Method and device for reducing failure rate of unit air cooling island speed reducer

Abstract

The invention provides a method for reducing the failure rate of a unit air cooling island speed reducer. The method comprises the following steps that S1, a multi-module cooperative prevention and control system is built; s2, configuring a parameter monitoring module assembly; s3, standardizing the installation standard of the sensor; s4, building a data transmission and analysis platform; s5, starting an intelligent diagnosis and data tracing function; s6, executing a monitor calibration and maintenance process; s7, carrying out preventive maintenance operation; s8, starting a working condition linkage adjusting mechanism; s9, activating an operation and maintenance training auxiliary module; and S10, a supplement lubricating oil leakage monitoring link. According to the method for reducing the failure rate of the unit air cooling island speed reducer, full-dimension real-time monitoring and intelligent diagnosis of operation parameters of the speed reducer are achieved by building a multi-module cooperative prevention and control system, and by combining graded early warning and preventive maintenance, fault hidden dangers are accurately positioned and handled; the working condition linkage adjusting mechanism can actively adjust the operation state when parameters are abnormal, and fault expansion is avoided.

Description

Technical Field

[0001] This invention relates to the field of air-cooled island speed reducers, and more particularly to a method and apparatus for reducing the failure rate of air-cooled island speed reducers in generator sets. Background Technology

[0002] The air-cooled island reducer is the core transmission reduction device in the direct air-cooling system. It is mainly used to match the speed and torque requirements of the drive motor and impeller of the air-cooled island fan, so as to achieve smooth power transmission and efficient conversion. It is one of the key devices to ensure the stable operation of the air-cooled island.

[0003] This equipment operates in harsh outdoor environments for extended periods, facing multiple challenges such as large temperature fluctuations, dust erosion, and vibration impact. Furthermore, its operating status is strongly correlated with operating conditions such as unit load and fan speed.

[0004] Currently, the industry relies heavily on traditional manual inspections for monitoring air-cooled island gearboxes. This results in problems such as delayed parameter acquisition, untimely fault warnings, and insufficient targeted maintenance. This can easily lead to the failure to detect faults such as gear wear, bearing overheating, and oil deterioration in a timely manner, which in turn can cause gearbox shutdowns or even damage, seriously affecting the stable operation of the air-cooled island system and the unit's thermal cycle efficiency.

[0005] Therefore, it is necessary to provide a method to reduce the failure rate of the air-cooled island reducer in the unit and solve the above-mentioned technical problems. Summary of the Invention

[0006] This invention provides a method for reducing the failure rate of the air-cooled island reducer in a generator unit, solving the problem that existing air-cooled island reducers rely on manual inspections, resulting in delayed fault monitoring and a lack of targeted maintenance, thus leading to a high failure rate.

[0007] To solve the above-mentioned technical problems, the present invention provides a method for reducing the failure rate of the air-cooled island reducer in a generator set, comprising the following steps:

[0008] S1. Build a multi-module collaborative prevention and control system, including a parameter monitoring module, a data transmission and analysis module, an operation and maintenance execution module, and a working condition linkage module. Clarify the functional positioning of each module, ensure signal communication and collaborative operation between modules, and lay the system foundation for fault prevention and control.

[0009] S2. Configure parameter monitoring module components, install vibration sensor groups at the bearing seats of the input and output shafts of the reducer as required, arrange temperature sensor groups and keep them away from high temperature radiation sources, install oil level and oil pressure sensors at key nodes of the lubricating oil pipeline, embed oil quality water content and particle size detection modules into the oil circulation system, and equip auxiliary sensors for working conditions to collect ambient temperature, unit load and fan speed data.

[0010] S3. Standardize sensor installation to ensure that the vibration sensor is in close contact with the surface of the bearing housing being measured, avoid vibration interference, and ensure the accuracy of vibration acceleration, velocity, displacement and other parameters. At the same time, ensure that each sensor is installed firmly and the wiring is in accordance with the specifications.

