Metal repairing device and method for bearing abrasion of wind generating set

Abstract

The invention relates to the technical field of wind power equipment, in particular to a metal repairing device and method for bearing abrasion of a wind generating set. The metal repairing device comprises a wind power main shaft, a first mounting part and a second mounting part are arranged on the wind power main shaft, and a bearing seat assembly is arranged on the first mounting part and the second mounting part and comprises a shell; a bearing assembly is arranged in the shell, an air inlet input end, a lubricating grease input end and a lubricating grease extraction end which are connected with the bearing assembly are arranged on the shell, and an electromagnetic part is arranged on the outer side of the shell; the bearing assembly comprises an inner ring arranged on the wind power main shaft, and a retainer is arranged on the outer side of the inner ring; a circulating assembly is arranged in the retainer, rollers distributed in an array mode are arranged on the retainer, an outer ring is arranged on the outer sides of the rollers, the outer ring is fixedly connected with the shell, and a bundling assembly is arranged on the inner side of the outer ring; by arranging the circulating assembly and the collecting assembly, the problem of excessive abrasion between the roller and the roller path due to roller slipping is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power equipment, and in particular to a metal repair device and a repair method for a worn bearing of a wind power generator set. Background Art

[0002] As an important part of renewable energy, the performance and life of wind turbines are directly related to the efficiency and economic benefits of wind power generation. However, in actual operation, wind turbines often face various challenges, among which bearing wear is a particularly prominent problem. Bearing wear is a key component of wind turbines. Bearing wear not only affects the operating efficiency of the generator, but may also cause serious mechanical failures and even lead to the scrapping of the entire machine.

[0003] The Chinese patent application number CN202320122041.2 discloses a portable pressure detection tool for the automatic lubrication and grease injection system of a wind turbine, including a pressure gauge 1 and a pressure gauge 2, one end of the pressure gauge 1 is connected to the lubrication pump, the other end of the pressure gauge 1 is connected to the ball valve switch, one end of the pressure gauge 2 is connected to the ball valve switch, and the other end of the pressure gauge 2 is connected to the lubrication point through a distributor or directly connected to the lubrication point; the device has a simple structure and good maintenance effect, and solves the problem that the main shaft, pitch and yaw configuration of the wind turbine self-lubricating and grease injection system is affected by the performance degradation of the grease injection pump due to long-term operation and the blockage of the circuit oil pipe, resulting in poor bearing lubrication, and the performance and lubrication quality of the bearing lubrication system cannot be detected and judged on site. The quality of the lubrication pump and the blockage of the lubrication oil pipe are judged according to the deviation of the pressure gauge reading, so as to ensure the effective lubrication of the large components of the unit and reduce the replacement cost of high-value large components.

[0004] Although current technology can evaluate the performance of the lubrication pump and the unobstructed condition of the lubrication oil pipe based on the deviation of the pressure gauge reading, thereby ensuring the effective lubrication of the key components of the unit, in actual operation, especially for the cylindrical roller bearings commonly used in wind turbine main shafts, the performance challenges are particularly significant. When such bearings are running at high speeds, the rollers are subjected to significant centrifugal force, resulting in a weakened contact force with the inner ring, which in turn causes the rollers to change from rolling friction to sliding friction, that is, roller slippage. This change not only increases the heating of the bearing, but also promotes the wear of the rollers and the inner ring raceway, seriously shortening the service life of the bearing.

[0005] In addition, the gaps between the cage rollers cannot be ignored. These gaps can easily become obstacles to the circulation of grease, making it difficult for the grease to fully penetrate between the rollers for effective lubrication, which in turn causes the problem of insufficient lubrication. At the same time, if the impurity content in the grease is too high, it will also aggravate the heating and wear of the bearing, and the existing technology is still insufficient in monitoring and responding to such complex working conditions.

[0006] In view of the problems and deficiencies revealed by the above analysis, it is particularly urgent and important to develop a metal repair device and repair method for wind turbine bearing wear. The aim is to effectively cope with the special challenges of cylindrical roller bearings in high-speed operation through innovative cooling and lubrication mechanisms, extend bearing life, and improve overall operating efficiency and reliability. Summary of the invention

[0007] The purpose of the present invention is to provide a metal repair device and a repair method for worn bearings of a wind turbine generator set, so as to solve the technical problems raised in the above-mentioned background technology.

[0008] To achieve the above object, the present invention provides the following technical solutions: A metal repair device for bearing wear of a wind turbine generator set, comprising a wind turbine main shaft, wherein a first mounting portion and a second mounting portion are provided on the wind turbine main shaft, wherein the first mounting portion and the second mounting portion are both provided with a bearing seat assembly, wherein the bearing seat assembly comprises a shell, wherein a bearing assembly is provided inside the shell, wherein an air intake input end, a grease input end and a grease extraction end connected to the bearing assembly are provided on the shell, and an electromagnetic component is provided on the outer side of the shell; The bearing assembly includes an inner ring arranged on the wind turbine main shaft, a retaining frame is provided on the outer side of the inner ring, a circulation assembly is provided inside the retaining frame, rollers distributed in an array are provided on the retaining frame, an outer ring is provided on the outer side of the roller, the outer ring is fixedly connected to the shell, and a convergence assembly is provided on the inner side of the outer ring.

[0009] Preferably, the retaining frame comprises a mounting frame, the mounting frame is provided with embedding grooves distributed in an array, the embedding grooves are used to install the rollers, and a fixing frame is provided on the outer side of the mounting frame, and the fixing frame is connected to the mounting frame by bolts.

[0010] Preferably, the circulation component includes a mounting groove opened inside the mounting frame, the mounting grooves are distributed in an array on the mounting frame, a magnetic part is provided inside the mounting groove, elastic parts are provided at both ends of the magnetic part, and the ends of the two elastic parts away from the magnetic part are respectively connected to a first stopper and a second stopper, and the first stopper and the second stopper are used to seal the extraction and exhaust part arranged on the mounting groove.

