Modular and combined wind power drive system

Abstract

The present invention discloses a modular and combined wind power transmission system, which has good reliability and maintainability during operation. A modular and combined wind power transmission system includes an impeller and a gearbox. Inside the gearbox, an input shaft and an output shaft are arranged in parallel. One end of the input shaft is connected to the impeller. The input shaft and the output shaft are driven by a gear pair. The other end of the output shaft is sequentially connected to a speed increaser and a generator.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power generation, and in particular to a modular and combined wind power generation transmission system. Background Art

[0002] The positive significance of wind power generation to energy, natural environment, social economy and other aspects, the current status of the transmission route and layout adopted by wind power generation is described. Due to the particularity of the installation location of wind power generation equipment - in special areas such as grasslands, deserts, mountains, beaches, islands, etc. where few people go, on towers of dozens or even hundreds of meters, the difficulty of its installation and maintenance and the high cost of work are incomparable to the transmission equipment working on the ground and indoors in other industries such as steel, building materials, and chemicals. Therefore, the reliability and maintainability of its equipment are the most important.

[0003] At present, there are many wind power transmission system layouts in use, mainly in the following forms:

[0004] 1. The common layout of wind turbines in the early days: the main shaft is independently supported, the end is connected to the gearbox, and the high-speed end of the gearbox is connected to the generator. Figure 1 shown.

[0005] This structure is often called "straight" layout. The abnormal load of the impeller is usually borne by two large shaft bearings, the gearbox is less affected, and the intervals between the main components are relatively large, which is convenient for installation and maintenance. However, the axial dimension of the cabin is longer, the overall size of the unit is larger, and the weight is also heavier.

[0006] 2. In order to make the axial dimension of the entire transmission system shorter, people have made improvements based on the first structure, eliminating the support bearing at the far end of the impeller of the main shaft and adopting a structure in which the end of the main shaft is directly connected to the input shaft of the gearbox, as shown below Figure 2 shown.

[0007] This is a commonly used structure at present, and this structure is basically adopted in large quantities from 750KW to MW level.

[0008] In this layout, although the axial dimension is shortened, it is not good for the gearbox. Measures need to be taken to strengthen the supporting rigidity of the gearbox, especially the output bearing. In addition, the locking plate connection method is equivalent to a rigid connection. The vibration generated when the impeller is running, especially when the wind speed changes greatly, will directly act on the gearbox. The abnormal load caused by the vibration, especially the axial load acting on the impeller, will have a greater impact on the speed-increasing gearbox.

[0009] 3. The transmission system has a short axial dimension, which is more conducive to the adjustment of the center of gravity of the entire system and the safety of the entire tower. Some of them also adopt Figure 3The system structure of the U-shaped drive route shown.

[0010] In this structure, the generator is arranged in reverse to shorten the length dimension of the nacelle. The generator straddles the large axle box. At this time, the input and output shafts of the gearbox are on the same side. The gearbox is designed in a "U" shape. The large axle box and the main bracket are made into one body, with sufficient support rigidity. The concentration of the weights of various parts in the nacelle is relatively good, but the spatial position of the nacelle is relatively compact, and maintenance and repair are not very convenient.

[0011] 4. In order to further reduce the nacelle volume, the large axle can also be omitted. As Figure 4 shown, the input shaft of the gearbox and the impeller hub are directly connected by a transition flange, and the transition flange is supported by a special bearing.

[0012] 5. There are also a small number of cases where the gearbox is made into one body with the main bracket of the nacelle. The planet carrier of the low-speed stage of the gearbox is directly connected to the hub, making the drive line shorter and increasing the structural rigidity of the unit. However, the manufacturing difficulty of the main frame and the gearbox is increased. As Figure 5 .

[0013] 6. Semi-direct drive structure form. MingYang Smart Energy's SCD ultra-compact semi-direct drive structure form integrates the medium-speed speed-increasing gearbox and the motor into one body, with the characteristics of small volume and light weight. However, the manufacturing requirements for the gearbox are relatively high, and the maintainability of the unit is not good.

