Freedom degree loading device adaptive to 25MW + level large megawatt fan transmission chain test bench and construction method
By designing a degree-of-freedom loading device adapted to the drive train of 25MW+ class large megawatt wind turbines, the problem of the inability to accurately simulate complex loads in existing technologies has been solved, realizing high-strength and high-precision drive train performance testing and meeting the simulation needs of the entire life cycle.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-03
AI Technical Summary
Existing technologies cannot provide a degree-of-freedom loading device for test benches that are compatible with the drive trains of 25MW+ class large megawatt wind turbines, and cannot accurately simulate complex loads, resulting in large errors in drive train performance testing.
A degree-of-freedom loading device was designed, comprising a U-shaped base and a wedge-shaped support. Combined with a vertical hydraulic cylinder anchor fixing component, a horizontal hydraulic cylinder through-position fixing component, and a transmission mechanism support fixing component, a stable loading system is formed through high-strength concrete and precise component welding to meet the requirements of 100MNm level bending moment output and 10MN level loading capacity.
It has enabled full life-cycle simulation testing of the drive train of 25MW+ large-megawatt wind turbines, providing stable and reliable support, reducing construction errors, and improving the reliability and accuracy of test data.
Smart Images
Figure CN121783546A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wind power generation, and in particular to a degree-of-freedom loading device and construction method adapted to a test bench for the transmission chain of a 25MW+ class wind turbine. Background Technology
[0002] Wind energy is a clean and pollution-free renewable energy source, and generating electricity using wind power is very environmentally friendly. Offshore wind power already accounts for a significant proportion of the total installed capacity of renewable energy. However, with the increasing demand for grid parity in the wind power industry and the growing problem of rising costs due to the expansion of development areas from nearshore to deep-sea areas, there is an urgent need to address these demands and issues through various measures and methods. Increasing the capacity of a single wind turbine is the most direct method.
[0003] The increase in wind turbine capacity directly leads to an increase in the swept area of the wind turbine blades. This increase in swept area, in turn, results in increased wind turbine load and load complexity. The equipment and mechanical components within the wind turbine drivetrain are larger and more complex. Simply relying on CAE software to simulate the entire lifecycle may introduce errors. Currently, there is an urgent need for a test bench capable of simulating the entire lifecycle of large-capacity drivetrains.
[0004] The degree-of-freedom loading device is the core and key equipment of the transmission chain test bench. It needs to output complex loads that match the actual working conditions in order to achieve accurate simulation testing of the transmission chain performance.
[0005] Therefore, there is a need to provide a degree-of-freedom loading device and construction method that can be adapted to the test bench of the transmission chain of 25MW+ class wind turbines. Summary of the Invention
[0006] The technical problem to be solved by this invention is: how to provide a degree-of-freedom loading device and construction method adapted to a test bench for the transmission chain of 25MW+ class wind turbines.
[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a degree-of-freedom loading device adapted to a 25MW+ class large megawatt wind turbine transmission chain test bench, characterized in that it includes a base, the base including a U-shaped base, a wedge-shaped support, and a pre-embedded fixing component, the wedge-shaped support being located in the middle of the U-shaped base, both the U-shaped base and the wedge-shaped support being made of high-strength concrete, the U-shaped base including a boss, the pre-embedded fixing component including a vertical hydraulic cylinder anchor bolt fixing component, a horizontal hydraulic cylinder through-position fixing component, and a transmission mechanism support fixing component, the vertical hydraulic cylinder anchor bolt fixing component being located on the boss, the horizontal hydraulic cylinder through-position fixing component being located on the upper part of the wedge-shaped support, and the transmission mechanism support fixing component being located in the middle of the wedge-shaped support.
[0008] Furthermore, the two protrusions of the U-shaped base are arranged in the front-rear direction, the height of the front protrusion is higher than the height of the rear protrusion, and the top of both protrusions is a horizontal bearing surface.
[0009] Furthermore, the side projection of the wedge-shaped support pier, from top to bottom, consists of a small rectangle, a right-angled trapezoid, and a large rectangle. The top edge of the right-angled trapezoid coincides with the bottom edge of the small rectangle, and the bottom edge of the right-angled trapezoid coincides with the top edge of the large rectangle. A rectangular doorway is provided at the bottom of the large rectangle. The frontal projection of the wedge-shaped support pier is U-shaped, with wedge-shaped structures on both sides and connected in the middle by a cuboid structure. An isosceles right-angled triangular notch is provided on the side of the wedge-shaped structure near the middle. The height of the cuboid structure is lower than that of the wedge-shaped structure. One side of the cuboid structure is aligned with the edge of the wedge-shaped structure, and the other side is aligned with the edge of the rectangular doorway.
[0010] Furthermore, each set of the vertical hydraulic cylinder anchor bolt fixing assembly consists of two rows of sleeves. Each row of sleeves is arranged in a mixed manner of type I and type II fixing sleeves. Adjacent sleeves in the same row are fixed together by a second connecting assembly and bolts, and the two rows of sleeves are fixed together by a first connecting assembly and bolts. The first connecting assembly consists of two L-shaped angle steels and a first rectangular steel plate. The two L-shaped angle steels are arranged in a 45-degree mirror image. Each end of the L-shaped angle steel has a hole. The L-shaped angle steels are welded to the first rectangular steel plate.