[0011] Preferably, the suction and exhaust member comprises a first one-way suction hole and a first one-way exhaust hole provided at one end of the mounting groove, and the positions of the first one-way suction hole and the first one-way exhaust hole correspond to the position of the first stopper; A second one-way suction hole and a second one-way discharge hole are provided at the other end of the installation groove, and the positions of the second one-way suction hole and the second one-way discharge hole correspond to the position of the second stopper.

[0012] Preferably, the first one-way suction holes and the second one-way row holes are located on a side of the retaining frame facing the outer ring, and the first one-way row holes and the second one-way suction holes are located on a side of the retaining frame facing the inner ring.

[0013] Preferably, the focusing assembly includes an annular groove, which is arranged on the inner side of the outer ring and is symmetrically distributed. An annular member is provided inside the annular groove, and the annular member is connected to the air vent opened on the outer ring, and the air vent is connected to the air inlet input end on the shell.

[0014] Preferably, an input hole and a discharge hole are provided on the outer ring, the input hole is connected to the grease input end on the shell, and the discharge hole is connected to the grease extraction end on the shell, the input hole is used to introduce grease into the space between the outer ring and the inner ring, and the discharge hole is used to extract the grease between the outer ring and the inner ring.

[0015] Preferably, when the annular member is in the first working state, the annular member is in a contracted state, and the inner side of the annular member is located inside the annular groove; When the annular member is in the second working state, the annular member is in an expanded state, and the inner side of the annular member and the outer surface of the roller are in an extruded state; When the annular member is in the third working state, the annular member is in an expanded state, the inner side of the annular member and the outer surface of the roller are in an extruded state, and are also in an extruded state with the retaining frame.

[0016] A repair method for repairing the worn part of a wind turbine bearing by using a metal repair device for a wind turbine bearing, the repair method comprising the following steps: S1. First, inject grease into the space between the inner ring and the outer ring through the grease input port. Due to the interference fit between the wind turbine main shaft and the inner ring, when the wind turbine main shaft rotates, the inner ring will drive the cage and the roller to rotate together. In this process, the rotation of the roller distributes the grease to the outer side of the inner ring and the inner side of the outer ring to ensure the lubrication effect. S2. During the rotation of the roller, the electromagnetic component controls the movement of the magnetic component in the installation groove, so that the grease circulates in the space between the inner ring and the outer ring, achieving comprehensive lubrication of the bearing and all-round cooling treatment; S3. When the roller slips, the annular component is controlled to be in the second working state, the electromagnetic component delivers grease to between the cage and the inner ring through the magnetic component, the annular component squeezes the roller, so that the contact force between the roller and the inner ring is strengthened, and the grease repairs the wear of the roller and the inner ring; S4. When the impurity content in the grease is too high, the annular component is controlled to be in the third working state, and the magnetic component transports the grease to between the retaining frame and the outer ring through the magnetic component. Under the joint action of the annular component and the magnetic component, the grease is squeezed to the middle of the retaining frame and is extracted from the bearing through the grease extraction end.

[0017] Technical effects and advantages of the present invention: 1. The present invention ensures the stable operation of the bearing assembly through real-time monitoring and relative regulation. By synchronously monitoring the numerical changes of the vibration sensor and the temperature sensor, the operating status of the bearing assembly can be judged in real time. Once a bad condition is found in the bearing, such as poor grease fluidity or roller thermal expansion, the control system can immediately start the convergence component and the circulation component to make corresponding adjustments. It effectively prevents further damage to the bearing assembly, ensures the stable operation of the wind turbine main shaft, and reduces downtime and maintenance costs caused by bearing failure.

[0018] 2. The present invention improves the heat dissipation efficiency of the bearing assembly by driving the grease to circulate, and realizes the circulation of the grease in the inner and outer areas of the cage by controlling the reciprocating switching of the circulation assembly between the first working state and the second working state. This circulation mechanism significantly improves the heat dissipation effect of the grease, effectively removes the friction heat generated during the operation of the bearing, and prevents the bearing assembly from being damaged due to excessive temperature; at the same time, the uniform distribution of the grease also improves the lubrication conditions of the bearing and extends the service life of the bearing.

[0019] 3. The present invention uses dynamic adjustment to deal with the roller slip problem. When the control system detects roller slip, it can quickly control the convergence component and the circulation component to enter a specific working state, and restore the roller to a rolling friction state by reducing the clearance distance between the roller and the inner ring and increasing the supply of grease. This dynamic adjustment mechanism not only solves the slip problem, but also self-repairs the wear area between the roller and the inner ring through the repair effect of grease, generating a hard and smooth metal ceramic protective layer, further improving the wear resistance and operating stability of the bearing.

[0020] 4. The present invention ensures the cleanliness of the bearing by efficiently cleaning the grease impurities: In order to solve the problem of excessive grease impurities in the bearing assembly, the control system realizes the effective cleaning of the grease by controlling the coordinated work of the collection assembly and the circulation assembly. The circulation assembly moves the grease with concentrated impurities to the middle of the cage and extracts it from the bearing assembly, and then injects fresh grease. This process ensures the cleanliness of the bearing assembly, reduces the friction resistance and imbalance caused by the mixing of impurities, and improves the operating efficiency and reliability of the bearing. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the structure of the wind turbine main shaft of the present invention; Figure 3 It is a structural schematic diagram of the bearing seat assembly of the present invention; Figure 4 It is a structural schematic diagram of the bearing assembly of the present invention; Figure 5 It is a schematic diagram of the exploded structure of the bearing assembly of the present invention; Figure 6 It is a schematic diagram of the exploded structure of the retainer of the present invention; Figure 7 It is a structural schematic diagram of the circulation component of the present invention; Figure 8 It is a schematic diagram of the structure of the bundling assembly of the present invention; Fig. 9 It is a schematic diagram of a first working state of the bundling assembly of the present invention; Fig.10 It is a schematic diagram of the second working state of the bundling assembly of the present invention; Fig.11 It is a schematic diagram of the third working state of the bundling assembly of the present invention; Fig.12 It is a structural schematic diagram of the extraction and exhausting member of the present invention; Fig.13 This is a schematic diagram of a first working state of the extraction and exhausting device of the present invention; Fig.14 This is a schematic diagram of the second working state of the extraction and exhaust component of the present invention.