[0014] 7. Direct drive unit, the whole machine does not use a gearbox for speed increase, and the impeller and the generator are directly connected. It cannot increase the speed, which is not conducive to power generation, and the application environment is less.

[0015] The above seven layout types are the main layout types of the drive devices in the current wind power generation system.

[0016] II. Analysis of the application characteristics and deficiencies of various layout types:

[0017] According to statistics:

[0018] The most commonly used non-direct drive models at present are the first and second structures. The second structure is a simplified version of the first structure. As mentioned above, after simplification, the conditions for the main gearbox are relatively more severe, and its reliability in use is greatly affected by factors such as installation, and there may be relatively large uncontrollability during the installation process.

[0019] The third structure is extremely rare in China. The 600kW model of Tack is similar to this. This gearbox is a parallel shaft structure without a planetary structure, and the overall volume is relatively larger.

[0020] In the fourth structure, the impeller and the input shaft are connected by a very large locking disc;

[0021] The fifth structure is currently less used.

[0022] The common features of the above five transmission structures and layout forms are as follows:

[0023] 1. Rigid connection between the main shaft and the speed-increasing main gearbox;

[0024] 2. Overall integration of the transmission system.

[0025] Let's first talk about the rigid connection between the main shaft and the gearbox, that is, the use of a locking disc connection. This connection method has obvious advantages and disadvantages: The advantage is that the connecting shaft extends into the inner hole of the other shaft, which not only shortens the axial dimension. When the component with a relatively small mass is suspended on another large component, there is no need for alignment, but only the bolts of the locking disc need to be tightened directly.

[0026] However, in a transmission system such as wind power generation, there are several deficiencies in using a locking disc to connect the main shaft and the speed-increasing main gearbox:

[0027] 1. When the connection between the main shaft and the speed-increasing main gearbox is rigidified, almost all the additional loads generated by the operation of the impeller and the various vibrations when it is affected by the wind will be transmitted into the gearbox. After these vibrations are affected by factors such as speed ratio changes, they will be amplified at the high-speed stage of the gearbox and other parts, and the adverse effects on the gears and bearings will also become larger, which is one of the main reasons for gearbox failures; and these vibrations are diverse and difficult to control, so efforts should be made to eliminate their influence on the gearbox.

[0028] 2. When two moving components are connected and the mass of one component is relatively small and can be suspended at the outer extension end of the other component, when its own weight needs to be borne by the outer extension end of the large component, using a locking disc for this connection method should be the best choice. Because the locking disc can not only transmit torque, but also has the best fastening effect on the cantilever part of the suspended component's own weight. However, the mass of the wind turbine speed-increasing gearbox is too large, especially for future high-power gearboxes, the installation method and effect of one-end cantilever will be very poor:

[0029] 2.1. If the gearbox has no installation base, the entire weight of the system is borne on the front bearing, and this structure has technical defects.

[0030] 2.2. If the speed-increasing main gearbox has its own installation base, this installation method will cause over-positioning between the gearbox and the main shaft bearing. When the positioning accuracy is not good, additional loads due to poor installation will also be generated. Once these two additional loads are superimposed, the service life of the gearbox will surely be greatly reduced.

[0031] 3. The installation of the locking disc also requires a relatively professional method and patience from the installer: the bolts need to be tightened repeatedly according to the rules. Once there is any improper operation by the installer - and these improper operations are not easy to be detected during inspection - it is very easy for the inner holes of the large shaft and the low-speed shaft of the gearbox to be scratched and glued together, which will cause many subsequent troubles to the system and cost a lot.

[0032] Tightening a locking disc according to the rules generally takes a relatively long time. It is difficult to control the quality during large-scale installation of locking discs.

[0033] III. Simple analysis of the reasons for the poor maintainability of wind power system equipment

[0034] Another problem with the entire drive system: integration.

