A gearbox fault diagnosis and lubrication and cooling system training platform

Abstract

A gearbox fault diagnosis and lubrication and cooling system training platform, comprising a gearbox scaled training unit, a cooling system unit arranged above the gearbox scaled training unit and fixedly connected thereto, a lubrication unit arranged below the gearbox scaled training unit and connected thereto, a transmission unit arranged at the input end of the gearbox scaled training unit, a wind source simulation unit arranged on the opposite side of the input end of the gearbox scaled training unit, a crane unit arranged directly above the gearbox scaled training unit, and a human-computer interaction unit electrically connected to the gearbox scaled training unit and the wind source simulation unit. This training platform can be used for gearbox, cooling system and lubrication system operation, maintenance training, and fault diagnosis training of gearbox internal components.

Description

Technical Field

[0001] The invention relates to a training platform, in particular to a gearbox fault diagnosis and lubrication cooling system training platform. Background Art

[0002] As one of the "green energy" that can replace traditional energy in the future, wind power generation has the fastest market scale and the most promising development speed among renewable energy sources such as solar energy, biomass energy and tidal energy. In some countries, wind power generation can already provide 10% to 20% of the national electricity demand, and some even reach more than 50%. Although China's wind power industry started relatively late, with the strong support of national policies, the average annual growth rate of wind power installed capacity in the past 10 years has reached more than 55%, and the prospects are promising.

[0003] Due to the vigorous development of wind power, the rapid construction of wind farms and the substantial growth of wind turbine installed capacity have brought a series of challenges, the most prominent of which is the quality problem of the unit, among which gearbox failure is one of the main problems that occurs frequently, seriously affecting the normal operation of the unit and causing huge economic losses. As a large rotating machinery, wind turbines operate in harsh environments for a long time. In addition, since wind turbines are generally installed in high mountains, wilderness, beaches, islands and other wind outlets, they are subject to irregular wind force of changing direction and load and the impact of strong gusts, and the service life and failure of the unit are frequent. As the core component of the transmission system in the wind turbine, the gearbox is continuously subjected to alternating impact force and heavy load, and is a high-incidence part of the failure. Common faults of the gearbox include broken gear teeth, damage to the inner and outer rings of the bearing, and unbalanced shaft. When these faults exist, they will cause modulation problems of the gearbox vibration signal. Faults in different parts will cause different characteristic frequencies of the vibration signal, and different degrees of faults in the same part will cause different degrees of vibration amplitude. Summary of the invention

[0004] In view of the above problems, the technical problem to be solved by the present invention is to propose a gearbox fault diagnosis and lubrication and cooling system training platform, which can make a corresponding assessment of the health status of the gearbox by analyzing the vibration signals of the fault, and can carry out gearbox lubrication system operation and maintenance training.

[0005] The present invention adopts the following technical scheme: a gearbox fault diagnosis and lubrication and cooling system training platform, comprising a gearbox scaled training unit, a cooling system unit arranged above the gearbox scaled training unit and fixedly connected thereto, a lubrication unit arranged below the gearbox scaled training unit and connected thereto, a transmission unit arranged at the input end of the gearbox scaled training unit, a wind source simulation unit arranged on the opposite side of the input end of the gearbox scaled training unit, a crane unit arranged directly above the gearbox scaled training unit, and a human-computer interaction unit electrically connected to the gearbox scaled training unit and the wind source simulation unit; the gearbox scaled training unit is a training gearbox manufactured in proportion to the actual size, which is used to display the structure and conduct disassembly and assembly exercises. So that the trainees can understand the internal structure, part shape, part name, etc.; the cooling system unit dissipates heat from the gearbox to prevent overheating during operation and cause damage to parts; the lubrication unit is used to provide lubricating oil to the inside of the gearbox, reduce gear friction, lower the body temperature, and take away the debris generated by the body operation, while having a certain buffering effect on the gear meshing movement; the transmission unit is used to connect the wind source simulation unit and the gearbox scaled training unit, and transmit power from the wind source simulation unit to the gearbox scaled training unit to transfer power; the wind source simulation unit provides a power source, and the power size can be adjusted by changing the current strength or by changing motors with different rated power to obtain different powers; the human-computer interaction unit controls the start and stop, speed, forward and reverse rotation of the motor through electrical signals.

