Test bed and test method for large-scale semi-direct-driven wind driven generator

Abstract

The invention provides a test bench and a test method for a large-scale semi-direct-drive wind driven generator, and relates to the field of wind driven generator assembly and test, the test bench comprises a test bench main body and a shaft system module, the test bench main body comprises a test bench support and a cylinder; an arc-shaped groove is formed in the upper portion of the test bed support and used for fixedly installing a cylinder. The test bed bracket is fixed on the bottom plate, and a plurality of first reinforcing rib plates are fixedly mounted on the two sides of the test bed bracket in the length direction; inner first vertical rib plates are fixedly connected to two sides of the width direction of the test bed bracket; a plurality of second vertical rib plates are fixedly connected in the test bed bracket at intervals; and a plurality of second reinforcing rib plates are fixedly connected at equal intervals along the circumference in a shafting module mounting position formed by fixedly connecting the annular cylinder wall, the first annular plate, the reinforcing cylinder, the second annular plate and the third annular plate. The device structure is further simplified, the problem of difficulty and complexity in test pairing installation is solved, the operation stability of the test device is improved, and the test precision is improved.

Description

Technical Field

[0001] This invention relates to the field of wind turbine assembly and testing, specifically to a test bench and test method for a large semi-direct drive wind turbine. Background Technology

[0002] Type testing is a crucial step in verifying the performance and reliability of wind turbines. Traditionally, type testing for small and medium-sized semi-direct drive motors typically employs two testing schemes. One scheme involves using two sets of single-unit test fixtures for paired type testing, which relies on a traditional coupling-driven structure to connect the single-unit test fixtures used by the two motors. The other scheme uses dedicated drive testing equipment, where the drive is connected to the motor for type testing. Due to the significant investment in equipment, some motor manufacturers usually choose the first testing scheme.

[0003] With the increasing size of direct-drive wind turbines in the past two and a half years, the problems of the above two testing methods have become increasingly apparent. As the motor capacity increases, the size and weight of the generator also increase. The instability of single-unit testing fixtures and the alignment deviation of assembled units directly affect the air gap value of the generator, thus affecting the accuracy of motor testing. Furthermore, there are very few dedicated testing equipment options for large-capacity motor type testing, and the high equipment costs are a huge economic burden for motor manufacturers. Therefore, a new type of type testing solution for large-megawatt motors is urgently needed.

[0004] To address the testing challenges of large semi-direct-drive wind turbines, Chinese patent literature, publication number CN117741427A, published on March 22, 2024, discloses an invention patent entitled "Test Fixture and Assembly Method for a Megawatt-Class Compact Semi-Direct-Drive Wind Turbine," which includes a test bench, sliding bearings, a main shaft, a secondary shaft, end caps, rolling bearings, and bearing cover plates. The test fixture, through its segmented design of the main and secondary shafts, combined with sliding and rolling bearings, enables support for the generator and load testing on the main shaft. This prior art focuses on optimizing the assembly and turning process for single-unit testing, reducing lifting and turning procedures to some extent and improving production efficiency. However, type testing still requires multiple turnings of the test fixture to complete the arrangement of the single-unit test device, and the alignment of the main and secondary shafts also requires significant production resources to achieve the required alignment accuracy for testing.

[0005] Publication number CN119222111A, publication date December 31, 2024, discloses a horizontal test device for permanent magnet wind turbines. It adopts a horizontal symmetrical design, with two generators arranged on either side of a support, serving as the drive unit and test machine respectively. Rotating components are connected to the rotors at both ends via tooling shafts supported by two sets of sliding bearings to meet type test requirements. This test device optimizes the shaft system, eliminating the need for the traditional assembly of two sets of single-unit tooling. However, this increases the requirements for drive shaft installation, necessitating adjustment of the drive shaft's position and ensuring coaxiality between the shaft system and the stator positioning stops at both ends to guarantee test accuracy. Furthermore, the fixing interfaces of key components such as the stator and rotor are independent, which, while providing convenience for later maintenance, reduces the overall stability of the device. Summary of the Invention

[0006] To address the shortcomings of the existing technology, this invention provides a test bench and test method for a large semi-direct drive wind turbine. This invention further simplifies the device structure, solves the difficulties and complexities of test assembly installation, improves the operational stability of the test device, and enhances the test accuracy.

