Intelligent fan high-speed shaft bearing seat and production method thereof

Abstract

The invention discloses an intelligent fan high-speed shaft bearing seat and a production method thereof, and belongs to the technical field of fan bearing seats. The device comprises an assembly sleeve, an outer edge is coaxially and fixedly arranged on the outer side of the assembly sleeve, an outer ring sleeve is coaxially and fixedly arranged on the outer side of the assembly sleeve, and the assembly sleeve is directly connected with a bearing in a matched mode and used for providing supporting force. The liquid cooling heat dissipation mechanism takes away heat conducted out when the bearing rotates at a high speed by inputting cooling liquid between the assembling sleeve and the outer ring sleeve, and an intelligent monitoring module is further arranged between the outer ring sleeve and the assembling sleeve in a matched mode. When the cooling device is used, cooling liquid enters the cooling tank through the liquid inlet, is in direct contact with the assembly sleeve, and then flows out to the heat dissipation pipeline through the liquid outlet. The temperature transmission contact in the liquid outlet monitors the temperature of backflow cooling liquid in real time, the system can improve the power of the cooling pump to accelerate flowing of the cooling liquid when the temperature is too high, and the heat guiding-out efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of wind turbine bearing housings, and in particular to a smart wind turbine high-speed shaft bearing housing and its manufacturing method. Background Technology

[0002] Fan bearings are components that support the rotation of the fan rotor. They are installed at both ends of the fan's main shaft to reduce rotational friction and withstand axial and radial loads. Fan bearing housings are fixed components that support the fan bearings. They are used to fix the outer ring of the bearing, ensuring that the inner ring rotates with the shaft while the outer ring remains stationary, maintaining consistent transmission direction and operational balance.

[0003] Due to their large mass, the impeller of a wind turbine generates a significant amount of heat in the bearing housing during high-speed rotation, due to both friction and load. Among existing technologies, air cooling is a commonly used heat dissipation method. It utilizes the airflow generated by the wind turbine's operation to deliver cool outside air to the bearing housing, reducing its temperature through heat exchange. Alternatively, an external water cooling system can be installed, with water pipes fixed to the outside of the wind turbine bearing housing, achieving cooling through heat transfer.

[0004] The shortcomings of the existing technical solutions are as follows: For large-mass fans, the bearing housing accumulates a large amount of heat during operation due to impeller drive and frictional load. Although air cooling is simple to operate, its heat dissipation efficiency is significantly insufficient under high heat loads, making it difficult to cool down quickly and effectively. While water cooling has better heat dissipation effect, the system is difficult to maintain, and the equipment purchase and installation costs are high. There are also risks such as water leakage in the later stages, which may affect the stable operation of the fan. Summary of the Invention

[0005] This invention provides a smart fan high-speed shaft bearing housing and its manufacturing method, which can solve the problems of low efficiency of air cooling and high cost of water cooling systems in the prior art.

[0006] A smart fan high-speed shaft bearing housing includes an assembly, an outer edge coaxially fixed to the outer side of the assembly, and an outer ring sleeve coaxially fixed to the outer side of the assembly. The assembly directly engages with the bearing to provide support. A liquid cooling mechanism is fitted between the outer ring sleeve and the assembly, which removes heat generated by the bearing during high-speed rotation by introducing coolant between the assembly and the outer ring sleeve. An intelligent monitoring module is also fitted between the outer ring sleeve and the assembly, which detects the support status of the assembly.

[0007] As a further aspect of the present invention: the liquid cooling heat dissipation mechanism includes a cooling groove formed on the inner side of the outer ring sleeve, the cooling groove is arranged around the assembly, and the coolant flows from the cooling groove around the assembly to remove the temperature on the assembly.

[0008] As a further aspect of the present invention: the intelligent monitoring module includes multiple sets of MEMS vibration sensors that are equidistantly fitted and fixed inside the outer ring sleeve. The MEMS vibration sensors are used to detect the vibration of the assembly and thus determine the operating status of the bearing.

[0009] As a further aspect of the present invention: an optical fiber strain sensor is embedded around the inner side of the assembly, and the optical fiber strain sensor is used to detect the micro-deformation of the side wall of the assembly under the high-speed operation of the bearing, thereby monitoring the state of the assembly during use.

[0010] As a further aspect of the present invention: the cooling tank is provided with an inlet at one end and an outlet at the other end, both of which are connected to the outside and are used to connect to a coolant delivery pipeline to deliver coolant.

