Five-degree-of-freedom wind driven generator main bearing test bench for simulating real working conditions

Abstract

The invention belongs to the technical field of wind driven generator main bearing test equipment, and discloses a five-degree-of-freedom wind driven generator main bearing test bench for simulating real working conditions, which comprises a loading system, a test system and a driving system. The loading system adopts a sliding bearing loading disc to simulate a hub of the wind driven generator, and adopts a hydraulic cylinder array to simulate five-degree-of-freedom hub loads of three-direction forces including axial force, radial force and vertical force and two-direction moments including pitching moment and yawing moment. The test system adopts a two-point supported tapered roller bearing main shaft system to simulate the main shaft configuration of the wind driven generator, and can be independently disassembled to replace the model of a test bearing. The driving system adopts a variable-frequency and variable-speed motor, the rotating speed range is 0-200 rpm, and the requirements of various working conditions such as frequent start and stop, performance tests and strengthening tests can be met. According to the invention, through multi-dimensional load loading and multi-working-condition simulation, a key platform is provided for reliability test and failure mechanism research of the wind power main bearing.

Description

Technical Field

[0001] The invention belongs to the technical field of wind turbine main bearing test equipment and relates to a five-degree-of-freedom wind turbine main bearing test bench capable of simulating real working conditions. Background Art

[0002] Amidst the global energy transition, wind power, thanks to its abundant resources, widespread distribution, and environmentally friendly nature, has become one of the most mature forms of renewable energy generation. As a core component of wind turbines, main bearings play a crucial role in supporting the rotor and transmitting torque and load. With the continuous expansion of the wind power industry, increasingly stringent requirements are being placed on the performance, reliability, and lifespan of wind turbine main bearings. To gain a deeper understanding of main bearing performance under actual operating conditions, the development of an efficient and reliable wind turbine main bearing test bench is crucial.

[0003] At present, there is still a certain gap between China and the international advanced level in terms of wind turbine main bearing testing technology and equipment research and development. There is a lack of high-end testing equipment with independent intellectual property rights, and most test benches are low-end yaw and pitch bearing test benches. In addition, most test benches can only simulate a single or limited load and operating conditions, making it difficult to truly and comprehensively reflect the stress state and working characteristics of the main bearing in the complex and changeable actual operating environment, resulting in limited reliability and validity of the test results. In addition, existing test benches generally do not simulate the actual mechanical structure of the wind turbine main shaft system. The loading position is mostly located on the main bearing rather than the hub, which makes the stress pattern, dynamic response and operating state of the main bearing in the test significantly different from the actual situation. The test data is difficult to accurately reflect the working performance of the main bearing in the wind power system. Summary of the Invention

[0004] The present invention aims to provide a five-degree-of-freedom wind turbine main bearing test bench that simulates real working conditions. Through a multi-degree-of-freedom loading system, modular structural design, and working condition simulation methods, it can achieve high-precision simulation of the mechanical environment and working state of the main bearing in actual operation, providing a reliable platform for bearing performance testing, life prediction, and failure mechanism research.

[0005] The technical solution of the present invention:

[0006] A five-degree-of-freedom wind turbine main bearing test bench that simulates real working conditions includes a loading system 1, a test system 2, and a drive system 3. The three systems are independent of each other but influence each other, which improves the versatility and flexibility of the five-degree-of-freedom wind turbine main bearing test bench and can effectively meet the diverse testing needs of main bearings of different models and specifications.