[0006] Furthermore, the gearbox scaled training unit includes a gearbox body, an input shaft, a base and a fixed frame, the input shaft is arranged at the input end of the gearbox body, the base is arranged on the lower side of the gearbox body, the fixed frame is arranged between the base and the gearbox body, and is bolted to the base and the gearbox body; the base effectively ensures the stability of the gearbox body and reduces damage to the machine body, and the base has the function of counterweight, each side of the gearbox body ensures the balance of the machine body and reduces the running noise of the machine body, the fixed frame is used to connect the gearbox body and the base, and a spline is arranged at one end of the input shaft outside the machine body.

[0007] Furthermore, the cooling system unit includes a fan and a fan fixing frame, the fan fixing frame is arranged above the gear box body and fixedly connected to the gear box body, and the upper surface of the fan fixing frame is parallel to the horizontal ground, a hole is arranged in the center of the fan fixing frame, and the fan is connected to the upper surface of the fan fixing frame by bolts.

[0008] Furthermore, the lubrication unit includes an oil pump, an oil inlet pipe, an oil return pipe, an oil tank and a filter element. The oil pump is connected to the interior of the gear box body. The oil pump is connected to the oil tank through the oil inlet pipe to draw lubricating oil from the oil tank. The power of the oil pump comes from the power transmitted by the gears inside the gear box. The power is obtained through gear meshing to complete the oil suction function; the gear box body is connected to the oil tank through the oil return pipe, and the filter element effectively filters impurities in the oil tank.

[0009] Furthermore, the wind source simulation unit is a servo motor provided with an output shaft. The servo motor can control the rotation speed according to the current, which is convenient for control and demonstration. A sensor is provided on the motor to feed back the rotation speed signal to the human-machine interaction unit in real time. The output shaft is provided with a spline at one end outside the motor.

[0010] Furthermore, the transmission unit includes bearings, gear sleeves and box walls. There are two bearings, which are relatively arranged on both sides of the transmission unit. The bearings are interference fit with the box walls and the input shaft and the output shaft. The bearings effectively reduce the rotational friction of the input shaft and the output shaft. A disassembly and assembly port is provided on the top of the transmission unit to facilitate the installation of the gear sleeve.

[0011] Furthermore, the input shaft and the output shaft heads are matched with the gear sleeve via splines, and such matching is more stable, has higher transmission efficiency, and is convenient for loading and unloading, and can be installed and disassembled through the upper mounting hole of the transmission unit.

[0012] Furthermore, the human-machine interaction unit includes a display screen, a signal light arranged below the display screen, an operating keyboard arranged below the signal light, and a control cabinet arranged below the operating keyboard. The control cabinet includes a PLC controller, a frequency converter, a contactor, a circuit breaker, a relay, a switching power supply, etc., to realize the functions of electrical control and fault triggering of the training platform. The device layout in the electrical control cabinet is arranged according to the component category, which can facilitate the experimenter to identify and wire the electrical components; the human-machine interface interaction unit can realize the monitoring and control of the working status of the training equipment, the setting of fault and maintenance content, and the assessment and management of the training.

[0013] Furthermore, the crane unit includes a shell, a winch arranged inside the shell, a motor arranged at one end of the winch, a hook arranged under the winch, and a control handle arranged under the motor and electrically connected to the motor. The crane unit adopts a 5t crane, which can lift heavier parts during the process of disassembling, repairing and troubleshooting the demonstration gearbox, which is safe and convenient.

[0014] Furthermore, a gearbox fault diagnosis and lubrication and cooling system training platform also includes a wire storage unit arranged below the ground. This structure is a hollow structure used to store the connections between devices, thereby preventing leakage and electric shock accidents during the training process, and can reduce line aging and save operating costs.

[0015] Beneficial effects of the invention: Beneficial effects of the invention: The technical problem to be solved by the invention is to disclose a gearbox fault diagnosis and lubrication and cooling system training platform.

