A wind turbine gearbox with improved maintenance

Abstract

The application discloses a wind driven generator gear box convenient to maintain, relates to the technical field of wind driven power generation, and comprises a gear box, a generator and inertia deceleration correction assemblies, gear transmission assemblies and self-repairing assemblies respectively arranged in the gear box, the inertia deceleration correction assemblies and the self-repairing assemblies are respectively arranged at left and right ends of the gear transmission assemblies, and the self-repairing assemblies are symmetrically arranged, through cooperation of the self-repairing assemblies, switching of hot melting repair and bidirectional guide and spray heads can be utilized to process all types of damage from micro cracks to deep broken teeth, manual intervention is not needed, repair efficiency is improved, a magnetic field controller can adjust magnetic field strength in real time according to damage depth, for example, the magnetic field is strengthened to improve particle filling density when deep cracks are repaired, the magnetic field is reduced to ensure that materials are uniformly laid when surface wear is repaired, resource waste is avoided, and the repair cavities and internal structures can be arranged in two groups or more according to the structure of the gear box, so that operation and maintenance costs are reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of wind power generation, in particular to a wind generator gear box convenient to maintain. BACKGROUND

[0002] With the continuous development of the wind power industry, the installed capacity of wind power is increasing, and the weight and maintenance cost of the main gear box are increasing. It is urgent to optimize the maintenance scheme.

[0003] In the prior art, the Chinese patent publication number CN210859058U discloses a replacement device for a wind generator gear box, which comprises two fixed bases, a mounting rack is fixedly installed on the upper surface of the fixed base, a main shaft pressing tool is arranged between the two mounting racks, the main shaft pressing tool comprises a plurality of main shaft pressing pieces, first fixing holes are formed at both ends of each main shaft pressing piece, two limiting ears are fixedly arranged on the upper surface of the mounting rack, second fixing holes are formed on the surface of each limiting ear, and the two ends of the main shaft pressing piece are arranged between the two limiting ears, and the first fixing holes and the second fixing holes are fixed by a fixing pin. The patent overcomes the shortcomings of the prior art, and the main shaft pressing tool is divided into a plurality of main shaft pressing pieces, so that the device can be transported between the ground and the wind generator cabin without the need for large lifting equipment, and the device is convenient for manual transportation and is convenient and fast.

[0004] However, in the maintenance process of the wind generator gear box, the traditional gear box maintenance requires the whole machine to be shut down, and the single machine power of the wind generator is usually megawatt level, so the maintenance time is long, which may cause large loss of power generation, and the existing maintenance requires technicians to climb to a height of hundreds of meters, which is greatly affected by the weather and takes a long time for single maintenance. Therefore, a wind generator gear box convenient to maintain is needed. SUMMARY

[0005] The present application aims to provide a wind generator gear box convenient to maintain, which solves the problem of the prior art that the traditional gear box maintenance requires the whole machine to be shut down, and the single machine power of the wind generator is usually megawatt level, so the maintenance time is long, which may cause large loss of power generation, and the existing maintenance requires technicians to climb to a height of hundreds of meters, which is greatly affected by the weather and takes a long time for single maintenance.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a wind generator gear box convenient to maintain, comprising a gear box, a generator, and an inertia deceleration correction assembly, a gear transmission assembly and a self-repairing assembly arranged in the gear box respectively, the inertia deceleration correction assembly and the self-repairing assembly are arranged at the left and right ends of the gear transmission assembly respectively, and the self-repairing assembly is arranged symmetrically.

[0007] The inertial deceleration correction assembly comprises a flywheel energy storage structure, an electromagnetic coupler, an inertial quantity corrector and a deceleration gear, the flywheel energy storage structure is connected with an input shaft of the gear transmission assembly through the electromagnetic coupler, and the deceleration gear is externally meshed with an outer deceleration gear ring for providing controllable deceleration force when the gear is switched, thereby providing operation time for the subsequent self-repair assembly.

[0008] The self-repair assembly comprises a hot melt repair conversion nozzle, a shape memory alloy driving cavity and a magnetic particle driving element, the shape memory alloy driving cavity is electrically connected with an intelligent monitoring sensor, and is used for driving the hot melt repair conversion nozzle to move to a damaged position when the tooth surface damage is detected.

[0009] Preferably, the side end of the magnetic particle driving element is communicated with a nano magnetic repair particle guide cavity, the side end of the nano magnetic repair particle guide cavity is symmetrically provided with an electromagnetic coil, the electromagnetic coil generates a gradient magnetic field when energized, thereby driving the nano magnetic repair particles to be directionally filled in the damaged area, the side end surface of the electromagnetic coil is respectively provided with a magnetic field controller and a Hall sensor, the side end of the electromagnetic coil is provided with a semi-arc guide rail, a small shaft end mechanical arm is slidably connected in the semi-arc guide rail, the hot melt repair conversion nozzle is arranged at the execution end of the small shaft end mechanical arm, the hot melt repair conversion nozzle is composed of a hot melt repair nozzle and a bidirectional guide nozzle, which can be converted and adjusted according to requirements, the bidirectional guide nozzle comprises a first guide channel and a second guide channel, the first guide channel is communicated with the nano magnetic repair particle guide cavity for conveying the nano magnetic repair particles, and the second guide channel is communicated with the shape memory alloy driving cavity for conveying the shape memory alloy particles and the high polymer repair agent.