[0007] This invention is achieved through the following technical solution: The first aspect of the present invention provides a test bench for a large semi-direct drive wind turbine, comprising a test bench body and a shaft system module. The test bench body is flipped 90° in the axial direction and supported by a square box to make it horizontal with respect to the ground. The shaft system module is vertically lifted so that the small end of the shaft system module is facing down and the large end is facing up, and it is lowered into the shaft system module mounting position on the test bench body. After being fixed by bolts, the test bench body is flipped back to its original position. The main body of the test bench includes a test bench support and a cylinder; the upper part of the test bench support has an arc-shaped groove for fixing and installing the cylinder; the test bench support is fixed to the base plate, and multiple first reinforcing ribs are fixedly installed on both sides of the test bench support along its length, with one side of the first reinforcing ribs fixedly connected to the test bench support and the other side fixedly connected to the base plate; inner first vertical ribs are fixedly connected on both sides of the test bench support along its width; multiple second vertical ribs are fixedly connected at intervals inside the test bench support. The cylinder includes an annular cylindrical wall, a first annular plate, a reinforcing cylinder, a second reinforcing rib plate, a second annular plate, and a third annular plate. The first annular plate, the reinforcing cylinder, the second annular plate, and the third annular plate are fixedly connected to both sides of the annular cylindrical wall from the outside to the inside. In the shaft module mounting position formed by the fixed connection of the annular cylindrical wall, the first annular plate, the reinforcing cylinder, the second annular plate, and the third annular plate, multiple second reinforcing rib plates are fixedly connected at equal intervals along the circumference. The shaft system module includes a fixed shaft, a rotating shaft, a single-row tapered roller bearing, a bearing pressure ring, and an oil seal cover plate, which are assembled sequentially to form the shaft system module.

[0008] Furthermore, the first ring plate is provided with a first stop; the second ring plate is provided with a second stop; and the rotating shaft is equipped with adapter flanges with different interfaces.

[0009] Furthermore, the first vertical stiffener, the second vertical stiffener, and the second reinforcing stiffener are provided with access holes for people to pass through.

[0010] Furthermore, the first reinforcing rib is triangular in shape.

[0011] Furthermore, the bearing pressure ring and the rotating shaft transmit torque through an axial cylindrical pin.

[0012] Furthermore, the fixed axis adopts an asymmetrical tower-shaped structure, and the assembly mating surface on the cylinder corresponds to and matches the tower-shaped structure.

[0013] Furthermore, an grease collection cover is installed on the oil seal cover.

[0014] Furthermore, multiple lifting lugs are mounted on the base plate and multiple lifting lugs are mounted on the cylinder wall.

[0015] Furthermore, during the assembly process of the shaft system module: Step 1: First, fix the shaft in the assembly position, install and test the lifting tool in advance to ensure that the lifting tool can safely and accurately lift the remaining parts; Step 2: Start the heating equipment to heat the inner ring of the single-row tapered roller bearing; Step 3: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing and quickly put it onto the left end of the shaft. Use the bearing retainer to tighten the inner ring of the bearing. Use the extended screw to tighten the bearing retainer from the inner hole of the shaft and tighten it with a pneumatic wrench. Step 4: After the single-row tapered roller bearing has cooled to room temperature, remove the pressure ring fixture, clean the inner ring of the bearing, check the cleanliness of the bearing, and check the clearance between the shaft shoulder and the bearing. It is required that a 0.02mm feeler gauge should not be completely inserted, and the local insertion range should not exceed 1 / 4 of the circumference.

[0016] Step 5: Apply lubricating grease evenly to the inner ring of the single-row tapered roller bearing on the left end of the shaft.

[0017] Step 6: Fit the two ends of the fixed shaft with the outer ring of the single-row tapered roller bearing; before fitting, check the bearing stop of the fixed shaft to ensure there are no foreign objects at the same height. Step 7: When installing the inner ring of the single-row tapered roller bearing at the left end of the rotating shaft and the outer ring of the single-row tapered roller bearing at the left end of the fixed shaft, instant adhesive is required for temporary fixation. Apply the instant adhesive to the outer circle of the bearing pressure ring at the left end of the rotating shaft. Step 8: Flatten the fixed shaft and assemble it with the rotating shaft assembly; Step 9: Lubrication of the outer raceway of the bearing at the right end of the fixed shaft: Apply lubricating grease evenly to the outer raceway of the single-row tapered roller bearing at the right end of the fixed shaft. Step 10: Check the cleanliness of the bearing retaining ring and the right end face of the shaft. Pre-install the bearing retaining ring on the right end of the shaft and check the fit. Step 11: Restart the heating equipment to heat the inner ring of the single-row tapered roller bearing; Step 12: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing and quickly put it onto the right end of the shaft. Use the bearing retainer to tighten the inner ring. While the inner ring is hot, tighten the bolts connecting the bearing retainer and the shaft symmetrically multiple times. Install 4-5 bolts symmetrically around the circumference and tighten them with a pneumatic wrench. Step 13, Axial clearance measurement and adjustment: After the single-row tapered roller bearing has cooled to room temperature, measure the axial clearance using the suspension method.

