Wind driven generator gear box convenient to maintain

Abstract

The invention discloses a wind driven generator gear box convenient to maintain, which relates to the technical field of wind power generation, and comprises a gear box, a generator, and an inertia deceleration correction assembly, a gear transmission assembly and a self-repairing assembly which are respectively arranged in the gear box, the inertia deceleration correction assembly and the self-repairing assembly are arranged at the left end and the right end of the gear transmission assembly correspondingly, the self-repairing assembly is symmetrically arranged, under cooperation of the self-repairing assembly, through switching of hot melting repairing and a bidirectional guide spray head, full-type damage from microcracks to deep tooth breakage can be treated, manual intervention is not needed, the repairing efficiency is improved, and the repairing cost is reduced. The magnetic field controller adjusts the magnetic field intensity in real time according to the damage depth, for example, when deep cracks are repaired, the magnetic field is enhanced to improve the particle filling density, when surface abrasion is repaired, the magnetic field is reduced to ensure that materials are evenly laid, resource waste is avoided, and two or more repairing cavities and internal structures can be installed according to the structure of the gearbox; the operation and maintenance cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of wind power generation technology, specifically to a wind turbine gearbox that is easy to maintain. Background Technology

[0002] With the continuous development of the wind power industry and the increasing installed capacity of wind power, the weight and maintenance costs of the main gearbox are constantly rising. There is an urgent need to optimize maintenance solutions.

[0003] In the prior art, Chinese Patent Publication No. CN210859058U, entitled "A Replacement Device for Wind Turbine Gearbox," includes two fixed bases. A mounting bracket is fixedly installed on the upper surface of each fixed base. A main shaft clamping fixture is disposed between the two mounting brackets. The main shaft clamping fixture comprises multiple main shaft clamping plates, each with a first fixing hole at both ends. Two limiting ears are fixedly disposed on the upper surface of the mounting bracket, each limiting ear having a corresponding second fixing hole. The two ends of the main shaft clamping plates are respectively positioned between the two limiting ears, and the first and second fixing holes are aligned and fixed by fixing pins. This patent overcomes the shortcomings of the prior art by dividing the main shaft clamping fixture into multiple main shaft clamping plates, thus facilitating the transport of the device from the ground to the wind turbine nacelle. It eliminates the need for large lifting equipment, allowing for convenient and quick manual handling.

[0004] However, in the current maintenance of wind turbine gearboxes, traditional gearbox maintenance requires the entire machine to be shut down. Since the power of a single wind turbine is usually in the megawatt range, the long downtime for maintenance can easily lead to a large loss of power generation. In addition, existing maintenance requires technicians to climb to a height of hundreds of meters to work, which is greatly affected by the weather and takes a long time for each maintenance. Therefore, there is a need to propose a wind turbine gearbox that is easy to maintain. Summary of the Invention

[0005] The purpose of this invention is to provide a wind turbine gearbox that is easy to maintain, in order to solve the problems mentioned in the background art. Traditional gearbox maintenance requires the entire machine to be shut down, while the power of a single wind turbine is usually in the megawatt range. The long downtime for maintenance can easily lead to a large loss of power generation. In addition, existing maintenance requires technicians to climb hundreds of meters into the air to work, which is greatly affected by the weather and takes a long time for each maintenance.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a wind turbine gearbox that is easy to maintain, comprising a gearbox, a generator, and an inertial deceleration correction component, a gear transmission component, and a self-repairing component respectively installed inside the gearbox. The inertial deceleration correction component and the self-repairing component are respectively installed at the left and right ends of the gear transmission component, and the self-repairing component is symmetrically installed. The inertial deceleration correction assembly includes a flywheel energy storage structure, an electromagnetic coupler, an inertial quantity corrector, and a reduction gear. The flywheel energy storage structure is connected to the input shaft of the gear transmission assembly via the electromagnetic coupler. The reduction gear is externally meshed with an external reduction gear ring, which provides controllable deceleration force during gear switching, providing working time for the subsequent self-healing assembly. The self-healing component includes a hot melt repair conversion nozzle, a shape memory alloy driving cavity, and a magnetic particle driving component. The shape memory alloy driving cavity is electrically connected to an intelligent monitoring sensor and is used to drive the hot melt repair conversion nozzle to move to the damaged area when tooth surface damage is detected.

[0007] Preferably, the magnetic particle driving component has a nano-magnetic repair particle delivery cavity connected to its side end. Electromagnetic coils are symmetrically mounted on the side end of the nano-magnetic repair particle delivery cavity. When energized, the electromagnetic coils generate a gradient magnetic field, driving the nano-magnetic repair particles to directionally fill the damaged area. A magnetic field controller and a Hall sensor are respectively mounted on the side surface of the electromagnetic coils. A semi-arc guide rail is mounted on the side end of the electromagnetic coils. A small shaft-end robotic arm is slidably connected inside the semi-arc guide rail. The hot-melt repair conversion nozzle is mounted at the execution end of the small shaft-end robotic arm. The hot-melt repair conversion nozzle consists of a hot-melt repair nozzle and a bidirectional delivery nozzle, which can be converted and adjusted according to requirements. The bidirectional delivery nozzle includes a first delivery channel and a second delivery channel. The first delivery channel is connected to the nano-magnetic repair particle delivery cavity for conveying nano-magnetic repair particles. The second delivery channel is connected to the shape memory alloy driving cavity for conveying shape memory alloy particles and polymer repair agent.