[0007] The loading system 1 comprises a loading housing 11, a loading plate assembly 12, a loading hydraulic cylinder assembly 13, a loading shaft 14 and a connecting flange 15; the loading housing 11 comprises a lower half 111 and an upper half 112, which are positioned by the stop and pin hole on the connecting surface and are bolted together through the mounting holes; the lower half 111 is bolted to the ground through the base hole; the lower half 111 and the upper half 112 are provided with through holes for the cylinder body 131 to extend; the loading plate assembly 12 comprises a radial guide shoe 121, an axial thrust shoe 122 and a loading shaft 14; Loading disc 123; The loading disc 123 is a cantilever structure and is placed in the loading housing 11; a plurality of radial guide bushes 121 are evenly distributed on the outer circumference of the loading disc 123; a plurality of axial thrust bushes 122 are evenly distributed on the two end faces of the loading disc 123, and the number of radial guide bushes 121 is consistent with the number of axial thrust bushes 122 on each end face; the radial guide bushes 121 and the axial thrust bushes 122 are both self-lubricating sliding bushes, which bear the external input load when the loading disc 123 rotates; the loading hydraulic cylinder assembly 13 is included in the loading The load plate 123 is provided with multiple radial hydraulic cylinders evenly distributed circumferentially and multiple axial hydraulic cylinders evenly distributed circumferentially on both sides of the load plate 123; the number of radial hydraulic cylinders and the number of axial hydraulic cylinders are consistent with the number of radial guide bushes 121; the load hydraulic cylinder assembly 13 includes a cylinder body 131, a piston rod connecting plate 132, a pressure sensor 133, a stud 134, a hydraulic cylinder joint earring 135 and an earring support 136; the cylinder body 131 is connected to one end of the pressure sensor 133 through the piston rod connecting plate 132; the pressure sensor 133 is connected to the load plate 12 ...; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load plate 123; the pressure sensor 133 is connected to the load The other end is connected to the hydraulic cylinder joint earring 135 via a stud 134, and the hydraulic cylinder joint earring 135 is further connected to the radial guide shoe 121 and the axial thrust shoe 122 via earring supports 136. The loading hydraulic cylinder assembly 13 is connected to the loading housing 11 via a flange on the cylinder body 131. The large end face of the loading shaft 14 is provided with a flange, which is connected to the loading plate 123 via bolts. The small end face of the loading shaft 14 is fixed to the connecting flange 15 via threads. The test system can be replaced by replacing the connecting flange 15.

[0008] The test system 2 includes a main test bearing assembly 21, a secondary test bearing assembly 22 and a test main shaft 23; the main test bearing assembly 21 includes a main bearing seat 211, a main bearing seat end cover 212, a main lip-shaped skeleton oil seal 213, a main disassembly ring 214 and a main test bearing 215; the main test bearing 215 and the secondary test bearing 225 adopt the reverse installation configuration in the wind turbine; the main test bearing assembly 21 is circumferentially positioned by the main bearing seat 211, and the main test bearing assembly 21 is axially installed from left to right with the main bearing seat end cover 212, the main lip-shaped skeleton oil seal 213, the main disassembly ring 214, the main test bearing 215, the main lip-shaped skeleton oil seal 213, and the main bearing seat end cover 212; the secondary test bearing assembly 22 includes a secondary bearing seat 221, a secondary bearing seat end cover 222 , auxiliary lip-type skeleton oil seal 223, auxiliary disassembly ring 224, auxiliary test bearing 225, sleeve 226 and locking nut 227; the auxiliary test bearing assembly 22 is circumferentially positioned by the auxiliary bearing seat 221, and the auxiliary test bearing assembly 22 is axially installed with the auxiliary bearing seat end cover 222, auxiliary lip-type skeleton oil seal 223, auxiliary disassembly ring 224, auxiliary test bearing 225, auxiliary lip-type skeleton oil seal 223, auxiliary bearing seat end cover 222, sleeve 226 and locking nut 227 from left to right; the test main shaft 23 adopts a hollow stepped shaft design, and the left end face is provided with a flange with a threaded hole for connecting with the test system 2; the right end face is used to connect with the drive system 3; the main test bearing assembly 21 and the auxiliary test bearing assembly 22 are installed on the shoulder of the test main shaft 23 from left to right;

[0009] The drive system 3 includes a variable frequency reduction motor 31, a motor end connector 32, a torque sensor 33, a coupling end connector 34 and an elastic coupling 35; the variable frequency reduction motor 31 is connected to one end of the torque sensor 33 through the motor end connector 32; the other end of the torque sensor 33 is connected to the elastic coupling 35 through the coupling end connector 34, and the elastic coupling 35 is further connected to the test spindle 23.

