Wind turbine generator gearbox cooling system and method

Abstract

The invention belongs to the technical field of gear box cooling, and relates to a wind turbine generator gear box cooling system and method, which comprises a gear box, a filter, an air cooling radiator, a plurality of gear box oil temperature detection sensors and a controller, the filter is arranged in a circulating oil path of the gear box; the gear box oil temperature detection sensors are respectively arranged at an outlet and an inlet of a circulating oil path of the gear box and in the gear box; the air cooling radiator is arranged on a circulating oil way of the gear box; and a lubricating pump and a straight-through valve are arranged on a circulating oil path of the gear box. The oil temperature of the gearbox is adjusted through the air cooling radiator, the oil temperature of the gearbox can be effectively monitored and adjusted, a specific cooling control strategy is implemented according to the oil temperature of the gearbox, the oil temperature adjusting efficiency is improved, the oil temperature fault rate of the gearbox is reduced, and normal operation of a wind turbine generator is guaranteed.

Description

Technical Field

[0001] The present invention belongs to the technical field of gearbox cooling, and in particular, relates to a wind turbine gearbox cooling system and method. Background Art

[0002] The gearbox is an indispensable part of the transmission system of a doubly-fed wind turbine generator set. The failure rate of the gearbox in a doubly-fed wind turbine generator set increases year by year. The gearbox is generally cooled by water. The fan gearbox water cooling system will not only fail to provide better help in terms of the failure rate, utilization rate and power generation of the wind turbine, but will increase the failure rate due to the complexity of the water cooling system. In addition, the fan gearbox water cooling system is prone to high gearbox oil temperature and easy damage to the temperature control valve. Summary of the invention

[0003] In order to solve the above technical problems, the present invention provides a wind turbine gearbox cooling system and method.

[0004] In a first aspect, the present invention provides a wind turbine gearbox cooling system, including a gearbox, a filter, an air-cooled radiator, a plurality of gearbox oil temperature detection sensors and a controller;

[0005] The filter is arranged in the circulating oil circuit of the gear box; the gear box oil temperature detection sensors are arranged at the outlet and the inlet of the circulating oil circuit of the gear box and in the gear box respectively; the air-cooled radiator is arranged in the circulating oil circuit of the gear box;

[0006] The gearbox oil circulation circuit is provided with a lubrication pump and a through valve; the output end of the controller is electrically connected to the control input end of the through valve; the gearbox oil temperature detection sensor is electrically connected to the controller;

[0007] The output end of the controller is connected to the air-cooled radiator with an electrical signal;

[0008] The controller is communicatively connected with the control system of the fan unit.

[0009] In a second aspect, the present invention provides a method for cooling a wind turbine gearbox, comprising:

[0010] The unit starts, and the gearbox low-speed oil pump works. When the gearbox oil temperature is higher than the first set temperature, the gearbox oil pump works; the gearbox oil flows from the gearbox oil pump through the filter back to the gearbox;

[0011] When the gearbox oil temperature is higher than the second set temperature or the high-speed shaft bearing temperature is higher than the third set temperature, the through valve is closed, the air-cooled radiator is operated, and the lubricating oil enters the gearbox after being cooled by the air-cooled radiator;

[0012] When the gearbox oil temperature drops to the fourth set temperature and the high-speed shaft bearing temperature is lower than the fifth set temperature, the air-cooled radiator stops running, and the lubricating oil directly enters the gearbox through the through valve for forced lubrication;

[0013] When the gearbox temperature is lower than the sixth set temperature, the heating system in the gearbox heats the gearbox oil;

[0014] When the gearbox oil temperature is higher than the seventh set temperature or the high-speed shaft bearing temperature is higher than the eighth set temperature, the fan unit operates at limited load;

[0015] When the gearbox oil temperature is higher than the ninth set temperature or the high-speed shaft bearing temperature is higher than the tenth set temperature, the fan unit shuts down.

[0016] Based on the above technical solution, the present invention can also be improved as follows.

[0017] Furthermore, the air-cooled radiator includes an upper base plate, a support shaft, a fan and a lower base plate; the upper base plate is fixed on the gear box; a number of heat dissipation holes are provided on the upper base plate and the lower base plate; one end of the support shaft is fixed on the upper base plate, and the other end is fixed on the lower base plate; the fan is arranged on the support shaft; and heat dissipation fins are fixed on the lower base plate.

[0018] Furthermore, an oil pressure detection sensor, a first overflow valve and a second overflow valve are provided on the circulating oil circuit of the gear box; the oil pressure detection sensor is electrically connected to the controller; the output end of the controller is electrically connected to the control input end of the first overflow valve and the control input end of the second overflow valve.

