Planetary reduction driven vertical axial mixed-flow pump system and civil engineering in-situ technical improvement method

Abstract

The invention relates to a planetary reduction driven vertical axial mixed-flow pump system and a civil engineering in-situ technical improvement method, and belongs to the technical field of water conservancy projects. Comprising a high-pressure high-speed asynchronous motor, a planetary gear reduction gearbox, a combined bearing box and a vertical shaft mixed-flow pump section which are arranged from top to bottom and are respectively mounted on a motor layer foundation and a water pump layer foundation through a motor base and a water pump base. A high-speed asynchronous motor is adopted to drive a water pump through speed reduction of a first-stage planetary gearbox, and automatic centering and torque transmission are achieved through involute spline connection; the planetary gear reduction box adopts four planetary gears which are symmetrically arranged and an inner gear ring one-step forming process, so that the bearing capacity and the operation stability are improved, and reasonable heat dissipation measures are set; and the combined bearing box bears axial and radial loads and is integrally arranged on the water outlet elbow. The problem of rigid binding of the vertical unit motor and the water pump rotating speed in the low-lift pump station is effectively solved, the water pump rotating speed is not limited by the large low-speed gear span of a standard motor, and the method is suitable for new construction or in-situ technical improvement of the pump station.

Description

Technical Field

[0001] This invention belongs to the field of water conservancy engineering technology, specifically relating to a planetary gear reducer-driven vertical shaft mixed-flow pump system and a method for in-situ technical modification of civil engineering structures. It is applicable to the upgrading and technical transformation of pumping units in newly built pumping stations or under conditions where the civil engineering structure of existing pumping stations remains unchanged. Background Technology

[0002] Large and medium-sized low-lift vertical axial mixed-flow pump units are used in vertical installation scenarios in water conservancy projects, and their operation requires both efficiency and cavitation performance. For units with a pump diameter of DN900 and above or a rated power of 300kW and above, they must typically operate at lower speeds due to nD value constraints. Existing technologies mainly suffer from the following problems: (1) The technical and economic efficiency of low-speed asynchronous motor solutions is insufficient. To meet the low-speed requirements of shaft mixed-flow pumps, low-speed asynchronous motors often suffer from problems such as low power factor, reduced efficiency, poor starting performance, large planar volume, and high cost. Although the slender, box-type high-efficiency asynchronous motors promoted in recent years have improved efficiency, their power factor is even lower than that of conventional asynchronous motors at low speeds. They often require large-capacity reactive power compensation devices, resulting in a higher total system cost and complexity than synchronous motor solutions, making it difficult to reflect the advantages of asynchronous motors in terms of simple structure and convenient maintenance.

[0003] (2) The engineering adaptability of the direct-coupled synchronous motor scheme is limited. The direct-coupled synchronous motor requires an excitation system, which has obvious shortcomings in terms of equipment size, cost, system complexity and installation and maintenance, and the engineering implementation and operation and maintenance costs are high.

[0004] (3) Low-speed gear dispersion leads to mismatch between the speed and the optimal point of the water pump. Due to the limitation of the number of pole pairs of the synchronous motor and the matching of electromagnetic performance, the synchronous speed series has a large gap in the low-speed range, such as directly jumping from below 300 r / min to 250 r / min, 214.3 r / min, 187.5 r / min, 150 r / min, etc. When directly driven, it is difficult to accurately match the optimal hydraulic operating speed of the water pump, which affects the overall efficiency and stable operation of the unit.

[0005] (4) Direct connection installation is prone to problems of exceeding height and limit. In engineering, asynchronous motors are mostly transported and installed as a whole. Due to the limited installation space of the coupling, direct connection to water pump usually requires a long motor shaft extension, which can easily cause problems such as the equipment exceeding height and limit during transportation and installation.

[0006] (5) Insufficient engineering implementation of gear reduction transmissions in vertical units. Although gear reduction transmissions are common in general mechanical fields, they are limited by the alignment accuracy of the vertical unit's shaft, the spatial arrangement of the unit (i.e., the fixed installation conditions of the gearbox), and the complexity of the force path. In particular, the heat dissipation problem of the gear meshing of the planetary gearbox in the closed-box primary transmission has led to a lack of mature gear reduction applications for vertical shaft mixed-flow pump units in the field of water conservancy engineering. This makes it difficult to effectively solve the pumping problems under low head and extremely low head (the head range can cover 0m) conditions. This has created a technical bias, with the perception that vertically installed gearboxes are completely unsuitable for large and medium-sized vertical shaft mixed-flow pump units.

[0007] In addition, when upgrading or expanding the capacity of existing pumping stations, there are usually practical difficulties such as large changes in civil engineering structure, long construction period and high investment cost. There is an urgent need for a unit renovation plan that can make the most of the original civil engineering and flow channel conditions.

