展趋势 - 5 -

1.2.3存在的问题及展望 - 5 -

1.3课题意义 - 6 -

1.4论文的主要内容及设计要求 - 7 -

1.5设计标准 - 7 -

2.齿轮箱的设计 - 8 -

2.1 增速齿轮箱方案设计 - 8 -

2.2齿轮参数确定 - 12 -

2.2.1行星轮系的齿轮参数 - 12 -

2.2.2圆柱级齿轮参数 - 16 -

2.3受力分析与静强度校核 - 17 -

2.3.1受力分析 - 17 -

2.3.2低速级外啮合齿面静强度计算 - 21 -

2.4本章小结 - 25 -

3.传动轴和箱体的设计 - 26 -

3.1高速轴的设计 - 26 -

3.2低速轴的设计 - 26 -

3.3中间轴的设计 - 28 -

3.4箱体 - 29 -

4齿轮箱及其他部件的设计 - 30 -

4.1齿轮箱的密封 - 30 -

4.2齿轮箱的润滑、冷却 - 30 -

4.3轴系部件的结构设计 - 31 -

4.4行星架的结构设计 - 32 -

4.5传动齿轮箱箱体设计 - 32 -

5齿轮箱的使用及其维护 - 33 -

5.1安装要求 - 33 -

5.2定期更换润滑油 - 33 -

5.3齿轮箱常见故障 - 33 -

5.3.1齿轮损伤 - 34 -

5.3.2轴承损坏 - 34 -

5.3.3断轴 - 35 -

5.3.4油温高 - 35 -

心得体会 - 36 -

致谢 - 37 -

参考文献 - 38 -

1.引言

1.1课题来源

风是一种潜力很大的新能源，十八世纪初，横扫英法两国的一次狂暴大风，吹毁了四百座风力磨坊、八百座房屋、一百座教堂、四百多条帆船，并有数千人受到伤害，二十五万株大树连根拔起。仅就拔树一事而论，风在数秒钟内就发出了一千万马力(即750万千瓦；一马力等于0．75千瓦)的功率!有人估计过，地球上可用来发电的风力资源约有100亿千瓦，几乎是现在全世界水力发电量的10倍。目前全世界每年燃烧煤所获得的能量，只有风力在一年内所提供能量的三分之一。因此，国内外都很重视利用风力来发电，开发新能源。

近10年风力发电增长迅猛，200年以来，全球每年风电装机容量增长速度为 20%～30%。全球风能协会发布最新一期全球风电的增长数据显示， 2008年全球范围内新增风电装机容量 2 705万 kW，使得全球风电装机容量达到 1 . 20亿 kW，较 2007年增长 28 . 8%。 1998～2008年全球风电装机容量的增长情况。如图 1所示。