[0011] Furthermore, the type I fixing sleeve is composed of a rectangular steel pipe, a square steel block, and a square steel pipe welded together from top to bottom; a second rectangular steel plate is welded to one short side of the rectangular steel pipe, and a circular hole is opened at each of the upper and lower ends of the second rectangular steel plate; the lower part of the square steel pipe is sealed by a square sealing plate, and a first circular pipe is welded to the lower part of the square sealing plate, and the first circular pipe has two circular holes along its diameter at the middle of its height; the type I fixing sleeve also includes a second circular pipe and a circular steel plate, the second circular pipe is welded and fixed to the circular steel plate, the top of the second circular pipe has two circular holes along its diameter, the second circular pipe is connected to the first circular pipe by bolts, the circular steel plate has six circular holes, and the line connecting any two adjacent circular holes to the center of the circular plate forms a 60° angle; the square steel block is parallel to the two sides of the rectangular steel pipe, and a screw hole is opened at one end of one side, and the square steel block has a total of two screw holes.
[0012] Furthermore, the Type II fixing sleeve is composed of three rectangular steel pipes, three rectangular steel blocks, and three square steel pipes welded together from top to bottom; a second rectangular steel plate is welded to one short side of each of the two outermost rectangular steel pipes, and each second rectangular steel plate has a circular hole at both its top and bottom ends; an inverted first angle steel is welded between the three rectangular steel pipes, and the first angle steel is arranged on the short side of the rectangular steel pipe opposite to the rectangular steel plate; the lower part of the square steel pipe is sealed by a square sealing plate, and a first circular pipe is welded to the lower part of the square sealing plate, and the first circular pipe has two circular holes along its diameter at the middle of its height; the Type II fixing sleeve also includes a second circular pipe and a circular steel plate, the second circular pipe is welded and fixed to the circular steel plate, the top of the second circular pipe has two circular holes along its diameter, the second circular pipe is connected to the first circular pipe by bolts, and a screw hole is opened at each of the two longer sides of the rectangular steel block, for a total of four screw holes.
[0013] Furthermore, the horizontal hydraulic cylinder through-positioning and fixing assembly includes two identical external steel plates, two stabilizing steel plates, several positioning steel pipes, a connecting steel plate, a slender steel plate, and a supporting square steel plate. Both the external steel plates and the stabilizing steel plates have circular holes according to the number and position of the positioning steel pipes. The size of the circular holes is consistent with the outer diameter of the positioning steel pipes. The stabilizing steel plates have rectangular holes between each row of circular pipes. The two stabilizing steel plates are arranged in parallel and fixed together by welding with the connecting steel plate. The slender steel plate is welded to the opposite side of the connecting steel plate. The supporting square steel plate is welded below the connecting steel plate, the stabilizing steel plate, and the slender steel plate. The positioning steel pipes sequentially pass through one side of the external steel plate, the two stabilizing steel plates, and the other side of the external steel plate, and are fixed to all four steel plates by welding.
[0014] Furthermore, the transmission mechanism support and fixing assembly consists of a third rectangular steel plate and eight fixing anchor bars, all of which are welded to the bottom of the third rectangular steel plate; the top of the third rectangular steel plate has six bolt holes, which are arranged in two rows and close to the short edge of the third rectangular steel plate.
[0015] A construction method for a degree-of-freedom loading device adapted to a test bench for the transmission chain of a 25MW+ class wind turbine includes the following steps: S1. All components of the pre-embedded fixing assembly are processed in the steel structure processing plant, and all welding fixing parts are welded in the processing plant; S2. Reinforcing bars are tied to part of the bottom plate of the U-shaped base, and then concrete is poured. S3. After the concrete in step S2 has initially set, place each sleeve in the vertical hydraulic cylinder anchor bolt fixing assembly in the designated position, and use three expansion bolts to pass through three of the six holes in the circular steel plate to fix the sleeve. S4. Place the type I fixing sleeve and the type II fixing sleeve, and fix the first round tube and the second round tube together with bolts; S5. Install leveling bolts in the remaining three holes of the circular steel plate, and level the circular steel plate using the leveling bolts; S6. Weld the second angle steel, install the first connecting component and the second connecting component to form the complete vertical hydraulic cylinder anchor bolt fixing component; S7. Tie the remaining steel bars of the U-shaped base and the steel bars at the bottom of the wedge-shaped support, and use a mold to create two rectangular grooves on the top of the boss. S8. Pour the concrete to the bottom of the support plate of the horizontal hydraulic cylinder through the positioning and fixing assembly; S9. After the concrete in step S8 has initially set, install two sets of the horizontal hydraulic cylinder through-positioning and fixing components and fix them with expansion bolts. S10. Tie the remaining steel bars and install the transmission mechanism support and fixing assembly; S11. Complete the pouring of the remaining concrete; S12. Fix the sleeve in the reserved rectangular groove with expansion bolts, and fill the rectangular groove with high-strength grout.
[0016] Furthermore, during component processing in step S1, the dimensional deviation of each component of the type I fixed sleeve and the type II fixed sleeve is controlled within ±2mm, and the weld height at the weld joint is not less than 8mm.
[0017] The advantages of this invention are: it can be adapted to the test bench requirements of 25MW+ class large megawatt wind turbine drive train, and provides stable and reliable support for loading devices with 100MNm level bending moment output and 10MN level loading capacity, meeting the heavy load requirements of full life cycle simulation testing of large capacity wind turbine drive trains. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the present invention.