[0011] S4. Build a data transmission and analysis platform, using industrial Ethernet or wireless IoT technology as the data transmission unit to realize the real-time transmission of data collected by the parameter monitoring module to the background analysis system. The background analysis system has built-in fault diagnosis algorithms and a graded early warning threshold database. Based on the gearbox equipment manual standards, historical fault data and industry specifications, set three levels of thresholds: normal, early warning and alarm. Reserve a dynamic adjustment interface to adapt to changes in the unit's operating years.

[0012] S5. Enable intelligent diagnosis and data traceability functions. Through the fault diagnosis algorithm of the background analysis system, identify abnormal vibration frequency, temperature change trend and oil quality deterioration degree, generate early warning information, and at the same time enable data storage and trend analysis functions to regularly generate trend analysis reports of the full life cycle monitoring data of the reducer.

[0013] S6. Perform the calibration and maintenance process for the monitoring instrument. Through the calibration component of the monitoring instrument in the operation and maintenance module, regularly check the measurement errors of the vibration sensor and temperature sensor, clean the detection probe of the oil quality monitoring module, and check the sensor wiring terminals and the operating status of the data transmission module to ensure the accuracy and reliability of the monitoring equipment.

[0014] S7. Conduct preventive maintenance operations. Based on the trend analysis reports and early warning information from the background analysis system, maintenance personnel perform targeted maintenance work such as lubricant replacement, bearing repair, and gear precision calibration through the maintenance execution unit to prevent the fault from escalating.

[0015] S8. Activate the operating condition linkage adjustment mechanism to ensure smooth signal between the operating condition linkage module and the unit's DCS system. When the reducer operating parameters are detected to be close to the warning threshold, the adjustment signal is automatically sent to adjust the unit load or the air-cooled island fan speed. After the parameters return to normal, the original operating conditions are gradually restored.

[0016] S9. Activate the operation and maintenance training auxiliary module to organize operation and maintenance personnel to learn the operation process of the multi-parameter intelligent monitoring system built into the module, the method of interpreting early warning information and the fault location skills, so as to improve the efficiency and accuracy of fault handling.

[0017] S10. Supplement the lubricating oil leakage monitoring link. Through the oil leakage detection sensor of the lubrication system monitoring component, monitor the lubricating oil leakage in real time, and promptly detect and deal with potential leakage hazards.

[0018] A device for reducing the failure rate of the air-cooled island reducer in a generator set includes: a multi-position sensor body, a mounting assembly, a connecting assembly, a base, a placement slot, and a fixing assembly;

[0019] The mounting assembly is disposed at the bottom of the multi-position sensor body;

[0020] The connecting component is disposed below the mounting component;

[0021] The base is connected to the lower part of the connecting component;

[0022] The placement slot is located at the bottom of the base;

[0023] The fixing component is disposed inside the placement slot, and the fixing component includes a rotating seat and a fixing hoop, with the fixing hoop connected to one side of the rotating seat.

[0024] Preferably, the mounting assembly includes a mounting sleeve, multiple mounting blocks, and multiple bolts. The mounting sleeve is fitted onto the bottom of the multi-position sensor body, the multiple mounting blocks are respectively connected to one end of the mounting sleeve, and the multiple bolts are respectively disposed between the multiple mounting blocks and the multi-position sensor body.

[0025] Preferably, the connecting assembly includes a connecting sleeve, a connecting head, and a connecting bolt. The connecting sleeve is connected to the bottom of the mounting sleeve, the connecting head is plugged into one end of the connecting sleeve, and the connecting bolt is disposed between the connecting sleeve and the connecting head.

[0026] Preferably, the bottom of the mounting sleeve is provided with a sliding component, which includes a placement groove, a fixing rod, and a sliding member. The placement groove is opened at the bottom of the mounting sleeve, the fixing rod is installed inside the placement groove, and the sliding member is sleeved on the surface of the fixing rod.