[0010] Preferably, the side end of the electromagnetic coil is externally provided with a repair cavity, a belt pulley structure is arranged in the repair cavity, a standby gear is sleeved on the outside of the center of a synchronous wheel of the belt pulley structure, an inner groove rail ring is connected to the side end of the repair cavity, a track rotating ring is rotatably connected in the inner groove rail ring, a positioning sliding seat is slidably connected to the outside of the track rotating ring, a visual mechanical shaft arm is arranged on the top of the positioning sliding seat, a bidirectional rotating structure is arranged at the execution end of the visual mechanical shaft arm, clamping ends are arranged at the left and right ends of the bidirectional rotating structure, and contact pieces are arranged at the side ends of the clamping ends.

[0011] Preferably, the inertial deceleration correction assembly further comprises a blade hub connecting shaft, the flywheel energy storage structure is arranged on the outside of the blade hub connecting shaft through the electromagnetic coupler, and a rotating wheel ring is arranged at the side end of the flywheel energy storage structure.

[0012] Preferably, the outside of the electromagnetic coupler is provided with an inertial displacement amount detection structure, and the side end of the inertial displacement amount detection structure is provided with an inertial semi-arc ring, and the outside of the inertial semi-arc ring is in sliding connection with an inertial amount corrector.

[0013] Preferably, the side end of the input shaft is connected with an adapter wheel piece, three groups of wheel grooves are formed in the surface of the adapter wheel piece, a planetary gear is arranged in the inside of each of the three groups of wheel grooves, a sun gear output shaft is in meshing connection with the inside of the planetary gear, a connecting piece is connected around the outside of the adapter wheel piece, and a double outer ring gear is connected to the outside of the connecting piece.

[0014] Preferably, the side outer ring gear of the double outer ring gear is in meshing connection with an inner ring gear rotating ring, an electromagnetic interrupter is arranged at the meshing connection end side of the inner ring gear rotating ring, a connecting rod is connected to the side end of the inner ring gear rotating ring, and the side end of the connecting rod is connected to the surface of a track rotating ring.

[0015] Preferably, the other side outer ring gear of the double outer ring gear is in meshing connection with an inner tooth ring, and the planetary gear is in meshing connection with the inside of the inner tooth ring.

[0016] Preferably, the side end of the sun gear output shaft is connected with a transmission shaft, a differential mechanism is arranged on the outside of the transmission shaft, and a wear detection sensor and a position positioning sensor are arranged on the surface of the planetary gear, respectively.

[0017] Preferably, the side end of the transmission shaft is connected with the main shaft of the generator.

[0018] Compared with the prior art, the present application has the following beneficial effects:

[0019] In the present application, by using the switching of hot melt repair and bidirectional guide nozzle under the cooperation of the self-repairing assembly, all types of damage from micro-cracks to deep tooth damage can be processed without manual intervention, the repair efficiency is improved, the magnetic field strength is adjusted in real time according to the damage depth, for example, the magnetic field is strengthened to improve the particle filling density when repairing deep cracks, and the magnetic field is reduced to ensure that the material is evenly laid when repairing surface wear, resource waste is avoided, and the repair cavity and the internal structure can be provided with two or more groups according to the structure of the gear box, thereby reducing the operation and maintenance cost.

[0020] 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

[0021] Figure 1 This is a schematic diagram of the internal cross-sectional structure of the gearbox in a wind turbine generator gearbox that is easy to maintain according to the present invention;

[0022] 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;

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] Figure 7 This invention relates to a wind turbine gearbox that is easy to maintain. Figure 6 A magnified structural diagram at point A.