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内容简介：: Wind Turbine Testing in theNREL Dynamometer Test BedJune 2000 NREL/CP-500-28411Walt MusialNational Renewable Energy LaboratoryBrian McNiffMcNiff Light IndustryPresented at AWEAs WindPower 2000 ConferencePalm Springs, CaliforniaApril 30May 4, 2000National Renewable Energy Laboratory1617 Cole BoulevardGolden, Colorado 80401-3393NREL is a U.S. Department of Energy LaboratoryOperated by Midwest Research Institute Battelle BechtelContract No. DE-AC36-99-GO10337NOTICEThe submitted manuscript has been offered by an employee of the Midwest Research Institute (MRI), acontractor of the US Government under Contract No. DE-AC36-99GO10337. Accordingly, the USGovernment and MRI retain a nonexclusive royalty-free license to publish or reproduce the publishedform of this contribution, or allow others to do so, for US Government purposes.This report was prepared as an account of work sponsored by an agency of the United Statesgovernment. Neither the United States government nor any agency thereof, nor any of their employees,makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy,completeness, or usefulness of any information, apparatus, product, or process disclosed, or representsthat its use would not infringe privately owned rights. Reference herein to any specific commercialproduct, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarilyconstitute or imply its endorsement, recommendation, or favoring by the United States government or anyagency thereof. The views and opinions of authors expressed herein do not necessarily state or reflectthose of the United States government or any agency thereof.Available electronically at /bridgeAvailable for a processing fee to U.S. Department of Energyand its contractors, in paper, from:U.S. Department of EnergyOffice of Scientific and Technical InformationP.O. Box 62Oak Ridge, TN 37831-0062phone: 865.576.8401fax: 865.576.5728email: reportsAvailable for sale to the public, in paper, from:U.S. Department of CommerceNational Technical Information Service5285 Port Royal RoadSpringfield, VA 22161phone: 800.553.6847fax: 703.605.6900email: ordersonline ordering: /ordering.htmPrinted on paper containing at least 50% wastepaper, including 20% postconsumer waste1WIND TURBINE TESTING IN THE NREL DYNAMOMETER TEST BEDWalt MusialNational Wind Technology CenterNational Renewable Energy Laboratory1617 Cole BoulevardGolden, CO 80401Brian McNiffMcNiff Light Industry43 Dog Island RoadHarborside, ME 04642ABSTRACTA new facility has recently been completed at the National Renewable Energy Laboratory that allowsfull-scale dynamometer testing of wind turbine components, from generators to complete wind turbines.This facility is equipped with a 2.5 MW motor, gearbox, and variable speed drive system to deliver shafttorque. To simulate other aspects of wind turbine loading an MTS fatigue-rated loading system is fullyintegrated into the facility. This will allow actuators to cyclically load the structure in a variety of ways.Enron formally Zond Wind Corporation has installed the first test article in the facility to help maturethe Z-750 series wind turbine design. Tests include brake and control system tuning, endurance testing ofgear elements and bearings, and structural testing. Some aspects of the power converter will also betested. This paper describes the Dynamometer Test Bed and its capabilities. Also, an overview of theZond testing program is presented.INTRODUCTIONWind turbine systems have grown larger during the past decade. Although the cost of wind energycontinues to decrease, the per-turbine costs have increased making the empirical approach of prototypefield-testing increasingly risky. For new turbine designs, megawatt scale prototypes are expensive tobuild and long, single-unit production lead times consume the margins of production schedules. With thetypical rush from prototype to production, manufacturers often identify field problems too late to becorrected before large volume manufacturing runs are started. This can lead to premature field failuresand costly retrofits.Wind turbine drive problems are well-documented and may include gearbox failures and wear, bearinglife issues, generator failures, and controller induced system failures.1-3 Problems might arise duringinitial start-up, under extreme wind conditions, or may be related to long-term operation. In any case, thetime to find and solve these problems is when the first units are tested.For years, turbine manufacturers have relied on laboratory testing critical components, such as the rotorblades, to reduce their potential exposure to catastrophic field events.4 Until now they have not hadaccess to facilities capable of testing the whole turbine drive system, which is at the core of every turbinedesign.2At the National Renewable Energy Laboratory (NREL) a new Dynamometer Test Bed(DTB) was built totest wind turbine drive train systems and components. Born from industry requests, this new facility coulddramatically alter the approach to evaluating new wind turbine systems. It is now being used to verify thedrive train design of the Enron formally Zond Wind Corporations Z-750 turbine system.FACILITY DESCRIPTIONGeneral DescriptionThe DTB is located at NRELs National Wind Technology Center (NWTC) and is dedicated to testingwind turbine drive systems. These are normally comprised of some combination of gears, couplings,bearings, shafts, lubricant systems, gearboxes, generators, controllers, and power conversion systems.The size of the systems that can be tested range from 100 kW to 2.5 MW.The dynamometers prime mover is a variable-torque, variable-speed motor that is controlled by avariable frequency drive system. This 4160 VAC motor is coupled to a 2.5 MW, three-stage epicyclicgearbox. Test articles can be connected to the motor high-speed shaft, the low speed shaft of the gearbox,or an intermediate shaft depending on the speed