A general test device for semi-direct-drive wind power gear box

Abstract

This invention provides a universal testing device for a semi-direct drive wind turbine gearbox, comprising: a motor assembly connected to a universal joint; a speed-regulating gearbox connected to the universal joint via a locking disc; a connecting housing I and a connecting housing II connected to the speed-regulating gearbox; the two connecting housings enclosing the high-speed end of the auxiliary gearbox and connecting it to the output shaft of the speed-regulating gearbox via a transition plate I and a spline flange; the auxiliary gearbox being connected to a transition bearing seat via a low-speed end assembly; and a main test gearbox connected symmetrically to the connecting housing I; the auxiliary gearbox and the main test gearbox being mounted on an elastic support and sequentially fitted onto a high support, a high base, guide rail I, guide rail II, and a test bench pad. The device of this invention has a simple and compact structure, high reliability, and can be widely used by replacing inexpensive and simple-structured parts.

Description

Technical Field

[0001] This invention relates to the technical field of wind turbine gearbox testing, and more particularly to a universal testing device for semi-direct drive wind turbine gearboxes. Background Technology

[0002] In recent years, wind power generation has been rapidly promoted, gradually developing from the original 1.5 MW level to 6 MW or even larger levels, and transitioning from onshore wind power to offshore wind power. As a crucial component of wind turbines, the gearbox's performance directly determines the reliability and service life of the entire unit. However, wind turbine gearboxes operating in high-altitude and offshore locations face complex conditions, inconvenient transportation, and high maintenance costs. Therefore, the design and manufacturing of the gearbox must fully meet the performance requirements before installation and use. Thus, gearbox testing and verification need to accurately simulate the actual operating conditions of the gearbox within the wind turbine tower, and be able to test its performance indicators such as vibration, noise, thermal balance, efficiency, and gear meshing. Furthermore, the upper and lower test benches for the gearbox should be easy to assemble and disassemble, have good alignment, and possess good versatility.

[0003] Existing wind turbine gearbox test benches typically consist of two gearboxes connected back-to-back on a loading test bench. The alignment and adjustment of the gearbox connection is time-consuming and inaccurate. The motor input and output ends are suitable for connecting to the high-speed shaft ends of doubly-fed turbines, but the structure is not suitable for semi-direct-drive turbines. The test benches have a small testing range, many size restrictions for various turbine models, and poor versatility. Therefore, further improvements are needed. Summary of the Invention

[0004] To address the aforementioned technical problems of time-consuming and inaccurate adjustments, this invention provides a universal testing device for semi-direct-drive wind turbine gearboxes. This invention enables rapid and accurate gearbox alignment during installation; it allows adjustment of the horizontal position and vertical height of the entire testing system; it offers good interface compatibility between the test bench and the gearbox under test, broadening the range of turbine sizes that can be tested; it features adjustable speed ratios and is structurally suitable for both doubly-fed and semi-direct-drive gearboxes, allowing the motor to operate within a constant power range for better performance and expanding the test bench's application scope.

[0005] The technical means employed in this invention are as follows:

[0006] A general-purpose test apparatus for a semi-direct-drive wind turbine gearbox includes:

[0007] Motor assembly, universal joint, locking disc, speed regulating gearbox, connecting housing I, connecting housing II, test gearbox, low-speed end assembly, transition bearing seat, elastic support, high support, high base, main test gearbox, guide rail I, guide rail II, test bench pad, transition plate I, spline flange.

[0008] The motor assembly is connected to a universal joint, and the speed regulating gearbox is connected to the universal joint via the locking disc. The speed regulating gearbox is followed by a connecting housing and a connecting housing. The two connecting housings enclose the high-speed end of the auxiliary gearbox and are connected to the output shaft of the speed regulating gearbox via a transition plate I and a spline flange. The auxiliary gearbox is connected to the transition bearing seat via a low-speed end assembly. The main test gearbox is connected in a symmetrical manner with the connecting housing. The auxiliary gearbox and the main test gearbox are mounted on an elastic support and sequentially fitted onto a high support, a high base, guide rail I, guide rail II, and a test bench pad.

[0009] Furthermore, the rotational speed is adjusted to the working speed at the output end of the gearbox via the speed regulating gearbox and then delivered to the high-speed end of the test gearbox.

[0010] Furthermore, the test bench pad is provided with guide rail I and guide rail II; guide rail I enables axial movement of the gearbox; guide rail II enables radial movement of the gearbox.

[0011] Furthermore, the transition plate I and the spline flange are enclosed inside the housing connected to the junction box; one end of the spline flange is connected to the speed regulating gearbox in a spline configuration, and the other end is bolted to the output shaft of the test gearbox.

[0012] Furthermore, the transition plate I connects the connecting box I and the connecting box II.