[0028] In the figure: 100, gear box; 200, generator; 300, differential; 400, inertia deceleration correction assembly; 401, blade hub connecting shaft; 402, flywheel energy storage structure; 403, rotating wheel ring; 404, electromagnetic coupler; 405, inertia displacement amount detection structure; 406, deceleration gear; 407, outer deceleration gear ring; 408, inertia semi-arc ring; 409, inertia amount corrector; 500, gear transmission assembly; 501, input shaft; 502, engaging wheel part; 503, inner ring gear rotating ring; 504, connecting rod; 505, double outer ring gear; 506, planetary gear; 507, inner tooth ring; 508, sun gear output shaft; 509, wheel groove; 600, self-repairing assembly; 601, inner groove rail ring; 602, track rotating ring; 603, positioning sliding seat; 604, visual mechanical shaft arm; 605, bidirectional rotating structure; 606, clamping end; 607, contact piece; 608, repair cavity; 609, electromagnetic coil; 610, belt pulley structure; 611, spare gear; 612, shape memory alloy driving cavity; 613, magnetic particle driving part; 614, semi-arc guide rail; 615, small-sized shaft end mechanical arm; 616, nano-magnetic repair particle guide and delivery cavity; 617, hot melt repair conversion spray head. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0030] In the embodiments of the present application, reference is made to Figures 1-3 As shown in the figure: a wind turbine gear box convenient to maintain, comprising a gear box 100, a generator 200, and an inertia deceleration correction assembly 400, a gear transmission assembly 500, and a self-repairing assembly 600 respectively arranged inside the gear box 100, the inertia deceleration correction assembly 400 and the self-repairing assembly 600 are respectively arranged at the left and right ends of the gear transmission assembly 500, and the self-repairing assembly 600 is symmetrically arranged.

[0031] Specifically: when the wind turbine is operating and needs to be maintained, the self-repairing assembly 600 replaces and repairs the gears in the gear transmission assembly 500, and during this period, the inertia deceleration correction assembly 400 creates a safe and stable time window for repair work by dynamically controlling the rotational speed and inertia impact at the front end.

[0032] In some embodiments, according to Figure 1 , Figure 3 and Figure 4As shown, the inertia deceleration correction assembly 400 comprises a flywheel energy storage structure 402, an electromagnetic coupler 404, an inertia quantity correction device 409 and a deceleration gear 406, the flywheel energy storage structure 402 is connected with the input shaft 501 of the gear transmission assembly 500 through the electromagnetic coupler 404, the outside of the deceleration gear 406 is engaged with an external deceleration gear ring 407, which is used to provide controllable deceleration force when the gear is switched, and provide operation time for the subsequent self-repair assembly 600.

[0033] The inertia deceleration correction assembly 400 further comprises a blade hub connecting shaft 401, the flywheel energy storage structure 402 is arranged outside the blade hub connecting shaft 401 through the electromagnetic coupler 404, and the side end of the flywheel energy storage structure 402 is arranged with a rotating wheel ring 403.

[0034] The outside of the electromagnetic coupler 404 is arranged with an inertia displacement quantity detection structure 405, the side end of the inertia displacement quantity detection structure 405 is arranged with an inertia semi-arc ring 408, and the outside of the inertia semi-arc ring 408 is in sliding connection with the inertia quantity correction device 409.

[0035] 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 wheel ring 403 at the side end of the flywheel body rotates at high speed, and the kinetic energy is continuously stored, in this process, the inertia displacement quantity detection structure 405 monitors the displacement state of the electromagnetic coupler 404 in real time, ensures the stability of power transmission, and maximizes the flywheel energy storage efficiency.

[0036] When the wear detection sensor detects that the gear needs to be replaced or repaired due to wear, first send an instruction to the inertia deceleration correction assembly 400, so that the electromagnetic coupler 404 disconnects the rigid connection between the flywheel energy storage structure 402 and the input shaft 501, and at the same time starts the deceleration gear 406 to engage with the outer deceleration gear ring 407. The controllable resistance generated by the mechanical engagement gradually reduces the speed of the input shaft 501 from the normal running speed to the safe maintenance speed, avoiding the mechanical collision risk caused by replacing the gear at high speed, (that is, its outside is automatically engaged with the outer deceleration gear ring 407, and the outer deceleration gear ring 407 is fixed to the inner wall of the gear box 100. When the deceleration gear 406 rotates with the input shaft 501, the engagement with the outer deceleration gear ring 407 generates a reverse resistance, forming a controllable mechanical braking effect. This resistance forces the input shaft 501 and the gear transmission assembly 500 to gradually reduce the speed from the normal running speed), then the flywheel energy storage structure 402 temporarily stores the kinetic energy input by the blade based on its moment of inertia, preventing the generator 200 from overloading and shutting down due to sudden power interruption, while maintaining oil circulation and sensor power supply inside the gear box 100, ensuring that the system is still in a hot standby state during repair work. At this time, the blade hub connecting shaft 401 is still driven to rotate by the wind, but the power is no longer transmitted to the gear transmission assembly 500, creating conditions for subsequent deceleration operation. In this process, the flywheel energy storage structure 402 has been isolated from the power source, and the kinetic energy stored therein no longer participates in the transmission, avoiding the interference of inertial impact on gear switching.

[0037] After the speed drops, the impact force generated inside the gear transmission assembly 500 due to inertia gradually appears. At this time, the inertia semi-arc ring 408 and the inertia amount corrector 409 begin to play a role, so that the inertia amount corrector 409 slides along the arc track of the inertia semi-arc ring 408, absorbing the vibration energy generated during gear switching or repair through friction damping. For example, when the old gear is disengaged from the engaged state, the sliding of the inertia amount corrector 409 can effectively buffer the impact at the moment of gear disengagement, preventing damage to surrounding components (such as bearing misalignment, sensor loosening) caused by vibration. At the same time, the inertia displacement detection structure 405 continuously monitors the displacement data and adjusts the damping force of the inertia amount corrector 409 in real time to ensure the dynamic balance inside the gear box 100.