[0019] Furthermore, a lubrication heating system is provided in the gear box, including a pump body heater and an oil pipe heating rod.

[0020] Furthermore, the controller is connected with a wireless communication module and an infrared sensing device.

[0021] Furthermore, the gearbox is connected with an oil level indicator and a plurality of oil temperature display instruments.

[0022] Further, when the oil pressure of the gearbox is greater than or equal to the first set oil pressure threshold, the gearbox oil will flow back to the gearbox directly through the gearbox oil pump to the first overflow valve and the second overflow valve until the oil pressure of the gearbox is less than the first set oil pressure threshold and the first overflow valve is closed; when the oil pressure of the gearbox is less than the second set oil pressure threshold, the second overflow valve is closed; the first set oil pressure threshold is greater than the second set oil pressure threshold.

[0023] The beneficial effects of the present invention are as follows: the present invention adopts an air-cooled radiator to adjust the gear box oil temperature, which can effectively monitor and adjust the gear box oil temperature, implement a specific cooling control strategy according to the gear box oil temperature, and improve the oil temperature regulation efficiency; the use of a straight-through valve can reduce the oil temperature failure rate of the gear box and ensure the normal operation of the wind turbine. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic diagram of a wind turbine gearbox cooling system provided in Embodiment 1 of the present invention;

[0025] Figure 2 This is a schematic diagram of a wind turbine gearbox cooling method provided in Example 2 of the present invention. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, 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 part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0027] Example 1

[0028] As an example, Figure 1 As shown, in order to solve the above technical problems, this embodiment provides a wind turbine gearbox cooling system, including a gearbox, a filter, an air-cooled radiator, a plurality of gearbox oil temperature detection sensors and a controller;

[0029] The filter is arranged in the circulating oil circuit of the gear box; the gear box oil temperature detection sensors are arranged at the outlet and the inlet of the circulating oil circuit of the gear box and in the gear box respectively; the air-cooled radiator is arranged in the circulating oil circuit of the gear box;

[0030] The gearbox oil circulation circuit is provided with a lubrication pump and a through valve; the output end of the controller is electrically connected to the control input end of the through valve; the gearbox oil temperature detection sensor is electrically connected to the controller;

[0031] The output end of the controller is connected to the air-cooled radiator with an electrical signal;

[0032] The controller is communicatively connected with the control system of the fan unit.

[0033] In actual application, the gearbox oil temperature detection sensor detects the oil temperature, and the controller controls the operation status of the air-cooled radiator and the through valve. Compared with the traditional temperature control valve, the through valve has the advantages of stability and reliability, which can effectively reduce the failure rate of the cooling system.

[0034] After the unit is started, the gearbox low-speed oil pump works. When the gearbox oil temperature is higher than 40°C, the gearbox oil pump works; the gearbox oil flows from the gearbox oil pump through the filter back to the gearbox;

[0035] When the gearbox oil temperature is higher than 55°C or the high-speed shaft bearing temperature is higher than 70°C, the through valve is closed, the air-cooled radiator is running, and the lubricating oil enters the gearbox after being cooled by the air-cooled radiator;

[0036] When the gearbox oil temperature drops to 45°C and the high-speed shaft bearing temperature is lower than 65°C, the air-cooled radiator stops running and the lubricating oil directly enters the gearbox through the through valve for forced lubrication;

[0037] When the gearbox temperature is lower than -15℃, the heating system in the gearbox heats the gearbox oil; the gearbox oil goes directly through the lubrication pump to the through valve and then to the gearbox, accelerating the circulation of the oil so that the oil temperature rises rapidly.

[0038] When the gearbox oil temperature is higher than 75°C or the high-speed shaft bearing temperature is higher than 90°C, the fan unit will operate at limited load;

[0039] When the gearbox oil temperature is higher than 80℃ or the high-speed shaft bearing temperature is higher than 95℃, the fan unit will shut down.

[0040] The normal operating oil temperature of the unit gearbox is between -15℃ and 75℃. If the gearbox oil temperature is higher than 45℃ and lower than 60℃, the air-cooled radiator will operate.

[0041] When the gearbox oil temperature is higher than 75℃, the fan will automatically limit the output to protect the fan. When the gearbox oil temperature is higher than 80℃, the fan will automatically report the gearbox oil temperature is high and shut down.

[0042] The present invention adopts an air-cooled radiator to regulate the gear box oil temperature, can effectively monitor and regulate the gear box oil temperature, implement a specific cooling control strategy according to the gear box oil temperature, improve the oil temperature regulation efficiency, reduce the oil temperature failure rate of the gear box, and ensure the normal operation of the wind turbine set.