and torque requirements.TABLE 1 - DYNAMOMETER SHAFT OUTPUT RANGESLocation Ratio toMotorMax Speed(rpm)Max Power(kW)Speed at MaxPower (rpm)Low Speed Shaft 51.38:1 43.5 2500 23Intermediate 15.4:1 146 2500 78High Speed 1:1 2250 2500 1200Table 1 shows the operational capabilities at each shaft. System control logic allows the torque and speedto be continuously varied via manual operator command signals or in an automated manner bySupervisory Control and Data Acquisition (SCADA) command.Figure 1 shows the two operating envelopes, one for each drive shaft option, and a practical wind turbinedesign limit curve that was used to guide the dynamometer design. A representative group of actual windturbine designs (existing or planned) are represented as data points on this figure. These data are plottedbased on their rated output multiplied by a factor of between 1.3 and 1.7. This represents the approximatescaling factors that would be required to accelerate a full lifetime of operation into a few months ofcontinuous operation during an endurance test.The drive motor and gearbox assembly is mounted to a 169-kN (38-ton) elevating drive table that has avertical adjustment span of 3.05-m (10-ft), with tilting capabilities from 0 to 6 degrees. A 1.52-m (5-ft)deep pocket under the drive table allows the top of the table to be lowered 0.61-m (2-ft) in below gradelevel. This range will accommodate shaft elevations of up to 3.05-m (10 ft). Vertical table motion is3Zond Z-75001000200030000.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00Dynamometer Output Shaft Speed (RPM)Power(kW)Intermediate ShaftLow Speed ShaftTurbine Endurance TestsPractical Design EnvelopeFIGURE 1 NRELS 2.5 MW DYNAMOMETER OPERATING ENVELOPEactuated using four 222-kN (50-ton) motorized screw jacks that are located at each corner of the table.The screw jacks are operated in front and back pairs with an absolute position accuracy of .25-mm(0.010-in). This fine adjustment capability was built into the system to allow precise alignment betweenthe drive system shafts and the test article shaft. When the proper table position is reached, the table isfastened to the vertical faces of two reaction walls on either side of the drive table. This connection ismade using 10 steel angle brackets that bolt through the drive table and attach to vertical T-slots that aremachined into steel plates mounted to the wall.The table motion is controlled by a programmable logic controller (PLC) that receives exact positioninformation from absolute position encoders located at each jackscrew. This information is translatedinto shaft position and angles by the PLC.The facility is equipped with a 222-kN (50-ton) electric overhead bridge crane that runs the length of the27.4-m (90-ft) test bay. The crane is pendant controlled with multiple speed capabilities.All test articles are mechanically coupled to one of the three shafts in the drive system. Test articles canbe mounted to slotted base plates imbedded in the floor of the south end of the facility or to a grid ofimbedded fasteners north and south of the reaction walls.4FIGURE 2 NRELS 2.5 MW DYNAMOMETER POWER LOOPFigure 2 shows a schematic layout of the power loop for the DTB. Shaft power is typically convertedback to electrical energy by the test article and regenerated back into the NWTC power grid at either 480volts or 4160 volts, where it is reused by the dynamometer. Only the power losses of the drive systemneed to be added locally at the PMH-10 junction outside the facility to keep the system running at steadystate. Figure 3 shows a photo of the DTB.Shaft Bending LoadsMost of the loading experienced by a wind turbine is introduced by wind forces at the mainshaft in theform of shaft torsion and bending. Although numerous dynamic, aerodynamic, and inertial effectscombine to create the various load cases, each of the cases can usually be reduced to the torsional andbending reactions at the mainshaft/hub interface. Shaft torsion alone is often sufficient when testing thegear teeth of a given design. However, if a test of the gear case, bearings, shafts, bedplate, yaw support,or couplings is desired, additional shaft bending loads must be applied. The dynamometer drive producesthe torsional input, but the bending loads must be applied by side-loading the jack-shaft system.In the NREL dynamometer, shaft bending is applied using a servo-hydraulic system, with an actuatorcapable of delivering up to 110 kips. Using the hydraulic actuator system, shaft-bending loads can besynchronized with the rotation of the turbine shaft to give periodic, per-rev shaft loading, representativeof true field conditions.5FIGURE 3 PHOTO OF 2.5 MW DYNAMOMETERRegenerative PowerDuring in-field transient conditions the components of a wind turbine drive system are either acceleratingor decelerating. For a true simulation of the operating wind turbine the inertia and stiffness of thedynamometers rotating components should match the rotor system of the test article. This is not easy todo since these properties are fixed in the dynamometers design. However, inertia matching can beachieved by increasing or decreasing the dynamometer drive power under closed-loop torque control tomimic expected acceleration rates for representative rotor mass properties during rotational speedchanges. Stiffness matching may be done by clever jack-shaft design.Torque Versus Speed ControlThe dynamometer drive can be operated under either torque control or speed control. In speed controlmode, the dynamometer can be operated using a manual throttle control dial, or it can be driven throughthe SCADA system according to a prescribed speed time-history. This mode has been useful for testingthe Z-750 variable speed system. However, speed control may not be as useful when testing a fixed speedinduction or synchronous turbine system, or when inertial effects are critical.6Torque control mode has not been fully implemented yet, but