[0018] Furthermore, the inner ring of the single-row tapered roller bearing is heated to 105±5℃, not exceeding 110℃, to ensure that the overall temperature difference of the single-row tapered roller bearing is less than 10℃. When the average temperature reaches 100℃, it is kept at that temperature for 1 hour. A second aspect of the present invention provides a test method for a large semi-direct drive wind turbine, comprising the following steps: S1. Arrange the wind turbine horizontally and use a stator and rotor assembly fixture to assemble the stator and rotor of the wind turbine. During the assembly process, guide the assembly through the guide column in the middle of the stator and rotor assembly fixture. After the assembly is completed, measure the air gap to ensure that the air gap is within the design requirements.

[0019] S2. Install the stator and rotor fixing fixture, tighten it to the stator and rotor respectively with bolts, and then use the lifting lugs on the stator and rotor fixing fixture to lift the wind turbine. S3. Use the lifting lugs on the stator and rotor fixing fixture to flip the wind turbine over 90° and place it on the wooden support. Then remove the stator and rotor assembly fixture. S4. After removing the stator and rotor assembly fixture, lift the wind turbine generator and hang it on one end of the test bench using the lifting lugs on the stator and rotor fixing fixture. Position and connect the rotor to the transfer flange on the shaft. Position and connect the stator to the stop on the corresponding ring plate on the test bench using bolts. S5. Use an L-shaped lifting tool to remove the stator and rotor fixing fixtures, install the brake bracket, brake disc, and end cover, and conduct a single-unit dynamic test of the wind turbine.

[0020] Furthermore, it also includes mounting another wind turbine at the other end of the test bench to conduct a dual-generator pair test.

[0021] The beneficial effects of this invention are as follows: 1. The test bench in this invention has a simple and compact structure. Through reasonable design and combination of various components, a stable test bench support and shaft module are formed, which can effectively support the wind turbine and resist vibration, ensuring the safety and stability of the test process. Compared with the complex structural design in the prior art, this invention improves the stability of the device while simplifying the structure.

[0022] 2. The test method of the present invention is simple to operate. By horizontally arranging the stator and rotor of the wind turbine generator, and using the stator and rotor assembly tooling, the assembly is carried out and the air gap is controlled. The stop guide design reduces the difficulty of assembly and alignment, and reduces manual adjustment steps. Assembly can be completed by simply flipping the wind turbine generator once. There is no need to perform additional flipping operations on the test bench, which improves the efficiency of test preparation, reduces the difficulty of operation and the requirements for operators. Compared with the complex assembly and alignment adjustment process in the prior art, the operation of the present invention is simpler, faster and easier to implement.

[0023] 3. By setting stop plates on each ring plate and installing different transition flanges on the rotating shaft, the present invention reduces manual adjustment steps and achieves compatibility with different models of wind turbines. It has good versatility and flexibility. Compared with the existing technology, which has poor compatibility with specific motor models or requires complex adjustments, the present invention can better meet the testing needs of different types and models of motors and improve the applicability and practicality of the test bench.

[0024] 4. The design of each stiffener in the test bench of the present invention can effectively support the wind turbine and resist the vibration generated during the rotation of the wind turbine, ensuring stability and safety during the test, thereby improving the reliability of the test results. Compared with the prior art, where the test results may be deviated due to the instability of the device structure or vibration, the present invention can provide more accurate and reliable test data.

