Abrasion repair method for large gear ring gear of wind turbine generator

Abstract

The invention provides a wind turbine generator large gear ring gear wear repair method, belongs to the technical field of wind power generation, and aims to solve the problem of large gear ring gear wear repair. Comprising the following steps: S1, detecting the wear state of a gear to judge whether the gear has an on-tower repair value or not; s2, if the gear has the on-tower repair value, acquiring tooth profile parameters of the unworn part of the gear as repair parameters of the worn part; s3, according to the abrasion depth and the repairing parameters, laser coating is conducted on the abrasion position; s4, roughly repairing the coated part, and detecting the tooth surface hardness of the coated part so as to judge whether the tooth surface hardness reaches the standard or not; s5, if the hardness of the tooth surface reaches the standard, the coating position is subjected to fine trimming according to the repairing parameters; and S6, test run operation is carried out to confirm the tooth surface meshing state. The original performance of the gear can be recovered to the maximum extent, and the maintenance cost is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of wind power generation, and in particular relates to a method for repairing wear of a large ring gear of a wind turbine. Background Art

[0002] In wind turbines, large ring gears are used in components such as the yaw and pitch systems. In the yaw system, they help the wind turbine's nacelle adjust its position according to changes in wind direction, ensuring the turbine always faces the wind and improving power generation efficiency. In the pitch system, the large ring gear adjusts the pitch angle of the wind turbine blades, optimizing the turbine's operation, particularly in conditions of large wind speed fluctuations, ensuring safe and efficient operation. With the continuous advancement of control technology and wind power prediction technology, the utilization rate of wind turbines is also increasing, and the mileage of the yaw and pitch systems is gradually increasing. The large ring gears in these systems are subject to alternating loads and high friction, and their tooth surface lubrication conditions are poor, making them prone to excessive wear and leading to gear failure. Gear failure directly affects the mechanical transmission of the wind turbine, and thus the operational safety of the entire unit.

[0003] When a large ring gear fails due to wear, replacing the worn gear directly presents two immediate challenges. First, the gear's large size makes it difficult to store and spare parts are unavailable. If a temporary production is required, the cost and lead time will be higher than expected. Second, hoisting and replacing the gear is difficult, and the time required to assemble other parts is long. Gear repairs performed in-flight typically involve welding, milling, and metal repair agent coating. In-flight welding, typically performed using argon arc welding or gas shielded arc welding, creates a large heat-affected zone, which can damage the gear's thermal performance and easily cause cracks. It also fails to address overcurrent issues in the bearing raceways, creating potential hazards. Furthermore, the difficulty in controlling welding temperatures leads to significant deformation, resulting in extensive milling work and difficulty removing residual stresses. Furthermore, this can pollute the operating environment. While metal repair agent coatings can adhere to the gear surface for a short period of time, they can still partially peel off after prolonged operation. Furthermore, current in-flight repair procedures vary widely, with inconsistent standards, resulting in considerable subjectivity and arbitrariness, posing significant safety risks to wind turbines. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is to provide a method for repairing wear of the large ring gear of a wind turbine generator set, which can restore the original performance of the gear to the maximum extent, reduce maintenance costs, and alleviate safety hazards.

[0005] In order to solve the above problems, the present invention provides a method for repairing wear of a large ring gear of a wind turbine generator system, comprising the following steps:

[0006] S1. Check the wear condition of the gear to determine whether the gear is worth repairing on the tower;

[0007] S2. If the tower has repair value, then obtain the tooth profile parameters of the unworn part of the gear as the repair parameters of the worn part;

[0008] S3. Laser coating the worn area according to the wear depth and repair parameters;

[0009] S4. Perform a rough repair on the coated area and test the tooth surface hardness at the coated area to determine whether the tooth surface hardness meets the standard;

[0010] S5. If the tooth surface hardness meets the standard, the coating area is refined according to the repair parameters;

[0011] S6. Perform a test run to confirm the tooth meshing status.