[0019] Figure 2 This is a schematic diagram showing the connection of two Type II fixed sleeves and one Type I fixed sleeve.
[0020] Figure 3 This is a schematic diagram of the vertical hydraulic cylinder anchor bolt fixing assembly.
[0021] Figure 4 This is a schematic diagram of a horizontal hydraulic cylinder through-positioning and fixing assembly.
[0022] Figure 5 A schematic diagram of the supporting and fixed components for the transmission mechanism.
[0023] Label Explanation: 1. U-shaped base; 11. Boss; 2. Wedge-shaped support; 21. Wedge-shaped structure; 22. Cuboid structure; 23. Rectangular doorway; 3. Vertical hydraulic cylinder anchor bolt fixing assembly; 31. I-shaped fixing sleeve; 311. Rectangular steel pipe; 312. Square steel block; 313. Square steel pipe; 314. Square sealing plate; 315. First circular pipe; 316. Second circular pipe; 317. Circular steel plate; 318. Second rectangular steel plate; 32. 1. Type II fixed sleeve; 321. First angle steel; 33. First connecting assembly; 331. L-shaped angle steel; 332. First rectangular steel plate; 34. Second connecting assembly; 4. Horizontal hydraulic cylinder through-positioning and fixing assembly; 41. Outer steel plate; 42. Stabilizing steel plate; 43. Positioning steel pipe; 44. Slender steel plate; 45. Square steel plate; 46. Connecting steel plate; 5. Transmission mechanism support and fixing assembly; 51. Third rectangular steel plate; 52. Fixed anchor bar. Detailed Implementation
[0024] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.
[0025] Please refer to Figures 1-5 A degree-of-freedom loading device adapted to a test bench for the transmission chain of a 25MW+ class wind turbine includes a base, which includes a U-shaped base 1, a wedge-shaped support 2, and pre-embedded fixing components. The wedge-shaped support 2 is located in the middle of the U-shaped base 1. Both the U-shaped base 1 and the wedge-shaped support 2 are made of high-strength concrete. The U-shaped base 1 includes a boss 11. The pre-embedded fixing components include a vertical hydraulic cylinder anchor bolt fixing component 3, a horizontal hydraulic cylinder through-position fixing component 4, and a transmission mechanism support fixing component 5. The vertical hydraulic cylinder anchor bolt fixing component 3 is located on the boss 11, the horizontal hydraulic cylinder through-position fixing component 4 is located on the upper part of the wedge-shaped support 2, and the transmission mechanism support fixing component 5 is located in the middle of the wedge-shaped support 2.
[0026] As described above, by setting up a U-shaped base, a wedge-shaped support, and pre-embedded fixing components to adapt to the requirements of the 25MW+ class large megawatt wind turbine drive train test bench, a stable and reliable support is provided for the loading device with a bending moment output of 100MNm and a loading capacity of 10MN, meeting the heavy load requirements of the full life cycle simulation test of large-capacity wind turbine drive trains.
[0027] Furthermore, the two protrusions 11 of the U-shaped base 1 are arranged in the front-rear direction, the height of the front protrusion 11 is higher than the height of the rear protrusion 11, and the top of both protrusions 11 are horizontal bearing surfaces.
[0028] As described above, by designing the height difference between the two protrusions 11 of the U-shaped base 1 and optimizing the horizontal bearing surface, the installation posture requirements of the vertical hydraulic cylinder anchor bolt fixing component 3 are accurately matched, the load transmission path is optimized, local stress concentration is avoided, and the overall bearing stability of the base is significantly improved.
[0029] Furthermore, the side projection of the wedge-shaped support 2, from top to bottom, consists of a small rectangle, a right trapezoid, and a large rectangle. The top edge of the right trapezoid coincides with the bottom edge of the small rectangle, and the bottom edge of the right trapezoid coincides with the top edge of the large rectangle. A rectangular doorway 23 is provided at the bottom of the large rectangle. The frontal projection of the wedge-shaped support 2 is U-shaped, with wedge-shaped structures 21 on both sides and connected in the middle by a cuboid structure 22. An isosceles right-angled triangular notch is provided on the side of the wedge-shaped structure 21 near the middle. The height of the cuboid structure 22 is lower than that of the wedge-shaped structure 21. One side of the cuboid structure 22 is aligned with the edge of the wedge-shaped structure 21, and the other side is aligned with the edge of the rectangular doorway 23.
[0030] As described above, the multi-segment side projection and concave frontal projection design of the wedge-shaped support pier 2, combined with the rectangular doorway 23, the isosceles right-angled triangular notch of the wedge-shaped structure 21, and the connection design of the cuboid structure 22, not only ensure the structural strength of the support pier itself, but also reserve sufficient space for internal steel reinforcement and equipment installation, while enhancing the load distribution capability, perfectly adapting to high load testing scenarios.
[0031] Furthermore, each set of vertical hydraulic cylinder anchor bolt fixing assembly 3 consists of two rows of sleeves. Each row of sleeves adopts a mixed arrangement of type I fixing sleeves 31 and type II fixing sleeves 32. Adjacent sleeves in the same row are fixed together by a second connecting assembly 34 and bolts, and the two rows of sleeves are fixed together by a first connecting assembly 33 and bolts. The first connecting assembly 33 consists of two L-shaped angle steels 331 and a first rectangular steel plate 332. The two L-shaped angle steels 331 are arranged in a 45-degree mirror image. Each end of the L-shaped angle steel 331 has a hole. The L-shaped angle steel 331 and the first rectangular steel plate 332 are connected by welding.