[0022] In the figure: 1, wind turbine main shaft; 101, first mounting part; 102, second mounting part; 2, bearing seat assembly; 201, housing; 202, air inlet input end; 203, grease input end; 204, grease extraction end; 205, electromagnetic component; 3, bearing assembly; 301, inner ring; 302, retaining frame; 3021, mounting frame; 3022, embedded groove; 3023, fixing frame; 3024, bolt member; 303, roller; 30 4. Outer ring; 4. Circulation component; 401. Mounting groove; 402. Magnetic member; 403. Elastic member; 404. First stopper; 405. Second stopper; 406. Pumping and exhaust member; 4061. First one-way suction hole; 4062. Second one-way suction hole; 4063. First one-way exhaust hole; 4064. Second one-way exhaust hole; 5. Converging component; 501. Annular groove; 502. Annular member; 503. Vent hole; 6. Input hole; 7. Exhaust hole. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0024] Reference Figures 1 to 14 As shown, a metal repair device for worn bearings of a wind turbine generator set comprises a wind turbine main shaft 1, on which a first mounting portion 101 and a second mounting portion 102 are provided, and a bearing seat assembly 2 is provided on the first mounting portion 101 and the second mounting portion 102, and the bearing seat assembly 2 comprises a shell 201, inside of which a bearing assembly 3 is provided, and the shell 201 is provided with an air intake input end 202 connected to the bearing assembly 3, a grease input end 203 and a grease extraction end 204, and an electromagnetic component 205 is provided on the outer side of the shell 201.

[0025] The bearing assembly 3 includes an inner ring 301 arranged on the wind turbine main shaft 1, a retaining frame 302 is provided on the outer side of the inner ring 301, a circulation assembly 4 is provided inside the retaining frame 302, rollers 303 distributed in an array are provided on the retaining frame 302, an outer ring 304 is provided on the outer side of the roller 303, the outer ring 304 is fixedly connected to the shell 201, and a convergence assembly 5 is provided on the inner side of the outer ring 304.

[0026] The circulation component 4 is used to drive the grease inside the bearing component 3 to circulate inside the bearing component 3. On the one hand, it prevents the grease from stagnates in the blank part of the retaining frame 302, thereby improving the lubricating effect of the grease on the bearing component 3. On the other hand, during the flow of the grease, the contact parts between the roller 303 and the inner ring 301 and the outer ring 304 are subjected to all-round cooling treatment, thereby improving the service life of the bearing.

[0027] The convergence component 5 is used to drive the roller 303 to move toward the inner ring 301 to prevent the roller 303 from being affected by the centrifugal force generated when the wind turbine main shaft 1 rotates. The roller 303 moves toward the outer ring 304, resulting in a weakening of the contact force with the inner ring 301, thereby causing the roller 303 to transform from rolling friction to sliding friction.

[0028] Reference Figures 4 to 7 As shown, the retaining frame 302 includes a mounting frame 3021, which is provided with an array of embedding grooves 3022 for mounting the roller 303. A fixing frame 3023 is provided on the outer side of the mounting frame 3021, and the fixing frame 3023 is connected to the mounting frame 3021 through bolts 3024.

[0029] By providing the mounting frame 3021 and the fixing frame 3023 , the retaining frame 302 is made detachable, which facilitates the installation of the roller 303 and the subsequent replacement of the retaining frame 302 .

[0030] Reference Figures 4 to 14 As shown, the circulation component 4 includes a mounting groove 401 opened inside the mounting frame 3021, and the mounting grooves 401 are distributed in an array on the mounting frame 3021. A magnetic member 402 is provided inside the mounting groove 401, and elastic members 403 are provided at both ends of the magnetic member 402. The ends of the two elastic members 403 away from the magnetic member 402 are respectively connected to a first stop block 404 and a second stop block 405, and the first stop block 404 and the second stop block 405 are used to seal the exhaust member 406 set on the mounting groove 401.

[0031] The elastic member 403 includes a spring or an elastic telescopic rod, and the elastic coefficient of the elastic member 403 is greater than the negative pressure suction force generated between the stopper and the mounting groove 401 when the stopper moves, which means that when the first stopper 404 moves toward the second stopper 405, the elastic member 403 between the first stopper 404 and the magnetic member 402 will not be stretched due to the influence of the negative pressure suction force. When the second stopper 405 moves toward the first stopper 404, the elastic member 403 between the second stopper 405 and the magnetic member 402 will not be stretched due to the influence of the negative pressure suction force.

[0032] The elastic members 403 located at both ends of the magnetic member 402 are fixedly connected to the first stopper 404 and the second stopper 405 respectively. The elastic member 403 abuts against the first stopper 404 and the second stopper 405 so as to abut against the end of the installation slot 401 .

[0033] By providing the magnetic component 402, under the cooperation of the magnetic component 402 and the electromagnetic component 205, the first stop block 404 and the second stop block 405 are driven to produce different forms of movement inside the installation groove 401, so that the pumping member 406 on the installation groove 401 circulates the grease entering the bearing assembly 3, thereby improving the lubrication effect of the bearing assembly 3, reducing the high temperature phenomenon generated when the roller 303 moves, and improving the service life of the bearing.