[0012] Wherein, step S1 includes:

[0013] S11. Obtaining gear design parameters;

[0014] S12. Obtaining the gear tooth wear depth;

[0015] S13. Determine whether the wear depth exceeds the design limit. If it does not exceed the design limit, it is worth repairing on the tower.

[0016] Wherein, step S1 also includes: if the gear has no value for on-tower repair, then abandon the repair and replace the entire gear.

[0017] Wherein, step S2 further includes: if the tooth surface of the gear is completely worn or corroded, the original design parameters are used as repair parameters.

[0018] Wherein, step S3 includes:

[0019] S31. Install fire prevention equipment;

[0020] S32. Grind the worn areas smooth;

[0021] S34. Laser coating the worn area using a multi-layer coating method.

[0022] Among them, between step S32 and step S34 also includes:

[0023] S33. Clean the polished tooth surface.

[0024] Wherein, step S4 includes: using a customized tooth-shaped grinding knife to perform rough trimming on the coating area; wherein, the outer dimensions of the tooth-shaped grinding knife are adapted to the tooth shape of the gear.

[0025] Wherein, step S5 further includes: if the tooth surface hardness does not meet the standard, flame quenching is performed to improve the tooth surface hardness.

[0026] Wherein, step S6 includes: performing a test run in a manual adjustment manner and observing the meshing state of the tooth surfaces.

[0027] Wherein, step S6 further includes: if the tooth surfaces are poorly meshed, trimming the main meshing area to increase the contact area of ​​the tooth surfaces.

[0028] Beneficial effects:

[0029] The wind turbine ring gear wear repair method provided by the present invention can repair the wear of the wind turbine ring gear teeth of the wind turbine bearing that has been installed and operated on the tower without disassembly, and the heat-affected zone of the repair process is small, the deformation of the base body is small, and the mechanical properties of the gear base body are not damaged. The coating structure is tight, the bonding strength is high, and the process is easy to control, which can restore the original performance of the gear to the maximum extent and reduce maintenance costs. In addition, the present invention addresses the problem that gears are difficult to repair efficiently, accurately, and safely in the air, and provides a repair method with controllable thickness, controllable temperature, and controllable heat-affected zone, solving the problem of overcurrent caused by conventional welding repairs on bearing raceways, rollers and other unit parts. In addition, the present invention also addresses the problem that there is no unified standard for industry repairs and the repair effect is difficult to control and judge, and provides a repair method that is technologically advanced, comprehensive, highly instructive, and easy to quantify and evaluate the effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A flow chart of a method for repairing wear of a large ring gear of a wind turbine generator system according to an embodiment of the present invention;

[0031] Figure 2 A flow chart of a method for repairing wear of a large ring gear of a wind turbine generator set according to another embodiment of the present invention;

[0032] Figure 3 A flow chart of a method for repairing wear of a large ring gear of a wind turbine generator set according to another embodiment of the present invention;

[0033] Figure 4 This is a step diagram of a method for repairing wear of a large ring gear of a wind turbine set according to an embodiment of the present invention. DETAILED DESCRIPTION

[0034] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0035] This embodiment provides a method for repairing wear of a large ring gear of a wind turbine generator system. Figure 1Flowchart of the wind turbine ring gear wear repair method according to this embodiment.

[0036] like Figure 1 As shown, the wind turbine ring gear wear repair method of this embodiment includes the following steps:

[0037] S1. Check the wear condition of the gear to determine whether the gear is worth repairing on the tower;

[0038] Specifically, gear wear testing primarily involves examining wear depth. Key testing parameters include tooth surface hardness, quenching layer depth, and carburizing and nitriding layer depth. After testing is complete, design parameters and test data are combined to determine the repair direction. If the wear depth exceeds the critical limit (hardness, quenching layer depth, and carburizing and nitriding layer depth cannot be restored), the gear is not suitable for on-the-wheel repair and requires replacement. If the wear depth does not exceed the critical limit, repair can proceed.