[0032] As described above, by combining the type I fixing sleeve 31 and type II fixing sleeve 32, and coordinating the first connecting component 33 and the second connecting component 34, a modular and splicable vertical hydraulic cylinder anchor bolt fixing component 3 is formed, which not only improves the vertical bearing strength, but also has flexible installation characteristics and can be adapted to different test load requirements. Furthermore, the type I fixed sleeve 31 is composed of a rectangular steel pipe 311, a square steel block 312, and a square steel pipe 313 welded together from top to bottom; a second rectangular steel plate 318 is welded to one short side of the rectangular steel pipe 311, and a round hole is opened at each of the upper and lower ends of the second rectangular steel plate 318; the lower part of the square steel pipe 313 is sealed by a square sealing plate 314, and a first round pipe 315 is welded to the lower part of the square sealing plate 314, and the first round pipe 315 has two round holes along its diameter at the middle of its height; the type I fixed sleeve 31... The fixed sleeve 31 also includes a second circular tube 316 and a circular steel plate 317. The second circular tube 316 and the circular steel plate 317 are welded and fixed. The top of the second circular tube 316 has two circular holes along the diameter of the circle. The second circular tube 316 is connected to the first circular tube 315 by bolts. The circular steel plate 317 has six circular holes. The line connecting the center of any two adjacent circular holes to the center of the circular plate forms a 60° angle. The square steel block 312 is parallel to the two sides of the rectangular steel tube 311. A screw hole is opened at one end of one side. The square steel block 312 has a total of two screw holes.
[0033] As described above, the layered welding structure of the type I fixed sleeve 31, combined with the precise connection of the first round tube 315, the second round tube 316 and the round steel plate 317, achieves stable support and fine leveling of the sleeve; the six-hole 60° distribution design of the round steel plate 317 ensures the accuracy of the installation level and effectively improves the reliability of the test data.
[0034] Furthermore, the Type II fixed sleeve 32 is composed of three rectangular steel pipes 311, three rectangular steel blocks, and three square steel pipes 313 welded together from top to bottom; a second rectangular steel plate 318 is welded to one short side of each of the two outermost rectangular steel pipes 311, and each second rectangular steel plate 318 has a round hole at both its upper and lower ends; an inverted first angle steel 321 is welded between the three rectangular steel pipes 311, and the first angle steel 321 is arranged on the short side of the rectangular steel pipe 311 opposite to the rectangular steel plate; the lower part of the square steel pipe 313 passes through a square... The square sealing plate 314 is sealed and welded. The lower part of the square sealing plate 314 is welded with a first round tube 315. The first round tube 315 has two round holes along the diameter at the middle of its height. The type II fixing sleeve 32 also includes a second round tube 316 and a round steel plate 317. The second round tube 316 is welded and fixed to the round steel plate 317. The top of the second round tube 316 has two round holes along the diameter. The second round tube 316 is connected to the first round tube 315 by bolts. A screw hole is opened at each end of the two longer sides of the rectangular steel block. The rectangular steel block has a total of four screw holes.
[0035] As described above, the parallel design of the three rectangular steel pipes 311 of the Type II fixed sleeve 32 and the reinforcement connection of the first angle steel 321 enhance the overall rigidity and deformation resistance of the sleeve; the multi-bolt hole layout of the rectangular steel block and the adaptable connection with other components further improve the stability of the multi-sleeve collaborative load bearing and adapt to higher load transmission requirements.
[0036] Furthermore, the horizontal hydraulic cylinder through-positioning and fixing assembly 4 includes two identical external steel plates 41, two stabilizing steel plates 42, several positioning steel pipes 43, connecting steel plates 46, slender steel plates 44, and supporting square steel plates 45. The external steel plates 41 and stabilizing steel plates 42 are provided with round holes according to the number and position of the positioning steel pipes 43. The size of the round holes is consistent with the outer diameter of the positioning steel pipes 43. The stabilizing steel plates 42 are provided with rectangular holes between each row of round pipes. The two stabilizing steel plates 42 are arranged in parallel and fixed by welding with the connecting steel plates 46. The slender steel plates 44 are welded to the opposite side of the connecting steel plates 46. The supporting square steel plates 45 are welded below the connecting steel plates 46, stabilizing steel plates 42, and slender steel plates 44. The positioning steel pipes 43 pass through one side of the external steel plate 41, the two stabilizing steel plates 42, and the other side of the external steel plate 41 in sequence, and are fixed to all four steel plates by welding.
[0037] As described above, a robust through-and-through pressure-bearing system is formed by welding multiple components, including the external steel plate 41, stabilizing steel plate 42, positioning steel pipe 43, and connecting steel plate 46, through the horizontal hydraulic cylinder to the positioning and fixing assembly 4. The rectangular hole design of the stabilizing steel plate 42 takes into account both weight reduction and clearance functions, supports the synergistic effect of the square steel plate 45 and the slender steel plate 44, ensures the stable transmission of horizontal loading force, and avoids structural displacement during loading.
[0038] Furthermore, the transmission mechanism support and fixing component 5 consists of a third rectangular steel plate 51 and eight fixing anchor bars 52. The fixing anchor bars 52 are all welded to the bottom of the third rectangular steel plate 51. The top of the third rectangular steel plate 51 has six bolt holes, which are arranged in two rows and close to the short edge of the third rectangular steel plate 51.