[0011] As a further aspect of the present invention: a temperature sensor is provided inside the liquid outlet for real-time monitoring of temperature changes in the equipment.

[0012] As a further aspect of the present invention: the inlet and outlet are both located on the outside of the outer ring.

[0013] As a further aspect of the present invention: the mounting and the outer ring sleeve are each provided with a fixing pin hole on one side for fixing the bearing.

[0014] As a further aspect of the present invention, the assembly is made of carbon fiber reinforced composite material.

[0015] A method for producing a high-speed shaft bearing housing for an intelligent fan includes the following steps: S1. Pour the molten iron into a pre-made mold, and after cooling and solidification, obtain the bearing base blank and the outer ring blank. S2. Rough machining of the bearing base and outer ring blank is performed using a rough machining machine tool and cutting tool to form the inner hole, outer circle, and end face; S3. High-precision machine tools and cutting tools are used to finish the surface of the bearing housing so that the inner hole, outer circle, end face, etc. of the bearing housing meet the design requirements. Then, the fiber optic strain sensor distribution groove and sealing groove are cut on the outer side of the assembly. The fixing and fitting groove, cooling groove, liquid inlet and liquid outlet, and circuit slot hole are cut on the inner side of the outer ring. S4. The assembly and outer ring sleeve undergo normalizing, quenching and tempering heat treatment processes. S5. Install sealing components on the outside of the assembly, lay the wiring through the road groove hole, and electrically connect the interfaces of the MEMS vibration sensor and the fiber optic strain sensor. S6. Apply thermally conductive epoxy resin adhesive to the outside of the assembly, assemble the outer ring assembly onto the outside of the assembly, and fix the two ends by welding. After cooling, grind off the weld beads. S7. Test whether each circuit is normal through the groove hole, connect the pipeline in the inlet and outlet and test the sealing effect.

[0016] The beneficial effects of this invention are: 1. In use, the coolant enters the cooling tank through the inlet, directly contacting the assembly and fully absorbing the heat generated by the high-speed rotation of the bearing. It then flows out through the outlet to the heat dissipation pipes. A temperature sensor inside the outlet monitors the return coolant temperature in real time. If the temperature is too high, a signal is sent to the system, which increases the power of the cooling pump to accelerate coolant flow and enhance heat removal efficiency. This design, with its built-in cooling channel and flexible control of coolant flow rate, ensures more efficient and complete heat transfer, guaranteeing stable operation of the bearing within a suitable temperature environment.

[0017] 2. In use, multiple sets of MEMS vibration sensors are equidistantly fitted around the inner side of the outer ring, accurately sensing the vibration generated by the bearing's operation and converting the vibration signal into an electrical signal for real-time data visualization. When the bearing experiences abnormal vibration due to wear, the sensors can promptly capture changes in vibration frequency and amplitude and report the abnormal data, preventing minor issues from escalating into major losses. Simultaneously, the fiber optic strain sensor inside the assembly detects the bearing's minute deformation under high-speed operation, accurately measuring deformation based on fiber optic characteristics. Once deformation is detected, the assembly can be replaced promptly, effectively ensuring the stable operation of the entire wind turbine system. Attached Figure Description

[0018] Figure 1 This invention provides a schematic diagram of the overall structure of a high-speed shaft bearing housing for an intelligent fan. Figure 2 This invention provides a top view of a high-speed shaft bearing housing for an intelligent fan. Figure 3 This invention provides a schematic diagram of a cooling groove structure for a high-speed shaft bearing housing of an intelligent fan. Figure 4 This invention provides a schematic diagram of a fiber optic strain sensor structure for a high-speed shaft bearing housing of an intelligent wind turbine.

[0019] Explanation of reference numerals in the attached figures: 1. Outer edge; 2. Assembly; 201. Fiber optic strain sensor; 3. Outer ring; 301. Liquid inlet; 302. Liquid outlet; 303. Cooling tank; 304. MEMS vibration sensor; 305. Temperature sensor; 4. Fixing pin hole. Detailed Implementation

[0020] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0021] like Figures 1 to 4 As shown in the figure, an embodiment of the present invention provides a high-speed shaft bearing housing for an intelligent wind turbine, comprising an assembly 2 made of carbon fiber reinforced composite material. An outer edge 1 is coaxially fixed to the outside of the assembly 2, and the outer edge 1 and the assembly 2 together constitute the bearing base. An outer ring sleeve 3 is also coaxially fixed to the outside of the assembly 2, and the assembly 2 is directly connected to the bearing, the main function of which is to provide stable support for the bearing.