[0008] Preferably, a repair cavity is provided on the outside of the side end of the electromagnetic coil, and a pulley structure is provided inside the repair cavity. A spare gear is sleeved on the outside of the center of the synchronous pulley on the side end of the pulley structure. An inner groove rail ring is connected to the side end of the repair cavity. A trajectory rotating ring is rotatably connected inside the inner groove rail ring. A positioning sliding seat is slidably connected to the outside of the trajectory rotating ring. A vision mechanical shaft arm is provided on the top of the positioning sliding seat. A bidirectional rotating structure is provided at the execution end of the vision mechanical shaft arm. Clamping ends are provided at both the left and right ends of the bidirectional rotating structure. A contact element is provided on the side end of the clamping end.

[0009] Preferably, the inertial deceleration correction assembly further includes a blade hub connecting shaft, the flywheel energy storage structure is installed outside the blade hub connecting shaft via an electromagnetic coupler, and a rotating ring is installed on the side end of the flywheel energy storage structure.

[0010] Preferably, an inertial displacement detection structure is installed on the outside of the electromagnetic coupler, and an inertial semi-circular ring is installed on the side end of the inertial displacement detection structure. The outside of the inertial semi-circular ring is slidably connected to the inertial correction device.

[0011] Preferably, a connecting wheel is connected to the side end of the input shaft. Three sets of grooves are formed on the surface of the connecting wheel. Planetary gears are installed inside the three sets of grooves. The planetary gears are meshed with the sun gear output shaft. A connecting piece is connected around the outer periphery of the connecting wheel. A double outer ring gear is connected to the outside of the connecting piece.

[0012] Preferably, one side of the outer ring gear of the double outer ring gear is meshed with an inner ring gear rotating ring, and an electromagnetic blocker is installed on the side of the meshing connection end. A connecting rod is connected to the outside of the side end of the inner ring gear rotating ring, and the side end of the connecting rod is connected to the surface of the track rotating ring.

[0013] Preferably, the outer ring gear on the other side of the double outer ring gear is meshed with an internal gear ring, and the planetary gear is located inside the internal gear ring and meshes with it.

[0014] Preferably, a drive shaft is connected to the side end of the sun gear output shaft, a differential is installed on the outside of the drive shaft, and a wear detection sensor and a position positioning sensor are respectively installed on the surface of the planetary gear.

[0015] Preferably, the side end of the drive shaft is connected to the main shaft of the generator.

[0016] Compared with the prior art, the beneficial effects of the present invention are: In this invention, by using a self-healing component and switching between thermal fusion repair and bidirectional delivery nozzles, all types of damage, from microcracks to deep tooth breaks, can be handled without manual intervention, improving repair efficiency. Furthermore, the magnetic field controller adjusts the magnetic field strength in real time according to the damage depth. For example, when repairing deep cracks, the magnetic field is enhanced to increase particle filling density, while when repairing surface wear, the magnetic field is reduced to ensure uniform material distribution, avoiding resource waste. Moreover, the repair cavity and internal structure can be equipped with two or more sets according to the gearbox structure, reducing operation and maintenance costs.

[0017] 2. In this invention, by using the meshing of the reduction gear and the external reduction gear ring in conjunction with the inertial deceleration correction component, the deceleration force can be flexibly adjusted according to the degree of gear damage, avoiding stress concentration inside the gearbox caused by traditional emergency braking. Furthermore, the sliding friction design of the inertial semi-arc ring and the inertial quantity corrector effectively absorbs the impact vibration during gear switching, reducing the vibration amplitude and protecting precision components inside the gearbox (such as sensors and bearings) from damage. During maintenance, the kinetic energy released by the flywheel can meet approximately 80% of the energy consumption needs inside the gearbox, eliminating the need for external power supply. This reduces maintenance costs while improving energy efficiency. Simultaneously, through controllable deceleration, the rotational speed of the gear transmission component is reduced from high to low, increasing the tolerance for robotic arm operation errors and significantly reducing the risks of repair material splashing and component collisions caused by high-speed movement. This allows the inertial deceleration correction component to quickly isolate the power source in strong wind environments. Through the synergy of the reduction gear and the inertial quantity corrector, a safe operating window is created for the self-repair component while maintaining low-speed blade rotation, avoiding power generation loss and escalation risks due to downtime. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the internal cross-sectional structure of the gearbox in a wind turbine gearbox that is easy to maintain according to the present invention; Figure 2 This is a schematic diagram of the main structure of a wind turbine gearbox that is easy to maintain according to the present invention; Figure 3 This is a schematic diagram of the symmetrical installation position of a self-repairing component in a wind turbine gearbox that is easy to maintain, according to the present invention. Figure 4 This is a schematic diagram of the detachable structure of an inertial deceleration correction component in a wind turbine gearbox that is easy to maintain, according to the present invention. Figure 5 This is a schematic diagram of the separable structure of the gear transmission assembly in a wind turbine gearbox that is easy to maintain, according to the present invention. Figure 6 This is a schematic diagram of the structure of a self-repairing component in a wind turbine gearbox that is easy to maintain, according to the present invention. Figure 7 This invention relates to a wind turbine gearbox that is easy to maintain. Figure 6 A magnified structural diagram at point A.