[0035] The biggest feature of all the above-mentioned layout forms of the drive system is integration. Integration has its deficiencies, that is: when a component has a problem, all the equipment will be "affected". The consequence of removing all the components due to being affected is: difficult disassembly and assembly, high lifting difficulty; large transportation volume for the gearbox to be repaired at the factory, a lot of repair work, high cost, long downtime of the main engine, and the overall loss increases exponentially.

[0036] 1. The impeller, large shaft, and main speed-increasing gearbox are basically integrated into a whole. Among them, the gearbox is the most prone to failure. Even if there is a small problem inside the gearbox, such as just one bearing being damaged, almost all the components need to be removed. Especially for the 2nd, 3rd, 4th, 5th, etc. layout forms where the large shaft is installed inside the gearbox, even the impeller has to be removed.

[0037] 2. In many actual cases, due to the incorrect tightening method of the locking disc and the inability to detect it in time, the inner holes of the large shaft and the low-speed shaft of the gearbox are glued together, and it cannot be disassembled on-site. The large shaft and the gearbox can only be removed as a whole and sent back to the factory to be pressed out or cut off using special equipment, destroying important parts. This not only requires high requirements for the lifting equipment (the lifting cost is also very high, generally costing more than 100,000 yuan for one disassembly and assembly), but also takes a long time for disassembly and assembly, and the fan stops running for a long time. In addition, the weight for transportation back to the factory increases, and the requirements for vehicles are also much higher, resulting in a sharp increase in costs; after returning to the manufacturing factory, the disassembly, inspection, and restoration of the gearbox and the large shaft increase the workload and require more manufacturing equipment, and the costs generated also increase significantly.

[0038] 3. At the same time, the long repair time of components and the long downtime of the fan, the loss caused by the inability to generate electricity, combined with the adverse factors generated by various works such as disassembly, installation, and restoration of functions, form a vicious cycle and double losses.

[0039] It is precisely these characteristics that have resulted in the poor reliability and maintainability of current wind power generation equipment, high repair costs, and long downtime, which are extremely unfavorable to the equipment management and production operations of wind farms; especially since these devices are produced in large quantities and used in many applications, more attention should be paid to adopting transmission methods and layout types with good maintainability and low maintenance costs.

[0040] IV. The current status of measures taken by various parties for wind power generation systems with good maintainability and low maintenance costs

[0041] A wind power generation system with good maintainability and low maintenance cost is everyone's common hope. Different manufacturers are working hard to come up with solutions, including: direct drive, or semi-direct drive, improving the manufacturing accuracy of gearboxes, etc.

[0042] 1. Reduce the speed of the gearbox to ensure better reliability. Direct drive means that the impeller shaft directly drives the generator set to generate electricity.

[0043] Semi-direct drive means reducing the speed ratio of the gearbox, and the speed of the generator is relatively low.

[0044] In conventional wind power generation systems, the speed of the generator is generally set at 1500r / min, 1250r / min or 1000r / min, and the gearbox has the highest failure rate among all equipment, and a large proportion of gearbox failures occur in the high-speed shaft, so some manufacturers simply cancel the gearbox or reduce the operating speed of the gearbox in order to improve the reliability of the wind power generation system and reduce the failure rate. However, direct-drive power generation and semi-direct-drive power generation also have their own defects, namely, the number of motor stages, large size, and high cost.

[0045] 2. Improve the manufacturing accuracy of the gearbox to extend its service life. Many other manufacturers believe that the manufacturing accuracy of domestic gearboxes is not high enough and the overall quality is not good enough, so they import gearboxes from abroad, or buy gearbox drawings from abroad, configure the world's top machine tools and equipment, and try their best to improve the manufacturing accuracy of the gearbox, so as to improve the reliability of the gearbox, that is, the entire power generation system, and reduce the failure rate.

[0046] Improving the manufacturing quality of gearboxes is effective. It has greatly improved the reliability of gearboxes on the original basis. However, the cost of improving the gearbox precision is not proportional to the improved reliability. Moreover, this has not solved the chronic problem of poor maintainability of the currently commonly used wind power generation systems. When a gearbox failure occurs, the overall disassembly, lifting, and transportation of the system are troublesome, costly, time-consuming, and require long downtimes. This has not changed at all. Summary of the invention

[0047] The object of the present invention is to overcome the deficiencies of the prior art and provide a modular and combined wind power transmission system, which has good reliability and maintainability during operation.