[0039] S2. If the tower has repair value, then obtain the tooth profile parameters of the unworn part of the gear as the repair parameters of the worn part;

[0040] Specifically, the tooth profile parameters of the unworn portion of the gear are mainly the normal line, the dimensions of the modified surface, etc. However, it should be noted that the final repair parameters should be adjusted as appropriate based on the operating life of the gear to prevent impact loads caused by excessive tooth profile differences between teeth.

[0041] S3. Laser coating the worn area according to the wear depth and repair parameters;

[0042] Specifically, a mobile laser coating machine is used to determine the spraying thickness and length based on the gear's wear condition and repair parameters. The appropriate laser cladding powder is selected based on the gear material and tooth surface hardness. These control parameters are then input into the coating machine, and a multi-layer coating method is used to rapidly complete the coating process.

[0043] For example, if the gear material is 42 Luo Mo, nickel-based powder and medium manganese steel material can be used as laser cladding powder so that the performance indicators of the cladding layer can meet the use requirements.

[0044] Furthermore, during laser coating, the ambient temperature must be controlled. If the ambient temperature is too low, for example, below -5°C, the ambient temperature in the work area must be controlled based on the cooling characteristics of the coated metal layer to avoid cracking and quenching caused by uneven hardness due to overcooling.

[0045] S4. Perform a rough repair on the coated area and test the tooth surface hardness at the coated area to determine whether the tooth surface hardness meets the standard;

[0046] Specifically, before roughing, the coated area needs to be cooled to ambient temperature. A margin should be left during roughing, and a 1mm thickness margin is generally maintained.

[0047] S5. If the tooth surface hardness meets the standard, the coating area is refined according to the repair parameters;

[0048] Specifically, during finishing, the coated tooth surface should be ground to the same tooth profile as a previously run-in gear, or to the same profile as a non-meshing gear. The tooth profile should be checked periodically during the grinding process to prevent over-grinding. After grinding to the desired tooth profile, the backlash should be adjusted and the dimensions should be inspected, primarily focusing on the contact area, which should be equivalent to that of the previously run-in gear surface.

[0049] S6. Perform a test run to confirm the tooth meshing status.

[0050] Specifically, when confirming the meshing state of the tooth surface, if it is inconvenient for personnel to stay and observe, remote video monitoring and other methods can be used.

[0051] The wind turbine ring gear wear repair method of this embodiment can repair the wear of the wind turbine ring gear teeth of the wind turbine bearing that has been installed and operated on the tower without disassembly, and the heat-affected zone of the repair process is small, the deformation of the base body is small, and the mechanical properties of the gear base body are not damaged. The coating structure is tight, the bonding strength is high, and the process is easy to control, which can restore the original performance of the gear to the maximum extent and reduce maintenance costs. In addition, the present invention addresses the problem that gears are difficult to repair efficiently, accurately, and safely in the air, and provides a repair method with controllable thickness, controllable temperature, and controllable heat-affected zone, which solves the problem of overcurrent caused by conventional welding repairs on bearing raceways, rollers and other unit parts. In addition, the present invention also addresses the problem that there is no unified standard for industry repairs and the repair effect is difficult to control and judge, and provides a repair method that is technologically advanced, comprehensive, highly instructive, and easy to quantify and evaluate the effect.

[0052] Figure 2 This is a flow chart of another method for repairing wear of a large ring gear of a wind turbine provided in this embodiment.

[0053] Among them, such as Figure 2 As shown, step S1 includes:

[0054] S11. Obtaining gear design parameters;

[0055] Specifically, the design parameters of the gear include tooth shape, tooth spacing, tooth surface hardness, quenching layer depth, carburizing and nitriding layer depth, etc.

[0056] S12. Obtaining the gear tooth wear depth;

[0057] Specifically, the tooth surface wear depth is the height difference between the worn area and the unworn area.