[0027] Preferably, a sliding groove is provided at the center of the inner wall of the placement groove, and a slider is slidably connected inside the sliding groove, the slider being connected to the rotating seat.

[0028] Preferably, a magnetic ring is installed at the bottom of the base.

[0029] Preferably, a rotating assembly is provided between the connector and the base. The rotating assembly includes a rotating seat, a fixing ring, a fixing bracket, and a limiting bolt. The rotating seat is connected between the base and the connector, and the fixing ring is connected to the surface of the rotating seat.

[0030] Preferably, the fixing bracket is connected to one side of the fixing ring.

[0031] Preferably, the limiting bolt is disposed between the fixed bracket and the base.

[0032] Compared with related technologies, the method for reducing the failure rate of the air-cooled island reducer provided by the present invention has the following beneficial effects:

[0033] This invention provides a method for reducing the failure rate of the reducer in the air-cooled island of a power unit. By building a multi-module collaborative prevention and control system, it achieves real-time monitoring and intelligent diagnosis of the reducer's operating parameters in all dimensions. Combined with graded early warning and preventive maintenance, it accurately locates and addresses potential faults. The operating condition linkage adjustment mechanism can proactively adjust the operating status when parameters are abnormal to prevent the fault from escalating. At the same time, it is equipped with operation and maintenance training and oil leakage monitoring to form a full-process, all-round fault prevention and control system. This effectively solves the problems of lagging traditional manual inspection and insufficient targeted maintenance, significantly reduces the reducer failure rate, ensures the stable operation of the air-cooled island system, and improves the unit's operating efficiency and economy. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the first embodiment of a device for reducing the failure rate of the air-cooled island reducer in a generator unit, provided by the present invention.

[0035] Figure 2 for Figure 1 The enlarged schematic diagram of part A shown below;

[0036] Figure 3 for Figure 1 The diagram shows a three-dimensional structure of a multi-sensor sensor from a first-view perspective.

[0037] Figure 4 for Figure 3 The enlarged schematic diagram of section B is shown below;

[0038] Figure 5 for Figure 1 The diagram shows a three-dimensional structure of a multi-sensor second-view device.

[0039] Figure 6 for Figure 5 The enlarged schematic diagram of section C is shown below;

[0040] Figure 7 for Figure 1 The diagram shows a three-dimensional structure of a multi-sensor sensor from a third-view perspective.

[0041] Figure 8 for Figure 7 The enlarged schematic diagram of part D is shown below;

[0042] Figure 9 This is a schematic diagram of the second embodiment of a device for reducing the failure rate of the air-cooled island reducer provided by the present invention;

[0043] Figure 10 for Figure 9 The enlarged schematic diagram of part E is shown.

[0044] Numbered in the diagram: 1. Multi-position sensor body,

[0045] 2. Mounting components, 21. Mounting sleeve, 22. Mounting block, 23. Bolts.

[0046] 3. Connecting components; 31. Connecting sleeve; 32. Connecting head; 33. Connecting bolt.

[0047] 4. Sliding assembly; 41. Placement slot; 42. Fixing rod; 43. Sliding component.

[0048] 5. Base, 6. Magnetic ring, 7. Placement slot

[0049] 8. Fixing component; 81. Slide rail; 82. Slider; 83. Rotating seat; 84. Fixing clamp.

[0050] 9. Rotating assembly; 91. Rotating seat; 92. Fixing ring; 93. Fixing bracket; 94. Limit bolt. Detailed Implementation

[0051] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0052] First Embodiment

[0053] A method for reducing the failure rate of the air-cooled island gearbox in a generator set includes the following steps:

[0054] S1. Build a multi-module collaborative prevention and control system, including a parameter monitoring module, a data transmission and analysis module, an operation and maintenance execution module, and a working condition linkage module. Clarify the functional positioning of each module, ensure signal communication and collaborative operation between modules, and lay the system foundation for fault prevention and control.