[0048] The object of the present invention is achieved as follows:

[0049] A modular and combined wind power transmission system includes an impeller and a gearbox. Inside the gearbox, an input shaft and an output shaft are arranged in parallel. One end of the input shaft is connected to the impeller, and the input shaft and the output shaft are driven by a gear pair. The other end of the output shaft is sequentially connected to a speed increaser and a generator.

[0050] Preferably, both ends of the input shaft and the output shaft are supported on the box body of the gearbox through bearings. Among them, the end of the input shaft connected to the impeller is supported on the box body of the gearbox through a self-aligning bearing, and the other end of the input shaft is supported on the box body of the gearbox through a self-aligning bearing and a thrust bearing. The thrust bearing is located outside the corresponding self-aligning bearing.

[0051] Preferably, both ends of the output shaft are supported on the box body of the gearbox through radial bearings.

[0052] Preferably, the opposite ends of the output shaft and the speed increaser are connected through a drum-shaped gear sleeve.

[0053] Preferably, the transmission between the input shaft and the output shaft is a gear speed increasing transmission.

[0054] Preferably, the input shaft and the output shaft are driven by a herringbone gear.

[0055] Preferably, the input shaft is fixed to the corresponding herringbone gear through screws, and the output shaft and the corresponding herringbone gear are formed into a herringbone gear shaft.

[0056] Preferably, the number of output shafts is multiple, and the multiple output shafts are evenly distributed along the circumferential direction of the input shaft.

[0057] Preferably, the speed increaser adopts a planetary gear speed increaser.

[0058] The way to improve the maintainability of the wind power transmission speed increasing system should not lie in the integration of system equipment that is currently valued by the vast majority of people and for which extreme efforts are made. On the contrary, the way out should lie in the decentralization and modularization of equipment with various functions.

[0059] The present invention adopts the thinking of equipment decentralization and modularization, analyzes the speed increasing system, finds that the speed increasing gearbox is prone to failure, then separately arranges the parts prone to failure and the parts not prone to failure, and changes the layout type of "one failure, the whole is affected" in the prior art. This modular structure of the present invention is also beneficial to the mass production of wind power equipment. Description of the Drawings

[0060] Figures 1 - 5 is the layout form of the existing wind power transmission system.

[0061] Figure 6 is the structural schematic diagram of the present invention;

[0062] Figure 7a is the schematic diagram of the single - generator layout type of the present invention;

[0063] Figure 7b is the schematic diagram of the double - generator layout type of the present invention;

[0064] Figure 7c is the schematic diagram of the triple - generator layout type of the present invention;

[0065] Figure 7d 、 Figure 7e is the schematic diagram of the quadruple - generator set layout type of the present invention.

[0066] Reference Signs

[0067] In the drawings, 1 is the impeller, 2 is the gearbox, 3 is the input shaft, 4 is the herringbone gear, 5 is the herringbone gear shaft, 6 is the crowned gear sleeve, 7 is the planetary gearbox for speed increase, and 8 is the generator. Detailed Embodiments

[0068] Referring to Figure 6 , it is a modular and combined wind power transmission system, including an impeller and a gearbox. Inside the gearbox, an input shaft and an output shaft are arranged in parallel. One end of the input shaft is connected to the impeller. The input shaft and the output shaft are driven by a gear pair, and the input shaft and the output shaft are in gear speed - increasing transmission. The input shaft and the output shaft are driven by a herringbone gear. The input shaft and the corresponding herringbone gear (the large herringbone gear) are fixed by screws, and the output shaft and the corresponding herringbone gear (the small herringbone gear) form a herringbone gear shaft. The other end of the output shaft is sequentially connected to a speed - increasing box and a generator. The output end of the output shaft and the low - speed shaft end of the speed - increasing box are connected by a crowned gear sleeve. The speed - increasing box adopts a planetary gearbox for speed increase.