[0034] Reference Figures 4 to 14 As shown, the suction and exhaust member 406 includes a first one-way suction hole 4061 and a first one-way exhaust hole 4063 arranged at one end of the installation groove 401, and the positions of the first one-way suction hole 4061 and the first one-way exhaust hole 4063 correspond to the position of the first stopper 404.

[0035] A second one-way suction hole 4062 and a second one-way row hole 4064 are provided at the other end of the installation groove 401 . The positions of the second one-way suction hole 4062 and the second one-way row hole 4064 correspond to the position of the second stopper 405 .

[0036] When the first stop block 404 moves toward the second stop block 405, negative pressure suction is generated between the first stop block 404 and the mounting groove 401, so that the grease located on the outside of the retaining frame 302 can enter the interior of the mounting groove 401 through the first one-way suction hole 4061. When the first stop block 404 moves away from the second stop block 405, the first stop block 404 squeezes the grease so that it is discharged from the first one-way discharge hole 4063 and enters the space between the retaining frame 302 and the inner ring 301.

[0037] When the second stop block 405 moves toward the first stop block 404, negative pressure suction is generated between the second stop block 405 and the mounting groove 401, so that the grease located on the inner side of the retaining frame 302 can enter the interior of the mounting groove 401 through the second one-way suction hole 4062. When the second stop block 405 moves away from the first stop block 404, the second stop block 405 squeezes the grease so that it is discharged from the second one-way discharge hole 4064 and enters the space between the retaining frame 302 and the outer ring 304.

[0038] It should be noted that the elastic coefficient of the elastic member 403 is greater than the negative pressure suction force between the first stopper 404 and the installation groove 401 , and similarly, the elastic coefficient of the elastic member 403 is greater than the negative pressure suction force between the second stopper 405 and the installation groove 401 .

[0039] Reference Figures 4 to 14 As shown, the first one-way suction hole 4061 and the second one-way row hole 4064 are located on the side of the retaining frame 302 facing the outer ring 304 , and the first one-way row hole 4063 and the second one-way suction hole 4062 are located on the side of the retaining frame 302 facing the inner ring 301 .

[0040] Reference Figures 8 to 11 As shown, the convergence component 5 includes an annular groove 501, which is arranged on the inner side of the outer ring 304 and is symmetrically distributed. An annular member 502 is provided inside the annular groove 501. The annular member 502 is connected to the air vent 503 opened on the outer ring 304, and the air vent 503 is connected to the air inlet input end 202 on the shell 201.

[0041] The annular member 502 includes a rubber sheet, which expands by supplying air into the air vent 503, and squeezes the outer surface of the roller 303, driving the roller 303 to converge toward the center of the inner ring 301, thereby preventing the roller 303 from being subjected to excessive centrifugal force, resulting in a weakening of the contact force with the inner ring 301, and causing the roller 303 to change from rolling friction to sliding friction, that is, the roller 303 slips.

[0042] Reference Figures 4 to 8As shown, an input hole 6 and a discharge hole 7 are provided on the outer ring 304. The input hole 6 is connected to the grease input end 203 on the housing 201, and the discharge hole 7 is connected to the grease extraction end 204 on the housing 201. The input hole 6 is used to introduce grease into the space between the outer ring 304 and the inner ring 301, and the discharge hole 7 is used to extract the grease between the outer ring 304 and the inner ring 301.

[0043] Reference Figures 8 to 11 As shown, when the annular member 502 is in the first working state, the annular member 502 is in a contracted state, and the inner side of the annular member 502 is located inside the annular groove 501 .

[0044] When the annular member 502 is in the first working state, the annular member 502 located inside the annular groove 501 is in a contracted state, the annular member 502 gives way to the operation of the roller 303, and the air inside the bearing assembly 3 can flow in the annular groove 501 to achieve a heat dissipation effect.

[0045] When the annular member 502 is in the second working state, the annular member 502 is in an expanded state, and the inner side of the annular member 502 and the outer surface of the roller 303 are in an extruded state.

[0046] When the annular member 502 is in the second working state, the annular member 502 squeezes the outer surface of the roller 303, driving the roller 303 to converge toward the center of the inner ring 301 to prevent the roller 303 from slipping. At this time, the annular member 502 does not contact the retaining frame 302, thereby preventing the friction between the annular member 502 and the retaining frame 302 from being too high, affecting the normal operation of the wind turbine main shaft 1.

[0047] When the annular member 502 is in the third working state, the annular member 502 is in an expanded state, the inner side of the annular member 502 and the outer surface of the roller 303 are in an extruded state, and are also in an extruded state with the retaining frame 302 .

[0048] When the annular member 502 is in the third working state, the annular member 502 squeezes the outer surface of the roller 303 and the retaining frame 302, driving the grease adhering to the retaining frame 302 to move to the middle of the retaining frame 302, and finally being extracted from the bearing assembly 3 by the grease extraction end 204, waiting for subsequent fresh grease injection.

[0049] A control terminal is provided on the outer side of the bearing seat assembly 2, and a control system is provided inside the control terminal. The control system is used to control all electrical components on the bearing seat assembly 2 to continue to operate.

[0050] A temperature sensor and a vibration sensor are provided inside the housing 201. The temperature sensor is used to detect whether the temperature generated by the bearing assembly 3 during operation exceeds a set value. The vibration sensor is used to detect whether the vibration frequency generated by the bearing assembly 3 during operation exceeds a set value.