[0055] S2. Configure parameter monitoring module components, install vibration sensor groups at the bearing seats of the input and output shafts of the reducer as required, arrange temperature sensor groups and keep them away from high temperature radiation sources, install oil level and oil pressure sensors at key nodes of the lubricating oil pipeline, embed oil quality water content and particle size detection modules into the oil circulation system, and equip auxiliary sensors for working conditions to collect ambient temperature, unit load and fan speed data.

[0056] S3. Standardize sensor installation to ensure that the vibration sensor is in close contact with the surface of the bearing housing being measured, avoid vibration interference, and ensure the accuracy of vibration acceleration, velocity, displacement and other parameters. At the same time, ensure that each sensor is installed firmly and the wiring is in accordance with the specifications.

[0057] S4. Build a data transmission and analysis platform, using industrial Ethernet or wireless IoT technology as the data transmission unit to realize the real-time transmission of data collected by the parameter monitoring module to the background analysis system. The background analysis system has built-in fault diagnosis algorithms and a graded early warning threshold database. Based on the gearbox equipment manual standards, historical fault data and industry specifications, set three levels of thresholds: normal, early warning and alarm. Reserve a dynamic adjustment interface to adapt to changes in the unit's operating years.

[0058] S5. Enable intelligent diagnosis and data traceability functions. Through the fault diagnosis algorithm of the background analysis system, identify abnormal vibration frequency, temperature change trend and oil quality deterioration degree, generate early warning information, and at the same time enable data storage and trend analysis functions to regularly generate trend analysis reports of the full life cycle monitoring data of the reducer.

[0059] S6. Perform the calibration and maintenance process for the monitoring instrument. Through the calibration component of the monitoring instrument in the operation and maintenance module, regularly check the measurement errors of the vibration sensor and temperature sensor, clean the detection probe of the oil quality monitoring module, and check the sensor wiring terminals and the operating status of the data transmission module to ensure the accuracy and reliability of the monitoring equipment.

[0060] S7. Conduct preventive maintenance operations. Based on the trend analysis reports and early warning information from the background analysis system, maintenance personnel perform targeted maintenance work such as lubricant replacement, bearing repair, and gear precision calibration through the maintenance execution unit to prevent the fault from escalating.

[0061] S8. Activate the operating condition linkage adjustment mechanism to ensure smooth signal between the operating condition linkage module and the unit's DCS system. When the reducer operating parameters are detected to be close to the warning threshold, the adjustment signal is automatically sent to adjust the unit load or the air-cooled island fan speed. After the parameters return to normal, the original operating conditions are gradually restored.

[0062] S9. Activate the operation and maintenance training auxiliary module to organize operation and maintenance personnel to learn the operation process of the multi-parameter intelligent monitoring system built into the module, the method of interpreting early warning information and the fault location skills, so as to improve the efficiency and accuracy of fault handling.

[0063] S10. Supplement the lubricating oil leakage monitoring link. Through the oil leakage detection sensor of the lubrication system monitoring component, monitor the lubricating oil leakage in real time, and promptly detect and deal with potential leakage hazards.

[0064] Compared with related technologies, the method for reducing the failure rate of the air-cooled island reducer provided by the present invention has the following beneficial effects:

[0065] This invention provides a method for reducing the failure rate of the reducer in the air-cooled island of a power unit. By building a multi-module collaborative prevention and control system, it achieves real-time monitoring and intelligent diagnosis of the reducer's operating parameters in all dimensions. Combined with graded early warning and preventive maintenance, it accurately locates and addresses potential faults. The operating condition linkage adjustment mechanism can proactively adjust the operating status when parameters are abnormal to prevent the fault from escalating. At the same time, it is equipped with operation and maintenance training and oil leakage monitoring to form a full-process, all-round fault prevention and control system. This effectively solves the problems of lagging traditional manual inspection and insufficient targeted maintenance, significantly reduces the reducer failure rate, ensures the stable operation of the air-cooled island system, and improves the unit's operating efficiency and economy.