[0008] In summary, there is an urgent need to propose a new planetary geared vertical shaft mixed-flow pump system that can meet the requirements of low-speed and high-efficiency operation of water pumps under low and extremely low head conditions, while also taking into account transportation and installation conditions. This system should fully leverage the advantages of asynchronous motors in terms of simple structure, low cost, and convenient maintenance, while ensuring key performance indicators such as power factor and efficiency. This would break through existing technical bottlenecks and improve the overall economy and reliability of the project. Summary of the Invention

[0009] The purpose of this invention is to address the shortcomings of the aforementioned background technology by providing a planetary gear reducer-driven vertical shaft mixed-flow pump system and a method for in-situ technical modification of civil engineering structures. The planetary gear reducer-driven vertical shaft mixed-flow pump system utilizes a high-speed asynchronous motor paired with a high-efficiency planetary gear reducer to drive the vertical shaft mixed-flow pump at low speeds. This solves the problem of rigid coupling between pump speed and motor speed in low-head and ultra-low-head pumping stations in water conservancy projects, leveraging the core advantages of high-speed asynchronous motors: simple structure, low cost, high power factor, high efficiency, and convenient maintenance. The system's capacity expansion and energy-saving modification method allows for capacity expansion by appropriately increasing the pump diameter and matching the pump speed, while retaining the main civil engineering structures such as the pump station's inlet and outlet water channels, pump foundation, motor floor slab, and foundation. This replaces and improves the performance of the original low-speed motor or synchronous motor direct-drive system.

[0010] The technical solution adopted in this invention is: a planetary gear reducer-driven vertical shaft mixed-flow pump system, comprising a vertical shaft mixed-flow pump section, a pump base, a 60° outlet bend, a combined bearing housing, a motor base, a planetary gear reducer, and an asynchronous motor. The inlet of the vertical shaft mixed-flow pump section is used to connect to the inlet channel. The pump base is installed on the pump foundation civil structure, with its bottom connected to the vertical shaft mixed-flow pump section and its top connected to the 60° outlet bend. The motor base is installed on the motor foundation civil structure, the asynchronous motor is installed on the motor base, and the planetary gear reducer is installed on... Inside the motor base; the sun gear at the high-speed input end of the planetary gear reducer is connected to the output shaft of the asynchronous motor, and the low-speed output end is used to output torque. One end of the water pump shaft is connected to the low-speed output end of the planetary gear reducer via an involute spline, and the other end passes through the outlet bend and is connected to the impeller of the vertical shaft mixed-flow pump section. The combined bearing housing is installed on the outlet bend to support the water pump shaft and bear its axial and radial loads. The asynchronous motor, planetary gear reducer, and vertical shaft mixed-flow pump section are arranged independently in layers through the motor base and the water pump base.

[0011] In the above technical solution, the system achieves full utilization of the original motor foundation mounting holes and space through the independent layered arrangement of the motor base and water pump base, and the compact vertical integrated design of the planetary gear reducer. It does not require large-scale reconstruction of the motor floor slab or concrete foundation, and is particularly suitable for unit technical transformation using the original civil engineering structure.

[0012] Preferably, a first deep groove ball bearing is arranged at the non-driving end of the asynchronous motor, and a single row cylindrical roller bearing is arranged at the shaft extension end of the asynchronous motor. Both the first deep groove ball bearing and the single row cylindrical roller bearing are lubricated with grease.

[0013] Preferably, the output end of the planetary gear reducer is equipped with a second deep groove ball bearing, lubricated with thin oil. The sun gear input shaft of the planetary gear reducer is machined with a second external spline, which is machined as a multi-tooth involute spline. Torque is transmitted through the spline sleeve connected to the first external spline at the motor shaft end. A push rod is provided between the sun gear and both ends of the water pump shaft. The push rod is designed with a rolling bearing connection and consists of two parts. One part contacts the sun gear and rotates at high speed; the other part contacts the planet carrier and water pump shaft and rotates at low speed, with rolling bearings to reduce wear. The above structure has automatic alignment and micro-axial compensation capabilities, reducing the installation alignment accuracy requirements and improving the adaptability and reliability of the system operation. The internal teeth of the planetary gear internal gear ring of the planetary gear reducer are formed in one cut using a broaching machine, which effectively ensures the product machining accuracy, eliminates the cumulative error of single-tooth machining in traditional processes, enhances the stability and tightness of the fit with the planetary gears and sun gear, helps to further reduce operating noise, and ensures the long-term stability of key components such as bearings. The output shaft of the planetary gear reducer is integrated with the planetary carrier, resulting in better strength and rigidity, and higher axial and radial load capacity. The inner bore of the output shaft of the planetary gear reducer is machined into an internal spline, which connects to the corresponding third external spline on the water pump shaft to transmit torque.

[0014] Preferably, the asynchronous motor is a 6-pole or 8-pole 10kV high-voltage asynchronous motor with a power range of 300kW~1600kW. The ends of the motor shaft and the water pump shaft are both machined with involute external splines. The output shaft of the motor shaft is connected to the high-speed input end of the planetary gear reducer through a first spline pair. The water pump shaft is connected to the low-speed output end of the planetary gear reducer through a second spline pair.

[0015] Preferably, the planetary gear reducer is a single-stage transmission type, with four planetary gears arranged radially symmetrically inside; the internal gear rings of the planetary gears in the planetary gear reducer are manufactured using a broaching machine forming process.

[0016] In the above technical solution, the planetary gear reducer adopts a layout of 4 planetary gears, which has the following advantages compared with the common design of 3 planetary gears: the 4 planetary gears are arranged radially symmetrically, which can effectively counteract the internal radial force and greatly improve the torque carrying capacity under the same size; at the same time, it makes the gear transmission efficiency higher, and the operating pulsation and noise are significantly reduced, which has a significant advantage in noise control compared with similar products.

[0017] Preferably, the planetary gear reducer is equipped with a water cooling coil and integrates a self-circulating lubrication and heat dissipation system, including heat-absorbing fins disposed inside the reducer, propulsion blades arranged on the planetary carrier, oil chamber cooling coil, and heat dissipation fins disposed outside the reducer.

