A design method for horizontal test flange of direct-drive generator

Abstract

The present invention discloses a method for designing a horizontal test flange of a direct-drive generator, and relates to a method for designing a test flange. The test apparatus includes a horizontal test, a direct-drive wind turbine generator, and a horizontal test flange, wherein the upper end face of the horizontal test flange is connected to the fixed axis of the direct-drive generator by bolts, and the lower end face of the horizontal test flange is connected to the horizontal test bench by bolts. Only the basic test parameters of the generator and the test bench need to be obtained to obtain the optimal height of the flange. Compared with the prior art, the present application can calculate the size of the required test flange according to the relative positions of the test bench, the generator, and the flange, and the sizes of the test bench and the generator, and can quickly design flanges that are suitable for different test benches and generators, thereby accelerating the test time and improving the test efficiency.

Description

Technical Field

[0001] The invention relates to a design method of a test flange. Background Art

[0002] The horizontal rotation test is a routine test for large direct-drive generators before they leave the factory. This test is usually carried out during the trial production of new models of generators. In this process, the horizontal test connection flange is indispensable. The connection flange is used to connect the generator to the horizontal test bench. The design size of the flange is related to the labor-saving of the horizontal test bench turning over the generator and the strength of the flange itself to resist the overturning moment of the generator. The horizontal test flange is an important tooling with large forces. Flanges of different sizes in the horizontal test of large direct-drive generators have similar mechanical structures. They are welded from the upper end face, the lower end face, and the support tube. Although the flange structure is simple, it is still difficult to design a horizontal test flange that is good in both labor-saving and strength in turning over the motor. When designing the flange, engineers often spend a lot of time determining the size, which requires relying on the designer's design experience and is time-consuming and labor-intensive. Even so, it is difficult to determine whether the designed flange can make the horizontal test bench the most labor-saving and whether the flange strength meets the standard.

[0003] In order to solve the problems of rapidity, labor saving and reliability in the design of a horizontal test flange, the present invention proposes a universal design method for a horizontal test flange of a direct-drive generator. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a method for designing a horizontal test flange for a direct-drive generator. The method can calculate the size of the required test flange according to the relative positions of the test bench, the generator and the flange, as well as the sizes of the test bench and the generator. Flanges suitable for different test benches and generators can be quickly designed, thereby speeding up the test time and improving the test efficiency.

[0005] In order to solve the above technical problems, the present invention is solved by the following technical solutions: a method for designing a horizontal test flange of a direct-drive generator, wherein the test apparatus comprises a horizontal test bench 1, a direct-drive wind turbine 2 and a horizontal test flange 3, wherein the upper end surface of the horizontal test flange 3 is connected to the fixed axis of the direct-drive generator 2 by bolts, and the lower end surface of the horizontal test flange 3 is connected to the horizontal test bench by bolts.

[0006] The distance from the rotating shaft of the direct-drive wind turbine 2 to the bottom bearing surface of the horizontal test bench 1 is a, the distance from the center of mass of the direct-drive wind turbine 2 to the upper end surface of the horizontal test flange 3 is b, the distance from the center of mass of the horizontal test bench 1 to the bottom bearing surface of the test bench is c, the distance from the center of mass of the direct-drive wind turbine 2 to the rotating shaft of the horizontal test bench 1 is x, and the height of the horizontal test flange 3 is y, where a, b, and c are known quantities, and x and y are quantities to be measured;

[0007] Let the mass of the generator be M and the mass of the test bench be m, then the moment balance equation is: , we can deduce:

[0008] ,

[0009] From the assembly relationship among the horizontal test bench 1, the direct-drive wind turbine 2, and the horizontal test flange 3, it can be obtained that:

[0010] ,

[0011] Can launch:

[0012] ,

[0013] From the above, the optimal height of the horizontal test flange 3 can be known.

[0014] In the above technical method, preferably, the horizontal test flange 3 is welded by an upper end face, a support tube, and a lower end face. After determining the height y of the horizontal test flange 3, the dimensions of the upper end face, the support tube, and the lower end face are determined according to the assembly requirements and the size and shape of the horizontal test bench 1 and the direct-drive wind turbine 2.