[0066] Second Embodiment

[0067] Please refer to the following: Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 Based on the first embodiment of this application which provides a device for reducing the failure rate of the air-cooled island gearbox in a generator set, the second embodiment of this application proposes another device for reducing the failure rate of the air-cooled island gearbox in a generator set. The second embodiment is merely a preferred embodiment of the first embodiment, and the implementation of the second embodiment will not affect the separate implementation of the first embodiment.

[0068] Specifically, the second embodiment of this application provides a device for reducing the failure rate of the air-cooled island reducer of the unit, which is different in that it includes: a multi-position sensor body 1, a mounting component 2, a connecting component 3, a base 5, a placement slot 7, and a fixing component 8;

[0069] The mounting component 2 is disposed at the bottom of the multi-position sensor body 1;

[0070] The connecting component 3 is disposed below the mounting component 2;

[0071] The base 5 is connected to the lower part of the connecting component 3;

[0072] The placement slot 7 is located at the bottom of the base 5;

[0073] The fixing component 8 is disposed inside the placement groove 6. The fixing component 8 includes a rotating seat 83 and a fixing hoop 84, and the fixing hoop 84 is connected to one side of the rotating seat 83.

[0074] The mounting assembly 2 includes a mounting sleeve 21, multiple mounting blocks 22, and multiple bolts 23. The mounting sleeve 21 is fitted onto the bottom of the multi-position sensor body 1. The multiple mounting blocks 22 are respectively connected to one end of the mounting sleeve 21. The multiple bolts 23 are respectively disposed between the multiple mounting blocks 22 and the multi-position sensor body 1.

[0075] The connecting component 3 includes a connecting sleeve 31, a connecting head 32, and a connecting bolt 33. The connecting sleeve 31 is connected to the bottom of the mounting sleeve 21, the connecting head 32 is plugged into one end of the connecting sleeve 31, and the connecting bolt 33 is disposed between the connecting sleeve 31 and the connecting head 32.

[0076] The bottom of the mounting sleeve 21 is provided with a sliding component 4. The sliding component 4 includes a placement groove 41, a fixing rod 42, and a sliding member 43. The placement groove 41 is opened at the bottom of the mounting sleeve 21, the fixing rod 42 is installed inside the placement groove 41, and the sliding member 43 is sleeved on the surface of the fixing rod 42.

[0077] A sliding groove 81 is provided at the center of the inner wall of the placement groove 7. A slider 82 is slidably connected inside the sliding groove 81, and the slider 82 is connected to the rotating seat 83.

[0078] A magnetic ring 6 is installed at the bottom of the base 5.

[0079] The mounting sleeve 21 is made of elastic rubber with anti-slip texture on the inner wall, which can fit tightly to the bottom of the multi-position sensor body 1 and prevent loosening after installation. The mounting block 22 is integrally formed with the mounting sleeve 21, and the mounting block 22 has threaded holes that match the bolts 23. The mounting block 22 is locked and fixed to the multi-position sensor body 1 by the bolts 23, so as to achieve stable installation of the multi-position sensor body 1 and facilitate disassembly and maintenance later.

[0080] The inner wall of the connecting sleeve 31 fits tightly against the outer wall of the connector 32, and the connecting sleeve 31 has a through hole, while the connector 32 has a threaded hole at the corresponding position. The connecting bolt 33 passes through the through hole of the connecting sleeve 31 and is threadedly connected to the threaded hole of the connector 32, so as to realize the detachable fixing of the connecting sleeve 31 and the connector 32, which makes it easy to adjust the installation height of the sensor according to the installation scenario and improve the adaptability of the device.