[0019] In the diagram: 100, Gearbox; 200, Generator; 300, Differential; 400, Inertia Reduction Correction Component; 401, Blade Hub Connecting Shaft; 402, Flywheel Energy Storage Structure; 403, Rotating Ring; 404, Electromagnetic Coupler; 405, Inertia Displacement Detection Structure; 406, Reduction Gear; 407, External Reduction Gear Ring; 408, Inertia Semi-Arc Ring; 409, Inertia Corrector; 500, Gear Transmission Component; 501, Input Shaft; 502, Connecting Gear; 503, Inner Ring Gear Rotating Ring; 504, Connecting Rod; 505, Double Outer Ring Gear; 506, Planetary Gear; 507, Internal Gear. 508. Sun gear output shaft; 509. Wheel groove; 600. Self-healing component; 601. Inner groove rail ring; 602. Track rotating ring; 603. Positioning sliding seat; 604. Vision mechanical shaft arm; 605. Bidirectional rotation structure; 606. Clamping end; 607. Contact element; 608. Repair cavity; 609. Electromagnetic coil; 610. Pulley structure; 611. Spare gear; 612. Shape memory alloy drive cavity; 613. Magnetic particle drive component; 614. Semi-arc guide rail; 615. Small shaft end robotic arm; 616. Nanomagnetic repair particle delivery cavity; 617. Hot melt repair conversion nozzle. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] In an embodiment of the present invention, reference is made to Figures 1-3 As shown: A wind turbine gearbox that is easy to maintain includes a gearbox 100, a generator 200, and an inertia reduction correction component 400, a gear transmission component 500, and a self-repair component 600 respectively installed inside the gearbox 100. The inertia reduction correction component 400 and the self-repair component 600 are respectively installed at the left and right ends of the gear transmission component 500, and the self-repair component 600 is installed symmetrically.

[0022] Specifically: When the wind turbine is in operation and requires maintenance, the self-repairing component 600 replaces and repairs the gears in the gear transmission component 500. During this period, the inertial deceleration correction component 400 dynamically controls the front-end speed and inertial impact to create a safe and stable time window for the repair operation.

[0023] In some embodiments, according to Figure 1 , Figure 3 and Figure 4As shown, the inertial deceleration correction assembly 400 includes a flywheel energy storage structure 402, an electromagnetic coupler 404, an inertial quantity corrector 409, and a reduction gear 406. The flywheel energy storage structure 402 is connected to the input shaft 501 of the gear transmission assembly 500 through the electromagnetic coupler 404. The reduction gear 406 is externally meshed with an external reduction gear ring 407, which is used to provide controllable deceleration force during gear switching, providing working time for the subsequent self-repair assembly 600.

[0024] The inertial deceleration correction assembly 400 further includes a blade hub connecting shaft 401, a flywheel energy storage structure 402 is installed outside the blade hub connecting shaft 401 via an electromagnetic coupler 404, and a rotating ring 403 is installed on the side end of the flywheel energy storage structure 402.

[0025] An inertial displacement detection structure 405 is installed on the outside of the electromagnetic coupler 404. An inertial semi-circular ring 408 is installed on the side end of the inertial displacement detection structure 405. The outside of the inertial semi-circular ring 408 is slidably connected to the inertial correction device 409.

[0026] Specifically: First, the wind-driven blade hub connecting shaft 401 rotates, and the power is transmitted to the input shaft 501 of the gear transmission assembly 500 through the electromagnetic coupler 404. At this time, the flywheel energy storage structure 402 rotates synchronously with the blade hub connecting shaft 401 through the electromagnetic coupler 404. The rotating ring 403 at its side rotates at high speed with the flywheel body, continuously storing kinetic energy. During this process, the inertial displacement detection structure 405 monitors the displacement state of the electromagnetic coupler 404 in real time to ensure stable power transmission and maximize the flywheel energy storage efficiency.

[0027] When the wear detection sensor detects wear on the gears requiring replacement or repair, it first sends a command to the inertial deceleration correction component 400. This causes the electromagnetic coupler 404 to disconnect the rigid connection between the flywheel energy storage structure 402 and the input shaft 501. Simultaneously, it initiates the engagement of the reduction gear 406 with the external reduction gear ring 407. The reduction gear 406 generates controllable resistance through mechanical engagement, gradually reducing the speed of the input shaft 501 from the normal high speed to a safe maintenance speed. This avoids the risk of mechanical collision caused by replacing gears at high speeds. (That is, its external engagement with the external reduction gear ring 407 is automatic. The external reduction gear ring 407 is fixed to the inner wall of the gearbox 100. When the reduction gear 406 rotates with the input shaft 501, its engagement with the external reduction gear ring 407 generates reverse resistance, forming a controllable resistance.) The mechanical braking effect of the control forces the input shaft 501 and gear transmission assembly 500 to gradually reduce their speed from the high speed of normal operation. Then, the flywheel energy storage structure 402 temporarily stores the kinetic energy input by the blades by virtue of its rotational inertia, preventing the generator 200 from overloaded and shutting down due to a sudden power interruption. At the same time, it maintains the oil circulation inside the gearbox 100 and the power supply to the sensors, ensuring that the system is still in a hot standby state during the repair operation. At this time, the blade hub connecting shaft 401 is still driven to rotate by wind power, but the power is no longer transmitted to the gear transmission assembly 500, creating conditions for subsequent deceleration operations. During this process, the flywheel energy storage structure 402 is isolated from the power source, and its stored kinetic energy no longer participates in the transmission, avoiding interference from inertial impact on gear switching.