[0025] 5. The test bench of the present invention is not only suitable for single-machine testing, but also supports dual-machine pair testing. By rigidly connecting the rotors of two wind turbines through the shaft system module, it can complete the towing type test. Moreover, the space occupied during the test is relatively small, and the space requirements of the test site are lower. Compared with the existing technology, which requires a large space to prevent the test device from being flipped, the present invention reduces the space occupation while improving the test efficiency, and improves the applicability and flexibility of the test bench. Attached Figure Description

[0026] Figure 1 This is a half-sectional view of the overall structure of the present invention; Figure 2 This is a half-section view of the main body of the test bench of the present invention; Figure 3 This is a sectional view of the shaft system module of the present invention; Figure 4A schematic diagram showing the test bench of the present invention rotated 90° and supported by a square box to make it horizontal with the ground; Figure 5 The shaft system module is positioned in the shaft system module mounting position on the main body of the test bench. Figure 6 A schematic diagram showing the connection between the main body of the test bench and the shaft system module via bolts; Figure 7 A schematic diagram illustrating the use of a specially designed dial indicator bracket and dial gauge to detect the runout of the mating surface between the rotating shaft and the stator frame. Figure 8 This is a schematic diagram illustrating the assembly of the stator and rotor assembly tooling with the stator and rotor of a wind turbine generator in this invention. Figure 9 Schematic diagram of the fixture for installing the stator and rotor; Figure 10 Schematic diagram of the tooling for disassembling the stator and rotor assembly; Figure 11 A schematic diagram showing the positioning connection between the rotor and the shaft, and the positioning connection between the stator and the corresponding ring plate on the test bench. Figure 12 Schematic diagram of dismantling the stator and rotor fixing fixture using an L-shaped lifting tool; Figure 13 This is a schematic diagram of a single-machine dynamic test. Figure 14 This is a schematic diagram of a dual-machine pair test. Figure 15 Schematic diagram of adding a grease collection cover to the oil seal cover plate.

[0027] Figure 16 Diagram of the stop; Reference numerals in the attached drawings: 1. Main body of the test bench; 101. Cylinder wall; 102. First ring plate; 103. Reinforcing cylinder; 104. Second reinforcing rib plate; 105. Third ring plate; 106. Second ring plate; 107. Second vertical rib plate; 108. First vertical rib plate; 109. Base plate; 110. First reinforcing rib plate; 111. Lifting lug; 112. Test bench support; 113. First stop; 114. Second stop; 2. Shaft system module; 201. Fixed shaft; 202. Rotating shaft; 203. Bearing pressure ring; 204. Oil seal cover plate; 205. Single row tapered roller bearing; 206. Grease collection cover; 207. Adapter flange; 301. Stator; 302. Rotor; 303. Stator and rotor assembly fixture; 304. Stator and rotor fixing fixture; 305. L-shaped lifting tool. Detailed Implementation

[0028] Example 1 The first aspect of this invention provides a test bench for large semi-direct drive wind turbines, such as... Figure 1-6As shown, the test bench includes a main body 1 and a shaft module 2. The main body 1 of the test bench is flipped 90° along the axial direction and supported by a square box to make it horizontal with the ground. The shaft module 2 is lifted vertically so that the small end of the shaft module 2 is facing down and the large end is facing up, and it is lowered into the shaft module mounting position on the main body 1 of the test bench. After being fixed by bolts, the main body 1 of the test bench is flipped back to its original position. The main body 1 of the test bench includes a test bench support 112 and a cylinder; the upper part of the test bench support 112 has an arc-shaped groove for fixing and installing the cylinder; the test bench support 112 is fixed on the base plate 109, and multiple first reinforcing ribs 110 are fixedly installed on both sides of the test bench support 112 in the length direction. One side of the first reinforcing rib 110 is fixedly connected to the test bench support 112, and the other side is fixedly connected to the base plate 109; the two sides of the test bench support 112 in the width direction are fixedly connected to the inner first vertical ribs 108; and multiple second vertical ribs 107 are fixedly connected at intervals inside the test bench support 112. The cylinder includes an annular cylindrical wall 101, a first annular plate 102, a reinforcing cylinder 103, a second reinforcing rib plate 104, a second annular plate 106, and a third annular plate 105. The first annular plate 102, the reinforcing cylinder 103, the second annular plate 106, and the third annular plate 105 are fixedly connected to both sides of the annular cylindrical wall 101 from the outside to the inside. In the shaft module mounting position formed by the fixed connection of the annular cylindrical wall 101, the first annular plate 102, the reinforcing cylinder 103, the second annular plate 106, and the third annular plate 105, multiple second reinforcing rib plates 104 are fixedly connected at equal intervals along the circumference. The shaft system module 2 includes a fixed shaft 201, a rotating shaft 202, a single-row tapered roller bearing 205, a bearing pressure ring 203, and an oil seal cover plate 204, which are assembled in sequence to form the shaft system module 2.