[0022] A liquid cooling mechanism is provided between the outer ring sleeve 3 and the mounting assembly 2. This liquid cooling mechanism removes the heat generated by the bearing during high-speed rotation by introducing coolant into the space between the mounting assembly 2 and the outer ring sleeve 3. Specifically, the liquid cooling mechanism includes a cooling groove 303 formed inside the outer ring sleeve 3, which surrounds the mounting assembly 2. When the coolant flows from the cooling groove 303 around the mounting assembly 2, it directly contacts the mounting assembly 2, effectively removing the temperature from it. One end of the cooling groove 303 has an inlet 301, and the other end has an outlet 302. Both outlets are connected to the outside for connecting to coolant delivery pipes to facilitate coolant delivery and input. The outlets of the inlet 301 and the outlet 302 are located outside the outer ring sleeve 3 for easy connection to external liquid delivery pipes. Furthermore, the cooling groove 303 can be circular or threaded, creating a circulating liquid path between the mounting assembly 2 and the outer ring sleeve 3, enhancing the heat dissipation effect.

[0023] Compared with external water cooling systems, this structure has a built-in cooling channel, and the coolant comes into direct contact with the device 2, which makes heat transfer more complete and efficient. At the same time, by controlling the flow rate of the coolant, the heat dissipation rate can be controlled, making it more flexible to use.

[0024] A temperature sensor 305 is installed inside the outlet 302. This component is used to monitor the temperature changes of the assembly 2 in real time. When the temperature sensor 305 detects that the temperature of the return coolant is too high, it sends a signal to the system. Upon receiving the signal, the system increases the power of the cooling pump, accelerates the flow rate of the coolant, and thus improves the efficiency of heat dissipation. The coolant is responsible for transferring heat to the heat dissipation pipes, which are immersed inside the water tank to prevent the coolant from being contaminated by the outside environment and to improve heat dissipation efficiency.

[0025] An intelligent monitoring module is also installed between the outer ring sleeve 3 and the assembly 2. This module is used to detect the support status of the assembly 2. The intelligent monitoring module includes multiple sets of MEMS vibration sensors 304 that are equidistantly fitted and fixed inside the outer ring sleeve 3. The MEMS vibration sensor 304 is a vibration measurement device based on microelectromechanical systems technology. It senses vibration through a micro-mechanical structure and converts the vibration signal into an electrical signal output. This sensor has the advantages of small size, light weight, low power consumption, and easy integration. It is mainly used to detect the vibration of the assembly 2, thereby determining the operating status of the bearing.

[0026] In practical applications, the MEMS vibration sensor 304 monitors the vibration frequency and exports real-time change data graphs via an external detection system connected to the wiring hole. Under normal circumstances, the vibration varies within a suitable regular frequency and amplitude. Abnormal vibration only occurs when bearing wear leads to operational abnormalities, causing the high-speed impeller of the wind turbine to vibrate abnormally during high-speed rotation. This vibration is difficult to detect initially through sound and structural observation alone. If this situation is ignored in the early stages, instability will gradually increase, causing greater losses. This method allows for timely determination of the bearing's condition, ensuring the impeller can operate normally.

[0027] During operation, the bearing vibrates in all directions, generating pressure on the assembly 2. The assembly 2 and outer ring 3 limit the bearing's movement, ensuring the normal operation of the high-speed impeller. However, due to the high-frequency vibration and directional forces generated by the high-speed impeller, prolonged use may cause deformation of the assembly 2, leading to a mismatch with the bearing and affecting its stability. This deformation can also cause abnormal bearing vibration over time. To prevent this, a fiber optic strain sensor 201 can be embedded around the inner side of the assembly 2. The fiber optic strain sensor 201 detects the micro-deformation of the sidewall of the assembly 2 under high-speed bearing operation, thus monitoring the condition of the assembly 2 during use. When the assembly 2 deforms, it can be replaced promptly, preventing further damage.

[0028] Both the mounting 2 and the outer ring sleeve 3 have fixing pin holes 4 on their corresponding sides. These fixing pin holes 4 are used to fix the bearing and ensure the stable operation of the bearing.

[0029] The aforementioned high-speed shaft bearing housing has undergone significant structural improvements, and its production process, compared to traditional methods, includes the following steps: First, the molten iron is poured into a pre-made mold. After cooling and solidification, a bearing base blank and an outer ring sleeve blank are obtained.