[0028] As the rotational speed decreases, the impact force generated by inertia inside the gear transmission assembly 500 gradually becomes apparent. At this point, the inertial semi-circular ring 408 and the inertial quantity corrector 409 begin to function, causing the inertial quantity corrector 409 to slide along the arc-shaped track of the inertial semi-circular ring 408. Through frictional damping, the vibration energy generated during gear switching or repair is absorbed. For example, when the old gear disengages from the meshing state, the sliding of the inertial quantity corrector 409 can effectively buffer the impact at the moment of gear disengagement, preventing damage to surrounding components (such as bearing misalignment or sensor loosening) caused by vibration. At the same time, the inertial displacement detection structure 405 continuously monitors the displacement data and adjusts the damping force of the inertial quantity corrector 409 in real time to ensure the dynamic balance inside the gearbox 100.

[0029] When the input shaft 501 speed drops to a safe threshold (such as a low-speed rotation state), the reduction gear 406 and the external reduction gear ring 407 remain engaged, maintaining stable low-speed resistance, so that the gear transmission assembly 500 is in a "quasi-stop" state. At this time, the self-repair assembly 600 safely intervenes to perform old gear disassembly, new gear installation or damage repair operations. Although the flywheel energy storage structure 402 is isolated from the power source, its stored kinetic energy is still maintained at a certain speed through the inertial displacement detection structure 405, providing temporary power to the auxiliary system (such as the lubricating oil circulation pump) in the gearbox 100, ensuring the stability of the system environment during the repair operation.

[0030] After the self-healing component 600 completes its operation, the inertial deceleration correction component 400 enters the reset phase. First, the reduction gear 406 disengages from the outer reduction gear ring 407, releasing the mechanical brake. Then, the electromagnetic coupler 404 reconnects the flywheel energy storage structure 402 to the blade hub connecting shaft 401. The flywheel body quickly absorbs wind kinetic energy through the rotating wheel ring 403, driving the input shaft 501 to return to normal speed. During this process, the inertial quantity corrector 409 resets to its initial position along the inertial semi-circular ring 408, and the inertial displacement detection structure 405 monitors the displacement data again to confirm that the power transmission has returned to normal. The gearbox 100 returns to full-load operation.

[0031] The entire system utilizes the meshing of the reduction gear 406 and the external reduction gear ring 407 to flexibly adjust the reduction force according to the degree of gear damage, avoiding stress concentration inside the gearbox 100 caused by traditional emergency braking. Furthermore, the sliding friction design of the inertial semi-circular ring 408 and the inertia corrector 409 effectively absorbs the impact vibration during gear switching, reducing vibration amplitude and protecting precision components inside the gearbox 100 (such as sensors and bearings) from damage. During maintenance, the kinetic energy released by the flywheel can meet approximately 80% of the energy consumption needs inside the gearbox 100, eliminating the need for external power supply and thus reducing maintenance costs while increasing energy efficiency. This improves power utilization and, through controllable deceleration, reduces the rotational speed of the gear transmission assembly 500 from high speed (e.g., 1500 rpm) to low speed (e.g., below 100 rpm), thereby increasing the tolerance for operational errors of the robotic arm and significantly reducing the risks of repair material splashing and component collisions caused by high-speed movement. This allows the inertial deceleration correction assembly 400 to quickly isolate the power source in strong wind environments. Through the synergy of the reduction gear 406 and the inertial correction device 409, a safe operating window is created for the self-repair assembly 600 while maintaining low-speed rotation of the blades, avoiding power generation loss and the risk of escalation of faults due to downtime.

[0032] In some embodiments, according to Figure 1 , Figure 3 , Figure 6 and Figure 7As shown, the self-healing component 600 includes a hot melt repair conversion nozzle 617, a shape memory alloy driving cavity 612, and a magnetic particle driving component 613. The shape memory alloy driving cavity 612 is electrically connected to an intelligent monitoring sensor and is used to drive the hot melt repair conversion nozzle 617 to move to the damaged area when tooth surface damage is detected.

[0033] The magnetic particle driving component 613 has a nano-magnetic repair particle delivery cavity 616 connected to its side end. Electromagnetic coils 609 are symmetrically mounted on the side end of the nano-magnetic repair particle delivery cavity 616. When the electromagnetic coils 609 are energized, they generate a gradient magnetic field, driving the nano-magnetic repair particles to directionally fill the damaged area. A magnetic field controller and a Hall sensor are respectively mounted on the side end surface of the electromagnetic coils 609. A semi-arc guide rail 614 is mounted on the side end of the electromagnetic coils 609. A small shaft-end robotic arm 615 is slidably connected inside the semi-arc guide rail 614. A hot melt repair conversion nozzle 617 is mounted at the execution end of the small shaft-end robotic arm 615. The hot melt repair conversion nozzle 617 consists of a hot melt repair nozzle and a bidirectional delivery nozzle, which can be converted and adjusted according to needs. The bidirectional delivery nozzle includes a first delivery channel and a second delivery channel. The first delivery channel is connected to the nano-magnetic repair particle delivery cavity 616 and is used to transport nano-magnetic repair particles. The second delivery channel is connected to the shape memory alloy driving cavity 612 and is used to transport shape memory alloy particles and polymer repair agent.