[0038] When the input shaft 501 speed is reduced to the safety threshold (such as low-speed rotation state), the reduction gear 406 and the outer reduction gear ring 407 remain engaged, maintaining a 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 the old gear disassembly, new gear installation or damage repair operation. The flywheel energy storage structure 402 is isolated from the power source, but its stored kinetic energy still maintains a certain speed through the inertial displacement detection structure 405, providing temporary power for the auxiliary systems (such as lubricating oil circulating pump) in the gearbox 100, ensuring stable system environment during repair work.

[0039] Subsequently, after the self-repair assembly 600 completes the work, the inertial deceleration correction assembly 400 enters the reset stage. First, the reduction gear 406 and the outer reduction gear ring 407 are disengaged to release the mechanical brake. Then, the electromagnetic coupler 404 reconnects the flywheel energy storage structure 402 and the blade hub connecting shaft 401. The flywheel body quickly absorbs wind kinetic energy through the rotating ring 403 to drive the input shaft 501 to restore to normal speed. During this process, the inertial amount corrector 409 resets to the initial position along the inertial semi-arc ring 408. The inertial displacement detection structure 405 again monitors the displacement data to confirm that the power transmission has returned to normal, and the gearbox 100 returns to full load operation state.

[0040] Through the engagement of the reduction gear 406 and the outer reduction gear ring 407, the deceleration force can be flexibly adjusted according to the gear damage degree, avoiding stress concentration inside the gearbox 100 caused by traditional emergency braking. The sliding friction design of the inertial semi-arc ring 408 and the inertial amount corrector 409 can effectively absorb the impact vibration during gear switching, reduce the vibration amplitude, and protect the precision components (such as sensors, bearings) inside the gearbox 100 from damage. During maintenance, the kinetic energy released by the flywheel can meet about 80% of the energy consumption demand inside the gearbox 100, eliminating the need for external power supply, reducing operation and maintenance costs, and improving energy utilization. By controllable deceleration, the speed of the gear transmission assembly 500 is reduced from high speed (such as 1500 rpm) to low speed (such as below 100 rpm), which improves the mechanical arm operation error tolerance, significantly reduces the risk of repair material splashing and component collision caused by high-speed movement, and enables the inertial deceleration correction assembly 400 to quickly isolate the power source in strong wind environment, creating a safe working window for the self-repair assembly 600 while maintaining low-speed rotation of the blade, avoiding power loss and fault escalation risk caused by waiting for shutdown.

[0041] In some embodiments, according to Figure 1 、 Figure 3 、 Figure 6 and Figure 7As shown, the self-repairing assembly 600 includes a hot melt repair conversion spray head 617, a shape memory alloy driving cavity 612, and a magnetic particle driving member 613, the shape memory alloy driving cavity 612 is electrically connected with the intelligent monitoring sensor, for driving the hot melt repair conversion spray head 617 to move to the damage site when the tooth surface damage is detected.

[0042] The side end of the magnetic particle driving member 613 is communicated with a nano magnetic repair particle guide cavity 616, the side end of the nano magnetic repair particle guide cavity 616 is symmetrically provided with an electromagnetic coil 609, the electromagnetic coil 609 generates a gradient magnetic field when energized, driving the nano magnetic repair particles to fill the damage area in a directional manner, the side end surface of the electromagnetic coil 609 is respectively provided with a magnetic field controller and a Hall sensor, the side end of the electromagnetic coil 609 is provided with a semicircular guide rail 614, the semicircular guide rail 614 is slidably connected with a small shaft end mechanical arm 615, the hot melt repair conversion spray head 617 is arranged at the execution end of the small shaft end mechanical arm 615, the hot melt repair conversion spray head 617 is composed of a hot melt repair spray head and a bidirectional guide spray head, which can be converted and adjusted according to requirements, the bidirectional guide spray head includes a first guide channel and a second guide channel, the first guide channel is communicated with the nano magnetic repair particle guide cavity 616 for conveying nano magnetic repair particles, and the second guide channel is communicated with the shape memory alloy driving cavity 612 for conveying shape memory alloy particles and a high polymer repair agent.

[0043] The side end of the electromagnetic coil 609 is externally provided with a repair cavity 608, the inside of the repair cavity 608 is provided with a belt pulley structure 610, the center of the synchronous pulley of the side end of the belt pulley structure 610 is externally sleeved with a standby gear 611, the side end of the repair cavity 608 is connected with an inner groove rail ring 601, the inside of the inner groove rail ring 601 is rotatably connected with a track rotating ring 602, the outside of the track rotating ring 602 is slidably connected with a positioning sliding seat 603, the top of the positioning sliding seat 603 is provided with a visual mechanical shaft arm 604, the execution end of the visual mechanical shaft arm 604 is provided with a bidirectional rotating structure 605, the left and right ends of the bidirectional rotating structure 605 are both provided with a clamping end 606, and the side end of the clamping end 606 is provided with a contact piece 607.

