Wind turbine generator sliding bearing supporting transmission chain based on magnetic coupler connection

Abstract

The invention discloses a wind turbine generator sliding bearing supporting transmission chain based on magnetic coupling connection, and relates to the technical field of wind power. The problems that due to the fact that a sliding bearing is adopted in a wind power transmission chain system, a large relative gap is generated between the output end of the main shaft and the input end of the gear box, vibration noise of a wind turbine generator is too large, and the fault rate of the gear box is increased are solved, the actual service life of the wind turbine generator is prolonged, and maintenance cost is reduced. According to the specific scheme, the device comprises a spindle system, a magnetic coupler and a gearbox; the main shaft system is connected with the gear box through a magnetic coupler; the main shaft system comprises a main shaft, a main shaft bearing and a bearing seat; the magnetic coupling comprises a left main rotor, a right auxiliary rotor and a permanent magnet; the gearbox comprises a single-stage planetary gear train and a step-up gearbox shell. The single-stage planetary gear train is composed of a planet carrier bearing, a planet carrier, a planet gear, a gear ring, a sun gear, an output shaft and an output shaft bearing.

Description

Technical Field

[0001] This invention relates to the field of wind power technology, and in particular to a wind turbine transmission system involving a magnetic coupling. Background Technology

[0002] Wind energy, as a green and renewable energy source, plays a vital role in protecting the ecological environment and alleviating energy shortages. Wind power generation is currently the most mature and efficient way to develop and utilize wind energy. Wind turbines are key equipment in wind power systems, and the turbine drivetrain system is the core component, responsible for converting wind energy into mechanical energy and ultimately into electrical energy. However, with the increasing size of wind turbines and the development of offshore wind power, traditional rolling bearings are struggling to meet design and industrialization requirements in terms of size, weight, load-bearing capacity, and cost. In contrast, sliding bearings offer high stability, good tolerance to material defects and external impurities, low processing costs, and the ability to be replaced in sections. They represent an effective way to achieve leapfrog development in the drivetrain of large wind turbines, and the use of fully sliding bearings is the future trend in wind turbine technology.

[0003] The inventors discovered that current wind turbine drivetrain systems use sliding bearings for both the main bearing and gearbox bearings. Compared to rolling bearings, this "sliding-driven-rolling" method results in a more compact wind turbine structure and higher power density. However, using sliding bearings causes significant relative clearance between the main shaft end and the gearbox input end during operation, leading to severe misalignment and excessive vibration and noise. In severe cases, this can increase gearbox failure rates and reduce the actual lifespan of the turbine. To address these issues, this invention proposes a wind turbine drivetrain supported by sliding bearings and connected by a magnetic coupling. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a wind turbine transmission chain supported by sliding bearings based on magnetic couplings. Magnetic couplings enable completely contactless transmission, are highly adaptable to misalignment, and can transmit high torque. They also provide overload automatic decoupling protection when the torque is too high. By using magnetic couplings to connect the main shaft system and the speed-increasing gearbox, the problems of high vibration and noise, and increased gearbox failure rate caused by using sliding bearings to support the entire transmission chain system can be solved.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] A wind turbine sliding bearing support transmission chain based on magnetic coupling includes a main shaft system, a magnetic coupling, and a gearbox; the main shaft system and the gearbox are connected by a magnetic coupling; the main shaft system includes a main shaft, a main shaft bearing, and a bearing housing; the magnetic coupling includes a left main rotor, a right auxiliary rotor, and a permanent magnet; the gearbox includes a single-stage planetary gear train and a gearbox housing; the single-stage planetary gear train consists of a planet carrier bearing, a planet carrier, planetary gears, an external gear ring, a sun gear, an output shaft, and an output shaft bearing.

[0007] Furthermore, the bearing housing of the main shaft system is rigidly connected to the fan frame, and the gearbox housing is rigidly connected to the fan frame.

[0008] Furthermore, the spindle of the spindle system has an internal hollow structure, and both ends of the spindle are supported by spindle bearings. The right end of the spindle is connected to the gearbox via a magnetic coupling.

[0009] Furthermore, the spindle bearing, planetary gear bearing, and output shaft bearing of the spindle system are all segmented sliding bearings, and the bearing material is PEEK material.

[0010] Furthermore, the left main rotor of the magnetic coupling is connected to the right end of the main shaft, and the right auxiliary rotor is connected to the left end of the planetary carrier of the planetary gear system in the gearbox by bolts.

[0011] Furthermore, the permanent magnets of the coupling are embedded in the inner ring at the right end of the left main rotor and the outer ring at the left end of the right auxiliary rotor, arranged in an alternating N / S pattern, and the permanent magnet material is neodymium iron boron magnet.

[0012] Furthermore, the planetary carrier serves as the input shaft of the gearbox.

[0013] Furthermore, the output shaft is an integrated pin shaft.