[0051] When in use, grease is injected into the grease input end 203. Since the grease input end 203 is connected to the input hole 6 on the outer ring 304, after the grease enters the grease input end 203, it enters the inner space of the outer ring 304 through the input hole 6 and contacts the roller 303 on the retaining frame 302. Since the inner ring 301 is interference fit with the wind turbine main shaft 1, the inner ring 301 is synchronously driven to rotate during the rotation of the wind turbine main shaft 1. Since the inner ring 301 contacts the roller 303 set on the retaining frame 302, the inner ring 301 is rotated synchronously. During the rotation of the electric spindle 1, the roller 303 rotates synchronously due to the influence of contact friction. When the roller 303 rotates, the grease located on the outside of the retaining frame 302 will adhere to the roller 303, and the roller 303 distributes the grease to the inner side of the outer ring 304 and the outer area of ​​the inner ring 301, so as to lubricate the contact area between the roller 303 and the outer ring 304 and the inner ring 301, so as to avoid excessive friction between the contact area between the roller 303 and the outer ring 304 and the contact area between the roller 303 and the inner ring 301, thereby causing wear in the contact area.

[0052] During the rotation of the wind turbine main shaft 1, the control system synchronously detects the detection value of the vibration sensor and the detection value of the temperature sensor set on the shell 201. By analyzing the changes in the values ​​of the two, it is possible to determine whether the bearing assembly 3 has any abnormal condition. According to the abnormal phenomenon, the convergence assembly 5 and the circulation assembly 4 are controlled to perform corresponding state changes to solve the abnormal condition of the bearing assembly 3.

[0053] When the control system detects that the value detected by the temperature sensor is in a continuously rising state, and as the temperature rises, the value detected by the vibration sensor is also in a steadily rising state, that is, as the bearing temperature rises, the vibration frequency of the bearing is also in an rising state, and the rising trends of the two are tending to be homogenized, it indicates that during the operation of the bearing assembly 3, the grease distributed inside the bearing assembly 3 has poor fluidity, and most of the grease accumulates in the blank part of the retaining frame 302 (the blank part is the area between two adjacent rollers 303 on the retaining frame 302), and cannot flow normally, resulting in a reduction in the lubrication and cooling effect of the grease on the roller 303, causing the roller 303 to thermally expand, and then the thermal expansion causes the vibration of the bearing assembly 3.

[0054] When the control system detects that the roller 303 in the bearing assembly 3 has thermal expansion, the control system controls the contraction assembly 5 to be in the first working state, and controls the circulation assembly 4 to switch back and forth between the first working state and the second working state, so that the grease circulates between the outer and inner areas of the retaining frame 302. The flowing grease can better take away the friction heat generated during the operation of the bearing, thereby achieving effective heat dissipation of the roller 303 and preventing the bearing assembly 3 from being damaged due to excessive temperature. At the same time, when the annular member 502 is in the first working state, the annular member 502 located inside the annular groove 501 is in a contracted state, and the annular member 502 makes way for the operation of the roller 303, so that the air inside the bearing assembly 3 can flow in the annular groove 501, thereby improving the heat dissipation effect of the grease.

[0055] The circulation component 4 can switch back and forth between the first working state and the second working state, and its working principle relies on the control system's current control of the electromagnetic component 205, aiming to realize the circulation flow of the grease between the retainer 302 and the outer ring 304 and between the retainer 302 and the inner ring 301. Specifically, the control system realizes this process by alternately passing a forward current and a reverse current into the electromagnetic component 205.

[0056] First, when the control system passes a reverse current to the electromagnetic member 205, the circulation component 4 is triggered to enter the first working state. As the reverse current gradually increases, the electromagnetic member 205 generates an attractive force to the magnetic member 402, and the magnetic member 402 drives the first stopper 404 to move toward the second stopper 405 (see Fig.13 As shown). In this process, the elastic member 403 between the first stopper 404 and the magnetic member 402 remains unchanged, while the elastic member 403 between the second stopper 405 and the magnetic member 402 is compressed due to the movement of the magnetic member 402. At the same time, the negative pressure suction force generated between the first stopper 404 and the mounting groove 401 causes the grease on the outside of the retaining frame 302 to enter the interior of the mounting groove 401 through the first one-way suction hole 4061. Subsequently, the reverse current is controlled to gradually decrease, and the suction force of the electromagnetic member 205 on the magnetic member 402 also decreases accordingly. With the help of the elastic restoring force of the elastic member 403 between the second stopper 405 and the magnetic member 402, the magnetic member 402 begins to move toward the first stopper 404, and the first stopper 404 squeezes the grease, causing it to be discharged through the first one-way discharge hole 4063 and finally enter the space between the retaining frame 302 and the inner ring 301.

[0057] Next, when the control system passes a positive current to the electromagnetic member 205, the electromagnetic member 205 generates a repulsive force against the magnetic member 402, pushing the second stopper 405 to move toward the first stopper 404 (see Fig.14As shown in the figure, the circulation component 4 enters the second working state. In this process, the elastic member 403 between the second stopper 405 and the magnetic member 402 remains unchanged, while the elastic member 403 between the first stopper 404 and the magnetic member 402 is compressed due to the movement of the magnetic member 402. At the same time, the negative pressure suction force generated between the second stopper 405 and the mounting groove 401 causes the grease on the inner side of the retaining frame 302 to enter the interior of the mounting groove 401 through the second one-way suction hole 4062. Subsequently, the positive current passed through is controlled to gradually decrease, and the repulsive force of the electromagnetic member 205 on the magnetic member 402 also decreases accordingly. With the help of the elastic restoring force of the elastic member 403 between the first stopper 404 and the magnetic member 402, the magnetic member 402 begins to move toward the second stopper 405, and the second stopper 405 squeezes the grease, so that it is discharged through the second one-way discharge hole 4064 and finally enters the space between the retaining frame 302 and the outer ring 304.

[0058] Through the above process, the circulation component 4 realizes smooth switching between the two working states under the precise regulation of the control system, accompanied by effective circulation of the grease in the specified space.