[0015] In the above technical method, preferably, the dimensions of the upper end face of the horizontal test flange include the pitch circle diameter of the bolt holes on the upper end face of the flange, the diameter of the upper end face of the horizontal test flange, the size and number of the bolt holes on the upper end face of the horizontal test flange, the pitch circle diameter of the bolt holes on the upper end face of the horizontal test flange must be equal to the pitch circle diameter of the bolt holes reserved on the fixed axis of the direct-drive wind turbine, the diameters of the upper and lower end faces of the horizontal test flange are larger than the pitch circle diameters of the bolt holes distributed thereon, the size of the bolt holes on the upper end face of the horizontal test flange is larger than the size of the threaded holes on the fixed axis of the direct-drive wind turbine, and the number of bolt holes on the horizontal test flange is an even number and is not less than half of the number of bolt holes on the fixed axis.

[0016] In the above technical method, preferably, the relevant dimensions of the lower end face of the horizontal test flange include the pitch circle diameter of the lower end face bolt holes, the diameter of the lower end face of the horizontal test flange, the size and number of the bolt holes on the lower end face of the horizontal test flange, the pitch circle diameter of the bolt holes on the lower end face of the horizontal test flange is equal to the pitch circle diameter of the bolt holes on the selected horizontal test bench, the size of the bolt holes on the lower end face of the horizontal test flange is equal to the size of the bolt holes on the horizontal test bench, and the number of bolt holes on the horizontal test flange is an even number and not less than half of the number of bolt holes on the horizontal test bench.

[0017] In the above technical method, preferably, the dimensions of the support tube between the upper and lower end faces of the horizontal test flange include the height, outer diameter and inner diameter of the support tube, the height of the support tube is equal to the height of the horizontal test flange minus the thickness of the upper and lower end faces of the horizontal test flange, and the cross-section of the horizontal test flange support tube is a circular ring.

[0018] At present, from the perspective of the design method of the horizontal test flange of the direct-drive wind turbine in the wind power industry, there has not yet been a universal flange design method for the labor-saving and flange reliability of the horizontal test bench flipping the generator. The universal design method of the horizontal test flange of the direct-drive generator proposed in the present invention mainly proposes a theoretical calculation formula for the key parameter of the horizontal test flange height when the horizontal test bench flips the generator with the most labor-saving condition: The height y of the horizontal test flange of the direct-drive generator directly affects the force required by the test bench to flip the generator. In order to minimize this flipping force, the total center of mass of the test bench and the generator can be located near the axis of the test bench's rotating shaft, so that the eccentricity of rotation is as close to zero as possible. At this time, the moment of the generator's own gravity on the axis of the rotating shaft is balanced with the moment of the test bench's gravity on the axis of the rotating shaft, and the test bench can flip the generator with the least effort.

[0019] Compared with the prior art, the present application can calculate the size of the required test flange according to the relative positions of the test bench, generator and flange and the sizes of the test bench and generator, and can quickly design flanges suitable for different test benches and generators, thereby speeding up the test time and improving the test efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is the overall structural diagram of the horizontal test of the direct-drive generator of the present invention. DETAILED DESCRIPTION

[0021] The following will clearly and completely describe the technical solutions of various embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments described in the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] Example 1: Figure 1 As shown, it includes a horizontal test bench 1, a direct-drive wind turbine 2, and a horizontal test flange 3, wherein the upper end face of the horizontal test flange 3 is connected to the fixed axis of the direct-drive generator 2 by bolts, and the lower end face of the horizontal test flange 3 is connected to the horizontal test bench by bolts. a is the distance from the rotating shaft of the test bench flip motor to the bottom bearing surface of the test bench, b is the distance from the center of mass of the generator to the upper end face of the flange, and dimension c is the distance from the center of mass of the test bench to the bottom bearing surface of the test bench. a, b, and c are all basic parameters of the generator and the test bench, and are known quantities. x is the distance from the center of mass of the generator to the rotating shaft of the test bench, and dimension y is the height of the horizontal test flange, which is a quantity that needs to be solved.