[0016] (1) This training bench can be used for gearbox lubrication system operation and maintenance training;

[0017] (2) This training bench can be used for gearbox cooling system operation and maintenance training;

[0018] (3) This training bench can be used for fault diagnosis training of internal components of gearboxes;

[0019] (4) This training platform can use the alignment instrument to detect the coaxiality of the gearbox high-speed shaft and the motor;

[0020] (5) This training bench can be used for maintenance and training of gearbox high-speed shaft damage;

[0021] (6) This training bench can be used for training on internal inspection of gearboxes with endoscopes;

[0022] (7) This training platform can complete the gearbox regular inspection and patrol inspection;

[0023] (8) This training platform can replace the gears and bearings of the center gear shaft system;

[0024] (9) This training platform can replace the gears and bearings of the high-speed shaft system;

[0025] (10) This training bench can replace the bearings of the parallel shaft system; (11) This training bench can replace the filter element of the lubrication system. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0027] The structures, proportions, sizes, etc. illustrated in this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with the technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantial technical significance. Any structural modification, change in proportion or adjustment of size shall still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and purposes that can be achieved by the present invention.

[0028] The present invention is further described below in conjunction with the accompanying drawings and embodiments; Figure 1 It is a schematic diagram of the structure of the present invention;

[0029] Figure 2 It is a schematic diagram of the gearbox and lubrication and cooling structure of the present invention;

[0030] Figure 3 It is a schematic diagram of the transmission unit structure of the present invention;

[0031] Figure 4 It is a schematic diagram of the structure of the electric vehicle unit of the present invention;

[0032] Figure 5 It is a schematic diagram of the structure of the human-computer interaction unit of the present invention.

[0033] Among them: 1 gearbox scale training unit, 11 gearbox body, 12 input shaft, 13 base, 14 fixing frame,

[0034] 2 cooling system unit, 21 fan, 22 fan fixing frame,

[0035] 3 transmission unit, 31 bearing, 32 gear sleeve, 33 box wall,

[0036] 4 wind source simulation units, 41 output shafts,

[0037] 5 human-machine interaction unit, 51 display screen, 52 signal light, 53 operation keyboard, 54 control cabinet,

[0038] 6 crane unit, 61 winch, 62 housing, 63 motor, 64 hook, 65 control handle,

[0039] 7 lubrication unit, 71 oil pump, 72 oil supply pipe, 73 oil return pipe, 74 oil tank, 75 filter element, 8 wire storage unit. DETAILED DESCRIPTION

[0040] The present invention is described in further detail below with reference to the accompanying drawings.

[0041] like Figure 1-5As shown, a gearbox fault diagnosis and lubrication and cooling system training platform is characterized in that it includes: a gearbox scaled training unit 1, a cooling system unit 2 arranged above the gearbox scaled training unit 1 and fixedly connected thereto, a lubrication unit 7 arranged below the gearbox scaled training unit 1 and connected thereto, a transmission unit 3 arranged at the input end of the gearbox scaled training unit 1, a wind source simulation unit 4 arranged on the opposite side of the input end of the gearbox scaled training unit 1, a crane unit 6 arranged directly above the gearbox scaled training unit 1, and a human-computer interaction unit 5 electrically connected to the gearbox scaled training unit 1 and the wind source simulation unit 4.

[0042] The gearbox scale training unit 1 includes a gearbox body 11, an input shaft 12, a base 13 and a fixing frame 14, wherein the input shaft 12 is arranged at the input end of the gearbox body 11, the base 13 is arranged on the lower side of the gearbox body 11, and the fixing frame 14 is arranged between the base 13 and the gearbox body 11, and is bolted to the base 13 and the gearbox body 11.

[0043] The cooling system unit 2 includes a fan 21 and a fan fixing frame 22. The fan fixing frame 22 is arranged above the gear box body 11 and fixedly connected to the gear box body 11, and the upper surface of the fan fixing frame 22 is parallel to the horizontal ground. A hole is arranged in the center of the fan fixing frame 22, and the fan 21 is connected to the upper surface of the fan fixing frame 22 by bolts.