[0044] Specifically, the wear detection sensor installed on the surface of the planetary gear 506 continuously scans the tooth surface state, collects data in real time and transmits to the external PLC controller, when the external PLC controller identifies that the tooth surface has cracks or the wear exceeds the normal threshold (such as invisible micro cracks or surface peeling), immediately issues an instruction to the self-repairing assembly 600.

[0045] The visual mechanical arm 604 on one side is first removed from the pulley structure 610 of the repair cavity 608 by the clamping end 606, the track rotary joint 602 is rotated along the inner groove rotary joint 601, the positioning sliding seat 603 and the spare gear 611 clamped by the visual mechanical arm 604 are first prepared, then the clamping end 606 and the contact piece 607 on the other side take out the gears in the three groups of planetary gears 506 that exceed the wear threshold, and timely move the spare gear 611 on the other side to the gear transmission assembly 500, after taking out, it is placed on the pulley structure 610 by the visual mechanical arm 604 and the clamping end 606, so that the gears exceeding the wear threshold rotate, and self-repair operation is carried out by the self-repair assembly 600, so that it forms a new spare gear 611.

[0046] At this time, the electromagnetic blocker cuts off the engagement of the original damaged gear and the double outer ring gear 505, the inertia deceleration correction assembly 400 is started, so that the electromagnetic coupler 404 disconnects the connection between the flywheel energy storage structure 402 and the input shaft 501, the deceleration gear 406 is engaged with the outer deceleration gear ring 407 to generate controllable resistance, the inertia correction device 409 slides along the inertia semi-arc ring 408 to absorb the impact energy in the switching moment, at the same time, the flywheel releases the stored kinetic energy, maintains the stability of the transmission shaft speed, and avoids the sudden drop of the output power of the generator 200.

[0047] Then the shape memory nickel-titanium alloy particles in the shape memory alloy driving cavity 612 are guided to the hot melt repair conversion nozzle 617, and the small shaft end mechanical arm 615 slides along the semi-arc guide rail 614 to accurately position the hot melt repair conversion nozzle 617 to the damaged part, preparing for repair work.

[0048] Subsequently, according to the damage type, the hot melt repair conversion nozzle 617 automatically switches the working mode:

[0049] Deep crack repair: switch to the hot melt repair nozzle, the induction coil inside generates a high-frequency magnetic field, quickly heats the nano-magnetic repair particles to a molten state, and injects the molten material into the crack through the conical nozzle, fills and closes the damage.

[0050] Surface wear repair: switch to the bidirectional guide nozzle, the first guide channel is in communication with the nano-magnetic repair particle guide cavity 616, and the micro-magnetic particles form a structural framework; the second guide channel synchronously transports a high polymer repair agent (such as an epoxy resin-based material) to cover and seal the worn surface. In this process, the electromagnetic coil 609 is energized to generate a gradient magnetic field to guide the directional arrangement of nano-magnetic repair particles to form “reinforcing ribs” consistent with the stress direction of the gear surface, and the Hall sensor monitors the magnetic field distribution in real time to ensure uniform filling of the repair material, and the micro ultrasonic vibrator installed on the surface of the bidirectional guide nozzle is started synchronously to promote the penetration of the high polymer repair agent into the micro pores to improve the bonding strength.

[0051] After the repair or replacement is completed, the visual mechanical arm 604 detects the repaired part or the new gear again, the contact 607 confirms the hardness of the repaired surface through physical touch, the ultrasonic flaw detection reviews the crack closure, and the Hall sensor verifies the bonding density of the repaired material under the action of the magnetic field. If all indicators meet the standards (such as the hardness close to the original factory standard, and the crack closure degree > 95%), the external PLC controller sends a command to make the hot melt repair switching nozzle 617 retreat to the initial position, the electromagnetic coupler 404 reconnects the flywheel energy storage structure 402, the gear box 100 resumes operation, and the data of the entire process (such as the damage location, the amount of repair material, the switching time, etc.) is uploaded to the cloud database for reference for subsequent maintenance.

[0052] Through the switching of the hot melt repair and the bidirectional guide nozzle, all types of damage from micro-cracks to deep broken teeth can be processed without manual intervention, improving the repair efficiency. The magnetic field controller adjusts the magnetic field strength in real time according to the damage depth, such as increasing the magnetic field to improve the particle filling density when repairing deep cracks, and reducing the magnetic field to ensure uniform material paving when repairing surface wear, avoiding resource waste. The repair cavity 608 and the internal structure can be installed with two or more groups according to the structure of the gear box 100, reducing maintenance costs.