[0069] Both ends of the input shaft and the output shaft are respectively supported by bearings on the box body of the gearbox. Among them, the end of the input shaft connected to the impeller is supported by a self - aligning bearing on the box body of the gearbox, and the other end of the input shaft is supported by a self - aligning bearing and a thrust bearing on the box body of the gearbox, and the thrust bearing is located outside the corresponding self - aligning bearing. Both ends of the output shaft are respectively supported by radial bearings on the box body of the gearbox.

[0070] Referring to Figures 7a - 7e, the number of the output shafts can be single or multiple. When the number of the output shafts is multiple, the multiple output shafts are evenly distributed along the circumferential direction of the input shaft. Each output shaft is respectively connected to a speed-increasing planetary gearbox and a generator.

[0071] The basic transmission route of the present invention is as follows:

[0072] The impeller is directly installed at the front end of the input shaft (main shaft). When the impeller rotates, the herringbone gear (large gear) installed on the input shaft drives the herringbone gear (small gear) on the output shaft. The output shaft drives the speed-increasing planetary gearbox through a crowned gear sleeve. The high-speed shaft of the speed-increasing planetary gearbox is connected to the main shaft of the generator to drive the generator to generate electricity.

[0073] In the transmission route where multiple output shafts are evenly distributed along the circumferential direction of the input shaft, the evenly distributed layout type of multiple generators has the following characteristics or advantages:

[0074] 1. Herringbone gear transmission, the axial forces of gear meshing are offset. The parameter settings of the herringbone gear pair are designed with reference to the working conditions of high power and high impact in other industries to ensure the reliable service performance and long service life.

[0075] 2. Multiple generator units are evenly distributed, and the gear meshing forces on the large gear are offset, which is very beneficial to the bearings on the main shaft. The main shaft itself only bears the torque.

[0076] 3. Regarding the bearings on the main shaft, the bearings on the main shaft only bear the gravity generated by the weight of the main shaft itself and the impeller, and the gear meshing forces do not affect the bearings.

[0077] The axial thrust generated by the wind blowing the impeller to rotate is borne by a dedicated thrust roller bearing, and the effect is better than only using a spherical roller bearing at present. There are the following two problems with only using a spherical roller bearing in the prior art:

[0078] 3.1 First, the spherical roller bearing is very sensitive to axial force: when the ratio of the axial force to the combined radial force is greater than the e value, when calculating the equivalent load of the bearing, the coefficient Y2 multiplied by the axial force can reach more than 6, which has a great and adverse impact on the service life of the bearing.

[0079] 3.2 Second, at present, the main shaft is arranged separately, and it is very convenient to check, repair, install and disassemble the bearings. It is not as inconvenient as the previous situation where the main shaft extends into the low-speed shaft of the gearbox and even relies on the bearings of the gearbox to bear the thrust of the impeller.

[0080] 4. The main shaft is arranged separately, and various control pipelines required for pitch control and yaw control are directly installed from the tail of the main shaft and no longer pass through the speed-increasing gearbox; because the rotation speed of the main shaft is low, the space is large, and there is no more lubricating oil and other interferences in the middle, it is more convenient and simple to install and detect the pipelines.

[0081] 5. The axial forces of the two sides of the herringbone gear pair are offset from each other during transmission. The load-bearing capacity of the gear pair can be greater than that of conventional gears, which helps to minimize the gear diameter, weight, etc., and helps to control the manufacturing cost.

[0082] A drum-shaped tooth connection is adopted between the small herringbone gear shaft and the speed-increasing gearbox, which can eliminate the slight axial movement of the gears during operation. At the same time, it can filter out the influence of the vibration generated by the impeller operating under conditions such as variable wind speed on the speed-increasing gearbox to the greatest extent.

[0083] Moreover, the drum-shaped tooth sleeve can be easily removed from the output shafts of the small herringbone gear and the speed-increasing gearbox to cut off the power flow, so that the speed-increasing gearbox with the highest failure rate can be simply disassembled from the system.