[0081] The sliding member 43 is fixedly connected to the top of the connecting sleeve 31, and the inner wall of the sliding member 43 slides in cooperation with the surface of the fixed rod 42, allowing it to slide freely along the length of the fixed rod 42, thereby driving the connecting component 3 and the base 5 and the fixed component 8 below to move laterally, which facilitates the adjustment of the sensor's monitoring position and ensures that the sensor can be accurately aligned with the measured part.

[0082] The slide groove 81 has an arc-shaped structure, and the size of the slider 82 is adapted to the slide groove 81. The rotating seat 83 can rotate along the slide groove 81 through the slider 82, thereby driving the fixing hoop 84 to adjust the angle, which is convenient to adapt to the fixing requirements of different pipe diameters or different mounting surfaces and improves the installation flexibility of the device.

[0083] The magnetic ring 6 is made of a strong magnetic material and can be attracted to the metal casing of the reducer or the mounting bracket to initially fix the device in position. Together with the fixing component 8, it achieves double fixation, enhancing the stability of the device installation and preventing the device from shifting or falling off due to vibration during reducer operation.

[0084] The working principle of the device for reducing the failure rate of the air-cooled island reducer provided by this invention is as follows:

[0085] During installation, the base 5 is first attached to the preset monitoring position of the reducer using the magnetic ring 6 to achieve initial fixation. According to the sensor monitoring requirements, the sliding member 43 is pushed along the fixed rod 42 to adjust the lateral position of the multi-position sensor body 1. The rotating seat 83 is rotated, and the slider 82 slides along the slide groove 81 to adjust the angle of the fixing hoop 84. The fixing hoop 84 is then used to lock and fix the device to the measured part, completing the secondary fixation. The installation height of the multi-position sensor body 1 is adjusted by the plugging and unplugging of the connecting sleeve 31 and the connecting head 32 of the connecting component 3. After adjustment, the connecting bolt 33 is tightened for fixation. If it is necessary to disassemble or replace the multi-position sensor body 1, the bolt 23 on the mounting block 22 is unscrewed to separate the mounting sleeve 21 from the multi-position sensor body 1. During use, the multi-position sensor body 1 can simultaneously collect multiple parameters such as vibration and temperature, providing data support for the background analysis system.

[0086] Compared with related technologies, the device for reducing the failure rate of the air-cooled island reducer provided by the present invention has the following beneficial effects:

[0087] This invention provides a device for reducing the failure rate of the air-cooled island reducer in a generator unit. The device features a mounting component 2 for stable installation and easy disassembly of the multi-position sensor body 1; a connecting component 3 for flexible adjustment of the sensor's installation height; a sliding component 4 for easy adjustment of the lateral monitoring position; and a fixing component 8, in conjunction with a magnetic ring 6, for dual fixation and angle adjustment, adapting to different installation scenarios and measured locations. The overall structure is compact, flexible in installation, and reliable in fixation, ensuring stable operation of the sensors under reducer vibration conditions and accurate acquisition of various operating parameters, providing reliable hardware support for reducing reducer failure rates.

[0088] Third Embodiment

[0089] Please refer to the following: Figure 9 and Figure 10Based on the first embodiment of this application which provides a device for reducing the failure rate of the air-cooled island gearbox in a generator set, the third embodiment of this application proposes another device for reducing the failure rate of the air-cooled island gearbox in a generator set. The third embodiment is merely a preferred embodiment of the first embodiment, and the implementation of the third embodiment will not affect the separate implementation of the first embodiment.

[0090] Specifically, the third embodiment of this application provides a device for reducing the failure rate of the air-cooled island reducer of the unit, which is different in that it also includes a rotating component 9. The rotating component 9 is disposed between the connector 32 and the base 5. The rotating component 9 includes a rotating seat 91, a fixing ring 92, a fixing bracket 93 and a limiting bolt 94. The rotating seat 91 is connected between the base 5 and the connector 32, and the fixing ring 92 is connected to the surface of the rotating seat 91.

[0091] The fixing bracket 93 is connected to one side of the fixing ring 92.