[0059] When the control system detects that the temperature sensor value continues to rise and fluctuates significantly when the wind turbine main shaft 1 is running at high speed, and the vibration sensor also feeds back the characteristics of rising values ​​and high-frequency changes, this indicates that there is an abnormality in the operation of the wind turbine main shaft 1. The roller 303 is subjected to excessive centrifugal force, resulting in a reduction in the clearance with the outer ring 304 and an increase in the clearance with the inner ring 301, thereby weakening the contact force with the inner ring 301, causing the original rolling friction to be converted into sliding friction, that is, the roller 303 slips.

[0060] When slipping occurs, the friction coefficient of sliding friction is much higher than that of rolling friction, which significantly increases the generation of frictional heat, causing the bearing temperature to rise sharply. In addition, slipping also causes dynamic imbalance inside the bearing, further promoting the intensification of friction and vibration, forming a vicious cycle and making the temperature fluctuation more significant.

[0061] More seriously, during the slipping period, the contact between roller 303 and inner ring 301 becomes unstable, changing from stable rolling to sliding or even impacting. This high-frequency impact force is quickly transmitted to the entire mechanical system through the bearing seat, causing the vibration frequency to increase sharply and fluctuate frequently. These abnormal high-frequency vibration signals are the key information captured by the vibration sensor, providing an important basis for timely detection and treatment of roller 303 slipping problems.

[0062] When the control system detects that the roller 303 inside the bearing assembly 3 is slipping, the control system controls the convergence assembly 5 to enter the second working state, and controls the circulation assembly 4 to enter the first working state, so that the roller 303 converges toward the center of the inner ring 301, reduces the clearance distance between the roller 303 and the inner ring 301, and avoids the slippage of the roller 303. At the same time, the grease is driven to flow to the area between the retaining frame 302 and the inner ring 301, and the grease repairs the worn area between the inner ring 301 and the roller 303.

[0063] The specific operation is as follows: the control system passes a reverse current to the electromagnetic component 205, the circulation component 4 is triggered to enter the first working state, the electromagnetic component 205 drives the first block 404 to move toward the second block 405 through the magnetic component 402, and a negative pressure suction force is generated between the first block 404 and the mounting groove 401, so that the grease enters the interior of the mounting groove 401 through the first one-way suction hole 4061. Subsequently, the reverse current passed through the control is gradually reduced, and the suction force of the electromagnetic component 205 on the magnetic component 402 is also reduced accordingly, and the magnetic component 402 begins to move toward the first block 404. The first block 404 squeezes the grease so that it is discharged through the first one-way discharge hole 4063 and finally enters the space between the retainer 302 and the inner ring 301. The grease that enters between the retainer 302 and the inner ring 301 repairs the wear area where the roller 303 contacts the inner ring 301.

[0064] When the circulation component 4 is triggered to enter the first working state, the control system injects gas into the air input terminal 202 through an external air pump, and the gas enters the space between the annular member 502 and the annular groove 501 through the air vent 503. After the annular member 502 expands, it is squeezed with the roller 303, forcing the roller 303 to converge toward the center of the inner ring 301, reducing the clearance distance between the roller 303 and the inner ring 301, so that the sliding friction between the roller 303 and the inner ring 301 is restored to rolling friction, and the rotating roller 303 finely grinds, adsorbs and cleans the grease that enters between the retaining frame 302 and the inner ring 301, generates a repair layer, and maintains the repair layer, thereby completing the self-repair of the metal wear parts and generating a metal ceramic protective layer with a strong surface hardness and smoothness.

[0065] It should be noted that the four-step dynamics of grease repairing worn parts include the following: Fine grinding: There will be "serrated" convex and concave bodies in the wear area between the inner ring 301 and the roller 303. When the grease enters the "serrated" convex and concave bodies between the retaining frame 302 and the inner ring 301, the anti-wear self-repairing material in the grease will be further ground and fully refined.

[0066] Adsorption and cleaning: The refined anti-wear self-repairing material is adsorbed and penetrates into the friction surface. The pollutants remaining in the surface pits are removed by the anti-wear self-repairing material and filled with the refined self-repairing material.

[0067] Generation of repair layer: An instantaneous flash temperature may be generated between the friction surfaces of the retainer 302 and the inner ring 301, which may cause the self-repairing material to undergo micro-sintering and micro-metallurgical processes under the action of catalysts and activators, thereby forming a metal-ceramic repair layer.

[0068] Repair layer maintenance: When the friction surface of the cage 302 and the inner ring 301 is severely worn, the surface unevenness is more obvious, and there are more opportunities to generate higher flash temperatures during movement, and there are more and more opportunities for metal anti-wear self-repairing materials to undergo micro-sintering and micro-metallurgy. As the worn parts are repaired, they cannot provide the friction energy required to form the repair layer during movement, and the thickness of the repair layer no longer increases.

[0069] It should be noted that the main components of the anti-wear self-repairing materials in grease are hydroxy magnesium silicate Mg3(Si2O5)(OH)4, boron (B), rare earth compounds and some metals and oxides. When in use, it uses lubricating oil (grease) as a carrier to enter the surface of the friction pair, and completes the self-repair of the metal wear parts through four dynamic steps: fine grinding, adsorption cleaning, repair layer generation, and repair layer maintenance, generating a metal ceramic protective layer with strong surface hardness and smoothness.

[0070] When the control system detects that the wind turbine main shaft 1 is in normal operation, the temperature sensor monitors that its temperature value shows a continuous and stable upward trend. At the same time, the data fed back by the vibration sensor shows that the vibration intensity increases, accompanied by periodic changes in medium and low frequencies, indicating that the bearing assembly 3 may have problems due to impurities mixed into the grease. The mixing of impurities increases the friction resistance inside the bearing. Due to the decrease in lubrication performance and the increase in friction resistance, the heat generated by the bearing during operation cannot be effectively dissipated, and thus gradually accumulates inside the bearing, causing the bearing temperature to continue to rise.