it may prove to be more useful forgenerating a fixed power output or for generating a variable torque load on constant speed generators.Transient load testing will require torque control to balance the rotating inertia. The ultimate goal is tomake the dynamometer behave like the wind, and force the test articles control system to respond in realtime to random turbulent fluctuations. Under closed-loop control, a random wind time history such asSNLWIND3D 5 will be used to compute real-time torque values through a simple Cpversus G0 (powercoefficient versus tip-speed-ratio) transfer function, or through a more complex aerodynamics code suchas AeroDyn 6. Turbine responses would be monitored to assess proper controller function.TYPES OF TESTSThe primary advantage of dynamometer testing is that loads to the test turbine can be controlled. Thetypes of testing are divided into wind turbine system tests and component tests. In most cases, one mustinstall a representative drivetrain of the wind turbine to be tested to transmit the loads from thedynamometer. Some of the different types of testing that may be conducted are described below, but theauthors do not presume that this is an exhaustive list.Wind Turbine System TestsDrivetrain Endurance Testing - Endurance testing is done to demonstrate the fatigue life of a particulardrive system to ensure that it can survive its full operating life. Endurance testing will involve 3 to 6months of continuous operation at elevated loads, combined with the application of the significanttransient load cases that are part of long-term operating spectrum. Transverse shaft loads are applied tosimulate actual operating rotor bending loads that can influence the tooth contact stresses, and the fatiguelife of bearings, shafts, and housings. Such testing requires high, steady-state power levels that vary from1.3 to 1.7 times the rated capacity of the test article.Turbulent Wind Simulation Testing - This type of testing can demonstrate the proper operation of theturbines systems under design conditions. Operating the dynamometer under closed-loop torque control,random wind turbulence data are converted into shaft torque by a computer algorithm using feedbackfrom the turbines own control system. Severe stochastic torque conditions can be simulated demandingthat the turbine control system perform at its operational limits under all conditions.Load Event Testing - This type of testing allows measuring the turbine system response under extremeoperating events. Transient torsion and bending loads are applied to the drive train system to simulate thetrue field environment. System inertia can be matched by using the regenerative power system of theelectric variable speed drive. Transverse bending loads can be applied to drive shafts, bearing housings,or yaw systems to recreate specific design load cases. This type of testing also includes self-induced loadsthat arise from the test turbines own components and do not enter through the rotor system. Examples ofself-induced loads are brake system tests, generator failures and grid faults, and normal generatortransients.7Component TestingTesting of individual turbine components is commonly the focus of testing versus the evaluation of awhole system. The dynamometer can be used for qualifying and optimizing various other componentsprior to field installation or retrofit. Tests can be conducted on gears, shafts, housings, bearings,generators, isolated control systems, brakes, or power electronics components, with or without arepresentative drive train assembly.Gearbox Testing - Gearboxes have been the source of widespread field failure throughout the windindustry. It is often necessary to test, evaluate, and optimize the individual effects of operation on thegearbox sub-components to increase life or decrease turbine cost. 7 Some gear tests include: evaluating and mitigating gear tooth loads, evaluating and mitigating tooth wear mechanisms, optimizing gear lubricant properties, optimizing oil system levels, temperatures, and filtration, gear case stress measurements, bearing life testing, and evaluating proper tooth meshing under specific loads to establish optimum lead and profilemodifications.Generators The generator is a critical part of the drivetrain system. It contributes significantly to themechanical loads generated in the entire driveline both in normal operation and when faulted. Thegenerator performance under a range of conditions can be isolated and tested on the dynamometer. Somegenerator tests include: evaluating electrical characteristics and fault settings, evaluating bearing and winding temperatures, measuring torque-speed characteristics, determining breakaway torque and extreme operating performance, determining system efficiencies, and measuring transient response characteristics.Control systems can also be tuned and evaluated during this process. This can be done on high or low-speed (direct-drive) generators. To accommodate direct-drive generators that may have oversized radialdimensions, the dynamometer test bay has a pit built into the test section floor. In these instances, part ofthe generator may be mounted in the pit below the surface of the test bay floor to allow proper heightmatching with the dynamometer output shafts.Z-750 TEST PROGRAMZ-750 BackgroundUnder the cost-shared U.S. Department of Energy (DOE)/NREL sponsored Near-term Research andTesting subcontract, Zond has endeavored to reduce fabrication and installation costs of the Z-750 serieswind turbine through value-engineering methods. To support that activity, NREL has installed a fully8configured Z-750 wind turbine in the DTB to evaluate measures for reducing costs while maintaininghigh quality and the ability to tolerate the various operational and design loads. The components wefocused on in this test program include the gear-case, all gear elements, shafts

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