[0034] A repair cavity 608 is installed on the outside of the side end of the electromagnetic coil 609. A pulley structure 610 is installed inside the repair cavity 608. A spare gear 611 is sleeved on the outside of the center of the synchronous pulley on the side end of the pulley structure 610. An inner groove track ring 601 is connected to the side end of the repair cavity 608. A track rotating ring 602 is rotatably connected inside the inner groove track ring 601. A positioning sliding seat 603 is slidably connected to the outside of the track rotating ring 602. A vision mechanical shaft arm 604 is installed on the top of the positioning sliding seat 603. A bidirectional rotation structure 605 is installed at the execution end of the vision mechanical shaft arm 604. A clamping end 606 is installed at both the left and right ends of the bidirectional rotation structure 605. A contact element 607 is installed on the side end of the clamping end 606.

[0035] Specifically: The wear detection sensor installed on the surface of planetary gear 506 continuously scans the tooth surface condition, collects data in real time and transmits it to the external PLC controller. When the external PLC controller detects cracks on the tooth surface or wear exceeding the normal threshold (such as micro-cracks or surface peeling that are not visible to the naked eye), it immediately sends a command to the self-healing component 600.

[0036] The visual mechanical arm 604 on one side removes the spare gear 611 from the pulley structure 610 of the repair cavity 608 through the clamping end 606. The track ring 602 rotates along the inner groove track ring 601, which drives the positioning sliding seat 603 and the spare gear 611 clamped by the visual mechanical arm 604 to prepare first. Then, the clamping end 606 and the contact member 607 on the other side remove the gear that exceeds the wear threshold from the three sets of planetary gears 506, and promptly transfer the spare gear 611 on the other side to the gear transmission assembly 500. After removal, it is placed on the pulley structure 610 through the visual mechanical arm 604 and the clamping end 606, so that the gear with the wear threshold rotates and performs self-repair operation through the self-repair assembly 600, so that it becomes a new spare gear 611.

[0037] At this time, the electromagnetic interruptor cuts off the meshing of the original damaged gear with the double outer ring gear 505, the inertial deceleration correction component 400 is activated, causing the electromagnetic coupler 404 to disconnect the flywheel energy storage structure 402 from the input shaft 501, the reduction gear 406 meshes with the outer reduction gear ring 407 to generate controllable resistance, the inertial quantity corrector 409 slides along the inertial semi-circular ring 408 to absorb the impact energy at the moment of switching, and at the same time the flywheel releases the stored kinetic energy to maintain the stable speed of the transmission shaft and prevent the output power of the generator 200 from dropping suddenly.

[0038] Then, the shape memory nickel-titanium alloy particles in the shape memory alloy drive cavity 612 are guided to the hot melt repair conversion nozzle 617, and the small shaft-end robotic arm 615 slides along the semi-arc guide rail 614 to accurately position the hot melt repair conversion nozzle 617 to the damaged area, ready to carry out the repair operation.

[0039] Subsequently, the 617 heat fusion repair nozzle automatically switches its working mode according to the type of damage: Deep Crack Repair: Switch to the hot melt repair nozzle, where the internal induction coil generates a high-frequency magnetic field, rapidly heating the nano-magnetic repair particles to a molten state, and then injecting the molten material into the crack through the conical nozzle to fill and repair the damage.

[0040] Surface wear repair: Switch to the bidirectional delivery nozzle. The first delivery channel is connected to the nano-magnetic repair particle delivery cavity 616, delivering micron-sized magnetic particles to form a structural skeleton. The second delivery channel simultaneously delivers polymer repair agent (such as epoxy resin-based material) to cover and seal the worn surface. During this process, the electromagnetic coil 609 is energized to generate a gradient magnetic field, guiding the nano-magnetic repair particles to oriented and form "reinforcing ribs" consistent with the stress direction of the tooth surface. At the same time, the Hall sensor monitors the magnetic field distribution in real time to ensure uniform filling of the repair material and simultaneously activates the micro-ultrasonic vibrator installed on the surface of the bidirectional delivery nozzle to promote the penetration of the polymer repair agent into the micropores with high-frequency vibration, thereby improving the bonding strength.

[0041] After repair or replacement, the vision mechanical arm 604 re-inspects the repaired area or new gear. The contact part 607 confirms the hardness of the repaired surface through physical touch, ultrasonic testing re-checks the crack closure, and the Hall sensor verifies the bonding density of the repair material under the action of the magnetic field. If all indicators meet the standards (such as hardness close to the original factory standard and crack closure > 95%), the external PLC controller sends a command to make the hot melt repair conversion nozzle 617 return to the initial position, the electromagnetic coupler 404 reconnects to the flywheel energy storage structure 402, the gearbox 100 resumes operation, and the data of the entire process (such as damage location, amount of repair material used, switching time, etc.) are synchronously uploaded to the cloud database to provide a reference for subsequent maintenance.

[0042] The system can handle all types of damage, from microcracks to deep tooth fractures, by switching between thermal fusion repair and bidirectional delivery nozzles. No manual intervention is required, which improves repair efficiency. The magnetic field controller adjusts the magnetic field strength in real time according to the damage depth. For example, when repairing deep cracks, the magnetic field is strengthened to increase the particle filling density, and when repairing surface wear, the magnetic field is reduced to ensure that the material is evenly spread and avoids waste of resources. The repair cavity 608 and its internal structure can be equipped with two or more sets according to the structure of the gearbox 100, which reduces operation and maintenance costs.