[0014] Furthermore, the planetary gears, external gear ring, and sun gear of the single-stage planetary gear train in the gearbox all have helical teeth, and there are three planetary gears that are evenly distributed in the circumferential direction.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0016] (1) The bearings used in the main shaft system and speed-increasing gearbox of this invention are all sliding bearings. The "sliding belt rolling" support form makes the overall size of the wind turbine more compact and the power density of the unit higher.

[0017] (2) The sliding bearing bush material of the present invention is PEEK material, which can improve the wear resistance and corrosion resistance of the bearing and overcome the disadvantages of hydrodynamic sliding bearings being easy to wear and having a short service life;

[0018] (3) The present invention uses a magnetic coupling to connect the spindle system and the gearbox, which can solve the problems of high vibration and noise and reduced gearbox service life caused by the use of sliding bearings. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the fully sliding bearing support transmission chain of the wind turbine generator of the present invention.

[0021] Figure 3 This is a schematic diagram of the spindle system structure of the present invention.

[0022] Figure 4 This is a schematic diagram of the magnetic coupling structure of the present invention.

[0023] Figure 5 This is a schematic diagram of the main rotor of the magnetic coupling of the present invention.

[0024] Figure 6 This is a schematic diagram of the auxiliary rotor of the magnetic coupling of the present invention.

[0025] Figure 7 This is a schematic diagram of a single-stage planetary gear train inside the gearbox of the present invention.

[0026] The markings in the diagram are: 1. Main spindle system; 2. Magnetic coupling; 3. Gearbox; 4. Main spindle; 5. Main bearing; 6. Bearing housing; 7. Main rotor; 8. Secondary rotor; 9. Single-stage planetary gear train; 10. Gearbox housing; 11. Planet carrier; 12. Planet carrier bearing; 13. Gear ring; 14. Planetary gear; 15. Sun gear; 16. Output shaft bearing; 17. Output shaft; 701. Permanent magnet (main rotor); 801. Permanent magnet (secondary rotor). Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the embodiments described herein are only for explaining the invention and are not intended to limit the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0028] Please see Figures 1 to 7This invention provides a wind turbine sliding bearing support transmission chain based on magnetic coupling: a wind turbine sliding bearing support transmission chain based on magnetic coupling includes a main shaft system 1, a magnetic coupling 2, a gearbox 3, and a generator; the main shaft system 1 and the gearbox 3 are connected by the magnetic coupling 2; the main shaft system 1 includes a main shaft 4, a main bearing 5, and a bearing housing 6; the magnetic coupling 2 includes a left main rotor 7 and a right auxiliary rotor 8; the gearbox 3 includes a single-stage planetary gear train 9 and a gearbox housing 10; the single-stage planetary gear train includes a planet carrier 11, a planet carrier bearing 12, a gear ring 13, planetary gears 14, a sun gear 15, an output shaft bearing 16, and an output shaft 17.

[0029] In this embodiment, the bearing housing 6 of the main shaft system 1 and the gearbox housing 10 are both rigidly supported. The main shaft system 1 and the gearbox 3 are connected by a magnetic coupling 2. The support connection of this transmission chain adopts an "inner flexible, outer rigid" scheme, that is, the outer part of the transmission chain (between the transmission chain and the wind turbine frame) is rigidly supported, while the inner part (between the main shaft system and the gearbox) is a flexible connection using a magnetic coupling. This design scheme can improve the power density of the wind turbine while reducing the industrialization cost of the wind turbine. More specifically, the use of sliding bearings can reduce the design and manufacturing costs, and the use of magnetic couplings can solve the vibration problem caused by the positive clearance due to the replacement of the sliding bearing support form, thereby reducing the failure rate of the wind power transmission chain.

[0030] In this embodiment, the spindle of the spindle system 1 has an internal hollow structure. This hollow structure is beneficial for reducing the manufacturing cost of the transmission chain, for the delivery of lubricating oil, and for the arrangement of the internal circuitry of the control system.

[0031] In this embodiment, the main bearing 5 of the main shaft system 1, the planetary gear bearing 12, and the output shaft bearing 16 are all sliding bearings. The bearing bush material of the sliding bearing is PEEK material. PEEK material has excellent mechanical properties, which can improve the wear and corrosion resistance of the bearing and solve the problems of easy wear and short life of sliding bearings in the wind power field.

[0032] In this embodiment, the left end of the left main rotor 7 of the magnetic coupling 2 is connected to the right end of the main shaft 4 by bolts. The bolt connection scheme is mature and widely used in the wind power field, and it is simpler to use and easier to install and disassemble.

[0033] In this embodiment, the right end of the right auxiliary rotor 8 of the magnetic coupling 2 is connected to the left end of the planetary carrier 11 by an expansion sleeve. The expansion sleeve connection method can make the alignment accuracy of the transmission chain system higher, the disassembly and assembly more convenient, and also has a certain overload protection function.