[0010] Technical effects of the present invention:

[0011] The test bench of the present invention can achieve independent control and high-precision composite loading of the three-axis forces and bidirectional moments acting on the main bearing through the coordinated cooperation of the axial and radial hydraulic cylinder arrays, filling the gap in multi-degree-of-freedom dynamic loading technology in wind power bearing tests; the test bench of the present invention completely simulates the real mechanical structure of the main shaft system of the wind turbine, and utilizes the dynamic pressure bearing characteristics of the tilting pad bearing to achieve dynamic loading on the hub in a rotating state. Compared with traditional static loading disks or direct loading on the outer ring of the test bearing, it can more realistically simulate the rotational load transfer characteristics of the wind turbine hub, thereby improving the authenticity and reliability of the test data. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1This is a schematic diagram of the overall structure of the wind turbine main bearing test bench.

[0013] Figure 2 Schematic diagram of the loading system structure of the wind turbine main bearing test bench.

[0014] Figure 3 Schematic diagram of the loading plate assembly structure of the wind turbine main bearing test bench.

[0015] Figure 4 This is a schematic diagram of the loading hydraulic cylinder assembly structure of the wind turbine main bearing test bench.

[0016] Figure 5 Schematic diagram of the loading shaft assembly structure of the wind turbine main bearing test bench.

[0017] Figure 6 This is one of the test system structure diagrams of the wind turbine main bearing test bench.

[0018] Figure 7 This is the second schematic diagram of the test system structure of the wind turbine main bearing test bench.

[0019] Figure 8 This is a schematic diagram of the drive system structure of the wind turbine main bearing test bench.

[0020] In the figure: 1 loading system; 11 loading housing; 12 loading plate assembly; 13 loading hydraulic cylinder assembly; 14 loading shaft; 15 connecting flange; 111 lower half; 112 upper half; 121 radial guide bushing; 122 axial thrust bushing; 123 loading plate; 131 cylinder body; 132 piston rod connecting plate; 133 pressure sensor; 134 stud; 135 hydraulic cylinder joint earring; 136 earring support; 21 main test bearing assembly; 22 auxiliary test bearing assembly ; 23 test spindle; 211 main bearing seat; 212 main bearing seat end cover; 213 main lip-type skeleton oil seal; 214 main disassembly ring; 215 main test bearing; 221 secondary bearing seat; 222 secondary bearing seat end cover; 223 secondary lip-type skeleton oil seal; 224 secondary disassembly ring; 225 secondary test bearing; 226 sleeve; 227 locking nut; 31 variable frequency reduction motor; 32 motor end connector; 33 torque sensor; 34 coupling end connector; 35 elastic coupling. DETAILED DESCRIPTION

[0021] The specific implementation of the present invention is further described below in conjunction with the accompanying drawings and technical solutions.

[0022] like Figure 1 As shown, the present invention provides a five-degree-of-freedom wind turbine main bearing test bench that simulates real working conditions. The whole machine is mainly composed of a loading system 1, a test system 2, and a drive system 3.

[0023] like Figure 2 As shown, the loading system 1 comprises a loading housing 11, a loading plate assembly 12, a loading hydraulic cylinder assembly 13, a loading shaft 14, and a connecting flange 15. The loading housing 11 comprises a lower housing portion 111 and an upper housing portion 112, which are positioned by stoppers and pin holes on the connecting surfaces and bolted together through mounting holes. The lower housing portion 111 is bolted to the ground through base holes in the lower housing portion 111. Through holes are formed in the upper housing portion 112 and the lower housing portion 111, through which the cylinder 131 extends. Reinforcing ribs are provided near the through holes to enhance the strength and rigidity of weak points in the loading housing 11.