[0084] 6. Characteristics of the speed-increasing gearbox:

[0085] 6.1 Since there is a stage of herringbone gear speed change after the impeller, the speed ratio of the speed-increasing gearbox is smaller than that of the current speed-increasing gearbox with three-stage transmission. Its volume and weight are also much smaller, and it can be easily removed alone. The disassembly and assembly workload and costs during maintenance can be reduced significantly.

[0086] 6.2 At the same time, since there is no need to arrange the pipelines required for pitch control in the gearbox, the transmission method with concentric input and output shafts of the planetary gear can be directly adopted, which can minimize the weight of the gearbox to the greatest extent.

[0087] 6.3 At the same time, this transmission method directly liberates the bearings of the high-speed shaft. For the speed-increasing gearbox with three-stage transmission before, its high-speed shaft is in a parallel shaft expansion transmission mode. Due to the high speed, large power of the high-speed shaft, and the combined action of the circumferential force, radial force, axial force, etc. generated by gear meshing on the high-speed bearings, the load on the bearings is very large, resulting in the failure to meet the required limit speed and short service life of the bearings, etc., which has delayed the widespread application of high-power wind speed-increasing gearboxes.

[0088] When the planetary transmission has concentric input and output, the gear meshing force at the gear part on the high-speed shaft as the sun gear is offset. The high-speed shaft only bears pure torque, and the bearings no longer bear the gear meshing force and only bear the weight of the high-speed shaft itself. The equivalent load during bearing operation can be almost ignored, and the requirements for various indicators such as the limit speed and life of the bearings are easily met, which can improve the operating reliability of the gearbox and extend the service life of the gearbox.

[0089] 6.4 Explanation on the speed ratio setting of the gearbox:

[0090] Regarding the gearbox speed ratio, there are two ways: When the generator power is relatively small, the generator generally operates at a speed of 1500 r / min. The planetary gearbox needs to adopt two-stage planetary transmission, with the speed ratio set at more than 30. Adding the speed ratio of the herringbone gear pair, the total speed ratio is greater than 80; (It is also necessary to consider the wind field conditions in low-wind-speed areas, and the speed ratio may need to be appropriately increased). When the generator power is relatively large (especially greater than 1.5 MW), it is recommended to adopt a speed of 740 r / min. In this configuration, the planetary gearbox can adopt single-stage transmission, with the speed ratio around 9 - 10, and the total speed ratio is set at a little more than 40. The structure of the single-stage planetary gearbox is simpler. Moreover, due to its simple structure, when the parameter design is reasonable, its reliability in use will be greatly improved. The manufacturing, maintenance prices, and workload, etc., will also decrease relatively significantly. The specific setting of the speed ratio needs to be determined according to the specific characteristics of the wind power system.

[0091] Rough comparison of prices and advantages description after the decentralized and modular layout of wind power generation system equipment: To illustrate the overall price after the decentralization and modularization of the entire system, take a 1.5 MW wind turbine with a generator speed of 1500 r / min as an example for a simple explanation.

[0092] 1. The main shaft, herringbone gear spokes, conventional bearings and bases (the wind turbine nacelle is relatively heavy and expensive), with a price of about 550,000 yuan.

[0093] 2. The price of the speed-increasing gearbox is about 400,000 yuan. Imported bearings are used, and all gears including the internal gear ring are ground (if a single-stage planetary transmission structure is adopted, the price of the gearbox should be able to be reduced by about 15% more).

[0094] 3. The base, the common installation base for the gearbox and the motor in the conventional installation method, with a price of more than 100,000 yuan.

[0095] If such a price can be achieved, compared with the current three-stage transmission speed-increasing gearbox, plus the main components such as the main shaft, the mounting seat and the locking disc of the main shaft, the total price is not much different and should be slightly lower. (All prices are preliminarily estimated for the gearbox according to the conventional requirements of industries such as building materials and steel. If there are special requirements for the materials of important parts of the gearbox and overall on-line monitoring in wind power generation, it is necessary to carefully calculate according to specific parameters and requirements.