[0023] The height y of the horizontal test flange of the direct-drive generator directly affects the force required by the test bench to flip the generator. In order to minimize this flipping force, the total center of mass of the test bench and the generator can be located near the axis of the test bench shaft, so that the eccentricity of the rotation is as close to zero as possible. At this time, the moment of the generator's own gravity on the axis of the shaft is balanced with the moment of the test bench gravity on the axis of the shaft, and the test bench flips the generator with the least effort. Let the mass of the generator be M and the mass of the test bench be m, and use the above analysis to list the moment balance equation:

[0024] ,

[0025] Can launch:

[0026] ,

[0027] According to the assembly relationship among the horizontal test bench 1, the direct-drive wind turbine 2, and the horizontal test flange 3, it can be obtained that:

[0028] ,

[0029] Finally, the calculation formula for the horizontal test flange height y can be obtained:

[0030] ,

[0031] This is the flange height dimension algorithm required when the horizontal test bench flips the generator with the least effort. From the above formula, it can be seen that the optimal flange height can be obtained by only obtaining the basic test parameters of the generator and the test bench.

[0032] The structure of the horizontal test flange is welded by the upper end face, the support tube and the lower end face. The height dimension is the most obvious distinguishing point for designing horizontal test flanges of different direct-drive generator models. After this dimension is determined, the other structural dimensions are mainly related to assembly.

[0033] Calculation method of flange upper end face dimensions. The dimensions of the flange upper end face include the pitch circle diameter of the flange upper end face bolt holes, the flange upper end face diameter, and the size and number of the flange upper end face bolt holes. Since the upper end face of the horizontal test flange is connected to the fixed shaft of the direct-drive wind turbine, the pitch circle diameter of the flange upper end face bolt holes must be equal to the pitch circle diameter of the bolt holes reserved on the generator fixed shaft. Generally, a variety of bolt hole arrangements of specifications are reserved on the generator fixed shaft. Considering the overturning moment of the horizontal test flange, the bolt holes on the outermost circle of the fixed shaft are connected to the horizontal test flange. The diameter of the upper and lower end faces of the flange only needs to be slightly larger than the pitch circle diameter of the bolt holes on it. According to our company's experience in designing horizontal flanges for direct-drive models, it is reliable that the diameter of the upper and lower end faces of the flange is more than 130mm larger than the pitch circle diameter of the bolt holes on it. The size of the bolt hole on the end face of the flange is slightly larger than the size of the threaded hole on the fixed shaft of the generator, with a difference of 3-5mm. The number of bolt holes is an even number and not less than half of the number of bolt holes on the fixed shaft.

[0034] Calculation method of flange lower end face dimensions. The relevant dimensions of flange lower end face include the pitch circle diameter of lower end face bolt holes, flange lower end face diameter, and the size and number of bolt holes on flange lower end face. The circularly distributed bolt holes reserved on the horizontal test bench are connected to the lower end face of the horizontal test flange. The test bench generally reserves bolt holes of various specifications. When designing a horizontal test flange for a new model of direct-drive generator, the greater the power of the generator, the larger the pitch circle diameter of the bolt holes used in the horizontal test bench during the horizontal test. This size can be determined with the help of an old model horizontal test flange of a generator with similar power. The pitch circle diameter of the bolt holes on the flange lower end face is equal to the pitch circle diameter of the bolt holes on the selected test bench. The size of the bolt holes on the flange lower end face is equal to the size of the bolt holes on the test bench. The number of bolt holes is an even number and not less than half of the number of bolt holes on the test bench. The diameter of the flange lower end face is at least 130mm larger than the pitch circle diameter of the bolt holes on it.

[0035] Calculation method of flange support tube size. The size of the support tube between the upper and lower end faces of the horizontal test flange includes the height, outer diameter and inner diameter of the support tube. According to the structural geometric relationship of the flange, the height of the support tube is equal to the flange height minus the thickness of the upper and lower end faces of the flange. The cross section of the flange support tube is a circular ring, and the inner diameter and outer diameter of the cross section circular ring need to be determined as a more appropriate value. According to strength analysis and our design experience, it is reliable that the outer diameter of the flange support tube is equal to the pitch circle diameter of the bolt hole distribution on the upper end face of the flange minus about 140mm. The inner diameter of the support tube is equal to the outer diameter of the support tube minus 2 times the thickness of the support tube.

[0036] The above is a universal design algorithm for the horizontal test flange of a direct-drive generator, which can be used for the size calculation of the horizontal test flange of a full-power direct-drive wind turbine model in the current wind power industry. On this basis, in order to improve the design efficiency of the horizontal test flange and save design time, the present invention proposes to encapsulate this universal design algorithm into software with a program and present it in a visual way. Designers only need to input some necessary test parameters to directly read the design size of the flange, which will greatly increase the work efficiency. The present invention builds a universal design tool software for the horizontal test flange of a direct-drive generator in the G language environment of LabVIEW.