[0024] like Figure 3 As shown, the loading disc assembly 12 includes a radial guide shoe 121, an axial thrust shoe 122 and a loading disc 123; the loading disc 123 is a cantilever structure, placed in the loading housing 11, and is used to simulate the hub of a wind turbine and can withstand five-degree-of-freedom loads input from the outside; a plurality of radial guide shoes 121 are evenly distributed on the outer circumference of the loading disc 123; a plurality of axial thrust shoes 122 are evenly distributed circumferentially on the two end faces of the loading disc 123, and the number of radial guide shoes 121 is consistent with the number of axial thrust shoes 122 on each end face; the radial guide shoes 121 and the axial thrust shoes 122 have a self-lubricating function, and after being loaded, they swing through the fulcrum to form a load-bearing oil wedge, which withstands the load input from the outside when the loading disc 123 rotates, and is used to simulate the wind load borne by the wind turbine hub when it rotates.

[0025] like Figure 4As shown, the loading hydraulic cylinder assembly 13 includes a plurality of radial hydraulic cylinders uniformly distributed circumferentially on the loading plate 123 and a plurality of axial hydraulic cylinders uniformly distributed circumferentially on both sides of the loading plate 123; the number of radial hydraulic cylinders and the number of axial hydraulic cylinders are consistent with the number of radial guide bushes 121; by coordinating the control of the hydraulic cylinders, the five-degree-of-freedom dynamic composite loading of the main bearing is achieved; the loading hydraulic cylinder assembly 13 includes a cylinder body 131, a piston rod connecting plate 132, a pressure sensor 133, a stud 134, a hydraulic cylinder joint Earring 135 and earring support 136; cylinder body 131 is connected to one end of pressure sensor 133 via piston rod connecting plate 132; pressure sensor 133 enables real-time monitoring and feedback control of applied load; the other end of pressure sensor 133 is connected to hydraulic cylinder joint earring 135 via stud 134, and hydraulic cylinder joint earring 135 is further connected to radial guide shoe 121 and axial thrust shoe 122 via earring support 136, thereby achieving load application from hydraulic cylinder 13 to loading plate 123. The cylinder body 131 of loading hydraulic cylinder assembly 13 is provided with a flange, which is connected to loading housing 11 by bolts. The connection is strong and can withstand large impact loads; joint bearings are embedded in joint earring 135 to adapt to the tilting of loading plate 123 caused by excessive load during loading, thereby improving stability and safety during loading.

[0026] like Figure 5 As shown, the large end face of the loading shaft 14 is provided with a flange, which is connected to the loading disc by bolts, thereby realizing radial and axial positioning of the loading disc 123 on the loading shaft 14; the small end face of the loading shaft 14 is fixed to the connecting flange 15 by a thread, and the test system can be replaced by replacing the connecting flange 15; the size of the loading shaft 14 adopts a large radius fillet for smooth transition, which can effectively improve the stress concentration caused by the large load input by the loading disc 123.