[0039] As described above, the welded fixing structure of the third rectangular steel plate 51 supporting the fixed component 5 and the eight fixed anchor bars 52 enhances the connection between the component and the wedge-shaped support pier 2; the six-hole arrangement design of the third rectangular steel plate 51 enables precise positioning and installation of the transmission mechanism, ensuring the transmission stability during the transmission chain test.
[0040] A construction method for a degree-of-freedom loading device adapted to a test bench for the transmission chain of a 25MW+ class wind turbine includes the following steps: S1. All components for pre-embedded fixing parts are processed in the steel structure processing plant, and all welding fixing parts are welded in the processing plant. S2. Reinforcing steel bars are tied to part of the bottom plate of the U-shaped base 1, and then concrete is poured. S3. After the concrete in step S2 has initially set, place the welded parts consisting of the second round pipe 316 of each sleeve and the round steel plate 317 in the vertical hydraulic cylinder anchor bolt fixing assembly 3 at the designated position, and fix the round steel plate 317 by passing three expansion bolts through three of the six holes in the round steel plate 317. S4. Place type I fixing sleeve 31 and type II fixing sleeve 32, and fix the first round tube 315 and the second round tube 316 by bolts. S5. Install leveling bolts in the remaining three holes of the circular steel plate 317, and level the circular steel plate 317 using the leveling bolts. S6. Weld L-shaped angle steel 331, install the first connecting component 33 and the second connecting component 34 to form a complete vertical hydraulic cylinder anchor bolt fixing component 3; S7. The remaining steel bars of the U-shaped base and the steel bars at the bottom of the wedge-shaped support 2 are tied together. Two rectangular grooves are separated on the top of the boss 11 using a mold. S8. Pour concrete until the bottom of the support plate of the horizontal hydraulic cylinder through the positioning and fixing component 4 is reached; S9. After the concrete in step S8 has initially set, install two sets of horizontal hydraulic cylinder through-positioning and fixing components 4 and fix them with expansion bolts. S10. Tie the remaining steel bars and install the transmission mechanism support and fixing component 5; S11. Complete the pouring of the remaining concrete; S12. Fix the sleeve in the reserved rectangular groove with expansion bolts, and fill the rectangular groove with high-strength grout.
[0041] As described above, this method enables the precise construction of a degree-of-freedom loading device adapted to a 25MW+ level large-megawatt wind turbine transmission chain test bench. Specifically, by prefabricating and precisely positioning the welded component consisting of the second circular pipe 316 and the circular steel plate 317 of the vertical hydraulic cylinder anchor bolt fixing assembly 3, and coordinating the bolt connection between the first circular pipe 315 and the second circular pipe 316, as well as the leveling operation of the leveling bolts, the installation accuracy of the type I fixing sleeve 31 and type II fixing sleeve 32 is ensured. Furthermore, the welding and fixing of the first connecting assembly 33, the second connecting assembly 34, and the L-shaped angle steel 331 forms a stable vertical bearing system. Simultaneously, the step-by-step installation of the wedge-shaped support pier 2, the horizontal hydraulic cylinder through-positioning fixing assembly 4, and the transmission mechanism support fixing assembly 5, along with layered concrete pouring, reduces on-site construction errors and minimizes the impact of concrete hydration heat on the structure. Ultimately, this ensures the structural strength and installation stability of the entire loading device, enabling it to adapt to bending moment outputs of 100MNm and 10MNm. The requirement to use the level loading capability.
[0042] Furthermore, during the processing of the components in step S1, the dimensional deviation of each component of the type I fixed sleeve 31 and the type II fixed sleeve 32 is controlled within ±2mm, and the weld height at the welding point is not less than 8mm. As described above, step S1 explicitly limits the dimensional deviation of each component of the Type I fixed sleeve 31 and the Type II fixed sleeve 32 to within ±2mm, ensuring the assembly accuracy of each component of the sleeve and avoiding connection gaps or uneven force caused by dimensional errors.
[0043] Please refer to Figures 1-2 Embodiment 1 of the present invention is as follows: The core load-bearing structure of this device is the base, which is integrally cast from a U-shaped base 1 and a wedge-shaped support 2. Both are made of C80 high-strength concrete to ensure the overall load-bearing strength. The wedge-shaped support 2 is centrally located in the middle of the U-shaped base 1, forming a stable integrated force-bearing system with the U-shaped base 1. The U-shaped base 1 is symmetrically provided with two protrusions 11, arranged in the front-rear direction. The design height of the front protrusion 11 is 1.8m, and the design height of the rear protrusion 11 is 1.5m. The tops of both protrusions 11 are mechanically ground to form a horizontal load-bearing surface.
[0044] The side projection of the wedge-shaped support pier 2, from top to bottom, consists of a small rectangle, a right-angled trapezoid, and a large rectangle: the small rectangle has a height of 0.5m and a width of 1.2m; the top edge of the right-angled trapezoid coincides perfectly with the bottom edge of the small rectangle; the bottom edge of the right-angled trapezoid is 2.0m long and 1.2m high; the large rectangle has a height of 2.0m and a width consistent with the bottom edge of the right-angled trapezoid; and a rectangular opening 23, 3.0m long and 1.5m wide, is provided at the bottom of the large rectangle to distribute the bottom bearing stress; The frontal projection of the wedge-shaped support 2 is concave, with symmetrical wedge-shaped structures 21 on both sides and rigidly connected in the middle by a cuboid structure 22. The wedge-shaped structure 21 has an isosceles right-angled triangular notch with a right-angled side length of 0.3m on the side closest to the middle. The height of the cuboid structure 22 is 1.8m, which is 0.4m lower than the wedge-shaped structures 21 on both sides. One side of it is flush with the outer edge of the wedge-shaped structure 21, and the other side is flush with the inner edge of the rectangular doorway 23, forming a balanced force transmission path.