[0037] The universal design tool software for the horizontal test flange of the direct-drive generator of the present invention is written in the G language environment of LabVIEW, and consists of two parts: a main program and an initialization program. The main program is used to calculate and display the operation results of each input parameter, and the initialization program assigns an initial value of 0 to each variable when the program is running. The design method of the horizontal test flange of the direct-drive generator of the present invention adopts the scheme of first using the software to quickly calculate the size values ​​of each component of the flange, then using the size calculated by the software to establish a three-dimensional model of the flange, and performing finite element strength analysis on the flange model to ensure fast design and reliable structure.

Claims

1. A method for designing a horizontal test flange for a direct-drive generator, characterized in that the test apparatus comprises a horizontal test bench, a direct-drive wind turbine and a horizontal test flange, wherein the upper end surface of the horizontal test flange is connected to the fixed axis of the direct-drive generator by bolts, and the lower end surface of the horizontal test flange is connected to the horizontal test bench by bolts. The distance from the shaft of the direct-drive wind turbine to the bottom bearing surface of the horizontal test bench is a, the distance from the center of mass of the direct-drive wind turbine to the upper end surface of the horizontal test flange is b, the distance from the center of mass of the horizontal test to the bottom bearing surface of the test bench is c, the distance from the center of mass of the direct-drive wind turbine to the shaft of the horizontal test bench is x, and the height of the horizontal test flange is y, where, a, b, c are known quantities, x and y are quantities to be measured; Let the mass of the generator be M and the mass of the test bench be m, then the moment balance equation is: , we can deduce: ， From the assembly relationship among the horizontal test bench, direct-drive wind turbine and horizontal test flange, we can get: ， Can launch: ， From the above, we can know the optimal height of the horizontal test flange.

2. According to the method for designing a horizontal test flange of a direct-drive generator according to claim 1, the characteristic is that the horizontal test flange is welded by an upper end face, a support tube, and a lower end face. After determining the height y of the horizontal test flange, the upper end face size, the support tube size, and the lower end face size are determined according to the size and shape of the horizontal test bench, the size and shape of the direct-drive wind turbine, and the assembly requirements.

3. A method for designing a horizontal test flange for a direct-drive generator according to claim 2, characterized in that the dimensions of the upper end face of the horizontal test flange include the pitch circle diameter of the bolt holes on the upper end face of the flange, the diameter of the upper end face of the horizontal test flange, the size and number of the bolt holes on the upper end face of the horizontal test flange, the pitch circle diameter of the bolt holes on the upper end face of the horizontal test flange must be equal to the pitch circle diameter of the bolt holes reserved on the fixed axis of the direct-drive wind turbine, the diameters of the upper and lower end faces of the horizontal test flange are larger than the pitch circle diameters of the bolt holes distributed thereon, the size of the bolt holes on the upper end face of the horizontal test flange is larger than the size of the threaded holes on the fixed axis of the direct-drive wind turbine, and the number of bolt holes on the horizontal test flange is an even number and not less than half of the number of bolt holes on the fixed axis.

4. A method for designing a horizontal test flange for a direct-drive generator according to claim 2, characterized in that the relevant dimensions of the lower end face of the horizontal test flange include the pitch circle diameter of the lower end face bolt holes, the diameter of the lower end face of the horizontal test flange, the size and number of the bolt holes on the lower end face of the horizontal test flange, the pitch circle diameter of the bolt holes on the lower end face of the horizontal test flange is equal to the pitch circle diameter of the bolt holes on the selected horizontal test bench, the size of the bolt holes on the lower end face of the horizontal test flange is equal to the size of the bolt holes on the horizontal test bench, and the number of bolt holes on the horizontal test flange is an even number and not less than half of the number of bolt holes on the horizontal test bench.

5. According to a method for designing a horizontal test flange of a direct-drive generator as described in claim 2, it is characterized in that the dimensions of the support tube between the upper and lower end faces of the horizontal test flange include the height, outer diameter and inner diameter of the support tube, the height of the support tube is equal to the height of the horizontal test flange minus the thickness of the upper and lower end faces of the horizontal test flange, and the cross-section of the horizontal test flange support tube is a circular ring.

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