[0053] In some embodiments, according to Figure 1 , Figure 3 and Figure 5 , the side end of the input shaft 501 is connected with the adapter wheel 502, three groups of wheel grooves 509 are opened on the surface of the adapter wheel 502, and the inside of each of the three groups of wheel grooves 509 is provided with a planetary gear 506. The inside of the planetary gear 506 is meshingly connected with a sun gear output shaft 508, the outside of the adapter wheel 502 is connected with a connecting piece, and the outside of the connecting piece is connected with a double outer ring gear 505.

[0054] One side outer ring gear of the double outer ring gear 505 is meshingly connected with an inner ring gear rotating ring 503, and an electromagnetic blocker is arranged on the meshing connection end side of the double outer ring gear 505. The side end of the inner ring gear rotating ring 503 is connected with a connecting rod 504, and the side end of the connecting rod 504 is connected with the surface of the track rotating ring 602.

[0055] The other side outer ring gear of the double outer ring gear 505 is meshingly connected with an inner tooth ring 507, and the planetary gear 506 is meshingly connected inside the inner tooth ring 507.

[0056] The side end of the sun gear output shaft 508 is connected with a transmission shaft, the outside of the transmission shaft is provided with a differential 300, and the surface of the planetary gear 506 is respectively provided with a wear detection sensor and a position positioning sensor.

[0057] The side end of the transmission shaft is connected with the main shaft of the generator 200.

[0058] Further specifically: first, the wind-driven input shaft 501 rotates, driving the synchronous rotation of the adapter wheel 502, and the three sets of wheel grooves 509 on the surface of the adapter wheel 502 are each installed with a planetary gear 506, which is simultaneously meshed 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 adapter 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 and transmits torque to the transmission shaft.

[0059] Next, one side of the double outer ring gear 505 is meshed with the inner ring gear rotating ring 503, and 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 interrupter 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 ring 601 through the connecting rod 504. At the same time, the other side of the double outer ring gear 505 is meshed with the inner tooth ring 507, which is fixedly not rotating, and the meshing of the planetary gear 506 in the inner tooth ring 507 further reduces the rotating speed, forming a speed reduction. After the speed reduction, the rotating 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.

[0060] Subsequently, the sun gear output shaft 508 is connected to the differential 300 through the transmission shaft, and the differential 300 is used to automatically adjust the torque distribution when the rotating speed of the gear transmission assembly 500 fluctuates, ensuring the smooth output of the transmission shaft and avoiding damage to the generator 200 due to overload. The transmission shaft finally transmits power to the main shaft of the generator 200, driving the generator 200 to generate electricity.

[0061] During this process, the wear detection sensor and the position positioning sensor installed on the surface of the planetary gear 506 monitor the gear state in real time. The former detects the degree of tooth surface wear, and the latter tracks the position of the planetary gear 506, providing data support for intelligent maintenance.

[0062] When the wear detection sensor finds that a certain set of planetary gears 506 is damaged and needs to be replaced, the electromagnetic blocker connects the engagement of the double outer ring gear 505 and the inner ring gear rotating ring 503, at this time, the inner ring gear rotating ring 503 drives the track rotating ring 602 to rotate in the inner groove track ring 601 through the connecting rod 504, so as to drive the operation of the above-mentioned visual mechanical shaft arm 604 and related structure, such as moving the spare gear 611 to the meshing position, during the whole switching process, the inertia deceleration correction assembly 400 maintains the low-speed rotation of the transmission shaft through the flywheel energy storage and the deceleration gear 406, ensures that the generator 200 does not stop, and at the same time provides a safe repair environment for the self-repairing assembly 600.

[0063] During normal operation and maintenance, the position positioning sensor of the planetary gear 506 continuously tracks the gear position to ensure the engagement accuracy, and the wear detection sensor collects the gear surface deformation data in real time, which is transmitted to the external PLC controller through wireless transmission. The external PLC controller analyzes the data through an algorithm, predicts the remaining life of the gear, triggers the maintenance process in advance, realizes predictive maintenance, and avoids sudden failure.

[0064] The wiring diagram of the differential 300, the flywheel energy storage structure 402, the electromagnetic coupler 404, the inertia correction device 409, the visual mechanical shaft arm 604, the magnetic field controller and the Hall sensor in the application belongs to the common knowledge in the art, and the working principle is a known technology. The model is selected according to the actual use, so the control mode and wiring arrangement of the differential 300, the flywheel energy storage structure 402, the electromagnetic coupler 404, the inertia correction device 409, the visual mechanical shaft arm 604, the magnetic field controller and the Hall sensor are not explained in detail.