[0018] In the above technical solution, the planetary gear reducer uses a cooling coil with water cooling, eliminating the need for a dedicated thin oil station cooling device. Optimized design of the reducer and housing support structure, appropriate increase of the heat absorption surface inside the reducer oil chamber and the heat dissipation surface outside the housing, arrangement of a certain number of heat absorption ribs, and the installation of propulsion blades on the planetary carrier that rotate with it, combined with the installed circulating oil pipes, allows the lubricating oil inside the reducer oil chamber to form a self-circulating channel, promptly exchanging heat generated by the reducer gears or bearings with the outside environment, effectively reducing the room temperature rise in the oil chamber.

[0019] Preferably, the combined bearing housing is equipped with spherical thrust roller bearings and spherical self-aligning roller bearings; the spherical self-aligning roller bearings are configured to withstand both radial loads and instantaneous reverse water thrust.

[0020] Preferably, the combined bearing housing further includes a cooling water tank surrounding the bearing body and a removable cover plate; the combined bearing housing adopts a split structure, and the bearing housing shell is disassembled along the split surface during disassembly; the bearing is installed in a bushing, and the bushing can be axially disassembled together with the bearing.

[0021] In the above technical solution, the cooling water tank and washable cover plate significantly improve maintenance convenience; the bearing is set in the bushing, and the bushing can be disassembled and installed together with the bearing, which effectively protects the pump shaft and simplifies the replacement process; the combined bearing housing is also equipped with a temperature monitoring and sealing structure; the spherical self-aligning roller bearing not only bears the radial force during normal operation, but also instantaneously bears the reverse water thrust, as a lifting protection measure, and is completely isolated from the water flow.

[0022] Preferably, both the combined bearing housing and the planetary gear reducer are equipped with temperature and vibration monitoring sensors, which communicate with the central control unit to realize real-time monitoring of the operating status and fault early warning, and support predictive maintenance.

[0023] Preferably, a combined bearing housing cylindrical support is welded onto the 60° water outlet bend, and the combined bearing housing cylindrical support is provided with a mating surface stop to facilitate the precise installation of the entire combined bearing housing component.

[0024] Preferably, the motor base is configured as a mounting plate structure that adapts to the existing motor foundation anchor bolt holes, or it is equipped with a transition pad for adaptation. This allows for direct utilization of the existing installation foundation, minimizing the amount of civil engineering work required.

[0025] A method for in-situ technical modification of a vertical shaft mixed-flow pump system based on the planetary reduction drive, used to update or expand the unit while retaining the original inlet and outlet water channels, pump foundation, and motor layer foundation of the pump station, includes the following steps: S1: Perform selection calculations for updating or upgrading units, and determine the pump impeller diameter, operating speed, transmission ratio of planetary gear reducer, and number of poles and power of asynchronous motor; S2: Remove the original drive motor and transmission components, and verify the elevation, plan layout and anchor bolt hole positions of the original water pump foundation and motor layer foundation to provide an installation benchmark for the new equipment. S3: Position the pump base on the existing pump foundation civil structure, connect the vertical shaft mixed flow pump section to the pump base from the bottom, and reserve the connection interface between the top and the 60° outlet bend. S4: Position the motor base on the existing motor foundation civil structure to fit the existing anchor bolt holes, or achieve fit by setting transition pads; install the planetary gear reducer inside the motor base, reserving connection positions for the asynchronous motor and water pump shaft; S5: Install and connect the main components; specifically: Install a 60° water outlet bend, on which a combined bearing housing cylindrical support is welded; A combined bearing housing is installed on the cylindrical support of the combined bearing housing. The water pump shaft passes through the outlet bend and the combined bearing housing from top to bottom. One end is connected to the impeller of the vertical shaft mixed flow pump section, and the other end is connected to the low-speed output end of the planetary gear reducer through the second spline pair. The asynchronous motor is mounted on the motor base, and the motor shaft is connected to the sun gear at the high-speed input end of the planetary gear reducer through the first spline pair. The cooling and lubrication systems of the planetary gear reducer are connected and adjusted. After completing the above assembly, check the connection and coaxiality of the motor shaft, planetary gear reducer and water pump shaft, confirm the direction of rotation and clearance, and conduct no-load and load test runs to make the asynchronous motor, planetary gear reducer and vertical shaft mixed flow pump section be arranged independently in layers through the motor base and water pump base, thereby completing the technical transformation.

[0026] Furthermore, in step S1, the operating speed of the water pump is reduced by selecting the transmission ratio of the planetary gear reducer, and the impeller diameter of the vertical shaft mixed flow pump section is increased to achieve unit capacity expansion, provided that the original inlet and outlet water flow channel boundary conditions are met. In step S5, the spherical thrust roller bearing and spherical self-aligning roller bearing in the combined bearing housing are configured to withstand axial water thrust and instantaneous reverse water thrust, and the thermal stability and operational reliability of the shaft system and gear transmission under capacity expansion conditions are ensured by the cooling water tank and the self-circulating lubrication and heat dissipation system of the planetary gear reducer.

[0027] Compared with the prior art, the beneficial effects of the present invention are: Overall, there are currently no deceleration schemes directly applied to vertical shaft mixed-flow pump units in water conservancy projects.