[0058] S13. Determine whether the wear depth exceeds the design limit, if not, it has the tower repair value.

[0059] Specifically, assuming that the single-sided wear depth is H, combined with the hardness of the tooth surface, the quenching layer depth, the carburizing and nitriding layer depth data, generally 1mm≤H≤5mm, then it has the tower repair value.

[0060] Wherein, step S1 further comprises: if the gear does not have the tower repair value, then give up repair and replace the whole. Specifically, generally H≥5mm, then it does not have the tower repair value, then give up repair and remove the gear as a whole.

[0061] Wherein, step S2 further comprises: if the tooth surface of the gear is worn out or corroded, then use the original design parameters as the repair parameters. Specifically, if the tooth surface of the gear is worn out or corroded, the tooth profile parameters of the unworn part of the gear cannot be obtained accurately, so the original design parameters can be used as the repair parameters. However, it should be noted that when using the original design parameters as the repair parameters, the repair parameters should be corrected according to the running time of the gear to avoid impact load caused by too large tooth profile difference between teeth.

[0062] Figure 3 The flow chart of the wind turbine gear wear repair method provided in this embodiment is shown in the figure. As shown in the figure, Figure 3 Step S3 comprises:

[0063] S31. Set up fire prevention equipment;

[0064] Specifically, laser coating repair is a high-temperature operation, and before operation, the matching professional fireproofing layer and emergency fire extinguishing design and setting are completed to ensure the safety of the operators and equipment.

[0065] S32. Grind the worn part flat;

[0066] Specifically, it mainly grinds the surface of the meshing surface to about 1mm below the basic damaged surface to avoid further damaging the original quenching layer and carburizing and nitriding layer. In addition, the non-working contact surface of the gear also needs to be treated and ground to be basically the same height as the worn part for easy spraying together later.

[0067] S34. Adopt multi-layer coating method for laser coating of the worn part.

[0068] Specifically, the multi-layer coating method can cool and solidify the coating layer in time and improve the coating efficiency.

[0069] As shown in the figure, Figure 3 Between step S32 and step S34, it further comprises:

[0070] S33. Clean the polished tooth surface.

[0071] Specifically, cleaning the tooth surface can remove impurities left by grinding, so as to ensure that the coating material is tightly bonded to the worn area during laser coating.

[0072] Step S4 includes performing a rough trim on the coated area using a customized tooth-shaped grinding tool, wherein the outer dimensions of the tooth-shaped grinding tool are adapted to the tooth profile of the gear. Specifically, using the customized tooth-shaped grinding tool to perform a rough trim on the coated area can ensure repair accuracy, reduce repair difficulty, and improve repair efficiency.

[0073] Step S5 further includes: if the tooth surface hardness does not meet the standard, flame quenching is performed to improve the tooth surface hardness. Specifically, if the tooth surface hardness does not meet the standard, flame quenching is performed, and the flame temperature must be controlled to prevent cracking. After cooling to ambient temperature, hardness testing is performed again. This process is repeated until the hardness meets the standard.

[0074] Step S6 includes: performing a test run using manual adjustment and observing the meshing state of the tooth surfaces. Specifically, manual adjustment can avoid severe load on the repaired tooth surfaces and facilitate observation of the meshing state of the tooth surfaces.

[0075] Step S6 further includes: if the tooth meshing is poor, trimming the primary meshing area to increase the tooth contact area. Specifically, if the tooth meshing area exhibits poor contact under load during the test run, trimming the primary meshing area to increase the tooth contact area. Ensure that the contact area reaches that of an unworn tooth surface, while ensuring that the backlash does not exceed the specified value.

[0076] The above is a detailed introduction to the wind turbine ring gear wear repair method of this embodiment. Next, a specific repair step is provided in combination with the above description. Figure 4 As shown:

[0077] First, check the gear wear. If the wear depth on a single side exceeds 5mm, abandon the repair and remove the entire gear.