[0030] Next, the bearing base blank and the outer ring sleeve 3 blank are sent to the cutting workshop. Here, the bearing base and outer ring sleeve 3 blanks are rough-machined using roughing machine tools and cutting tools to form the basic shapes such as the inner hole, outer circle, and end face. Then, the surface of the bearing base is finished using high-precision machine tools and cutting tools to make the inner hole, outer circle, and end face of the bearing base meet the design requirements. Afterwards, the distribution groove and sealing groove of the fiber optic strain sensor 201 are cut on the outer side of the assembly 2, and the fixing and fitting groove, cooling groove 303, liquid inlet 301 and liquid outlet 302, and circuit slots are cut on the inner side of the outer ring sleeve 3.

[0031] Then, the finished assembly 2 and outer ring sleeve 3 are transported to the quenching furnace workshop for normalizing, quenching and tempering heat treatment processes to improve their mechanical properties and wear resistance.

[0032] Next, high-temperature seals are installed on the outside of assembly 2, and wiring is routed through the slots. The interfaces of the MEMS vibration sensor 304 and the fiber optic strain sensor 201 are electrically connected, ensuring the wiring connectors are evenly positioned for easy subsequent electrical connections. Thermally conductive epoxy resin is applied to the outside of assembly 2, and the outer ring 3 is assembled onto the outside of assembly 2, with both ends fixed by welding. After cooling, the weld beads are polished to smooth the surface. Finally, voltmeter contacts are inserted into the corresponding wiring slots to test the functionality of each circuit. Pipelines are connected to the inlet 301 and outlet 302 to check the sealing effect and ensure that the bearing housing will not leak during use.

[0033] Working Principle: During operation, coolant enters the cooling tank 303, located inside the outer ring 3 and surrounding the assembly 2, through the inlet 301. Since the cooling tank 303 is in direct contact with the assembly 2, the coolant flowing within it exchanges heat effectively with the assembly 2, efficiently removing the heat generated by the high-speed rotation of the bearing. After absorbing heat, the coolant flows out through the outlet 302 and enters the heat dissipation pipes.

[0034] A temperature sensor 305 installed inside the outlet 302 monitors the temperature of the return coolant in real time. When the return coolant temperature is detected to be too high, the temperature sensor 305 sends a signal to the system. Upon receiving the signal, the system automatically increases the power of the cooling pump, accelerating the flow rate of the coolant. The increased coolant flow rate enhances the heat removal capacity per unit time, thereby improving heat dissipation efficiency and enabling the temperature of assembly 2 to drop rapidly, ensuring the bearing operates within a suitable temperature environment.

[0035] Multiple MEMS vibration sensors 304 are equidistantly fitted and fixed inside the outer ring 3. When the bearing operates, it generates vibrations of different frequencies and amplitudes, which are transmitted to the assembly 2. The MEMS vibration sensors 304 convert the sensed vibration signals into electrical signals and export the change status data graph in real time through the detection system connected to the wiring hole.

[0036] Under normal circumstances, the vibrations generated by bearing operation will vary within a suitable regular frequency and amplitude. When bearing wear leads to abnormal operation, the high-speed rotation of the wind turbine impeller will cause abnormal vibrations in the bearing. These abnormal vibrations are difficult to detect in the early stages through sound and structural analysis, but the MEMS vibration sensor 304 can accurately capture changes in vibration frequency and amplitude and feed the abnormal data back to the detection system. By analyzing this data, the condition of the bearing can be determined in a timely manner, avoiding larger losses later due to overlooking small problems.

[0037] Due to the high-frequency vibration and directional force generated by the high-speed impeller, the mounting assembly 2 may deform after prolonged use, leading to mismatch with the bearing and affecting the bearing's stability. To avoid this, a fiber optic strain sensor 201 is embedded around the inner side of the mounting assembly 2.

[0038] When the bearing operates at high speed, assembly 2 will experience micro-deformation due to forces in various directions. The fiber optic strain sensor 201 can detect this micro-deformation of the sidewall of assembly 2. Its working principle is based on the optical properties of optical fibers. When assembly 2 deforms, it causes a change in the light transmission characteristics within the fiber. By detecting this change, the deformation of assembly 2 can be accurately measured. When deformation of assembly 2 is detected, it indicates that assembly 2 may no longer be able to provide stable support for the bearing. In this case, assembly 2 can be replaced promptly to prevent abnormal bearing vibration caused by deformation of assembly 2, thereby ensuring the stable operation of the entire fan system.