[0013] Furthermore, the test apparatus also has a transition plate II; the transition plate II connects the connecting housing II to the test gearbox housing.

[0014] Furthermore, the interior of the low-speed end unit 8 is also provided with a transition flange 20 and a connecting flange 21; the transition flange 20 is connected to the low-speed end planetary carrier of the test gearbox 7, and the connecting flange 21 is connected to the transition bearing seat 9. By replacing the transition flange 20, the low-speed end planetary carriers of different gearboxes can be connected.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] The structure described in this invention is simple, compact, and highly reliable. Its wide range of applications can be achieved by replacing inexpensive and simple-to-manufacture parts. This structure can accommodate the testing of two different gearbox types. It includes a speed-regulating gearbox for adjusting the transmission chain speed ratio during testing. The structure features a splined flange, achieving good versatility, high alignment accuracy during assembly, and convenient assembly and disassembly. It offers both high-mounted and high-base supports, suitable for gearboxes of different heights, and can be widely applied to models with varying outer diameters. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0019] Figure 2 This is a schematic diagram of the spline flange connection structure of the present invention.

[0020] Figure 3 This is a schematic diagram of the low-speed end-mount structure of the present invention.

[0021] In the diagram: 1 is the motor assembly; 2 is the universal joint; 3 is the locking disc; 4 is the speed regulating gearbox; 5 is the connecting housing; 6 is the connecting housing II; 7 is the test gearbox; 8 is the low-speed end assembly; 9 is the transition bearing housing; 10 is the elastic support; 11 is the high support; 12 is the high base; 13 is the main test gearbox; 14 is the guide rail I; 15 is the guide rail II; 16 is the test bench pad; 17 is the transition plate I; 18 is the spline flange; 19 is the transition plate II; 20 is the transition flange; 21 is the connecting flange. Detailed Implementation

[0022] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features; steps; operations; devices; components and / or combinations thereof.

[0025] Unless otherwise specifically stated, the relative arrangement of components and steps, numerical expressions, and values ​​illustrated in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and apparatus should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0026] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front; back; up; down; left; right"; "lateral; vertical; perpendicular; horizontal" and "top; bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0027] For ease of description, spatial relative terms such as "above," "over," "on the upper surface," "above," etc., may be used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0028] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0029] like Figure 1-3 As shown, the present invention provides a general testing device for a semi-direct drive wind turbine gearbox, comprising a motor assembly 1, a universal joint 2, a locking disc 3, a speed regulating gearbox 4, a connecting housing I 5, a connecting housing II 6, a test gearbox 7, a low-speed end assembly 8, a transition bearing seat 9, an elastic support 10, a high support 11, a high base 12, a main test gearbox 13, a guide rail I 14, a guide rail II 15, a test bench pad 16, a transition plate I 17, a spline flange 18, a transition plate II 19, a transition flange 20, and a connecting flange 21, etc.

[0030] like Figure 1 As shown, the motor assembly 1 is connected to the universal joint 2. A locking disc 3 connects the speed regulating gearbox 4 to the universal joint 2. The speed regulating gearbox 4 is then connected to connecting housing I5 and connecting housing II6. These two connecting housings enclose the high-speed end of the test gearbox 7 and connect it to the output shaft of the speed regulating gearbox 4 via a transition plate I17 and a spline flange 18. The test gearbox 7 is connected to the transition bearing seat 9 via the low-speed end assembly 8. The main test gearbox 13 is connected symmetrically. The test gearbox 7 and the main test gearbox 13 are mounted on the elastic support 10 and sequentially mounted on the high support 11, high base 12, guide rail I14, guide rail II15, and test bench pad 16.

[0031] A speed-regulating gearbox 4 was designed. The motor, given a corresponding speed according to test requirements, is adjusted to the operating speed at the gearbox output via the speed-regulating gearbox 4, and then transmitted to the high-speed end (i.e., the output end of the gearbox during operation) of the test gearbox 7. This speed-regulating gearbox 4 solves the problem that this semi-direct drive structure gearbox cannot be directly connected to a conventional wind power test bench, achieving a connection structurally. Simultaneously, the transmission ratio of a semi-direct drive wind turbine gearbox in the same megawatt range is relatively smaller than that of a doubly-fed induction generator (DFIG) model, while the output power range of the test bench motor is limited. The speed-regulating gearbox 4, by replacing different gear pairs, can achieve various transmission ratios, allowing the test bench motor to operate under constant power output, improving the test bench's operational quality and expanding the testing range to the megawatt level, and meeting the testing requirements for both semi-direct drive and DFIG wind turbine models.