[0096] 4. Price advantages of modular and combined units

[0097] 4.1 Adopting this mode, the total price of the single-generator system is not much different from the current system price;

[0098] If the double - generator layout is adopted, the total system power will be doubled (with corresponding changes to the impeller), while the main shaft, herringbone gear, and bearings do not need to be increased. One more speed - increasing gearbox that has already become smaller in size and lighter in weight is added, and one more generator is added. The cost will be much lower than the total price of the original 3000 - kW unit layout method.

[0099] 4.2 For the triple - generator layout and the four - generator layout, if the motors can be arranged separately, they can all be arranged, and the power generation will increase proportionally. However, only one main shaft and one large herringbone gear are still needed to meet the requirements. In this case, the comparison of the total price will have a greater advantage.

[0100] 4.3 By adopting this modular combined layout method, such a manufacturing situation can be formed: in different regions with different wind resources and greatly different power - generation capabilities, whether it is a 1MW, 2MW, 3MW, 4MW, or 1.5MW, 3MW, 4.5MW, 6MW unit, the gearbox and generator of 1MW or 1.5MW can be used for combined installation. For the equipment faced by users, regardless of the power, they are the same, only the combination methods are different.

[0101] 4.4 It is also of great positive significance to achieve the functions of large - scale equipment through the combination of multiple medium - and large - scale equipment. For example, taking the 1.5MW medium - and high - speed planetary and concentric drive speed - increasing gearbox as an example, the domestic existing machine - tool equipment has sufficient manufacturing capacity for the gearbox and the large herringbone gear pair, and the quantity is also sufficient.

[0102] If we want to manufacture a 6MW large - scale three - stage planetary reducer, not to mention many parts such as the planet carrier and imported bearings, just for the manufacturing of the large internal gear ring, most manufacturers' current manufacturing equipment is insufficient. Forging equipment, gear shaping machines, gear grinding machines, and even heat - treatment equipment may need to be upgraded, which also requires a large amount of money and time.

[0103] There are still many uncertain factors in the design, manufacture, and installation of super - large - power gearboxes, and it still needs time to verify. There are also some uncontrollable risks during this period. The modular combination mode resolves the whole - process risks of super - large - power gearboxes.

[0104] 4.5 For the manufacturer, only manufacturing one type of gear and one type of gearbox simplifies the production arrangement and makes it easier to adjust. The production schedule can be better guaranteed. Especially due to batch production, the manufacturing cost can be reduced again.

[0105] 5. There are also benefits for users:

[0106] 5.1 First of all, the installation and debugging work is simpler, more convenient, and easier to inspect. The installation status can be truly guaranteed (the inspection of gear meshing marks is convenient, easy to perform, and reliable); the alignment between the small herringbone gear and the speed increasing gearbox is convenient and simple. The drum gear coupling itself also allows a certain range of misalignment states. The drum gear drive is reliable and can filter out the vibration at the front end again, which is very beneficial to the operation of the gearbox.

[0107] 5.2 The operating status is easily guaranteed: For machinery and equipment, being too small or too large is not easy to manufacture. Or rather, for machinery and equipment that is too small or too large, their manufacturing costs and operating status will be disproportionate to the benefits; Medium-sized machines have the lowest manufacturing costs and have decades of mature usage experience in other industries. When designing new ones, there are no blind spots or obstacle points in parameter adjustment, and it is easy to meet the requirements. The reliability of their operating status is easily guaranteed.

[0108] 5.3 It is convenient to disassemble, relatively simple and easy, and the cost is greatly reduced: For current wind power generation equipment, the main speed increasing gearbox has the highest failure rate. Now, the medium- and high-speed parts that are prone to failure in the gearbox are set separately. In addition to simplifying its internal structure and enhancing its reliability in use, if a failure really occurs, disconnect the drum gear coupling, and the gearbox itself can be removed separately (this gearbox is much lighter than the three-stage transmission gearbox without the low-speed stage, can be easily lifted off, and because of its lighter weight, the disassembly and assembly time is short, and the lifting cost is also greatly reduced).