[0028] This invention employs an innovative design combining a high-speed asynchronous motor with a high-efficiency planetary gear reducer, successfully decoupling the rigid connection between pump speed and motor speed. By adjusting the gearbox transmission ratio, the pump speed is no longer limited by the large range of low-speed gears in standard motor series, allowing for more speed options and compatibility in the low-speed range. This invention can be applied in new pumping stations or in the technical upgrading of existing pumping units. Meanwhile, the shaft mounting connection method using multi-tooth spline connection has strong load-bearing capacity and can adapt to minor axial changes caused by thermal expansion and contraction or installation errors, avoiding the problem of ultra-high and over-limit transportation and installation caused by excessively long motor shaft extension. The planetary gear reducer innovatively adopts a layout of 4 planetary gears and a one-cut internal gear machining process, which not only greatly improves torque capacity and transmission smoothness, but also effectively reduces noise and vibration, extends the service life of the whole machine, and solves the reliability bottleneck in vertical high-power reduction transmission. This invention centrally arranges the combined bearing housing, pump shaft seal and 60° water outlet bend, eliminating the need for the water guide bearing and removing the difficulty of dry friction lubrication treatment of the water guide bearing. The pump shaft and motor shaft are flexibly connected by a planetary gear reducer. Compared with the traditional rigid connection scheme of pump shaft-intermediate shaft-motor shaft or direct connection scheme of pump shaft and motor shaft, it has the advantages of effectively isolating vibration and impact, compensating for installation alignment error and thermal expansion, protecting the motor from pump overload impact, and allowing greater axial and radial force isolation.

[0029] For the long shaft structure of vertical water pumps, the bearing arrangement of the rotating shaft system from top to bottom is more uniform. Multiple evenly distributed radial bearings significantly reduce the span, greatly improve shaft rigidity, and reduce deflection. This increases the critical speed and effectively suppresses vibration. The thrust bearing is placed closer to the impeller, reducing cantilever effect and better ensuring impeller clearance.

[0030] Especially for technical transformation projects, the system of this invention has significant advantages: it can utilize the existing water pump layer and motor layer foundation, and install the planetary gear reducer and high-voltage high-speed motor (asynchronous motor) by replacing the motor base mounting plate or adding an adapter plate; it eliminates the need for the water guide bearing and its lubrication system, simplifying the system structure and reducing the difficulty of transformation; the separate height of the high-speed motor and reducer is usually lower than the overall height of the original low-speed motor or synchronous motor with shaft, effectively solving the problem of ultra-high and over-limit transportation; while maintaining the flow channel performance and civil structure unchanged, the water pump speed can be optimized by adjusting the reduction ratio, thereby achieving the transformation goals of increasing capacity, improving efficiency, and saving energy.

[0031] This invention not only effectively overcomes many shortcomings of direct-drive synchronous motors, but also avoids the performance disadvantages of low-speed asynchronous motors. It demonstrates strong necessity and significant comprehensive benefits in reducing total project investment, optimizing equipment layout, and improving system reliability and operational economy. It is an important development direction for solving the existing technical bottlenecks in this field. Attached Figure Description

[0032] Figure 1 This is a cross-sectional schematic diagram of a planetary gear-driven vertical shaft mixed-flow pump system according to the present invention. Figure 2 This is a schematic diagram of the bearing arrangement of the unit's rotating shaft system according to the present invention; Figure 3 This is a schematic diagram showing the connection between the planetary gear reducer and the motor shaft and water pump shaft of the present invention; Figure 4 This is a schematic diagram of the heat dissipation configuration of the planetary gear reducer of the present invention; Figure 5 This is a schematic diagram of the centralized arrangement of the combined bearing housing, pump shaft seal, and 60° outlet bend of the present invention; Figure 6 This is a schematic diagram of a direct-drive synchronous motor for an existing vertical shaft mixed-flow pump unit; Figure 7 This is a schematic diagram of an existing vertical shaft mixed flow pump unit with an asynchronous motor directly connected.

[0033] In the diagram: 1-Asynchronous motor, 2-Planetary gear reducer (21-Low speed end of reducer, 22-High speed end of reducer), 3-Motor base, 4-Combined bearing housing, 5-Pump shaft seal, 6-60° outlet elbow, 7-Pump base, 8-Vertical shaft mixed flow pump section, 9-Motor shaft, 10-Pump shaft, 11-Impeller, 12-Guide vane, 13-First deep groove ball bearing, 14-Single row cylindrical roller bearing, 15-Second deep groove ball bearing, 16-Second external spline, 17-Spline 18-Planetary gear reducer output shaft, 19-Third external spline, 20-First external spline, 21-Spherical thrust roller bearing, 22-Spherical self-aligning roller bearing, 23-Combined bearing housing cylindrical support, 24-Cooling water tank, 25-Water guide bearing, 26-Sun gear, 27-Planetary carrier, 28-Internal gear ring, 29-Push rod, 30-Gear cover, 31-Cooling coil, 32-Thrust blade, 33-Circulating oil pipe, 34-Heat absorption fin, 35-Heat dissipation fin. Detailed Implementation