[0043] In some embodiments, according to Figure 1 , Figure 3 and Figure 5 As shown, a connecting wheel 502 is connected to the side end of the input shaft 501. Three sets of wheel grooves 509 are opened on the surface of the connecting wheel 502. Planetary gears 506 are installed inside the three sets of wheel grooves 509. The sun gear output shaft 508 is meshed inside the planetary gears 506. A connecting piece is connected around the outer periphery of the connecting wheel 502. A double outer ring gear 505 is connected to the outside of the connecting piece.

[0044] One side of the double outer ring gear 505 is meshed with an inner ring gear rotating ring 503, and an electromagnetic blocker is installed on the side of its meshing connection end. A connecting rod 504 is connected to the outside of the side end of the inner ring gear rotating ring 503, and the side end of the connecting rod 504 is connected to the surface of the track rotating ring 602.

[0045] The outer ring gear on the other side of the double outer ring gear 505 is meshed with an inner gear ring 507, and the planetary gear 506 is located inside the inner gear ring 507 and meshes with it.

[0046] A drive shaft is connected to the side end of the sun gear output shaft 508. A differential 300 is installed on the outside of the drive shaft. Wear detection sensors and position positioning sensors are respectively installed on the surface of the planetary gear 506.

[0047] The side end of the drive shaft is connected to the main shaft of the generator 200.

[0048] More specifically: First, the wind-driven input shaft 501 rotates, causing the connecting wheel 502 to rotate synchronously. Planetary gears 506 are installed in the three sets of grooves 509 on the surface of the connecting wheel 502. These planetary gears 506 mesh with the double outer ring gear 505 and the sun gear output shaft 508, forming the core structure of the planetary gear transmission system. At this time, the double outer ring gear 505 is fixedly connected to the connecting wheel 502 through the connecting piece and rotates at high speed with the input shaft 501, while the sun gear output shaft 508 serves as the power output end, transmitting torque to the drive shaft.

[0049] Next, one side of the outer ring gear 505 meshes with the inner ring gear rotating ring 503. The inner ring gear rotating ring 503 is connected to the track rotating ring 602 through the connecting rod 504. When the double outer ring gear 505 rotates, the inner ring gear rotating ring 503 rotates synchronously. At this time, the electromagnetic interruptor cuts off the meshing between the double outer ring gear 505 and the inner ring gear rotating ring 503, so that the inner ring gear rotating ring 503 does not drive the track rotating ring 602 to rotate in the inner groove track ring 601 through the connecting rod 504. At the same time, the other side of the outer ring gear 505 meshes with the inner gear ring 507. The inner gear ring 507 is fixed. The meshing of the planetary gear 506 in the inner gear ring 507 further reduces the speed, forming a deceleration. After deceleration, the speed of the sun gear output shaft 508 is significantly reduced and the torque is greatly increased, meeting the input requirements of the generator 200.

[0050] Subsequently, the sun gear output shaft 508 is connected to the differential 300 via the drive shaft. The differential 300 automatically adjusts the torque distribution when the speed of the gear transmission assembly 500 fluctuates, ensuring smooth output from the drive shaft and preventing damage to the generator 200 due to overload. The drive shaft ultimately transmits power to the main shaft of the generator 200, driving the generator 200 to generate electricity.

[0051] During this process, wear detection sensors and position positioning sensors installed on the surface of planetary gear 506 monitor the gear status in real time. The former detects the degree of wear on the tooth surface, while the latter tracks the position of planetary gear 506, providing data support for intelligent maintenance.

[0052] When the wear detection sensor detects that a set of planetary gears 506 is damaged and needs to be replaced, the electromagnetic interruptor connects the outer ring gear 505 to the inner ring gear rotating ring 503. At this time, the inner ring gear rotating ring 503 drives the trajectory rotating ring 602 to rotate in the inner groove track ring 601 through the connecting rod 504, which facilitates the operation of the aforementioned vision mechanical shaft arm 604 and related structures (such as moving the spare gear 611 to the meshing position). During the entire switching process, the inertial deceleration correction component 400 maintains the low-speed rotation of the transmission shaft through flywheel energy storage and reduction gear 406, ensuring that the generator 200 does not stop, and at the same time provides a safe repair environment for the self-repair component 600.

[0053] During normal operation and maintenance, the position sensor of planetary gear 506 continuously tracks the gear position to ensure meshing accuracy, and the wear detection sensor collects tooth surface deformation data in real time and transmits it wirelessly to the external PLC controller. The external PLC controller analyzes the data through algorithms, predicts the remaining life of the gear, and triggers the maintenance process in advance to achieve predictive maintenance and avoid sudden failures.

[0054] The wiring diagrams for the differential 300, flywheel energy storage structure 402, electromagnetic coupler 404, inertia corrector 409, vision mechanical arm 604, magnetic field controller, and Hall sensor in this invention are common knowledge in the field, and their working principles are known technologies. The appropriate model is selected according to actual use. Therefore, the control methods and wiring layouts of the differential 300, flywheel energy storage structure 402, electromagnetic coupler 404, inertia corrector 409, vision mechanical arm 604, magnetic field controller, and Hall sensor will not be explained in detail.