[0071] In addition, the mixing of impurities may also have an adverse effect on the mass distribution inside the bearing, causing the bearing to become unbalanced during rotation. This imbalance will further generate periodic centrifugal force, becoming the direct cause of inducing medium and low frequency vibrations.

[0072] When the control system detects that there are too many grease impurities inside the bearing assembly 3, the control system controls the collection assembly 5 to switch between the first working state and the third working state, and controls the circulation assembly 4 to enter the second working state, so that the grease inside the bearing assembly 3 moves to the middle of the retaining frame 302, and is extracted from the bearing assembly 3 by the grease extraction end 204, waiting for subsequent fresh grease injection.

[0073] The specific operation is as follows: the control system passes a positive current to the electromagnetic component 205, the circulation component 4 is triggered to enter the second working state, the electromagnetic component 205 drives the second stopper 405 to move toward the first stopper 404 through the magnetic component 402, and a negative pressure suction force is generated between the second stopper 405 and the mounting groove 401, so that the grease between the retaining frame 302 and the inner ring 301 enters the interior of the mounting groove 401 through the second unidirectional suction hole 4062, and then the reverse current passed through the control is gradually reduced, and the electromagnetic component The suction force of 205 on the magnetic part 402 also decreases, and the magnetic part 402 begins to move toward the second stop block 405. The second stop block 405 squeezes the grease so that it is discharged through the second one-way discharge hole 4064 and finally enters the space between the retaining frame 302 and the outer ring 304. The grease that enters between the retaining frame 302 and the inner ring 301 is squeezed by the annular member 502 and moves toward the middle of the retaining frame 302, and is extracted from the bearing assembly 3 by the grease extraction end 204 to achieve the cleaning of the bearing assembly 3.

[0074] When the circulation component 4 enters the second working state, the control system continuously injects and exhausts air into the space between the annular member 502 and the annular groove 501 through the external air pump. When the external air pump injects air, the annular member 502 expands, and the expanded annular member 502 squeezes the outer surface of the roller 303 and the retainer 302, driving the grease adhering to the retainer 302 to move to the middle of the retainer 302, and finally extracts the bearing component 3 from the grease extraction end 204, waiting for the subsequent fresh grease injection. When the external air pump exhausts air, the annular member 502 shrinks so that the grease between the retainer 302 and the inner ring 301 can enter the space between the retainer 302 and the outer ring 304 through the circulation component 4. Through the cooperation of the circulation component 4 and the contraction component 5, the grease inside the bearing component 3 is concentrated in the middle area outside the retainer 302, so that the grease extraction end 204 can extract the grease from the bearing component 3 through the discharge hole 7, waiting for the subsequent fresh grease injection.

[0075] The present invention monitors the temperature and vibration state of the bearing assembly 3 in real time through a temperature sensor and a vibration sensor. According to the monitoring data, the control system determines the operating state of the bearing assembly 3, and controls the working state of the convergence assembly 5 and the circulation assembly 4 accordingly. When the fluidity of the grease inside the bearing assembly 3 is poor, the control system puts the convergence assembly 5 in the first working state, and controls the circulation assembly 4 to switch between the first working state and the second working state, so as to promote the circulation of the grease. When the roller 303 slips, the control system puts the convergence assembly 5 into the second working state, controls the circulation assembly 4 to enter the first working state, reduces the clearance between the roller 303 and the inner ring 301, and promotes the grease to flow between the inner ring 301 and the roller 303, so as to repair the wear. When there are too many grease impurities inside the bearing assembly 3, the control system makes the convergence assembly 5 switch between the first working state and the third working state, controls the circulation assembly 4 to enter the second working state, concentrates the impure grease in the middle of the retaining frame 302 and extracts it from the grease extraction end 204.

[0076] The present invention also provides a repair method for a worn part of a wind turbine bearing using a metal repair device for a worn wind turbine bearing. The repair method comprises the following steps: S1. First, inject grease into the space between the inner ring 301 and the outer ring 304 through the grease input terminal 203. Due to the interference fit between the wind turbine main shaft 1 and the inner ring 301, when the wind turbine main shaft 1 rotates, the inner ring 301 will drive the retaining frame 302 and the roller 303 to rotate together. In this process, the rotation of the roller 303 distributes the grease to the outer side of the inner ring 301 and the inner side of the outer ring 304 to ensure the lubrication effect.

[0077] S2. During the rotation of the roller 303, the electromagnetic component 205 controls the magnetic component 402 to move in the mounting groove 401, so that the grease circulates in the space between the inner ring 301 and the outer ring 304, thereby achieving comprehensive lubrication of the bearing and all-round cooling treatment.

[0078] S3. When the roller 303 slips, the annular member 502 is controlled to be in the second working state, and the electromagnetic member 205 transports grease to between the retaining frame 302 and the inner ring 301 through the magnetic member 402. The annular member 502 squeezes the roller 303 to strengthen the contact force between the roller 303 and the inner ring 301. At the same time, the grease repairs the worn parts of the roller 303 and the inner ring 301.

[0079] S4. When the impurity content in the grease is too high, the annular member 502 is controlled to be in the third working state, and the magnetic member transports the grease to between the retaining frame 302 and the outer ring 304 through the magnetic member 402. Under the joint action of the annular member 502 and the magnetic member 402, the grease is squeezed to the middle part of the retaining frame 302 and is extracted from the bearing through the grease extraction end 204.