[0045] The pre-embedded fixing components include two sets of vertical hydraulic cylinder anchor bolt fixing components 3, two sets of horizontal hydraulic cylinder through-position fixing components 4, and one set of transmission mechanism support fixing components 5. Each component is precisely arranged according to the preset position: the two sets of vertical hydraulic cylinder anchor bolt fixing components 3 are respectively installed on the two protrusions 11, the two sets of horizontal hydraulic cylinder through-position fixing components 4 are symmetrically arranged on the upper two sides of the wedge-shaped support 2, and the transmission mechanism support fixing components 5 are fixed in the middle of the cuboid structure 22 in the middle of the wedge-shaped support 2.
[0046] Each set of vertical hydraulic cylinder anchor bolt fixing assembly 3 consists of two rows of sleeves, with 3 sleeves in each row. Type I fixing sleeves 31 and Type II fixing sleeves 32 are arranged alternately. Adjacent sleeves in the same row are fixed together by a second connecting assembly 34 and M16 high-strength bolts. The two rows of sleeves are fixed together by a first connecting assembly 33 and M16 high-strength bolts. The first connecting assembly 33 consists of two L-shaped angle steels 331 with a specification of L100×8 and a first rectangular steel plate 332 with a specification of 200×100×10mm. The two L-shaped angle steels 331 are arranged in a 45-degree mirror image. Each end of the angle steel has a hole with a diameter of 18mm. The angle steel and the first rectangular steel plate 332 are fixed by full welding with a weld height of 8mm. The second connecting assembly 34 is a rectangular steel plate with a specification of 150×30×5mm. Each end of the steel plate has an elongated hole with a length of 20mm and a width of 10mm for adjusting installation deviation.
[0047] The type I fixed sleeve 31 is composed of a rectangular steel pipe 311, a square steel block 312, and a square steel pipe 313, which are fully welded together from top to bottom. The rectangular steel pipe 311 has dimensions of 150×100×8mm, the square steel block 312 has dimensions of 100×100×50mm, and the square steel pipe 313 has dimensions of 100×100×8mm. A second rectangular steel plate 318 with dimensions of 120×80×8mm is welded to one short side of the rectangular steel pipe 311. The second rectangular steel plate 318 has a circular hole with a diameter of 16mm at both the top and bottom ends for auxiliary positioning. The lower part of the square steel pipe 313 is fully sealed by a square sealing plate 314 with dimensions of 120×120×10mm. A first circular pipe 315 with dimensions of φ80×6mm is welded to the lower part of the square sealing plate 314. The first circular tube 315 has two 16mm diameter holes at the midpoint of its height along its diameter. The I-type fixing sleeve 31 also includes a second circular tube 316 and a circular steel plate 317. The second circular tube 316 has the same specifications as the first circular tube 315 and is fully welded to the circular steel plate 317 with a diameter of 200mm and a thickness of 12mm. The top of the second circular tube 316 has two matching holes along its diameter, and the two are fixedly connected by M16 bolts. The circular steel plate 317 has six 16mm diameter holes, and the line connecting the center of any two adjacent holes to the center of the plate forms a 60° angle, which is used for supporting the fixing and leveling of the components. The square steel block 312 is parallel to the two sides of the rectangular steel tube 311, and has an M12 screw hole at one end, for a total of two screw holes, for auxiliary fixing.
[0048] The type II fixed sleeve 32 is composed of three rectangular steel pipes 311 with specifications of 150×100×8mm, three rectangular steel blocks of 150×100×50mm, and three square steel pipes 313 of 100×100×8mm, which are fully welded from top to bottom. A second rectangular steel plate 318 of 120×80×8mm is welded to the short side of each of the two outermost rectangular steel pipes 311. Each second rectangular steel plate 318 has a 16mm diameter hole at both its top and bottom ends. An inverted first angle steel 321 of L80×6 is welded between the three rectangular steel pipes 311. The first angle steel 321 is positioned on the opposite side of the rectangular steel blocks. On the short side of pipe 311, a structure is used to enhance the connection rigidity of the three steel pipes; the lower part of the square steel pipe 313 is fully sealed by a 120×120×10mm square sealing plate 314, and a φ80×6mm first round pipe 315 is welded to the lower part of the square sealing plate 314. The first round pipe 315 has two 16mm diameter round holes at the middle of its height along its diameter; the second round pipe 316 and the round steel plate 317 of the type II fixing sleeve 32 have the same structure as the type I fixing sleeve 31 and are fixedly connected to the first round pipe 315 by M16 bolts; the two longer sides of the rectangular steel block each have an M12 screw hole at one end, for a total of four screw holes, for multi-directional fixing.