[0044] The lubrication unit 7 includes an oil pump 71 , an oil inlet pipe 72 , an oil return pipe 73 and an oil tank 74 . The oil pump 71 is connected to the interior of the gearbox body 11 . The oil pump 71 is connected to the oil tank 74 through the oil inlet pipe 72 . The gearbox body 11 is connected to the oil tank 74 through the oil return pipe 73 .

[0045] The wind source simulation unit 4 is a servo motor and is provided with an output shaft 41 .

[0046] The transmission unit 3 includes a bearing 31 , a gear sleeve 32 and a box wall 33 . The bearings 31 are two in number and are arranged on both sides of the transmission unit 3 . The bearings 31 are interference fit with the box wall 33 , the input shaft 12 , and the output shaft 41 .

[0047] The heads of the input shaft 12 and the output shaft 41 are matched with the gear sleeve 32 through splines.

[0048] The human-machine interaction unit 5 includes a display screen 51, a signal light 52 disposed below the display screen, an operation keyboard 53 disposed below the signal light 52, and a control cabinet 54 disposed below the operation keyboard 53. The control cabinet includes a PLC controller, a frequency converter, a contactor, a circuit breaker, a relay, a switching power supply, etc., to realize functions such as electrical control and fault triggering of the training platform. The device layout in the electrical control cabinet is arranged according to the component category, which can facilitate the experimenter to identify and wire the electrical components.

[0049] The crane unit 6 includes a shell 62, a winch 61 arranged inside the shell 62, a motor 63 arranged at one end of the winch 61, a hook 64 arranged below the winch 61, and a control handle 65 arranged below the motor 63 and electrically connected to the motor 63.

[0050] It also includes a wire storage unit 8 disposed below the ground.

[0051] Workflow: open the crane unit 6, hoist the gearbox body 11 into place, connect the input shaft 12 and the transmission unit 3, tighten the bolts of the fixing frame 14 of the gearbox body 11 and the base 13, then fix the wind source simulation unit 4 on the base, connect the output shaft 41 of the wind source simulation unit 4 and the transmission unit 3, then set the gear sleeve of the transmission unit 3 on the splines of the input shaft 12 and the output shaft 41, so that the three are tightly engaged, then install the fan 21 of the cooling system unit 2 on the fan fixing frame 22, connect one end of the oil pipe 72 of the lubrication unit 7 to the oil pump, and the other end to the filter element, the oil pipe 72 passes through the filter element and then connects to the oil tank 74, then connect one end of the return oil pipe 73 to the bottom of the gearbox body 11, and the other end to To the oil tank 74, and then connect the wires of the gearbox body 11, the fan 21 and the wind source simulation unit 4 to the human-computer interaction unit 5 through the wire storage unit 8. At this time, you can press the start button of the operation keyboard 53, and start the wind source simulation unit 4 after the signal light 52 lights up. The servo motor starts to rotate, driving the transmission unit 3 to rotate, thereby driving the gearbox input shaft 12 to rotate, and then the gearbox starts to work. After preheating for 10 minutes, you can start observation and inspection, and carry out relevant training projects. When it is necessary to perform operations related to disassembly of the gearbox, first press the stop button on the operation keyboard 53, cut off all power supplies, and then start disassembly. Use the crane unit 6 to disassemble the parts. The removed parts must be placed neatly for use during assembly.

[0052] The practical training projects that can be realized on the training platform are: 1. Maintenance and repair of gearbox

[0053] 1) Gearbox fastener inspection

[0054] 2) Gearbox elastic support inspection

[0055] 3) Gearbox vibration inspection

[0056] 4) Gearbox gear and bearing inspection

[0057] 5) Gearbox sensor inspection

[0058] 2. Disassembly and replacement of gearbox internal parts:

[0059] 1) Air filter removal and replacement

[0060] 2) Heater disassembly and replacement

[0061] 3) Temperature sensor removal and replacement

[0062] 4) Disassembly and replacement of gearbox oil pump motor

[0063] 5) Disassembly and replacement of gearbox oil pipe

[0064] 6) Gearbox lubricating oil replacement

[0065] 3. Maintenance of gearbox lubrication and cooling system:

[0066] 1) Inspection and maintenance of lubrication system pipelines

[0067] 2) Inspection and maintenance of hose aging

[0068] 3) Heat exchanger inspection and maintenance

[0069] 4) Filter inspection and maintenance

[0070] 5) Oil pump inspection and maintenance

[0071] 6) Manual valve inspection

[0072] 7) Fastener inspection

[0073] 8) Sensor detection

[0074] 4. Common fault simulation of gearbox and cooling system

[0075] Gearbox oil pump overload

[0076] Gearbox oil level is too low

[0077] Gearbox oil temperature high limit power

[0078] Gear box high speed pump without pressure

[0079] Gearbox oil temperature is too high

[0080] 5. Practical training on gearbox and generator alignment

[0081] 1) Gearbox shock absorption practical training

[0082] 2) Generator shock absorber adjustment training

[0083] 3) Practical training on centering equipment

[0084] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein, and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A gearbox fault diagnosis and lubrication and cooling system training platform, characterized by: The invention comprises a gearbox scaled-down training unit (1), a cooling system unit (2) arranged above the gearbox scaled-down training unit (1) and fixedly connected thereto, a lubrication unit (7) arranged below the gearbox scaled-down training unit (1) and connected thereto, a transmission unit (3) arranged at the input end of the gearbox scaled-down training unit (1), a wind source simulation unit (4) arranged at the opposite side of the input end of the gearbox scaled-down training unit (1), a crane unit (6) arranged directly above the gearbox scaled-down training unit (1), and a human-machine interaction unit (5) electrically connected to the gearbox scaled-down training unit (1) and the wind source simulation unit (4); The training unit (1) comprises a gearbox body (11), an input shaft (12), a base (13) and a fixing frame (14), wherein the input shaft (12) is arranged at the input end of the gearbox body (11), the base (13) is arranged at the lower side of the gearbox body (11), and the fixing frame (14) is arranged between the base (13) and the gearbox body (11), and is bolted to the base (13) and the gearbox body (11); the cooling system unit (2) comprises a fan (21) and a fan fixing frame (22), wherein the fan fixing frame (22) is arranged above the gearbox body (11) and is bolted to the gearbox body (11). The gear box body (11) is fixedly connected, the center of the fan fixing frame (22) is provided with a hole, and the fan (21) is connected to the upper surface of the fan fixing frame (22) by bolts; the lubrication unit (7) comprises an oil pump (71), an oil inlet pipe (72), an oil return pipe (73), an oil tank (74) and a filter element (75), the oil pump (71) is communicated with the inside of the gear box body (11), the oil pump (71) is communicated with the oil tank (74) through the oil inlet pipe (72), the gear box body (11) is communicated with the oil tank (74) through the oil return pipe (73), and the filter element (75) is arranged in the oil inlet pipe (72). The wind source simulation unit (4) is a servo motor and is provided with an output shaft (41); the transmission unit (3) comprises a bearing (31), a gear sleeve (32) and a box wall (33); the bearings (31) are two in number and are arranged on two sides of the transmission unit (3) relative to each other; the bearings (31) are interference fit with the box wall (33) and the input shaft (12) and the output shaft (41); the human-machine interaction unit (5) comprises a display screen (51), a signal light (52) arranged below the display screen, an operating keyboard (53) arranged below the signal light (52), and a control cabinet (54) arranged below the operating keyboard (53);The crane unit (6) comprises a housing (62), a winch (61) disposed inside the housing (62), a motor (63) disposed at one end of the winch (61), a hook (64) disposed below the winch (61), and a control handle (65) disposed below the motor (63) and electrically connected to the motor (63). ; 2. A gearbox fault diagnosis and lubrication and cooling system training platform according to claim 1, characterized in that: The heads of the input shaft (12) and the output shaft (41) are matched with the gear sleeve (32) via splines.

3. A gearbox fault diagnosis and lubrication and cooling system training platform according to claim 1, characterized in that: The gearbox body (11) is provided with an output end flange, which is adapted to the input end of the generator.

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