[0027] like Figure 6-7As shown, the test system 2 includes a main test bearing assembly 21, a secondary test bearing assembly 22, and a test main shaft 23; the main test bearing assembly 21 includes a main bearing seat 211, a main bearing seat end cover 212, a main lip-shaped skeleton oil seal 213, a main disassembly ring 214, and a main test bearing 215; the main test bearing 215 and the secondary test bearing 225 adopt a reverse installation configuration in the wind turbine to transmit the axial force input from the end of the test main shaft 23; the main test bearing assembly 21 is installed with the main bearing seat end cover 212, the main lip-shaped skeleton oil seal 213, the main disassembly ring 214, the main test bearing 215, the main lip-shaped skeleton oil seal 211 in sequence from left to right in the axial direction. 3. Main bearing seat end cover 212; the main test bearing assembly 21 is circumferentially positioned by the main bearing seat 211, and is axially positioned by the end covers 212 on both sides of the main bearing seat 211; the auxiliary test bearing assembly 22 includes an auxiliary bearing seat 221, an auxiliary bearing seat end cover 222, an auxiliary lip-shaped skeleton oil seal 223, an auxiliary disassembly ring 224, an auxiliary test bearing 225, a sleeve 226, and a locking nut 227; the auxiliary test bearing assembly 22 is axially installed from left to right with the auxiliary bearing seat end cover 222, the auxiliary lip-shaped skeleton oil seal 223, the auxiliary disassembly ring 224, the auxiliary test bearing 225, the auxiliary lip-shaped skeleton oil seal 223, and the auxiliary bearing seat end cover. 222, sleeve 226 and locking nut 227; the auxiliary test bearing assembly 22 is circumferentially positioned by the auxiliary bearing seat 221, and axially positioned by the auxiliary bearing seat end cover 222 on one side of the auxiliary bearing seat 221 and the sleeve 226 and locking nut 227 on the other side; the test spindle 23 adopts a hollow stepped shaft design, and the left end face is provided with a flange with a threaded hole for connecting to the test system 2; the right end face is used to connect to the drive system 3; the main test bearing assembly 21 and the auxiliary test bearing assembly 22 are installed on the shaft shoulder of the test spindle 23 from left to right; the main test bearing 215 and the auxiliary test bearing 225 are installed on the test spindle 23, the bearing width must exceed the shaft shoulder to achieve axial positioning; the span between the main test bearing 215 and the auxiliary test bearing 225 is kept the same as the span of the main and auxiliary bearings of a certain type of wind turbine; the main test bearing 215 and the auxiliary test bearing 225 are lubricated by grease; due to the low test speed, the main test bearing 215 and the auxiliary test bearing 225 are respectively installed at both ends of the main test bearing 215 and the auxiliary test bearing 225 to achieve grease sealing to prevent lubricant leakage and intrusion of external impurities; a disassembly ring is installed at the left end of the main test bearing 215 and the auxiliary test bearing 225 to facilitate the installation and disassembly of the test bearings.

[0028] like Figure 8As shown, the drive system 3 includes a variable frequency reduction motor 31, a motor end connector 32, a torque sensor 33, a coupling end connector 34 and an elastic coupling 35; the variable frequency reduction motor 31 is connected to one end of the torque sensor 33 through the motor end connector 32, which can realize real-time monitoring and feedback of the motor torque; the other end of the torque sensor 33 is connected to the elastic coupling 35 through the coupling end connector 34, and the elastic coupling 35 is further connected to the test spindle 23; the rated power of the variable frequency reduction motor 31 is selected according to the maximum friction torque and speed required by the test bench, and the speed can be steplessly adjusted from 0 to 200 rpm to meet various working conditions such as performance testing, intensive testing and frequent start-stop testing.