[0029] like Figure 1 As shown, the test bench is initially set vertically; as Figures 4-6 As shown, the main body 1 of the test bench is flipped 90° along the axial direction and supported by a square box to make it horizontal with the ground.

[0030] like Figure 7 As shown, after the shaft module 2 is placed in the shaft module mounting position on the main body 1 of the test bench, a special dial indicator bracket and a dial indicator are used to check the runout of the contact surface between the rotating shaft and the dial indicator head. After passing the test, the bolts between the shaft module 2 and the main body 1 of the test bench are tightened, and the test bench is turned over to fix it.

[0031] During the assembly of shaft module 2: Step 1: First, fix the rotating shaft 202 in the assembly position, install and test the lifting tool in advance to ensure that the lifting tool can safely and accurately lift the remaining parts; Step 2: Start the heating equipment to heat the inner ring of the single-row tapered roller bearing 205; Step 3: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing 205 and quickly put it into the left end of the shaft 202, use the bearing pressure ring 203 to reverse the sleeve and press the inner ring of the bearing, use the extended screw to press the bearing pressure ring 203 from the inner hole of the shaft 202, and tighten it with a pneumatic wrench. Step 4: After the single-row tapered roller bearing 205 has cooled to room temperature, remove the pressure ring fixture, clean the inner ring of the bearing, check the cleanliness of the bearing, and check the clearance between the shaft shoulder and the bearing. It is required that a 0.02mm feeler gauge should not be completely penetrated, and the local insertion range should not exceed 1 / 4 of the circumference. Step 5: Apply lubricating grease evenly to the inner ring of the single-row tapered roller bearing 205 at the left end of the shaft 202; Step 6: Fit the two ends of the fixed shaft 201 with the outer ring of the single-row tapered roller bearing 205; before fitting, check the bearing stop of the fixed shaft 201 to ensure there are no foreign objects at the same height. Step 7: When installing the inner ring of the single-row tapered roller bearing 205 at the left end of the rotating shaft 202 and the outer ring of the single-row tapered roller bearing 205 at the left end of the fixed shaft 201, instant adhesive is required for temporary fixation. The instant adhesive is applied to the outer circle of the bearing pressure ring 203 at the left end of the rotating shaft 202. Step 8: Flat-suspend the fixed shaft 201 and assemble it with the rotating shaft 202; Step 9: Lubrication of the outer circle of the bearing at the right end of the fixed shaft 201: Apply lubricating grease evenly to the outer raceway of the single-row tapered roller bearing 205 at the right end of the fixed shaft 201. Step 10: Check the cleanliness of the bearing retaining ring 203 and the right end face of the rotating shaft 202. Pre-install the bearing retaining ring 203 on the right end of the rotating shaft 202 and check the fit. Step 11: Restart the heating equipment and heat the inner ring of the single-row tapered roller bearing 205. Step 12: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing 205 and quickly put it onto the right end of the shaft 202. Use the bearing retaining ring 203 to tighten the inner ring of the bearing. While the inner ring of the bearing is hot, tighten the bolts connecting the bearing retaining ring 203 and the shaft 202 symmetrically multiple times. Install 4-5 bolts symmetrically around the circumference and tighten them with a pneumatic wrench. Step 13, Axial clearance measurement and adjustment: After the single-row tapered roller bearing 205 has cooled to room temperature, measure the axial clearance using the suspension method.

[0032] Heat the inner ring of the single-row tapered roller bearing 205 to 105±5℃, not exceeding 110℃, ensuring that the overall temperature difference of the single-row tapered roller bearing 205 is less than 10℃. After the average temperature reaches 100℃, keep it at that temperature for 1 hour.

[0033] Example 2 This embodiment further elaborates and supplements the implementation of the present invention based on Embodiment 1.

[0034] like Figure 1 and Figure 16 As shown, the first ring plate 102 is provided with a first stop 113; the second ring plate 106 is provided with a second stop 114; and the rotary plate 202 is equipped with a transition flange 207 with different interfaces.

[0035] In this embodiment, stop plates are provided on each ring plate for positioning the stator 301 with the corresponding ring plate. Different interface adapter flanges are mounted on the rotating shaft 202 for positioning and connecting the rotor 302 to the adapter flanges on the rotating shaft 202. Providing stop plates on each ring plate and adding different adapter flanges to the rotating shaft 202 reduces the difficulty of assembly alignment and minimizes manual adjustment steps, achieving compatibility with different models of wind turbines. This invention offers good versatility and flexibility. Compared to existing technologies with poor adaptability to specific motor models or requiring complex adjustments, this invention better meets the testing needs of different types and models of motors, improving the applicability and practicality of the test bench.