[0080] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

[0081] Although embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A metal repair device for a worn bearing of a wind turbine generator set, comprising a wind turbine main shaft (1), wherein the wind turbine main shaft (1) is provided with a first mounting portion (101) and a second mounting portion (102), wherein the first mounting portion (101) and the second mounting portion (102) are both provided with a bearing seat assembly (2), characterized in that: The bearing seat assembly (2) comprises a housing (201), a bearing assembly (3) is arranged inside the housing (201), an air intake input end (202), a grease input end (203) and a grease extraction end (204) connected to the bearing assembly (3) are arranged on the housing (201), and an electromagnetic component (205) is arranged on the outer side of the housing (201); The bearing assembly (3) comprises an inner ring (301) arranged on a wind turbine main shaft (1); a retaining frame (302) is arranged on the outer side of the inner ring (301); a circulation assembly (4) is arranged inside the retaining frame (302); rollers (303) distributed in an array are arranged on the retaining frame (302); an outer ring (304) is arranged on the outer side of the roller (303); the outer ring (304) is fixedly connected to a housing (201); and a convergence assembly (5) is arranged on the inner side of the outer ring (304).

2. The metal repair device for worn bearings of a wind turbine generator set according to claim 1 is characterized in that: The retaining frame (302) comprises a mounting frame (3021), the mounting frame (3021) is provided with embedded grooves (3022) distributed in an array, the embedded grooves (3022) are used to install the rollers (303), and a fixing frame (3023) is provided on the outer side of the mounting frame (3021), and the fixing frame (3023) is connected to the mounting frame (3021) via bolts (3024).

3. The metal repair device for worn bearings of a wind turbine generator set according to claim 2 is characterized in that: The circulation component (4) comprises a mounting groove (401) provided inside the mounting frame (3021); the mounting grooves (401) are arranged in an array on the mounting frame (3021); a magnetic member (402) is provided inside the mounting groove (401); elastic members (403) are provided at both ends of the magnetic member (402); a first stopper (404) and a second stopper (405) are respectively connected to one end of the two elastic members (403) away from the magnetic member (402); the first stopper (404) and the second stopper (405) are used to block a pumping member (406) provided on the mounting groove (401).

4. The metal repair device for worn bearings of a wind turbine generator set according to claim 3 is characterized in that: The suction and exhaust member (406) comprises a first one-way suction hole (4061) and a first one-way exhaust hole (4063) arranged at one end of the mounting groove (401), and the positions of the first one-way suction hole (4061) and the first one-way exhaust hole (4063) correspond to the position of the first stopper (404); A second one-way suction hole (4062) and a second one-way row hole (4064) are provided at the other end of the installation groove (401), and the positions of the second one-way suction hole (4062) and the second one-way row hole (4064) correspond to the position of the second stopper (405).

5. The metal repair device for worn bearings of a wind turbine generator set according to claim 4 is characterized in that: The first one-way suction holes (4061) and the second one-way row holes (4064) are located on a side of the retaining frame (302) facing the outer ring (304), and the first one-way row holes (4063) and the second one-way suction holes (4062) are located on a side of the retaining frame (302) facing the inner ring (301).

6. The metal repair device for worn bearings of a wind turbine generator set according to claim 1, characterized in that: The convergence assembly (5) comprises an annular groove (501), the annular groove (501) being arranged on the inner side of the outer ring (304) and being symmetrically distributed, an annular member (502) being arranged inside the annular groove (501), the annular member (502) being connected to a vent hole (503) provided on the outer ring (304), and the vent hole (503) being connected to an air inlet input end (202) on the housing (201).

7. The metal repair device for worn bearings of a wind turbine generator set according to claim 1, characterized in that: The outer ring (304) is provided with an input hole (6) and a discharge hole (7); the input hole (6) is connected to a grease input end (203) on the housing (201); the discharge hole (7) is connected to a grease extraction end (204) on the housing (201); the input hole (6) is used to introduce grease into the space between the outer ring (304) and the inner ring (301); and the discharge hole (7) is used to extract the grease between the outer ring (304) and the inner ring (301).

8. The metal repair device for worn bearings of a wind turbine generator set according to claim 6, characterized in that: When the annular member (502) is in the first working state, the annular member (502) is in a contracted state, and the inner side of the annular member (502) is located inside the annular groove (501); When the annular member (502) is in the second working state, the annular member (502) is in an expanded state, and the inner side of the annular member (502) and the outer surface of the roller (303) are in an extruded state; When the annular member (502) is in the third working state, the annular member (502) is in an expanded state, the inner side of the annular member (502) and the outer surface of the roller (303) are in an extruded state, and are also in an extruded state with the retaining frame (302).

9. A method for repairing the worn part of a wind turbine bearing using the metal repair device for the worn bearing of a wind turbine bearing as claimed in claim 8, characterized in that: The repair method comprises the following steps: S1. First, grease is injected into the space between the inner ring (301) and the outer ring (304) through the grease input end (203). Due to the interference fit between the wind turbine main shaft (1) and the inner ring (301), when the wind turbine main shaft (1) rotates, the inner ring (301) drives the retaining frame (302) and the roller (303) to rotate together. During this process, the rotation of the roller (303) distributes the grease to the outer side of the inner ring (301) and the inner side of the outer ring (304), thereby ensuring the lubrication effect. S2. During the rotation of the roller (303), the electromagnetic component (205) controls the magnetic component (402) to move in the mounting groove (401), so that the grease circulates in the space between the inner ring (301) and the outer ring (304), thereby achieving comprehensive lubrication of the bearing and all-round temperature reduction treatment; S3. When the roller (303) slips, the annular member (502) is controlled to be in the second working state, the electromagnetic member (205) delivers grease to between the retaining frame (302) and the inner ring (301) through the magnetic member (402), the annular member (502) squeezes the roller (303), so that the contact force between the roller (303) and the inner ring (301) is strengthened, and at the same time, the grease repairs the worn parts of the roller (303) and the inner ring (301); S4. When the impurity content in the grease is too high, the annular member (502) is controlled to be in the third working state, and the magnetic member transports the grease to between the retaining frame (302) and the outer ring (304) through the magnetic member (402). Under the joint action of the annular member (502) and the magnetic member (402), the grease is squeezed to the middle of the retaining frame (302) and is extracted from the bearing through the grease extraction end (204).

Images