[0065] The use method and working principle of the device are as follows: first, make the wind-driven blade hub connecting shaft 401 rotate, transmit kinetic energy to the input shaft 501 of the gear transmission assembly 500 through the electromagnetic coupler 404, drive the engagement wheel 502 to rotate, make the three sets of planetary gears 506 in the wheel groove 509 engage the double outer ring gear 505 and the sun gear output shaft 508 synchronously, at this time, the double outer ring gear 505 is engaged with the inner ring gear rotating ring 503 on one side and the inner tooth ring 507 on the other side, forming a multi-stage speed reduction transmission path, finally connecting the transmission shaft through the sun gear output shaft 508 to drive the generator 200 to generate electricity, in this process, the flywheel energy storage structure 402 rotates synchronously with the input shaft 501 through the electromagnetic coupler 404, stores kinetic energy for subsequent use.

[0066] Then, the wear detection sensor installed on the surface of the planetary gear 506 continuously scans the gear surface state, collects data in real time and transmits it to the external PLC controller. When the external PLC controller identifies that the gear surface has cracks or the wear exceeds the normal threshold (such as invisible micro-cracks or surface peeling), it immediately issues an instruction to the self-repairing assembly 600.

[0067] The visual mechanical arm 604 on one side removes the standby gear 611 from the pulley structure 610 of the repair cavity 608 through the clamping end 606. The trajectory rotary ring 602 rotates along the inner groove rotary ring 601, driving the positioning sliding seat 603 and the standby gear 611 clamped by the visual mechanical arm 604 to be prepared first. Then, the clamping end 606 and the contact piece 607 on the other side remove the gears in the three groups of planetary gears 506 that exceed the wear threshold, and timely move the standby 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 exceeding the wear threshold rotates and is repaired by the self-repairing assembly 600, so that it forms a new standby gear 611.

[0068] At this time, the electromagnetic blocker cuts off the engagement of the original damaged gear with the double outer ring gear 505. The inertia deceleration correction assembly 400 is started, so that the electromagnetic coupler 404 disconnects the connection between the flywheel energy storage structure 402 and the input shaft 501, the deceleration gear 406 is engaged with the outer deceleration gear 407 to generate controllable resistance, and the inertia correction device 409 slides along the inertia semi-arc ring 408 to absorb the impact energy at the switching moment. At the same time, the flywheel releases the stored kinetic energy, maintains the stable speed of the transmission shaft, and avoids the sudden drop of the output power of the generator 200.

[0069] Then, the shape memory alloy particles in the shape memory alloy driving cavity 612 are guided to the hot melt repair conversion nozzle 617, and the small shaft end mechanical arm 615 slides along the semi-arc guide rail 614 to accurately position the hot melt repair conversion nozzle 617 to the damaged part, preparing for repair work.

[0070] Subsequently, according to the damage type, the hot melt repair conversion nozzle 617 automatically switches the working mode:

[0071] Deep crack repair: switch to a hot melt repair nozzle, and the induction coil inside generates a high-frequency magnetic field to quickly heat the nano-magnetic repair particles to a molten state, and inject the molten material into the crack through the conical nozzle to fill and heal the damage.

[0072] Surface wear repair: switch to a bidirectional delivery nozzle, the first delivery channel is in communication with the nano-magnetic repair particle delivery cavity 616, and the micron-sized magnetic particles are delivered to form a structural framework; the second delivery channel synchronously delivers a high polymer repair agent (such as an epoxy resin-based material) to cover and seal the worn surface. In this process, the electromagnetic coil 609 is energized to generate a gradient magnetic field, guiding the directional arrangement of nano-magnetic repair particles to 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 enables the micro ultrasonic vibrator installed on the surface of the bidirectional delivery nozzle to start simultaneously to promote the penetration of the high polymer repair agent into the micro pores and improve the bonding strength.

[0073] After the repair or replacement is completed, the visual mechanical arm 604 detects the repaired part or the new gear again. The contact piece 607 confirms the hardness of the repaired surface through physical touch, the ultrasonic flaw detection reviews 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 the hardness close to the original factory standard, the crack closure degree > 95%), the external PLC controller sends a command to make the hot melt repair conversion nozzle 617 retreat to the initial position, the electromagnetic coupler 404 reconnects the flywheel energy storage structure 402, and the gearbox 100 resumes operation. The data of the entire process (such as damage location, repair material usage, switching time, etc.) is uploaded to the cloud database simultaneously to provide a reference for subsequent maintenance.

[0074] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can modify the technical solutions described in the foregoing embodiments or make equivalent replacements to some technical features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A wind turbine gearbox for ease of maintenance, characterised in that: Including gear box (100), generator (200) and respectively install inside gear box (100) inertia deceleration correction assembly (400), gear transmission assembly (500) and self-repairing assembly (600), inertia deceleration correction assembly (400) and self-repairing assembly (600) respectively install in left and right ends of gear transmission assembly (500), and the self-repairing assembly (600) is symmetrically installed; The inertia deceleration correction assembly (400) includes a flywheel energy storage structure (402), an electromagnetic coupler (404), an inertia correction device (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) for providing controllable deceleration force when the gear is switched, providing operation time for the subsequent self-repairing assembly (600). The self-repairing assembly (600) includes a hot melt repair conversion nozzle (617), a shape memory alloy drive cavity (612), and a magnetic particle drive (613). The shape memory alloy drive cavity (612) is electrically connected to an intelligent monitoring sensor for driving the hot melt repair conversion nozzle (617) to move to the damaged part when the tooth surface damage is detected.