[0036] The first vertical stiffener 108, the second vertical stiffener 107, and the second reinforcing stiffener 104 are provided with access holes for people to pass through, providing operators with operating space inside the test bench support.

[0037] The first reinforcing rib plate 110 is triangular.

[0038] The first vertical stiffener 108, the second vertical stiffener 107, the first reinforcing stiffener 110, and the second reinforcing stiffener 104 can effectively support the wind turbine, resist the vibration generated during the rotation of the wind turbine, ensure the stability and safety of the test process, and thus improve the reliability of the test results.

[0039] Example 3 This embodiment further elaborates and supplements the implementation of the present invention based on Embodiment 1 or Embodiment 2.

[0040] Torque is transmitted between the bearing retaining ring 203 and the rotating shaft 202 via an axial cylindrical pin. In addition to bolt connections, the bearing retaining ring 203 and the rotating shaft 202 are also connected via an axial cylindrical pin to transmit torque, thus avoiding the problem of insufficient bolt friction.

[0041] The fixed shaft 201 adopts an asymmetrical tower-shaped structure, and the assembly mating surface on the cylinder corresponds to and mates with the tower-shaped structure. The fixed shaft adopts an asymmetrical tower-shaped structure, which facilitates the installation of the shaft system module 2 into the test bench support 112 from one side.

[0042] A grease collection cover 206 is installed on the oil seal cover plate 204 to prevent bearing lubricating grease from being thrown out during rotation.

[0043] Multiple lifting lugs 111 are mounted on the base plate 109 and the cylinder wall 101. The lifting lugs 111 facilitate the flipping and resetting of the test bench.

[0044] Example 4 This embodiment further elaborates and supplements the implementation of the present invention based on Embodiment 3.

[0045] like Figures 8-13 As shown, a second aspect of the present invention provides a test method for a large semi-direct drive wind turbine, comprising the following steps: S1. The wind turbine is arranged horizontally. The stator and rotor assembly tool 303 is used to assemble the stator 301 and rotor 302 of the wind turbine. During the assembly process, the guide column in the middle of the stator and rotor assembly tool 303 is used for guidance. After the assembly is completed, the air gap is measured to ensure that the air gap is within the design requirements.

[0046] S2. Install the stator and rotor fixing fixture 304, tighten it with the stator 301 and rotor 302 respectively with bolts, and then use the lifting lugs 111 on the stator and rotor fixing fixture 304 to lift the wind turbine. S3. Use the lifting lugs on the stator and rotor fixing fixture 304 to flip the wind turbine over 90° and place it on the wooden support. Then remove the stator and rotor assembly fixture 303. S4. After removing the stator and rotor assembly fixture 303, lift the wind turbine generator and hang it on one end of the test bench using the lifting lugs on the stator and rotor fixing fixture 304. Position and connect the rotor 302 to the transfer flange on the shaft 202. Position and connect the stator 301 to the stop on the corresponding ring plate on the test bench using bolts. S5. Use an L-shaped lifting tool to remove the stator and rotor fixing fixture 304, install the brake bracket, brake disc, and end cover, and conduct a single-unit dynamic test of the wind turbine.

[0047] After the test, the installed brake bracket, brake disc, and end cover components were removed. The stator and rotor fixing fixture 304 was reinstalled using an L-shaped lifting tool. The adapter flange and bolts were removed, and the wind turbine was separated from the test bench. The wind turbine was then lifted using the stator and rotor fixing fixture 304 and placed on a wooden support. It was then turned over, and finalized, packaged, and shipped.

[0048] In this test method, the assembly process of the wind turbine generator onto the test bench is simplified. The stator 301 and rotor 302 of the wind turbine generator are horizontally arranged, and the stator-rotor assembly fixture 303 is used for assembly and air gap control, eliminating the need for subsequent secondary adjustments to the air gap on the test bench. The use of a stop-guide design reduces the difficulty of assembly alignment and minimizes manual adjustment steps. Assembly can be completed by simply flipping the wind turbine generator once, without requiring additional flipping of the test bench. This improves test preparation efficiency, reduces operational difficulty and the requirements for operators. Compared to the complex assembly and alignment processes in existing technologies, the operation of this invention is simpler, faster, and easier to implement.

[0049] In addition to single-unit dynamic testing, this test bench also includes the option to mount another wind turbine at the other end of the test bench for dual-unit pair testing.