[0043] Optionally, the air-cooled radiator includes an upper base plate, a support shaft, a fan and a lower base plate; the upper base plate is fixed on the gear box; a number of heat dissipation holes are provided on the upper base plate and the lower base plate; one end of the support shaft is fixed to the upper base plate, and the other end is fixed to the lower base plate; the fan is arranged on the support shaft; and heat dissipation fins are fixed on the lower base plate.

[0044] The upper and lower base plates with heat dissipation holes and heat dissipation fins can improve the heat dissipation efficiency. The fan is arranged between the upper and lower base plates through a support shaft to ensure the stability of the heat sink.

[0045] Optionally, an oil pressure detection sensor, a first overflow valve and a second overflow valve are provided on the circulating oil circuit of the gear box; the oil pressure detection sensor is electrically connected to the controller by signal; the output end of the controller is electrically connected to the control input end of the first overflow valve and the control input end of the second overflow valve.

[0046] In actual application, when the temperature is between -15℃ and 45℃, the gearbox oil flows from the gearbox oil pump to the filter element and then to the gearbox. When the gearbox oil pressure is greater than or equal to 10bar, the gearbox oil will flow directly through the gearbox oil pump to the first relief valve and the second relief valve back to the gearbox until the gearbox oil pressure is less than 10bar and the first relief valve is closed; when the gearbox oil pressure is less than 3bar, the second relief valve is closed.

[0047] Optionally, a lubrication heating system is provided in the gearbox, including a pump body heater and an oil pipe heating rod.

[0048] In actual application, when the gearbox temperature is lower than -15℃, the heating system in the gearbox will automatically heat up and heat the gearbox oil temperature to above -15℃. A pump heater is installed on the filter, and an oil pipe heating rod with a thermal control system is also installed on each oil suction pipe. The pump heater and the oil pipe heating rod heat the lubricating oil in each pump body and oil suction pipe, so that the lubricating oil is stabilized in a suitable temperature range and a lower viscosity state.

[0049] Optionally, the controller is connected to a wireless communication module and an infrared sensing device.

[0050] By combining infrared remote control with wireless communication, the operation status of the air-cooled radiator and the fan unit can be remotely controlled on a remote control terminal or a mobile terminal. The wireless communication module is a Bluetooth module or a 4G network module.

[0051] Optionally, the gearbox is connected to an oil level indicator and a plurality of oil temperature displays.

[0052] The gearbox oil temperature detection sensors are respectively arranged at the outlet and inlet of the gearbox oil circulation circuit and inside the gearbox to detect the oil temperature at the outlet, inlet and inside the gearbox. The oil level indicator displays the oil level detection results in real time, and the oil temperature display displays the real-time oil temperature, realizing the real-time display of the oil level and oil temperature of the wind turbine gearbox.

[0053] Example 2

[0054] Based on the same principle as the method shown in Example 1 of the present invention, as shown in the attached Figure 2 As shown, an embodiment of the present invention also provides a wind turbine gearbox cooling method, comprising:

[0055] The unit starts, and the gearbox low-speed oil pump works. When the gearbox oil temperature is higher than the first set temperature, the gearbox oil pump works; the gearbox oil flows from the gearbox oil pump through the filter back to the gearbox;

[0056] When the gearbox oil temperature is higher than the second set temperature or the high-speed shaft bearing temperature is higher than the third set temperature, the through valve is closed, the air-cooled radiator is operated, and the lubricating oil enters the gearbox after being cooled by the air-cooled radiator;

[0057] When the gearbox oil temperature drops to the fourth set temperature and the high-speed shaft bearing temperature is lower than the fifth set temperature, the air-cooled radiator stops running, and the lubricating oil directly enters the gearbox through the through valve for forced lubrication;

[0058] When the gearbox temperature is lower than the sixth set temperature, the heating system in the gearbox heats the gearbox oil;

[0059] When the gearbox oil temperature is higher than the seventh set temperature or the high-speed shaft bearing temperature is higher than the eighth set temperature, the fan unit operates at limited load;

[0060] When the gearbox oil temperature is higher than the ninth set temperature or the high-speed shaft bearing temperature is higher than the tenth set temperature, the fan unit shuts down.

[0061] Specifically, after the unit is started, the gearbox low-speed oil pump works. When the gearbox oil temperature is higher than 40°C, the gearbox oil pump works; the gearbox oil flows back to the gearbox from the gearbox oil pump through the filter; when the gearbox oil temperature is higher than 55°C or the high-speed shaft bearing temperature is higher than 70°C, the straight-through valve is closed, the air-cooled radiator is running, and the lubricating oil enters the gearbox after being cooled by the air-cooled radiator; when the gearbox oil temperature drops to 45°C and the high-speed shaft bearing temperature is lower than 65°C, the air-cooled radiator stops running, and the lubricating oil directly enters the gearbox through the straight-through valve for forced lubrication; when the gearbox temperature is lower than -15°C, the heating system in the gearbox heats the gearbox oil; when the gearbox oil temperature is higher than 75°C or the high-speed shaft bearing temperature is higher than 90°C, the fan unit operates at limited load; when the gearbox oil temperature is higher than 80°C or the high-speed shaft bearing temperature is higher than 95°C, the fan unit stops.