[0078] If the wear depth on one side is between 1mm and 5mm, it can be repaired and fire protection equipment should be installed first; then the tooth surface should be polished to smooth the worn area and the polished tooth surface should be cleaned.

[0079] At the same time, the repair parameters need to be determined. Specifically, after the tooth surface is ground, the tooth surface in the non-meshing area can be measured or the design parameters can be obtained. The tooth surface in the meshing area that is not severely worn can also be measured as a basis for adjusting the repair parameters as appropriate.

[0080] Then the coating parameters of the laser coating machine are set and adjusted, and laser coating is performed.

[0081] After coating is completed, the coated surface is roughened; then the coated surface is quenched to increase the hardness.

[0082] The tooth surface is then roughed and finely trimmed to gradually achieve the required tooth profile parameters.

[0083] Afterwards, the tooth profile is checked, the tooth gap is adjusted, and the construction site is cleaned and restored.

[0084] Finally, a trial run is started to ensure that the repairs to the worn areas meet the requirements of use.

[0085] It is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0086] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention. The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art may make various improvements and variations without departing from the technical principles of the present invention, and such improvements and variations shall also be considered within the scope of protection of the present invention.

Claims

1. A method for repairing wear of a large ring gear of a wind turbine, characterized in that: The steps include: S1 detects the wear state of the gear to determine whether the gear has a tower repair value; S2. If the tower has a repair value, then obtain the tooth profile parameters of the gear at the unworn portion as the repair parameters at the worn portion; S3 according to the wear depth and the repair parameters, the wear portion is laser coated; S4. Perform a rough repair on the coating and detect the tooth surface hardness of the coating to determine whether the tooth surface hardness meets the standard; S5. If the tooth surface hardness meets the standard, the coating is refined according to the repair parameters; S6. Perform a test run to confirm the tooth meshing status.

2. The wind turbine ring gear wear repair method according to claim 1, characterized in that: Step S1 includes: S11. Obtaining the design parameters of the gear; S12 obtains the gear tooth wear depth; S13. Determine whether the wear depth exceeds the design limit. If it does not exceed the design limit, it is worth repairing on the tower.

3. The method for repairing the wear of the large ring gear of a wind turbine according to claim 1, characterized in that: Step S1 further includes: If the gear is not worth repairing on the tower, the repair is abandoned and the entire gear is replaced.

4. The wind turbine ring gear wear repair method according to claim 1, characterized in that: Step S2 further includes: If the tooth surface of the gear is completely worn or corroded, the original design parameters are used as the repair parameters.

5. The method for repairing the wear of the large ring gear of a wind turbine according to claim 1, characterized in that: Step S3 includes: S31. Install fire prevention equipment; S32. The worn area is polished smooth; S34. Laser coating the worn area using a multi-layer coating method.

6. The wind turbine ring gear wear repair method according to claim 5, characterized in that: The following steps are included between step S32 and step S34: S33. Clean the polished tooth surface.

7. The wind turbine ring gear wear repair method according to claim 1, characterized in that: Step S4 includes: Roughly trim the coating area using a customized toothed grinder; Wherein, the outer dimensions of the tooth grinder are adapted to the tooth shape of the gear.

8. The method for repairing the worn ring gear of a wind turbine according to claim 1, characterized in that: Step S5 further includes: If the tooth surface hardness does not meet the standard, flame quenching is performed to improve the tooth surface hardness.

9. The wind turbine ring gear wear repair method according to claim 1, characterized in that: Step S6 includes: Use manual adjustment to carry out trial operation and observe the tooth surface meshing status.

10. The method for repairing the wear of the large ring gear of a wind turbine according to claim 1, characterized in that: Step S6 further includes: If the tooth surfaces are poorly meshed, the main meshing area is trimmed to increase the contact area of ​​the tooth surfaces.

Images