[0055] The device is used and operates as follows: First, the wind-driven blade hub connecting shaft 401 rotates, and the kinetic energy is transmitted to the input shaft 501 of the gear transmission assembly 500 through the electromagnetic coupler 404. The input shaft 501 drives the connecting wheel 502 to rotate, causing the planetary gears 506 in the three sets of wheel grooves 509 to simultaneously mesh with the double outer ring gear 505 and the sun gear output shaft 508. At this time, one side of the double outer ring gear 505 meshes with the inner ring gear rotating ring 503, and the other side meshes with the inner gear ring 507, forming a multi-stage reduction transmission path. Finally, the generator 200 is driven to generate electricity through the sun gear output shaft 508 connected to the transmission shaft. During this process, the flywheel energy storage structure 402 rotates synchronously with the input shaft 501 through the electromagnetic coupler 404 to store kinetic energy for subsequent use.

[0056] Next, the wear detection sensor installed on the surface of the planetary gear 506 continuously scans the tooth surface condition, collects data in real time and transmits it to the external PLC controller. When the external PLC controller detects that cracks appear on the tooth surface or the wear exceeds the normal threshold (such as micro-cracks or surface peeling that are not visible to the naked eye), it immediately sends a command to the self-healing component 600.

[0057] The visual mechanical arm 604 on one side removes the spare gear 611 from the pulley structure 610 of the repair cavity 608 through the clamping end 606. The track ring 602 rotates along the inner groove track ring 601, which drives the positioning sliding seat 603 and the spare gear 611 clamped by the visual mechanical arm 604 to prepare first. Then, the clamping end 606 and the contact member 607 on the other side remove the gear that exceeds the wear threshold from the three sets of planetary gears 506, and promptly transfer the spare gear 611 on the other side to the gear transmission assembly 500. After removal, it is placed on the pulley structure 610 through the visual mechanical arm 604 and the clamping end 606, so that the gear with the wear threshold rotates and performs self-repair operation through the self-repair assembly 600, so that it becomes a new spare gear 611.

[0058] At this time, the electromagnetic interruptor cuts off the meshing of the original damaged gear with the double outer ring gear 505, the inertial deceleration correction component 400 is activated, causing the electromagnetic coupler 404 to disconnect the flywheel energy storage structure 402 from the input shaft 501, the reduction gear 406 meshes with the outer reduction gear ring 407 to generate controllable resistance, the inertial quantity corrector 409 slides along the inertial semi-circular ring 408 to absorb the impact energy at the moment of switching, and at the same time the flywheel releases the stored kinetic energy to maintain the stable speed of the transmission shaft and prevent the output power of the generator 200 from dropping suddenly.

[0059] Then, the shape memory nickel-titanium alloy particles in the shape memory alloy drive cavity 612 are guided to the hot melt repair conversion nozzle 617, and the small shaft-end robotic arm 615 slides along the semi-arc guide rail 614 to accurately position the hot melt repair conversion nozzle 617 to the damaged area, ready to carry out the repair operation.

[0060] Subsequently, the 617 heat fusion repair nozzle automatically switches its working mode according to the type of damage: Deep Crack Repair: Switch to the hot melt repair nozzle, where the internal induction coil generates a high-frequency magnetic field, rapidly heating the nano-magnetic repair particles to a molten state, and then injecting the molten material into the crack through the conical nozzle to fill and repair the damage.

[0061] Surface wear repair: Switch to the bidirectional delivery nozzle. The first delivery channel is connected to the nano-magnetic repair particle delivery cavity 616, delivering micron-sized magnetic particles to form a structural skeleton. The second delivery channel simultaneously delivers polymer repair agent (such as epoxy resin-based material) to cover and seal the worn surface. During this process, the electromagnetic coil 609 is energized to generate a gradient magnetic field, guiding the nano-magnetic repair particles to oriented and form "reinforcing ribs" consistent with the stress direction of the tooth surface. At the same time, the Hall sensor monitors the magnetic field distribution in real time to ensure uniform filling of the repair material and simultaneously activates the micro-ultrasonic vibrator installed on the surface of the bidirectional delivery nozzle to promote the penetration of the polymer repair agent into the micropores with high-frequency vibration, thereby improving the bonding strength.

[0062] After repair or replacement, the vision mechanical arm 604 re-inspects the repaired area or new gear. The contact part 607 confirms the hardness of the repaired surface through physical touch, ultrasonic testing re-checks the crack closure, and the Hall sensor verifies the bonding density of the repair material under the action of the magnetic field. If all indicators meet the standards (such as hardness close to the original factory standard and crack closure > 95%), the external PLC controller sends a command to make the hot melt repair conversion nozzle 617 return to the initial position, the electromagnetic coupler 404 reconnects to the flywheel energy storage structure 402, the gearbox 100 resumes operation, and the data of the entire process (such as damage location, amount of repair material used, switching time, etc.) are synchronously uploaded to the cloud database to provide a reference for subsequent maintenance.