[0062] Optionally, when the oil pressure of the gearbox is greater than or equal to the first set oil pressure threshold, the gearbox oil will flow directly through the gearbox oil pump to the first overflow valve and the second overflow valve back to the gearbox until the oil pressure of the gearbox is less than the first set oil pressure threshold and the first overflow valve is closed; when the oil pressure of the gearbox is less than the second set oil pressure threshold, the second overflow valve is closed; the first set oil pressure threshold is greater than the second set oil pressure threshold.

[0063] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. Wind turbine gearbox cooling system, characterized in that: It includes a gear box, a filter, an air-cooled radiator, several gear box oil temperature detection sensors and a controller; The filter is arranged in the circulating oil circuit of the gear box; the gear box oil temperature detection sensors are arranged at the outlet and the inlet of the circulating oil circuit of the gear box and in the gear box respectively; the air-cooled radiator is arranged in the circulating oil circuit of the gear box; The gearbox oil circulation circuit is provided with a lubrication pump and a through valve; the output end of the controller is electrically connected to the control input end of the through valve; the gearbox oil temperature detection sensor is electrically connected to the controller; The output end of the controller is connected to the air-cooled radiator with an electrical signal; The controller is communicatively connected with the control system of the fan unit.

2. The method for cooling a wind turbine gearbox according to claim 1, characterized in that: The air-cooled radiator includes an upper base plate, a support shaft, a fan and a lower base plate; the upper base plate is fixed on the gear box; a plurality of heat dissipation holes are arranged on the upper base plate and the lower base plate; one end of the support shaft is fixed on the upper base plate, and the other end is fixed on the lower base plate; the fan is arranged on the support shaft; and heat dissipation fins are fixed on the lower base plate.

3. The method for cooling a wind turbine gearbox according to claim 1, characterized in that: An oil pressure detection sensor, a first overflow valve and a second overflow valve are arranged on the circulating oil circuit of the gear box; the oil pressure detection sensor is electrically connected to the controller; the output end of the controller is electrically connected to the control input end of the first overflow valve and the control input end of the second overflow valve.

4. The method for cooling a wind turbine gearbox according to claim 1, characterized in that: The gearbox is equipped with a lubrication heating system, including a pump body heater and an oil pipe heating rod.

5. The method for cooling a wind turbine gearbox according to claim 1, characterized in that: The controller is connected with a wireless communication module and an infrared sensing device.

6. The method for cooling a wind turbine gearbox according to claim 1, characterized in that: The gearbox is connected to an oil level indicator and several oil temperature displays.

7. A method for cooling a gearbox of a wind turbine generator system, characterized in that: include: The unit starts, and the gearbox low-speed oil pump works. When the gearbox oil temperature is higher than the first set temperature, the gearbox oil pump works; the gearbox oil flows from the gearbox oil pump through the filter back to the gearbox; When the gearbox oil temperature is higher than the second set temperature or the high-speed shaft bearing temperature is higher than the third set temperature, the through valve is closed, the air-cooled radiator is operated, and the lubricating oil enters the gearbox after being cooled by the air-cooled radiator; When the gearbox oil temperature drops to the fourth set temperature and the high-speed shaft bearing temperature is lower than the fifth set temperature, the air-cooled radiator stops running, and the lubricating oil directly enters the gearbox through the through valve for forced lubrication; When the gearbox temperature is lower than the sixth set temperature, the heating system in the gearbox heats the gearbox oil; When the gearbox oil temperature is higher than the seventh set temperature or the high-speed shaft bearing temperature is higher than the eighth set temperature, the fan unit operates at limited load; When the gearbox oil temperature is higher than the ninth set temperature or the high-speed shaft bearing temperature is higher than the tenth set temperature, the fan unit shuts down.

8. The method for cooling a wind turbine gearbox according to claim 7, characterized in that: When the oil pressure of the gearbox is greater than or equal to the first set oil pressure threshold, the gearbox oil will flow directly through the gearbox oil pump to the first overflow valve and the second overflow valve back to the gearbox until the oil pressure of the gearbox is less than the first set oil pressure threshold and the first overflow valve is closed; when the oil pressure of the gearbox is less than the second set oil pressure threshold, the second overflow valve is closed; the first set oil pressure threshold is greater than the second set oil pressure threshold.

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