[0034] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that these descriptions are for the purpose of aiding understanding the present invention, but do not constitute a limitation thereof. Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0035] like Figures 1-2 As shown, this invention provides a planetary gear reducer-driven vertical shaft mixed-flow pump system, including a vertical shaft mixed-flow pump section 8, a pump base 7, a 60° outlet bend 6, a combined bearing housing 4, a motor base 3, a planetary gear reducer 2, and an asynchronous motor 1. The system is characterized in that: the inlet of the vertical shaft mixed-flow pump section 8 is used to connect to the water inlet channel; the pump base 7 is installed on the pump foundation civil structure, with its bottom connected to the vertical shaft mixed-flow pump section 8 and its top connected to the 60° outlet bend 6; the motor base 3 is installed on the motor foundation civil structure, the asynchronous motor 1 is installed on the motor base 3, and the planetary gear reducer 2 is installed on the motor base. Within 3; the high-speed input sun gear 26 of the planetary gear reducer 2 is connected to the output shaft of the asynchronous motor 1 via the motor shaft 9, and the low-speed output end is used to output torque. One end of the water pump shaft 10 is connected to the low-speed output end of the planetary gear reducer 2 via an involute spline, and the other end passes through the outlet bend 6 and is connected to the impeller 11 of the vertical shaft mixed flow pump section 8. The combined bearing housing 4 is installed on the outlet bend 6 to support the water pump shaft 10 and bear its axial and radial loads. The asynchronous motor 1, the planetary gear reducer 2, and the vertical shaft mixed flow pump section 8 are arranged independently in layers through the motor base 3 and the water pump base 7.

[0036] In technical transformation applications, the water pump base 7 and the water inlet channel are usually not changed. The motor base 3 can be customized according to the original motor foundation hole position. The 60° water outlet bend 6 is a non-civil engineering connection component that is customized to achieve installation without damaging the original civil engineering structure.

[0037] like Figure 2 As shown, a first deep groove ball bearing 13 is arranged at the non-driving end of the asynchronous motor 1, and a single row cylindrical roller bearing 14 is arranged at the shaft extension end of the asynchronous motor 1. Both the first deep groove ball bearing 13 and the single row cylindrical roller bearing 14 are lubricated with grease.

[0038] like Figure 3As shown, the output end of the planetary gear reducer 2 is equipped with a second deep groove ball bearing 15, which is lubricated with thin oil. The input shaft of the sun gear 26 of the planetary gear reducer is machined with a second external spline 16, which is machined as a multi-tooth involute spline. It is connected to the first end external spline 20 of the motor shaft 9 through a spline sleeve 17 to transmit torque. The first end external spline 20 is also machined as a multi-tooth involute spline. A push rod 29 is provided between the sun gear 26 and the two ends of the water pump shaft 10. The push rod 29 is designed with a rolling bearing connection and consists of two parts. One part contacts the sun gear 26 and rotates at high speed; the other part contacts the planetary carrier 27 and the water pump shaft 10 and rotates at low speed. The rolling bearing reduces wear. The above structure has automatic alignment and micro-axial compensation capabilities, reduces the installation alignment accuracy requirements, and improves the adaptability and reliability of the system operation.

[0039] like Figure 3 As shown, the internal teeth of the planetary gear internal ring 28 of the planetary gear reducer 2 are machined using a broaching machine in a single cut, effectively ensuring product machining accuracy, eliminating the cumulative error of single-tooth machining in traditional processes, enhancing the stability and tightness of the fit with the planetary gears and sun gear 26, helping to further reduce operating noise, and ensuring the long-term stability of key components such as bearings. The output shaft 18 of the planetary gear reducer is integrated with the planetary carrier 27, resulting in better strength and rigidity, and higher axial and radial load-bearing capacity. The inner hole of the output shaft 18 of the planetary gear reducer is machined into an internal spline, which connects to the corresponding third external spline 19 on the water pump shaft 10 to transmit torque. The third external spline 19 is machined into an involute external spline. It also includes a pump shaft seal 5, which is installed inside the 60° outlet bend 6.

[0040] like Figures 1-2 As shown, the water pump outlet diameter of the vertical shaft mixed flow pump section 8 is DN1400 or above. The water pump includes an impeller 11 and a guide vane body 12. A water guide bearing 25 is arranged inside the guide vane body 12. The water guide bearing 25 is a Sailong bearing and is lubricated by water.

[0041] like Figure 1 As shown, the asynchronous motor 1 is a 6-pole or 8-pole 10kV high-voltage asynchronous motor with a power range of 300kW~1600kW. It is installed as a whole and does not need to withstand additional axial water thrust. The ends of the motor shaft 9 and the water pump shaft 10 are both machined with involute external splines. The output shaft of the motor shaft 9 is connected to the high-speed input end of the planetary gear reducer 2 through a first spline pair; the water pump shaft 10 is connected to the low-speed output end of the planetary gear reducer 2 through a second spline pair.

[0042] In the above embodiments, the planetary gear reducer 2 is a single-stage transmission type, and its internal planetary gears are four in a radially symmetrical arrangement; the internal gear rings of the planetary gears of the planetary gear reducer 2 are manufactured by a broaching machine forming process.