[0063] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wind turbine gearbox that is easy to maintain, characterized in that: It includes a gearbox (100), a generator (200), and an inertial deceleration correction component (400), a gear transmission component (500), and a self-repairing component (600) respectively installed inside the gearbox (100). The inertial deceleration correction component (400) and the self-repairing component (600) are respectively installed at the left and right ends of the gear transmission component (500), and the self-repairing component (600) is symmetrically installed. The inertial deceleration correction assembly (400) includes a flywheel energy storage structure (402), an electromagnetic coupler (404), an inertial quantity corrector (409), and a reduction gear (406). The flywheel energy storage structure (402) is connected to the input shaft (501) of the gear transmission assembly (500) through the electromagnetic coupler (404). The reduction gear (406) is externally meshed with an external reduction gear ring (407) to provide controllable deceleration force during gear switching, providing working time for the subsequent self-repair assembly (600). The self-healing component (600) includes a hot melt repair conversion nozzle (617), a shape memory alloy driving cavity (612), and a magnetic particle driving component (613). The shape memory alloy driving cavity (612) is electrically connected to an intelligent monitoring sensor and is used to drive the hot melt repair conversion nozzle (617) to the damaged area when tooth surface damage is detected.

2. The wind turbine gearbox for easy maintenance according to claim 1, characterized in that: The magnetic particle driving component (613) has a nanomagnetic repair particle delivery cavity (616) connected to its side end. Electromagnetic coils (609) are symmetrically mounted on the side end of the nanomagnetic repair particle delivery cavity (616). When the electromagnetic coils (609) are energized, they generate a gradient magnetic field, driving the nanomagnetic repair particles to directionally fill the damaged area. A magnetic field controller and a Hall sensor are respectively mounted on the side surface of the electromagnetic coils (609). A semi-arc guide rail (614) is mounted on the side end of the electromagnetic coils (609). A small shaft-end mechanical device is slidably connected inside the semi-arc guide rail (614). Arm (615), the hot melt repair conversion nozzle (617) is installed at the execution end of the small shaft end robotic arm (615). The hot melt repair conversion nozzle (617) is composed of a hot melt repair nozzle and a bidirectional conveying nozzle, which can be converted and adjusted according to needs. The bidirectional conveying nozzle includes a first conveying channel and a second conveying channel. The first conveying channel is connected to the nanomagnetic repair particle conveying cavity (616) and is used to convey nanomagnetic repair particles. The second conveying channel is connected to the shape memory alloy driving cavity (612) and is used to convey shape memory alloy particles and polymer repair agent.

3. The wind turbine gearbox for easy maintenance according to claim 2, characterized in that: A repair cavity (608) is provided on the outside of the side end of the electromagnetic coil (609). A pulley structure (610) is provided inside the repair cavity (608). A spare gear (611) is sleeved on the outside of the center of the synchronous pulley on the side end of the pulley structure (610). An inner groove rail ring (601) is connected to the side end of the repair cavity (608). A track rotating ring (602) is rotatably connected inside the inner groove rail ring (601). A positioning sliding seat (603) is slidably connected to the outside of the track rotating ring (602). A vision mechanical shaft arm (604) is provided on the top of the positioning sliding seat (603). A bidirectional rotating structure (605) is provided at the execution end of the vision mechanical shaft arm (604). A clamping end (606) is provided at both the left and right ends of the bidirectional rotating structure (605). A contact element (607) is provided on the side end of the clamping end (606).

4. The wind turbine gearbox for easy maintenance according to claim 1, characterized in that: The inertial deceleration correction assembly (400) further includes a blade hub connecting shaft (401), and the flywheel energy storage structure (402) is installed outside the blade hub connecting shaft (401) via an electromagnetic coupler (404). A rotating ring (403) is installed on the side end of the flywheel energy storage structure (402).

5. The wind turbine gearbox for easy maintenance according to claim 1, characterized in that: An inertial displacement detection structure (405) is installed on the outside of the electromagnetic coupler (404), and an inertial semi-circular ring (408) is installed on the side end of the inertial displacement detection structure (405). The outside of the inertial semi-circular ring (408) is slidably connected to the inertial correction device (409).

6. The wind turbine gearbox for easy maintenance according to claim 1, characterized in that: The input shaft (501) is connected to a connecting wheel (502) at its side end. The connecting wheel (502) has three sets of grooves (509) on its surface. Planetary gears (506) are installed inside each of the three sets of grooves (509). The planetary gears (506) are meshed with a sun gear output shaft (508). A connecting piece is connected around the outer periphery of the connecting wheel (502). A double outer ring gear (505) is connected to the outside of the connecting piece.

7. The wind turbine gearbox for easy maintenance according to claim 6, characterized in that: One side of the double outer ring gear (505) is meshed with an inner ring gear rotating ring (503), and an electromagnetic blocker is installed on the side of its meshing connection end. A connecting rod (504) is connected to the outside of the side end of the inner ring gear rotating ring (503), and the side end of the connecting rod (504) is connected to the surface of the track rotating ring (602).

8. The wind turbine gearbox for easy maintenance according to claim 6, characterized in that: The outer ring gear on the other side of the double outer ring gear (505) is meshed with an inner gear ring (507), and the planetary gear (506) is located inside the inner gear ring (507) and meshes with it.

9. The wind turbine gearbox for easy maintenance according to claim 6, characterized in that: The side end of the sun gear output shaft (508) is connected to a drive shaft, and a differential (300) is installed on the outside of the drive shaft. Wear detection sensors and position positioning sensors are respectively installed on the surface of the planetary gear (506).

10. The wind turbine gearbox for easy maintenance according to claim 9, characterized in that: The side end of the drive shaft is connected to the main shaft of the generator (200).

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