[0092] The limiting bolt 94 is disposed between the fixed bracket 93 and the base 5.

[0093] The fixed ring 92 is welded and fixed to the rotating seat 91. The fixed bracket 93 is integrally formed with the fixed ring 92, and the fixed bracket 93 has a through hole that matches the limit bolt 94. The surface of the base 5 has a number of annularly distributed threaded holes to facilitate fixing the rotation angle of the rotating seat 91 through the limit bolt 94.

[0094] The top of the rotating base 91 is fixedly connected to the connector 32, and the bottom is rotated with the base 5, which can drive the multi-position sensor body above to rotate 1360° to adjust the monitoring angle. When the rotation reaches the appropriate angle, the limit bolt 94 passes through the through hole of the fixing bracket 93 and is threadedly connected to the threaded hole of the base 5 to lock the fixing bracket 93, thereby fixing the position of the rotating base 91 and ensuring the stability of the sensor monitoring angle.

[0095] The working principle of the device for reducing the failure rate of the air-cooled island reducer provided by this invention is as follows:

[0096] During installation, after the initial fixing of the device is completed, the limit bolt 94 can be loosened to push the fixing ring 92 to drive the rotating seat 91 to rotate, thereby adjusting the monitoring angle of the multi-position sensor body 1 so that the sensor can accurately align with the measured part of the reducer. After the angle adjustment is completed, the limit bolt 94 is tightened and the rotating seat 91 is locked and fixed by the fixing bracket 93 to prevent the angle from shifting due to vibration during operation.

[0097] Compared with related technologies, the device for reducing the failure rate of the air-cooled island reducer provided by the present invention has the following beneficial effects:

[0098] This invention provides a device for reducing the failure rate of the air-cooled island reducer in a generator set. By adding a rotating component 9, the monitoring angle of the multi-position sensor body 1 can be flexibly adjusted by 360°, which can adapt to the monitoring needs of different measured parts of the reducer and further improve the accuracy of sensor parameter acquisition. The cooperation between the limit bolt 94 and the fixed bracket 93 can ensure that the adjusted angle is stable and reliable, and avoid angle deviation caused by vibration.

[0099] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for reducing the failure rate of the air-cooled island reducer in a generator set, characterized in that, Includes the following steps: S1. Build a multi-module collaborative prevention and control system, including a parameter monitoring module, a data transmission and analysis module, an operation and maintenance execution module, and a working condition linkage module. Clarify the functional positioning of each module, ensure signal communication and collaborative operation between modules, and lay the system foundation for fault prevention and control. S2. Configure parameter monitoring module components, install vibration sensor groups at the bearing seats of the input and output shafts of the reducer as required, arrange temperature sensor groups and keep them away from high temperature radiation sources, install oil level and oil pressure sensors at key nodes of the lubricating oil pipeline, embed oil quality water content and particle size detection modules into the oil circulation system, and equip auxiliary sensors for working conditions to collect ambient temperature, unit load and fan speed data. S3. Standardize sensor installation to ensure that the vibration sensor is in close contact with the surface of the bearing housing being measured, avoid vibration interference, and ensure the accuracy of vibration acceleration, velocity, displacement and other parameters. At the same time, ensure that each sensor is installed firmly and the wiring is in accordance with the specifications. S4. Build a data transmission and analysis platform, using industrial Ethernet or wireless IoT technology as the data transmission unit to realize the real-time transmission of data collected by the parameter monitoring module to the background analysis system. The background analysis system has built-in fault diagnosis algorithms and a graded early warning threshold database. Based on the gearbox equipment manual standards, historical fault data and industry specifications, set three levels of thresholds: normal, early warning and alarm. Reserve a dynamic adjustment interface to adapt to changes in the unit's operating years. S5. Enable intelligent diagnosis and data traceability functions. Through the fault diagnosis algorithm of the background analysis system, identify abnormal vibration frequency, temperature change trend and oil quality deterioration degree, generate early warning information, and at the same time enable data storage and trend analysis functions to regularly generate trend analysis reports of the full life cycle monitoring data of the reducer. S6. Perform the calibration and maintenance process for the monitoring instrument. Through the calibration component of the monitoring instrument in the operation and maintenance module, regularly check the measurement errors of the vibration sensor and temperature sensor, clean the detection probe of the oil quality monitoring module, and check the sensor wiring terminals and the operating status of the data transmission module to ensure the accuracy and reliability of the monitoring equipment. S7. Conduct preventive maintenance operations. Based on the trend analysis reports and early warning information from the background analysis system, maintenance personnel perform targeted maintenance work such as lubricant replacement, bearing repair, and gear precision calibration through the maintenance execution unit to prevent the fault from escalating. S8. Activate the operating condition linkage adjustment mechanism to ensure smooth signal between the operating condition linkage module and the unit's DCS system. When the reducer operating parameters are detected to be close to the warning threshold, the adjustment signal is automatically sent to adjust the unit load or the air-cooled island fan speed. After the parameters return to normal, the original operating conditions are gradually restored. S9. Activate the operation and maintenance training auxiliary module to organize operation and maintenance personnel to learn the operation process of the multi-parameter intelligent monitoring system built into the module, the method of interpreting early warning information and the fault location skills, so as to improve the efficiency and accuracy of fault handling. S10. Supplement the lubricating oil leakage monitoring link. Through the oil leakage detection sensor of the lubrication system monitoring component, monitor the lubricating oil leakage in real time, and promptly detect and deal with potential leakage hazards.