[0034] In this embodiment, the permanent magnets 701 (801) of the magnetic coupling 2 are interleaved and embedded in the inner surface of the right end of the main rotor 7 (outer surface of the left end of the auxiliary rotor 8). The permanent magnets are interleaved with N and S poles to form a closed magnetic field by using the attraction (N pole attracts S pole) and repulsion (N pole repels N pole) between the magnetic poles, which drives the driven shaft to rotate synchronously. The permanent magnets 701 (801) are made of high-quality magnetic materials, preferably neodymium iron boron. Compared with traditional magnetic materials, they can improve the torque transmission and are convenient for application in the wind power field.

[0035] In this embodiment, the gear ring 13, planetary gears 14 and sun gear 15 of the single-stage planetary gear train 9 in the gearbox 3 are all helical gears. Helical gear transmission facilitates the smooth operation of the transmission chain, improves the load-bearing capacity of the transmission chain, and makes the transmission chain structure more compact. There are multiple planetary gears 14, preferably three. The planetary gears 14 are installed at equal intervals along the circumference. Multiple planetary gears help to improve the torque transmission efficiency of the gearbox.

[0036] In this embodiment, the planetary carrier 11 serves as the input shaft of the gearbox 3, which makes the entire transmission chain structure more compact. The output shaft 17 is an integrated pin, which facilitates disassembly and assembly and connection to the motor.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and variations. Any simple modifications, equivalent substitutions, or variations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention should be included within the protection scope of the present invention.

Claims

1. A wind turbine sliding bearing support transmission chain based on magnetic coupling connection, characterized in that, It includes a main spindle system 1, a magnetic coupling 2, and a gearbox 3; the main spindle system 1 and the gearbox 3 are connected by the magnetic coupling 2; the main spindle system 1 includes a main spindle 4, a main bearing 5, and a bearing housing 6; the magnetic coupling 2 includes a left main rotor 7 and a right auxiliary rotor 8; the gearbox 3 includes a single-stage planetary gear train 9 and a gearbox housing 10; the single-stage planetary gear train 9 is composed of a planet carrier 11, a planet carrier bearing 12, a gear ring 13, planetary gears 14, a sun gear 15, an output shaft bearing 16, and an output shaft 17.

2. The wind turbine sliding bearing support transmission chain based on magnetic coupling connection according to claim 1, characterized in that, The bearing housing 6 of the main shaft system 1 is rigidly supported to the fan frame, and the gearbox housing 10 of the gearbox 3 is rigidly supported to the fan frame.

3. The wind turbine sliding bearing support transmission chain based on magnetic coupling connection according to claim 1, characterized in that, The main shaft 4 of the main shaft system 1 has an internal hollow structure. The main shaft 4 is supported by the main bearing 5. The left end of the main shaft 4 is connected to the impeller, and the right end of the main shaft 4 is connected to the gearbox 3 through the magnetic coupling 2.

4. The wind turbine sliding bearing support transmission chain based on magnetic coupling connection according to claim 1, characterized in that, The main bearing 5 of the main spindle system 1 is a sliding bearing, and the support method is not limited to "double main bearing support" or "single main bearing" support. The bearing bush material of the sliding bearing is PEEK material.

5. A wind turbine sliding bearing support transmission chain based on a magnetic coupling as described in claim 1, characterized in that, The left main rotor 7 and the main shaft 4 of the magnetic coupling 2 are connected by bolts, and the right auxiliary rotor 8 is connected to the planetary carrier 11 of the gearbox 3 by an expansion sleeve.

6. The wind turbine sliding bearing support transmission chain based on magnetic coupling connection according to claim 1, characterized in that, The permanent magnets on the left main rotor 7 and right auxiliary rotor 8 of the magnetic coupling 2 are made of high-quality magnetic materials, preferably neodymium iron boron materials.

7. A wind turbine sliding bearing support transmission chain based on a magnetic coupling as described in claim 1, characterized in that, The planetary carrier 11 serves as the input shaft of the gearbox 3, and the output shaft 17 of the gearbox 3 is an integrated pin.

8. A wind turbine sliding bearing support transmission chain based on a magnetic coupling as described in claim 1, characterized in that, The planetary carrier bearing 12 and the output shaft bearing of the gearbox 3 are both sliding bearings.

9. A wind turbine sliding bearing support transmission chain based on a magnetic coupling as described in claim 1, characterized in that, The gear ring 13 meshes internally with the planetary gear 14 and externally with the sun gear 15; the planetary gear 14 is mounted on the planet carrier 11; the planet carrier 11 is supported by the planetary gear bearing 12; the sun gear 15 is mounted on the output shaft 17; the output shaft 17 is supported by the output shaft bearing 16.

10. A wind turbine sliding bearing support transmission chain based on a magnetic coupling according to claim 1, characterized in that, The tooth profiles of the gear ring 13, planetary gear 14 and sun gear 15 are helical; there are multiple planetary gears 14, which are installed at equal intervals in the circumferential direction.

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