[0043] like Figure 4 As shown, the planetary gear reducer 2 is equipped with a water-cooled coil 31 and integrates a self-circulating lubrication and heat dissipation system, including heat-absorbing fins 34 disposed inside the reducer, propulsion blades 32 arranged on the planetary carrier 27, an oil chamber cooling coil, and heat dissipation fins 35 disposed outside the reducer. The planetary gear reducer 2 is cooled by an oil chamber cooling coil, and the propulsion blades 32 arranged on the planetary carrier 27 drive the oil circuit of the oil chamber to circulate, combined with the heat-absorbing fins 34 inside the reducer and the heat dissipation fins 35 outside the reducer to assist in cooling. In the above embodiments, the planetary gear reducer 2 adopts a four-planet gear layout, which has the following advantages compared to the common three-planet gear design: the four planetary gears are radially symmetrically arranged, which can effectively counteract internal radial forces and significantly improve the torque-carrying capacity under the same size; at the same time, it makes the gear transmission efficiency higher, and significantly reduces operating pulsation and noise, showing a clear advantage in noise control compared to similar products. The planetary gear reducer 2 uses a cooling coil with water cooling, eliminating the need for a dedicated thin oil station oil cooling device. Figure 4 As shown, the optimized design of the support structure of the reducer and the housing, the appropriate increase of the heat absorption surface inside the reducer oil chamber and the heat dissipation surface outside the housing, the arrangement of a certain number of heat absorption ribs 34, and the installation of push-flow blades on the planetary carrier 27, which rotate together with the planetary carrier, combined with the set circulation oil pipe 33, enables the lubricating oil inside the reducer oil chamber to form a self-circulating channel, so as to exchange the heat generated by the reducer gears or bearings with the outside in a timely manner, effectively reducing the temperature rise of the oil chamber.

[0044] like Figure 5 As shown, the combined bearing housing 4 is equipped with a spherical thrust roller bearing 21 and a spherical self-aligning roller bearing 22; the spherical self-aligning roller bearing 22 is configured to withstand both radial loads and instantaneous reverse water thrust.

[0045] like Figure 5 As shown, the combined bearing housing 4 also includes a cooling water tank 24 surrounding the bearing body and a detachable cover plate; the combined bearing housing 4 adopts a split structure, and the bearing housing shell is disassembled along the split half when disassembling; the bearing is installed in the bushing, and the bushing can be axially disassembled together with the bearing.

[0046] like Figure 5 As shown, a combined bearing housing cylindrical support 23 is welded onto the 60° water outlet bend 6, and the combined bearing housing cylindrical support 23 is provided with a mating surface stop.

[0047] In the above embodiments, the motor base 3 is configured as a mounting plate structure that adapts to the existing motor foundation anchor bolt holes, or is provided with a transition pad for adaptation.

[0048] This invention also provides a method for in-situ technical modification of a vertical shaft mixed-flow pump system based on the planetary reduction drive, used to update or expand the unit while retaining the original inlet and outlet water channels, pump foundation, and motor layer foundation of the pump station, including the following steps: S1: Perform selection calculations for updating or upgrading the unit, and determine the diameter of the water pump impeller 11, the operating speed, the transmission ratio of the planetary gear reducer 2, and the number of poles and power of the asynchronous motor 1; S2: Remove the original drive motor and transmission components, and verify the elevation, plan layout and anchor bolt hole positions of the original water pump foundation and motor layer foundation to provide an installation benchmark for the new equipment. S3: Position the pump base 7 on the existing water pump foundation civil structure, connect the vertical shaft mixed flow pump section 8 to the pump base 7 from the bottom, and reserve the connection interface between the upper part and the 60° outlet bend 6. S4: Position the motor base 3 on the existing motor foundation civil structure to fit the existing anchor bolt holes, or achieve fit by setting a transition pad; install the planetary gear reducer 2 inside the motor base 3, and reserve the connection position with the asynchronous motor 1 and the water pump shaft 10. S5: Install and connect the main components; specifically: Install a 60° water outlet bend 6, on which a combined bearing housing cylindrical support 23 is welded; A combined bearing housing 4 is installed on the combined bearing housing cylindrical support 23; The water pump shaft 10 passes from top to bottom through the outlet elbow 6 and the combined bearing housing 4. One end is connected to the impeller 11 of the vertical shaft mixed flow pump section 8, and the other end is connected to the low-speed output end of the planetary gear reducer 2 through the second spline pair. The asynchronous motor 1 is mounted on the motor base 3, and the motor shaft 9 is connected to the sun gear 26 at the high-speed input end of the planetary gear reducer 2 through the first spline pair. The cooling and lubrication of planetary gear reducer 2 were connected and adjusted: After completing the above assembly, check the connection and coaxiality of the motor shaft 9, planetary gear reducer 2 and water pump shaft 10, confirm the direction of rotation and clearance, and conduct no-load and load test runs to make the asynchronous motor 1, planetary gear reducer 2 and vertical shaft mixed flow pump section 8 be arranged independently in layers through the motor base 3 and water pump base 7, thereby completing the technical transformation.

[0049] In the above technical solution, in step S1, the operating speed of the water pump is reduced by selecting the transmission ratio of the planetary gear reducer 2, and the diameter of the impeller 11 of the vertical shaft mixed flow pump section 8 is increased to achieve unit capacity expansion under the premise of meeting the original inlet and outlet water flow channel boundary conditions; in step S5, the spherical thrust roller bearing 21 and spherical self-aligning roller bearing 22 in the combined bearing housing 4 are configured to withstand axial water thrust and instantaneous reverse water thrust, and the thermal stability and operational reliability of the shaft system and gear transmission under capacity expansion conditions are ensured by the cooling water tank 24 and the self-circulating lubrication and heat dissipation system of the planetary gear reducer 2.

[0050] The present invention will now be described in comparison with embodiments thereof.