2. An apparatus for reducing the failure rate of the air-cooled island gearbox in a generator set, as described in claim 1, characterized in that, include: Multi-position sensor body, mounting components, connecting components, base, placement slot and fixing components; The mounting assembly is disposed at the bottom of the multi-position sensor body; The connecting component is disposed below the mounting component; The base is connected to the lower part of the connecting component; The placement slot is located at the bottom of the base; The fixing component is disposed inside the placement slot, and the fixing component includes a rotating seat and a fixing hoop, with the fixing hoop connected to one side of the rotating seat.

3. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 2, characterized in that, The mounting assembly includes a mounting sleeve, multiple mounting blocks, and multiple bolts. The mounting sleeve is fitted onto the bottom of the multi-position sensor body, the multiple mounting blocks are respectively connected to one end of the mounting sleeve, and the multiple bolts are respectively disposed between the multiple mounting blocks and the multi-position sensor body.

4. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 2, characterized in that, The connecting assembly includes a connecting sleeve, a connecting head, and a connecting bolt. The connecting sleeve is connected to the bottom of the mounting sleeve, the connecting head is plugged into one end of the connecting sleeve, and the connecting bolt is disposed between the connecting sleeve and the connecting head.

5. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 3, characterized in that, The bottom of the mounting sleeve is provided with a sliding component, which includes a placement groove, a fixing rod, and a sliding member. The placement groove is opened at the bottom of the mounting sleeve, the fixing rod is installed inside the placement groove, and the sliding member is sleeved on the surface of the fixing rod.

6. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 2, characterized in that, A sliding groove is provided at the center of the inner wall of the placement groove, and a slider is slidably connected inside the sliding groove. The slider is connected to the rotating seat.

7. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 2, characterized in that, A magnetic ring is installed at the bottom of the base.

8. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 3, characterized in that, A rotating assembly is provided between the connector and the base. The rotating assembly includes a rotating seat, a fixing ring, a fixing bracket, and a limiting bolt. The rotating seat is connected between the base and the connector, and the fixing ring is connected to the surface of the rotating seat.

9. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 8, characterized in that, The fixing bracket is connected to one side of the fixing ring.

10. The device for reducing the failure rate of the air-cooled island reducer of the unit according to claim 8, characterized in that, The limiting bolt is disposed between the fixed bracket and the base.

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