2. A wind turbine gearbox for ease of maintenance according to claim 1 characterised in that: The side end of the magnetic particle drive (613) is communicated with a nano magnetic repair particle guide cavity (616). The side end of the nano magnetic repair particle guide cavity (616) is symmetrically provided with an electromagnetic coil (609). The electromagnetic coil (609) generates a gradient magnetic field when energized, driving the nano magnetic repair particles to fill the damaged area in a directional manner. The side end surface of the electromagnetic coil (609) is respectively provided with a magnetic field controller and a Hall sensor. The side end of the electromagnetic coil (609) is provided with a semi-arc guide rail (614). The semi-arc guide rail (614) is internally slidably connected with a small shaft end mechanical arm (615). The hot melt repair conversion nozzle (617) is arranged at the execution end of the small shaft end mechanical arm (615). The hot melt repair conversion nozzle (617) is composed of a hot melt repair nozzle and a bidirectional guide nozzle, which can be converted and adjusted according to requirements. The bidirectional guide nozzle includes a first guide channel and a second guide channel. The first guide channel is communicated with the nano magnetic repair particle guide cavity (616) for conveying nano magnetic repair particles. The second guide channel is communicated with the shape memory alloy drive cavity (612) for conveying shape memory alloy particles and high polymer repair agents.

3. A maintenance-friendly wind turbine gearbox according to claim 2, characterized in that: The side end of the electromagnetic coil (609) is externally provided with a repair cavity (608), the inside of the repair cavity (608) is provided with a pulley structure (610), the side end of the pulley structure (610) is externally provided with a synchronous pulley, the outside of the synchronous pulley is sleeved with a standby gear (611), the side end of the repair cavity (608) is connected with an inner groove rail ring (601), the inside of the inner groove rail ring (601) is rotatably connected with a track swivel ring (602), the outside of the track swivel ring (602) is slidably connected with a positioning sliding seat (603), the top of the positioning sliding seat (603) is provided with a visual mechanical shaft arm (604), the execution end of the visual mechanical shaft arm (604) is provided with a bidirectional rotation structure (605), the left and right ends of the bidirectional rotation structure (605) are both provided with a clamping end (606), and the side end of the clamping end (606) is provided with a contact piece (607).

4. The maintenance-friendly wind turbine gearbox of claim 1, wherein: The inertia deceleration correction assembly (400) further comprises a blade hub connecting shaft (401), and the flywheel energy storage structure (402) is arranged outside the blade hub connecting shaft (401) through an electromagnetic coupler (404).

5. The maintenance-friendly wind turbine gearbox according to claim 1, characterized in that: The outside of the electromagnetic coupler (404) is provided with an inertia displacement amount detection structure (405), the side end of the inertia displacement amount detection structure (405) is provided with an inertia semi-arc ring (408), and the outside of the inertia semi-arc ring (408) is slidably connected with an inertia amount corrector (409).

6. The maintenance-friendly wind turbine gearbox of claim 1, wherein: The side end of the input shaft (501) is connected with an engaging wheel (502), three groups of wheel grooves (509) are formed in the surface of the engaging wheel (502), the inside of each of the three groups of wheel grooves (509) is provided with a planetary gear (506), the inside of the planetary gear (506) is meshingly connected with a sun gear output shaft (508), the outside of the engaging wheel (502) is circumferentially connected with a connecting piece, and the outside of the connecting piece is connected with a double-outer-ring gear (505).

7. A maintenance-friendly wind turbine gearbox according to claim 6, characterised in that: One side outer ring gear of the double-outer-ring gear (505) is meshingly connected with an inner-ring gear rotating ring (503), an electromagnetic interrupter is arranged at the meshing connection end side of the double-outer-ring gear (505), the side end of the inner-ring gear rotating ring (503) is externally connected with a connecting rod (504), and the side end of the connecting rod (504) is connected with the surface of the track swivel ring (602).

8. A maintenance-friendly wind turbine gearbox according to claim 6, characterized in that: The other side outer ring gear of the double-outer-ring gear (505) is meshingly connected with an inner tooth ring (507), and the planetary gear (506) is meshingly connected in the inside of the inner tooth ring (507).

9. The maintenance-friendly wind turbine gearbox according to claim 6, characterized in that: The side end of the sun gear output shaft (508) is connected with a transmission shaft, the outside of the transmission shaft is provided with a differential (300), and the surface of the planetary gear (506) is respectively provided with a wear detection sensor and a position positioning sensor.

10. A maintenance-friendly wind turbine gearbox according to claim 9, characterised in that: The side end of the transmission shaft is connected with the main shaft of the generator (200).

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