[0109] 5.4 The downtime is short and the number of standby machines required is small:

[0110] Previously, after the gearbox failed, it had to be removed completely. The large shaft was often "jammed" with the gearbox, and the gearbox structure was complex, so it could not be repaired on-site at the wind farm, and the fan would stop working completely. This downtime could be as short as one or two months.

[0111] After adopting this modular layout, after removing the damaged gearbox, a spare gearbox can be immediately lifted up. After simple alignment and fastening, the operation can be restored, and the entire fan can be restored to operation in three to five days.

[0112] 5.5 Moreover, even if there is no suitable spare gearbox, with one less motor working, the other undamaged units can still generate electricity, and the entire fan will not stop operating completely.

[0113] 5.6 Even more, one or two generators in the system can be manually cut off according to the seasonal wind speed changes, and the remaining units can still generate electricity normally.

[0114] In a wind farm, there may be hundreds or thousands of fans. By preparing a small number of spare gearboxes or other spare parts, the operating rate of the wind farm fans can be most effectively guaranteed, and its economic benefits are very considerable.

[0115] Conclusion:

[0116] For the wind power transmission system of the present invention, instead of adopting an integrated solution, a decentralized, modular, and combined solution is adopted. The speed increasing gearbox part prone to failure is separately proposed, and multiple medium-power models with mature performance after years of operation are configured for combined layout. This has the following advantages:

[0117] It can significantly improve the problems of inconvenient installation, difficult to ensure installation quality, difficult disassembly, difficult hoisting, large maintenance workload, and long downtime of current wind turbines;

[0118] It can reduce the exorbitant costs of disassembly, hoisting, transportation, etc.;

[0119] It can make the maintenance work easier, with less workload, lower costs, and smaller losses;

[0120] It can better improve the operational reliability of the speed increasing gearbox;

[0121] It can reduce the overall manufacturing cost, especially for large-power wind turbines, with a greater decline;

[0122] It can enable large-power wind turbines to operate and generate electricity under multiple working conditions;

[0123] It can minimize the downtime of wind turbines due to faults;

[0124] It can enable our wind power generation system to be self-designed, optimized according to its own characteristics, and no longer restricted by foreign companies;

[0125] This layout method is beneficial to both the manufacturer, the user, and the participants in future after-sales maintenance services.

[0126] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of the present invention and are not restrictive. Although the present invention has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made in form and details without departing from the scope defined by the claims of the present invention.

Claims

1. A modular and combined wind power transmission system, characterized in that: It includes an impeller and a transmission case. An input shaft and an output shaft are arranged in parallel in the transmission case. One end of the input shaft is connected to the impeller. The input shaft and the output shaft are driven by a gear pair. The other end of the output shaft is sequentially connected to a speed increasing box and a generator; Both ends of the input shaft and the output shaft are supported on the case of the transmission case by bearings. Among them, the end of the input shaft connected to the impeller is supported on the case of the transmission case by a self-aligning bearing. The other end of the input shaft is supported on the case of the transmission case by a self-aligning bearing and a thrust bearing. The thrust bearing is located outside the corresponding self-aligning bearing; The opposite ends of the output shaft and the speed increasing box are connected by a crowned gear sleeve; The transmission between the input shaft and the output shaft is a gear speed increasing transmission; The input shaft and the output shaft are driven by a herringbone gear; 2. The modular and combined wind power transmission system according to claim 1, characterized in that: Both ends of the output shaft are supported on the case of the transmission case by radial bearings; 3. The modular and combined wind power transmission system according to claim 1, wherein: The input shaft and the corresponding herringbone gear are fixed by screws, and the output shaft and the corresponding herringbone gear are formed into a herringbone gear shaft; 4. The modular and combined wind power transmission system according to claim 1, wherein: The number of the output shafts is multiple, and the multiple output shafts are evenly distributed along the circumference of the input shaft; 5. The modular and combined wind power transmission system according to claim 1, wherein: The speed increasing box adopts a speed increasing planetary gear box.

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