[0039] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A high-speed shaft bearing housing for an intelligent fan, comprising an assembly (2), wherein an outer edge (1) is coaxially fixedly disposed on the outer side of the assembly (2), characterized in that, An outer ring sleeve (3) is coaxially fixed on the outer side of the assembly (2). The assembly (2) is directly connected to the bearing to provide support force. A liquid cooling heat dissipation mechanism is provided between the outer ring sleeve (3) and the mounting assembly (2). The liquid cooling heat dissipation mechanism removes the heat generated by the bearing during high-speed rotation by inputting coolant between the mounting assembly (2) and the outer ring sleeve (3). An intelligent monitoring module is also provided between the outer ring sleeve (3) and the mounting assembly (2). The intelligent monitoring module is used to detect the support status of the mounting assembly (2).

2. The intelligent fan high-speed shaft bearing housing as described in claim 1, characterized in that, The liquid cooling heat dissipation mechanism includes a cooling tank (303) opened inside the outer ring (3). The cooling tank (303) is arranged around the assembly (2). Coolant flows from the cooling tank (303) around the assembly (2) to remove the temperature on the assembly (2).

3. The intelligent fan high-speed shaft bearing housing as described in claim 2, characterized in that, The intelligent monitoring module includes multiple sets of MEMS vibration sensors (304) that are equidistantly fitted and fixed inside the outer ring (3). The MEMS vibration sensors (304) are used to detect the vibration of the assembly (2) and thus determine the bearing operating status.

4. The intelligent fan high-speed shaft bearing housing as described in claim 3, characterized in that, The inner side of the assembly (2) is fitted with an optical fiber strain sensor (201). The optical fiber strain sensor (201) is used to detect the micro-deformation of the side wall of the assembly (2) under the high-speed operation of the bearing, thereby monitoring the state of the assembly (2) during use.

5. The intelligent fan high-speed shaft bearing housing as described in claim 4, characterized in that, The cooling tank (303) has an inlet (301) at one end and an outlet (302) at the other end. Both the inlet (301) and the outlet (302) are connected to the outside and are used to connect to the coolant delivery pipeline to deliver coolant.

6. The intelligent fan high-speed shaft bearing housing as described in claim 5, characterized in that, A temperature sensor (305) is provided inside the liquid outlet (302) for real-time monitoring of the temperature change of the equipment (2).

7. A high-speed shaft bearing housing for an intelligent fan as described in claim 6, characterized in that, The inlet (301) and outlet (302) are both located outside the outer ring (3).

8. The intelligent fan high-speed shaft bearing housing as described in claim 7, characterized in that, The mounting (2) and the outer ring (3) are each provided with a fixing pin hole (4) on one side for fixing the bearing.

9. A high-speed shaft bearing housing for an intelligent fan as described in claim 8, characterized in that, The assembly (2) is made of carbon fiber reinforced composite material.

10. A method for producing a high-speed shaft bearing housing for an intelligent fan as described in claim 8, characterized in that, Includes the following steps: S1. Pour the molten iron into a pre-made mold, and after cooling and solidification, obtain the bearing base blank and the outer ring sleeve (3) blank. S2. The bearing base and outer ring sleeve (3) blanks are rough machined using rough machining machine tools and cutting tools to form inner hole, outer circle and end face; S3. High-precision machine tools and cutting tools are used to finish the surface of the bearing housing so that the inner hole, outer circle, end face, etc. of the bearing housing meet the design requirements. Then, the distribution groove and sealing groove of the fiber strain sensor (201) are cut on the outside of the assembly (2). The fixing fitting groove, cooling groove (303), liquid inlet (301) and liquid outlet (302) of the MEMS vibration sensor (304) are cut on the inside of the outer ring (3). S4. Perform normalizing, quenching and tempering heat treatment processes on the assembly (2) and the outer ring sleeve (3); S5. Install a sealing element on the outside of the assembly (2), lay the line through the road groove hole, and electrically connect the interface of the MEMS vibration sensor (304) and the fiber optic strain sensor (201). S6. Apply thermally conductive epoxy resin adhesive to the outside of the assembly (2), assemble the outer ring (3) onto the outside of the assembly (2), fix the two ends by welding, and grind the weld beads after cooling. S7. Test whether each circuit is normal through the groove hole. Connect the pipeline in the liquid inlet (301) and liquid outlet (302) to test the sealing effect.

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