[0050] like Figure 14 As shown, during the pair test, following the steps described above, another wind turbine is mounted on the other end of the test bench to conduct type tests on the pair. In this test bench, the rotors 302 of the two wind turbines are rigidly connected via shaft module 2 during the pair test, enabling a towed type test of the two wind turbines. During the test, the shaft length in shaft module 2 is relatively short, resulting in a smaller overall space requirement compared to the existing solutions and lower space requirements for the test site. This method reduces the difficulty of wind turbine mounting through the stop-and-guide design. As long as both wind turbines are mounted correctly via the stop, alignment of the two wind turbines can be ensured without manual adjustment, reducing alignment deviations that may result from manual adjustment.

Claims

1. A test bench for large semi-direct drive wind turbines, characterized in that: The test bench includes a main body (1) and a shaft module (2). The main body (1) is flipped 90° along the axial direction and supported by a square box to make it horizontal with the ground. The shaft module (2) is lifted vertically so that the small end of the shaft module (2) is facing down and the large end is facing up. It is then placed into the shaft module installation position on the main body (1) of the test bench. After being fixed by bolts, the main body (1) of the test bench is flipped back to its original position. The main body (1) of the test bench includes a test bench support (112) and a cylinder; the test bench support (112) has an arc-shaped groove on the top for fixing the cylinder; the test bench support (112) is fixed on the base plate (109), and multiple first reinforcing ribs (110) are fixedly installed on both sides of the test bench support (112) in the length direction. One side of the first reinforcing rib (110) is fixedly connected to the test bench support (112), and the other side is fixedly connected to the base plate (109); the test bench support (112) has inner first vertical ribs (108) fixedly connected on both sides in the width direction; and multiple second vertical ribs (107) are fixedly connected at intervals inside the test bench support (112). The cylinder includes an annular cylindrical wall (101), a first annular plate (102), a reinforcing cylinder (103), a second reinforcing rib plate (104), a second annular plate (106), and a third annular plate (105). The first annular plate (102), the reinforcing cylinder (103), the second annular plate (106), and the third annular plate (105) are fixedly connected to both sides of the annular cylindrical wall (101) from the outside to the inside. In the shaft module mounting position formed by the fixed connection of the annular cylindrical wall (101), the first annular plate (102), the reinforcing cylinder (103), the second annular plate (106), and the third annular plate (105), multiple second reinforcing rib plates (104) are fixedly connected at equal intervals along the circumference. The shaft system module (2) includes a fixed shaft (201), a rotating shaft (202), a single-row tapered roller bearing (205), a bearing pressure ring (203), and an oil seal cover plate (204), which are assembled in sequence to form the shaft system module (2).

2. The test bench for a large semi-direct drive wind turbine as described in claim 1, characterized in that: The first ring plate (102) is provided with a first stop (113); the second ring plate (106) is provided with a second stop (114); and the rotating shaft (202) is equipped with a transition flange (207) with different interfaces.

3. A test bench for a large semi-direct drive wind turbine as described in claim 1 or 2, characterized in that: The first vertical stiffener (108), the second vertical stiffener (107), and the second reinforcing stiffener (104) are provided with access holes for people to pass through.

4. The test bench for a large semi-direct drive wind turbine as described in claim 3, characterized in that: The first reinforcing rib (110) is triangular.

5. A test bench for a large semi-direct drive wind turbine as described in claim 1, characterized in that: The bearing ring (203) and the rotating shaft (202) transmit torque through an axial cylindrical pin.

6. The test bench for a large semi-direct drive wind turbine as described in claim 5, characterized in that: The fixed shaft (201) adopts an asymmetrical tower-shaped structure, and the assembly mating surface on the cylinder corresponds to and matches the tower-shaped structure.

7. A test bench for a large semi-direct drive wind turbine as described in claim 5, characterized in that: Grease collection cover (206) is installed on the oil seal cover plate (204).

8. A test bench for a large semi-direct drive wind turbine as described in claim 1, characterized in that: Multiple lifting lugs (111) are mounted on the base plate (109), and multiple lifting lugs (111) are mounted on the cylinder wall (101).