[0051] Example 1: As Figure 6 As shown, a vertical shaft mixed-flow pump unit, using an existing synchronous motor scheme with direct drive, includes a synchronous motor a1, upper frame bearing a2, lower frame bearing a3, motor shaft a4, pump shaft a5, and upper water guide bearing a6. The pump size is 1800mm, the impeller diameter is 1600mm, the pump speed is 250r / min, and the motor power is 1120kW. The motor selected is TL1120-24. An excitation system is also included. Using the scheme of this invention, a 6-pole high-efficiency asynchronous motor 1 is configured, with a planetary gear reducer transmission ratio of 4. The pump speed is 247r / min, and the motor efficiency can be increased from 93% to 94.5%, while the overall planar dimensions are reduced from 2680mm to 1400mm. The 6-pole high-voltage asynchronous motor saves approximately 40% in price compared to a 24-pole high-voltage synchronous motor, reduces the installation period by about one week, and eliminates the need for a single-unit excitation system, saving approximately 250,000 yuan. It is especially suitable for energy-saving retrofitting of synchronous motor direct drive systems. The original motor foundation can continue to be used after simple adaptation, and the amount of civil engineering modification is minimal.

[0052] Example 2: Figure 7As shown, a vertical shaft mixed-flow pump unit, using an existing asynchronous motor scheme with direct drive, includes a low-speed asynchronous motor b1, a transmission device component b2, a motor shaft b3, an intermediate transmission shaft b4, an upper water guide bearing b5, and a pump shaft b6. The pump size is 1400mm, the impeller diameter is 1200mm, the pump speed is 371r / min, and the motor power is 630kW. The motor selected is YL630-16. A capacitor compensation system is included. Using the scheme of this invention, a 6-pole high-efficiency asynchronous motor 1 is configured, with a planetary gear reducer transmission ratio of 2.67. The pump speed is 370r / min, the motor efficiency can be increased from 91% to 93%, the power factor from 0.73 to 0.86, and the frame size can be reduced by two sizes. The 6-pole high-voltage asynchronous motor saves approximately 30% in price compared to a 16-pole high-voltage asynchronous motor, and the improved power factor significantly reduces the investment and operating costs of the capacitor compensation system. This solution is particularly suitable for replacing and upgrading existing low-speed asynchronous motor systems. It utilizes the existing motor foundation, eliminates the intermediate drive shaft and upper water guide bearing, simplifies the system structure, and improves operational reliability.

[0053] Example 3: As Figure 7 As shown, a vertical shaft mixed-flow pump unit, using an existing asynchronous motor scheme with direct drive, includes a low-speed asynchronous motor b1, a transmission device component b2, a motor shaft b3, an intermediate transmission shaft b4, an upper water guide bearing b5, and a pump shaft b6. The pump size is 1400mm, the impeller diameter is 1200mm, the pump speed is 297r / min, and the motor power is 355kW. The motor selected is YL355-20. A capacitor compensation system is included. Using the scheme of this invention, a 6-pole high-efficiency asynchronous motor 1 is configured, with a planetary gear reducer transmission ratio of 3.33. The pump speed is 296r / min, the motor efficiency can be increased from 91% to 93.6%, the power factor from 0.65 to 0.86, and the frame size can be reduced by at least two sizes. The 6-pole high-voltage asynchronous motor saves approximately 35% in price compared to a 20-pole high-voltage asynchronous motor, and the improved power factor significantly reduces the investment and operating costs of the capacitor compensation system. After the renovation, the motor's planar dimensions were reduced, effectively solving the problem of insufficient space in the original motor floor pump room, and without requiring any changes to the pump section and flow channel civil structure.

[0054] The undescribed parts of this invention are the same as or implemented using existing technology. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications should also be considered within the scope of protection of this invention.

[0055] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Contents not described in detail in this specification belong to prior art known to those skilled in the art.

Claims

1. A planetary gear reducer driven vertical shaft mixed-flow pump system, comprising a vertical shaft mixed-flow pump section (8), a pump base (7), a 60° outlet bend (6), a combined bearing housing (4), a motor base (3), a planetary gear reducer (2), and an asynchronous motor (1), characterized in that: The inlet of the vertical shaft mixed-flow pump section (8) is used to connect to the water inlet channel. The pump base (7) is installed on the water pump foundation civil structure. The bottom of the pump base (7) is installed with the vertical shaft mixed-flow pump section (8), and the top is installed with the 60° outlet bend (6). The motor base (3) is installed on the motor layer foundation civil structure. The asynchronous motor (1) is installed on the motor base (3). The planetary gear reducer (2) is installed inside the motor base (3). The sun gear (26) at the high-speed input end of the planetary gear reducer (2) is connected to the output shaft of the asynchronous motor (1) through the motor shaft (9). The low-speed output end is used to output torque. One end of the water pump shaft (10) is connected to the low-speed output end of the planetary gear reducer (2) through an involute spline, and the other end passes through the water outlet bend (6) and is connected to the impeller (11) of the vertical shaft mixed flow pump section (8). The combined bearing housing (4) is installed on the water outlet bend (6) to support the water pump shaft (10) and bear its axial and radial loads. The asynchronous motor (1), the planetary gear reducer (2) and the vertical shaft mixed flow pump section (8) are arranged independently in layers through the motor base (3) and the water pump base (7).

2. The planetary gear reducer-driven vertical shaft mixed-flow pump system according to claim 1, characterized in that: The asynchronous motor (1) is a 10kV high-voltage asynchronous motor with 6 poles or 8 poles and a power range of 300kW~1600kW. The ends of the motor shaft (9) and the water pump shaft (10) are both machined as involute external splines. The output shaft of the motor shaft (9) is connected to the high-speed input end of the planetary gear reducer (2) through the first spline pair. The water pump shaft (10) is connected to the low-speed output end of the planetary gear reducer (2) through the second spline pair.