[0032] Guide rails I14 and II15 are mounted on the test bench pad 16. Guide rail I14 enables the axial movement of the gearbox, and guide rail II15 enables the radial movement of the gearbox. During the process of connecting the gearbox to the test bench, its axial and radial positions can be finely adjusted through these two guide rails, making the installation process convenient and quick.

[0033] Two types of supports, the high support 11 and the high base 12, are designed to be suitable for gearboxes of different heights and can be widely used for models with different outer diameters.

[0034] like Figure 2 As shown, a transition plate I17 and a splined flange 18 are designed and enclosed inside the connecting housing I5. One end of the splined flange 18 is connected to the speed regulating gearbox 4 in a spline configuration, and the other end is bolted to the output shaft of the test gearbox 7. This design facilitates easy assembly and disassembly and provides good alignment. The transition plate I17 connects the connecting housing I5 to the connecting housing II6. Figure 1 As shown, the connecting housing II6 is connected to the test gearbox 7 housing by the transition plate II19. Different spline flanges can be designed to connect the output shafts of different gearboxes. Different transition plates I17 can achieve different axial distances. Different transition plates II19 can connect different gearbox housings. Moreover, the manufacturing cost of these three parts is low. The simple structure and low manufacturing cost have achieved good universality of the front end connection of the test bench.

[0035] like Figure 1 , Figure 3 As shown, the low-speed end unit 8 is internally designed with structures such as transition flange 20 and connecting flange 21. Transition flange 20 connects to the low-speed end planetary carrier of the test gearbox 7, and connecting flange 21 connects to the transition bearing seat 9. By replacing transition flange 20, the low-speed end planetary carriers of different gearboxes can be connected. The transition flange has low manufacturing cost and is easy to replace. With a simple structure and low manufacturing cost, the universality of the test bench connection to the low-speed end of the gearbox is well achieved.

[0036] The device of this invention, through the assembly and disassembly of the speed regulating gearbox 4 and the connection of the connecting housing I5, connecting housing II6, and other components, can meet the testing requirements of doubly-fed wind turbine gearboxes and semi-direct-drive wind turbine gearboxes, which are currently the two mainstream large-megawatt wind turbine gearbox models on the market, and has a wide range of applications.

[0037] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0038] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A general test device for a semi-direct drive wind power gear box, characterized in that, include: Motor assembly (1), universal joint (2), locking disc (3), speed regulating gearbox (4), connecting housing I (5), connecting housing II (6), test gearbox (7), low speed end assembly (8), transition bearing seat (9), elastic support (10), high support (11), high base (12), main test gearbox (13), guide rail I (14), guide rail II (15), test bench pad (16), transition plate I (17), spline flange (18); The motor assembly (1) is connected to the universal joint (2), and the speed regulating gearbox (4) is connected to the universal joint (2) through the locking disc (3). The speed regulating gearbox (4) is then connected to the connecting housing I (5) and the connecting housing II (6). The two connecting housings enclose the high-speed end of the test gearbox (7) and connect it to the output shaft of the speed regulating gearbox (4) through the transition plate I (17) and the spline flange (18). The test gearbox (7) is connected to the transition bearing seat (9) through the low-speed end assembly (8). The main test gearbox (13) is connected in a symmetrical manner with the connecting housing I (5). The main test gearbox (13) is mounted on the elastic support (10) and sequentially connected to the high support (11), high base (12), guide rail I (14), guide rail II (15) and test bench pad (16); the speed is adjusted to the working speed of the gearbox output end through the speed regulating gearbox (4) and delivered to the high speed end of the auxiliary test gearbox (7); the transition plate I (17) and the spline flange (18) are wrapped inside the connecting housing I (5); one end of the spline flange (18) is connected to the speed regulating gearbox (4) in a spline form, and the other end is bolted to the output shaft of the auxiliary test gearbox (7); the transition plate I (17) connects the connecting housing I (5) and the connecting housing II (6).

2. The universal test device for a semi-direct drive wind power gearbox according to claim 1, characterized in that, The test bench pad (16) is provided with guide rail I (14) and guide rail II (15); guide rail I (14) realizes the axial movement of the gearbox; guide rail II (15) realizes the radial movement of the gearbox.

3. The universal test device for a semi-direct drive wind turbine gearbox according to claim 1, characterized in that, The test apparatus also has a transition plate II (19); the transition plate II (19) connects the connecting box II (6) to the test gearbox (7).

4. The universal test apparatus for a semi-direct drive wind turbine gearbox according to claim 1, characterized in that, The low-speed end unit (8) is also provided with a transition flange (20) and a connecting flange (21); The transition flange (20) is connected to the low-speed end planetary carrier of the test gearbox (7), and the connecting flange (21) is connected to the transition bearing seat (9). By replacing the transition flange (20), the low-speed end planetary carriers of different gearboxes can be connected.

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