Claims

1. A five-degree-of-freedom wind turbine main bearing test bench simulating real working conditions, characterized by: The five-degree-of-freedom wind turbine main bearing test bench comprises a loading system (1), a test system (2) and a drive system (3); The loading system (1) comprises a loading housing (11), a loading plate assembly (12), a loading hydraulic cylinder assembly (13), a loading shaft (14) and a connecting flange (15); the loading housing (11) comprises a lower half (111) and an upper half (112), the two being positioned by a stop and a pin hole on a connecting surface and being bolted together by mounting holes; the lower half (111) is bolted to the ground through a base hole; the lower half (111) and the upper half (112) are provided with through holes through which a cylinder body (131) extends; the loading plate assembly (12) comprises a radial guide bush (121), an axial thrust bush (122 ) and a loading disc (123); the loading disc (123) is a cantilever structure and is placed in the loading housing (11); a plurality of radial guide bushes (121) are evenly distributed on the outer circumference of the loading disc (123); a plurality of axial thrust bushes (122) are evenly distributed on the two end faces of the loading disc (123), and the number of radial guide bushes (121) is consistent with the number of axial thrust bushes (122) on each end face; the radial guide bushes (121) and the axial thrust bushes (122) are both self-lubricating sliding bushes, which bear the load input from the outside when the loading disc (123) rotates; the loading hydraulic cylinder assembly (13) includes The loading plate (123) is provided with a plurality of radial hydraulic cylinders uniformly distributed circumferentially and a plurality of axial hydraulic cylinders uniformly distributed circumferentially on both sides of the loading plate (123); the number of radial hydraulic cylinders and the number of axial hydraulic cylinders are consistent with the number of radial guide bushes (121); the loading hydraulic cylinder assembly (13) includes a cylinder body (131), a piston rod connecting plate (132), a pressure sensor (133), a stud (134), a hydraulic cylinder joint earring (135) and an earring support (136); the cylinder body (131) is connected to one end of the pressure sensor (133) through the piston rod connecting plate (132); the pressure sensor (133) is connected to the cylinder body (131 ... ) The other end is connected to the hydraulic cylinder joint earring (135) through a stud (134), and the hydraulic cylinder joint earring (135) is further connected to the radial guide shoe (121) and the axial thrust shoe (122) through an earring support (136); the loading hydraulic cylinder assembly (13) is connected to the loading housing (11) through a flange on the cylinder body (131); the large end face of the loading shaft (14) is provided with a flange, which is connected to the loading plate (123) through bolts; the small end face of the loading shaft (14) is fixed to the connecting flange (15) through a thread, and the test system can be replaced by replacing the connecting flange (15); The test system (2) comprises a main test bearing assembly (21), a secondary test bearing assembly (22) and a test main shaft (23); the main test bearing assembly (21) comprises a main bearing seat (211), a main bearing seat end cover (212), a main lip-shaped skeleton oil seal (213), a main disassembly ring (214) and a main test bearing (215); the main test bearing (215) and the secondary test bearing (225) adopt a reverse installation configuration in a wind turbine; the main test bearing assembly (21) is circumferentially positioned by the main bearing seat (211), and the main test bearing assembly (21) is axially installed with the main bearing seat end cover (212), the main lip-shaped skeleton oil seal (213), the main disassembly ring (214), the main test bearing (215), the main lip-shaped skeleton oil seal (213), and the main bearing seat end cover (212) in sequence; the secondary test bearing assembly (22) comprises a secondary bearing seat (221), the secondary bearing seat end cover (22 2), auxiliary lip-shaped skeleton oil seal (223), auxiliary disassembly ring (224), auxiliary test bearing (225), sleeve (226) and locking nut (227); the auxiliary test bearing assembly (22) is circumferentially positioned by the auxiliary bearing seat (221), and the auxiliary test bearing assembly (22) is axially installed with the auxiliary bearing seat end cover (222), auxiliary lip-shaped skeleton oil seal (223), auxiliary disassembly ring (224), auxiliary test bearing (225), auxiliary lip-shaped skeleton oil seal (223), auxiliary bearing seat end cover (222), sleeve (226) and locking nut (227) in sequence from left to right; the test main shaft (23) adopts a hollow stepped shaft design, and the left end face is provided with a flange with a threaded hole for connecting with the test system (2); the right end face is used to connect with the drive system (3); the main test bearing assembly (21) and the auxiliary test bearing assembly (22) are installed on the shaft shoulder of the test main shaft (23) in sequence from left to right; The drive system (3) comprises a variable frequency reduction motor (31), a motor end connector (32), a torque sensor (33), a coupling end connector (34) and an elastic coupling (35); the variable frequency reduction motor (31) is connected to one end of the torque sensor (33) via the motor end connector (32); the other end of the torque sensor (33) is connected to the elastic coupling (35) via the coupling end connector (34), and the elastic coupling (35) is further connected to the test spindle (23).

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