[0049] The horizontal hydraulic cylinder through-and-position fixing assembly 4 includes two identical 300×200×12mm outer steel plates 41, two 280×180×10mm stabilizing steel plates 42, four φ60×5mm positioning steel pipes 43, a 250×80×8mm connecting steel plate 46, a 200×20×5mm slender steel plate 44, and a 200×200×10mm supporting square steel plate 45. Both the outer steel plates 41 and the stabilizing steel plates 42 have 60mm diameter circular holes according to the number and position of the positioning steel pipes 43. The stabilizing steel plates 42 have 50mm long holes between each row of circular pipes. A rectangular hole with a diameter of m and a width of 20mm is used for weight reduction and to avoid reinforcing bars; two stabilizing steel plates 42 are arranged in parallel and are fixed by a connecting steel plate 46 by full welding. A slender steel plate 44 is welded to the opposite side of the connecting steel plate 46 to form a reinforcing rib structure; a supporting square steel plate 45 is fully welded to the bottom of the connecting steel plate 46, the stabilizing steel plate 42 and the slender steel plate 44 to provide bottom support; a positioning steel pipe 43 passes through one side of the outer steel plate 41, the two stabilizing steel plates 42 and the other side of the outer steel plate 41 in sequence, and is fixed to all four steel plates by full welding. The weld height is not less than 8mm, forming a stable through-load-bearing structure.
[0050] The transmission mechanism support and fixing component 5 consists of a third rectangular steel plate 51 with a diameter of 400×300×16mm and eight fixing anchor bars 52 with a diameter of 25mm and a length of 800mm. The fixing anchor bars 52 are all vertically and fully welded to the bottom of the third rectangular steel plate 51, and the welding length is not less than 100mm. The top of the third rectangular steel plate 51 has six bolt holes with a diameter of 20mm. The six bolt holes are evenly arranged in two rows, with three bolt holes in each row. The center of the holes is 30mm away from the short edge of the third rectangular steel plate 51, which is used for precise fixing of the transmission mechanism.
[0051] The construction method of the device in this embodiment is as follows: First, all components of the pre-embedded fixing components are processed in the steel structure processing plant to ensure that the dimensional deviation of each component of the type I fixing sleeve 31 and type II fixing sleeve 32 is controlled within ±2mm, and the weld height of all welded joints is not less than 8mm; then, the bottom plate of the concave base 1 is reinforced and concrete is poured. After initial setting, the support component of the vertical hydraulic cylinder anchor bolt fixing component 3 is fixed, the type I fixing sleeve 31 and type II fixing sleeve 32 are placed, and the first round pipe 315 and the second round pipe 316 are connected by bolts. The horizontal deviation of the sleeve is controlled within 0.5mm / m by using leveling bolts; then, the second angle steel is welded, the first connecting component 33 and the second connecting component 34 are installed, the remaining reinforcing bars are tied, and the horizontal hydraulic cylinder through-position fixing component 4 and the transmission mechanism support fixing component 5 are installed. The concrete pouring is completed in layers; finally, the sleeve is fixed in the reserved rectangular groove by expansion bolts, C80 high-strength grout is filled into the groove and cured for no less than 7 days.
[0052] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.
Claims
1. A degree-of-freedom loading device adapted to a test bench for the transmission chain of a 25MW+ class wind turbine, characterized in that, The system includes a base, which comprises a U-shaped base, a wedge-shaped support, and pre-embedded fixing components. The wedge-shaped support is located in the middle of the U-shaped base. Both the U-shaped base and the wedge-shaped support are made of high-strength concrete. The U-shaped base includes a boss. The pre-embedded fixing components include a vertical hydraulic cylinder anchor bolt fixing component, a horizontal hydraulic cylinder through-positioning fixing component, and a transmission mechanism support fixing component. The vertical hydraulic cylinder anchor bolt fixing component is located on the boss. The horizontal hydraulic cylinder through-positioning fixing component is located on the upper part of the wedge-shaped support. The transmission mechanism support fixing component is located in the middle of the wedge-shaped support.
2. The degree-of-freedom loading device according to claim 1, characterized in that, The two protrusions of the U-shaped base are arranged in the front-rear direction, with the height of the front protrusion being higher than that of the rear protrusion, and the tops of both protrusions being horizontal bearing surfaces.
3. The degree-of-freedom loading device according to claim 1, characterized in that, The side projection of the wedge-shaped support structure, from top to bottom, consists of a small rectangle, a right-angled trapezoid, and a large rectangle. The top edge of the right-angled trapezoid coincides with the bottom edge of the small rectangle, and the bottom edge of the right-angled trapezoid coincides with the top edge of the large rectangle. A rectangular doorway is provided at the bottom of the large rectangle. The front projection of the wedge-shaped support structure is U-shaped, with wedge-shaped structures on both sides and connected by a cuboid structure in the middle. An isosceles right-angled triangular notch is provided on the side of the wedge-shaped structure near the middle. The height of the cuboid structure is lower than that of the wedge-shaped structure. One side of the cuboid structure is aligned with the edge of the wedge-shaped structure, and the other side is aligned with the edge of the rectangular doorway.
4. The degree-of-freedom loading device according to claim 1, characterized in that, Each set of the vertical hydraulic cylinder anchor bolt fixing assembly consists of two rows of sleeves. Each row of sleeves is arranged in a mixed manner of type I and type II fixing sleeves. Adjacent sleeves in the same row are fixed together by a second connecting assembly and bolts, and the two rows of sleeves are fixed together by a first connecting assembly and bolts. The first connecting assembly consists of two L-shaped angle steels and a first rectangular steel plate. The two L-shaped angle steels are arranged in a 45-degree mirror image. Each end of the L-shaped angle steel has a hole. The L-shaped angle steels are welded to the first rectangular steel plate.