3. The planetary gear reducer-driven vertical shaft mixed-flow pump system according to claim 1, characterized in that: The planetary gear reducer (2) is a single-stage transmission type, with four planetary gears arranged radially symmetrically inside; the internal gear rings of the planetary gears in the planetary gear reducer (2) are manufactured by a broaching machine forming process.

4. The planetary geared vertical shaft mixed-flow pump system according to claim 1 or 3, characterized in that: The planetary gear reducer (2) is equipped with a water cooling coil (31) and integrates a self-circulating lubrication and heat dissipation system, including heat-absorbing ribs (34) set in the housing, push-flow blades (32) arranged on the planetary carrier (27), oil chamber cooling coil, and heat dissipation fins (35) set outside the housing.

5. The planetary gear reducer-driven vertical shaft mixed-flow pump system according to claim 1, characterized in that: The combined bearing housing (4) is equipped with a spherical thrust roller bearing (21) and a spherical self-aligning roller bearing (22); the spherical self-aligning roller bearing (22) is configured to withstand both radial loads and instantaneous reverse water thrust.

6. The planetary geared vertical shaft mixed-flow pump system according to claim 1 or 5, characterized in that: The combined bearing housing (4) also includes a cooling water tank (24) surrounding the bearing body and a detachable cover plate; the combined bearing housing (4) adopts a split structure, and the bearing housing shell is disassembled along the split surface during disassembly; the bearing is installed in the bushing, and the bushing can be axially disassembled together with the bearing.

7. The planetary gear reducer-driven vertical shaft mixed-flow pump system according to claim 1, characterized in that: The 60° water outlet bend (6) is welded with a combined bearing housing cylindrical support (23), and the combined bearing housing cylindrical support (23) is provided with a mating surface stop.

8. The planetary gear reducer-driven vertical shaft mixed-flow pump system according to claim 1, characterized in that: The motor base (3) is configured as a mounting plate structure that adapts to the existing motor foundation anchor bolt holes, or is provided with a transition pad for adaptation.

9. A method for in-situ technical modification of a vertical shaft mixed-flow pump system based on planetary reduction drive according to any one of claims 1-8, used for updating or expanding the capacity of the unit while retaining the original inlet and outlet water channels, pump foundation and motor layer foundation of the pump station, characterized in that, Includes the following steps: S1: Perform selection calculations for updating or upgrading the unit, and determine the diameter of the water pump impeller (11), the working speed, the transmission ratio of the planetary gear reducer (2), and the number of poles and power of the asynchronous motor (1); S2: Remove the original drive motor and transmission components, and verify the elevation, plan layout and anchor bolt hole positions of the original water pump foundation and motor layer foundation to provide an installation benchmark for the new equipment. S3: Position the pump base (7) on the existing water pump foundation civil structure, connect the vertical shaft mixed flow pump section (8) to the pump base (7) from the bottom, and reserve the connection interface between the upper part and the 60° outlet bend (6). S4: Position the motor base (3) on the existing motor foundation civil structure to fit the existing anchor bolt holes, or achieve fit by setting a transition pad; install the planetary gear reducer (2) inside the motor base (3) and reserve the connection position with the asynchronous motor (1) and the water pump shaft (10); S5: Install and connect the main components; specifically: Install a 60° water outlet bend (6), on which a combined bearing housing cylindrical support (23) is welded. A combined bearing housing (4) is installed on the combined bearing housing cylindrical support (23); The water pump shaft (10) passes from top to bottom through the outlet bend (6) and the combined bearing box (4), one end is connected to the impeller (11) of the vertical shaft mixed flow pump section (8), and the other end is connected to the low speed output end of the planetary gear reducer (2) through the second spline pair. The asynchronous motor (1) is mounted on the motor base (3), and the motor shaft (9) is connected to the sun gear (26) of the high-speed input end of the planetary gear reducer (2) through the first spline pair; The cooling and lubrication of the planetary gear reducer (2) were connected and adjusted: After completing the above assembly, check the connection and coaxiality of the motor shaft (9), planetary gear reducer (2) and water pump shaft (10), confirm the direction of rotation and clearance, and conduct no-load and load test runs so that the asynchronous motor (1), planetary gear reducer (2) and vertical shaft mixed flow pump section (8) can be arranged independently in layers through the motor base (3) and water pump base (7), thereby completing the technical transformation.

10. The method for in-situ technical modification of the civil engineering of the planetary reduction driven vertical shaft mixed flow pump system according to claim 9, characterized in that: In step S1, the working speed of the water pump is reduced by selecting the transmission ratio of the planetary gear reducer (2), and the diameter of the impeller (11) of the vertical shaft mixed flow pump section (8) is increased to achieve unit capacity expansion under the premise of meeting the original inlet and outlet water flow channel boundary conditions; in step S5, the spherical thrust roller bearing (21) and spherical self-aligning roller bearing (22) in the combined bearing housing (4) are configured to withstand axial water thrust and instantaneous reverse water thrust, and the thermal stability and operational reliability of the shaft system and gear transmission under capacity expansion conditions are ensured by the cooling water tank (24) and the self-circulating lubrication and heat dissipation system of the planetary gear reducer (2).

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