9. A test bench for a large semi-direct drive wind turbine as described in claim 1, characterized in that: During the assembly process of the shaft system module: Step 1: First, fix the rotating shaft (202) in the assembly position, install and test the lifting tool in advance to ensure that the lifting tool can safely and accurately lift the remaining parts; Step 2: Start the heating equipment to heat the inner ring of the single-row tapered roller bearing (205); Step 3: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing (205) and quickly put it into the left end of the shaft (202), use the bearing pressure ring (203) to tighten the inner ring of the bearing, use the extended screw to tighten the bearing pressure ring (203) from the inner hole of the shaft (202), and tighten it with a pneumatic wrench; Step 4: After the single-row tapered roller bearing (205) has cooled to room temperature, remove the pressure ring fixture, clean the inner ring of the bearing, check the cleanliness of the bearing, and check the clearance between the shaft shoulder and the bearing. It is required that a 0.02mm feeler gauge should not be completely penetrated, and the local insertion range should not exceed 1 / 4 of the circumference. Step 5: Apply lubricating grease evenly to the inner ring of the single-row tapered roller bearing (205) at the left end of the shaft (202); Step 6: Fit the two ends of the fixed shaft (201) with the outer ring of the single-row tapered roller bearing (205); before fitting, check the bearing stop of the fixed shaft (201) to ensure that there are no foreign objects at the same height. Step 7: When installing the inner ring of the single-row tapered roller bearing (205) at the left end of the rotating shaft (202) and the outer ring of the single-row tapered roller bearing (205) at the left end of the fixed shaft (201), instant adhesive is required for temporary fixation. The instant adhesive is applied to the outer circle of the bearing pressure ring (203) at the left end of the rotating shaft (202). Step 8: Flat-suspend the fixed shaft (201) and assemble it with the rotating shaft (202); Step 9, Lubrication of the outer circle of the bearing at the right end of the fixed shaft (201): Apply lubricating grease evenly to the outer raceway of the single-row tapered roller bearing (205) at the right end of the fixed shaft (201); Step 10: Check the cleanliness of the bearing retaining ring (203) and the right end face of the rotating shaft (202), pre-install the bearing retaining ring (203) on the right end of the rotating shaft (202), and check the fit. Step 11: Restart the heating equipment and heat the inner ring of the single-row tapered roller bearing (205); Step 12: Remove the heating equipment, manually move the heated inner ring of the single-row tapered roller bearing (205) and quickly put it into the right end of the shaft (202). Use the bearing pressure ring (203) to tighten the inner ring of the bearing. While the inner ring of the bearing is hot, tighten the bolts connecting the bearing pressure ring (203) and the shaft (202) symmetrically multiple times. Install 4-5 bolts symmetrically around the circumference and tighten them with a pneumatic wrench. Step 13, Axial clearance measurement and adjustment: After the single-row tapered roller bearing (205) has cooled to room temperature, measure the axial clearance using the suspension method.

10. A test bench for a large semi-direct drive wind turbine as described in claim 9, characterized in that: Heat the inner ring of the single-row tapered roller bearing (205) to 105±5℃, not exceeding 110℃, to ensure that the overall temperature difference of the single-row tapered roller bearing (205) is less than 10℃. When the average temperature reaches 100℃, keep it at that temperature for 1 hour.

11. A test method for large semi-direct drive wind turbines, characterized in that: Includes the following steps: S1. The wind turbine is arranged horizontally. The stator and rotor assembly tool (303) is used to assemble the stator (301) and rotor (302) of the wind turbine. During the assembly process, the guide column in the middle of the stator and rotor assembly tool (303) is used for guidance. After the assembly is completed, the air gap is measured to ensure that the air gap is within the design requirements. 12.S2. Install the stator and rotor fixing fixture (304), tighten it with the stator (301) and rotor (302) respectively with bolts, and then use the lifting lugs (111) on the stator and rotor fixing fixture (304) to lift the wind turbine generator; S3. Use the lifting lugs on the stator and rotor fixing fixture (304) to turn the wind turbine over 90° and place it on the wooden support. Then remove the stator and rotor assembly fixture (303). S4. After removing the stator and rotor assembly fixture (303), the wind turbine is lifted and mounted on one end of the test bench by the lifting lugs on the stator and rotor fixing fixture (304). The rotor (302) is positioned and connected to the transition flange on the shaft (202). The stator (301) is positioned and connected to the stop on the corresponding ring plate on the test bench by bolts. S5. Use an L-shaped lifting tool to remove the stator and rotor fixing fixture (304), install the brake bracket, brake disc, and end cover, and conduct a single-unit dynamic test of the wind turbine.

13. The test method for a large semi-direct drive wind turbine as described in claim 9, characterized in that: It also includes mounting another wind turbine at the other end of the test bench to conduct a dual-generator pair test.

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