5. The degree-of-freedom loading device according to claim 4, characterized in that, The type I fixing sleeve is composed of a rectangular steel pipe, a square steel block, and a square steel pipe welded together from top to bottom. A second rectangular steel plate is welded to one short side of the rectangular steel pipe, and a circular hole is opened at each of the upper and lower ends of the second rectangular steel plate. The lower part of the square steel pipe is sealed by a square sealing plate, and a first circular pipe is welded to the lower part of the square sealing plate. The first circular pipe has two circular holes along its diameter at the middle of its height. The type I fixing sleeve also includes a second circular pipe and a circular steel plate. The second circular pipe is welded and fixed to the circular steel plate. Two circular holes are opened at the top of the second circular pipe along its diameter. The second circular pipe is connected to the first circular pipe by bolts. The circular steel plate has six circular holes, and the line connecting any two adjacent circular holes to the center of the circular plate forms a 60° angle. The square steel block is parallel to two sides of the rectangular steel pipe, and a screw hole is opened at one end of one side. The square steel block has a total of two screw holes.
6. The degree-of-freedom loading device according to claim 4, characterized in that, The Type II fixing sleeve is composed of three rectangular steel pipes, three rectangular steel blocks, and three square steel pipes welded together from top to bottom. A second rectangular steel plate is welded to the short side of each of the two outermost rectangular steel pipes, and each second rectangular steel plate has a circular hole at both its top and bottom ends. An inverted first angle steel is welded between the three rectangular steel pipes, positioned on the short side of the rectangular steel pipe opposite the rectangular steel plate. The lower part of the square steel pipe is sealed by a square sealing plate, and a first circular pipe is welded to the lower part of the square sealing plate. The first circular pipe has two circular holes along its diameter at the midpoint of its height. The Type II fixing sleeve also includes a second circular pipe and a circular steel plate. The second circular pipe is welded and fixed to the circular steel plate, and the top of the second circular pipe has two circular holes along its diameter. The second circular pipe is connected to the first circular pipe by bolts. A screw hole is provided at each end of the two longer sides of the rectangular steel block, for a total of four screw holes.
7. The degree-of-freedom loading device according to claim 1, characterized in that, The horizontal hydraulic cylinder through-and-position fixing assembly includes two identical outer steel plates, two stabilizing steel plates, several positioning steel pipes, connecting steel plates, slender steel plates, and supporting square steel plates. The outer steel plates and stabilizing steel plates each have circular holes corresponding to the number and position of the positioning steel pipes. The size of the circular holes is the same as the outer diameter of the positioning steel pipes. The stabilizing steel plates have rectangular holes between each row of circular pipes. The two stabilizing steel plates are arranged in parallel and fixed together by welding with the connecting steel plates. The slender steel plates are welded to the opposite side of the connecting steel plates. The supporting square steel plate is welded below the connecting steel plates, stabilizing steel plates, and slender steel plates. The positioning steel pipes pass sequentially through one side of the outer steel plate, the two stabilizing steel plates, and the other side of the outer steel plate, and are fixed to all four steel plates by welding.
8. The degree-of-freedom loading device according to claim 1, characterized in that, The transmission mechanism support and fixing assembly consists of a third rectangular steel plate and eight fixing anchor bars, all of which are welded to the bottom of the third rectangular steel plate. The top of the third rectangular steel plate has six bolt holes arranged in two rows and close to the short edge of the third rectangular steel plate.
9. A construction method for a degree-of-freedom loading device adapted to a test bench for the transmission chain of a 25MW+ class wind turbine, characterized in that, Includes the following steps: S1. All components of the pre-embedded fixing assembly are processed in the steel structure processing plant, and all welding fixing parts are welded in the processing plant; S2. Reinforcing bars are tied to part of the bottom plate of the U-shaped base, and then concrete is poured. S3. After the concrete in step S2 has initially set, place each sleeve in the vertical hydraulic cylinder anchor bolt fixing assembly in the designated position, and use three expansion bolts to pass through three of the six holes in the circular steel plate to fix the sleeve. S4. Place the type I fixing sleeve and the type II fixing sleeve, and fix the first round tube and the second round tube together with bolts; S5. Install leveling bolts in the remaining three holes of the circular steel plate, and level the circular steel plate using the leveling bolts; S6. Weld the second angle steel, install the first connecting component and the second connecting component to form the complete vertical hydraulic cylinder anchor bolt fixing component; S7. Tie the remaining steel bars of the U-shaped base and the steel bars at the bottom of the wedge-shaped support, and use a mold to create two rectangular grooves on the top of the boss. S8. Pour the concrete to the bottom of the support plate of the horizontal hydraulic cylinder through the positioning and fixing assembly; S9. After the concrete in step S8 has initially set, install two sets of the horizontal hydraulic cylinder through-positioning and fixing components and fix them with expansion bolts. S10. Tie the remaining steel bars and install the transmission mechanism support and fixing assembly; S11. Complete the pouring of the remaining concrete; S12. Fix the sleeve in the reserved rectangular groove with expansion bolts, and fill the rectangular groove with high-strength grout.
10. The construction method according to claim 9, characterized in that, During component processing in step S1, the dimensional deviation of each component of the type I fixed sleeve and the type II fixed sleeve is controlled within ±2mm, and the weld height at the weld joint is not less than 8mm.