Lifting lug load calculation method, lifting lug strength checking method, equipment and storage medium

Abstract

The invention relates to the technical field of wind driven generators, and discloses a lifting lug load calculation method, a lifting lug strength checking method, equipment and a storage medium. According to the method, coordinates of all lifting lug points, coordinates of the mass center of the gear box and the weight of the gear box are generated based on a gear box model, and the coordinates of all the lifting lug points comprise coordinates of all torque arm lifting lug points and coordinates of all rear box body lifting lug points; based on a preset rotation angle, the coordinates of the lifting lug points and the coordinates of the center of mass of the gear box, the coordinates of the lifting lug points after rotation and the coordinates of the center of mass of the gear box after rotation are generated, and the coordinates of the lifting lug points after rotation are the coordinates of the lifting lug points of the rear box body after rotation; generating each post-rotation lifting rope unit vector based on each lifting rope length and each post-rotation lifting lug point coordinate, wherein each lifting rope length is generated based on workshop lifting information; and based on the weight of the gearbox, the coordinates of the lifting lug points of the torque arms, the coordinates of the lifting lug points after rotation, the coordinates of the mass center of the gearbox after rotation and the unit vectors of the lifting ropes after rotation, the lifting lug loads of the lifting lug points in the specified direction are generated.

Description

Technical Field

[0001] This application relates to the field of wind turbine technology, and in particular to a method for calculating the load of a lifting lug, a method for verifying the strength of a lifting lug, equipment, and storage medium. Background Technology

[0002] In recent years, the wind turbine industry has developed rapidly, and the gearboxes of wind turbines have become increasingly heavy. Turning over is a critical step in the gearbox assembly process, involving significant dynamic rotational motion. During this process, the lifting lugs, as core load-bearing components, must withstand complex loads that change continuously with the turning angle. Therefore, the load calculation and strength verification of the lifting lugs directly affect the safety of the lifting operation and the reliability of the entire equipment.

[0003] Currently, conventional methods for analyzing and calculating the overturning and hoisting operations typically require overall structural modeling of the gearbox, and multiple analysis models often need to be established and verified for different overturning angles. This method not only involves a large amount of modeling work and a long calculation cycle, but also easily leads to incomplete load condition coverage due to the large number of models, potentially resulting in the omission of load states at certain critical locations. These problems increase the environmental, health, and safety (EHS) risks during the overturning operation, and have become a technical bottleneck restricting further improvements in assembly efficiency and safety assurance.

[0004] Therefore, how to quickly, accurately and comprehensively assess the load on the lifting lugs during continuous turning is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] The purpose of this application is to provide a method for calculating the load of the lifting lug, a method for verifying the strength of the lifting lug, an equipment, and a storage medium, which can quickly, accurately, and comprehensively evaluate the load of the lifting lug during continuous turning.

[0006] To address the aforementioned technical problems, this application provides a method for calculating the load on a lifting lug, applied during the overturning process of a wind turbine gearbox. The method includes: generating coordinates of each lifting lug point, coordinates of the gearbox's center of mass, and the gearbox weight based on a gearbox model; wherein the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear gearbox lifting lug point; generating coordinates of each rotating lifting lug point and the coordinates of the rotated gearbox's center of mass based on a preset rotation angle, the coordinates of each lifting lug point, and the coordinates of the gearbox's center of mass; wherein the coordinates of the rotating lifting lug points are the coordinates of the rotating rear gearbox lifting lug points; generating unit vectors of each rotating lifting rope based on each lifting rope length and the coordinates of each rotating lifting lug point; wherein the length of each lifting rope is generated based on workshop lifting information; and generating the lifting lug load of each lifting lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the rotated gearbox's center of mass, and the unit vectors of each rotating lifting rope.

[0007] The embodiments of this application also provide a method for verifying the strength of the lifting lug, applied in the process of wind turbine gearbox overturning, the method comprising: The coordinate system transformation is performed on the lifting loads of each lifting lug point in the specified direction to obtain the lifting loads of each lifting lug point in the specified direction in the gearbox coordinate system; wherein, the lifting loads of each lifting lug point in the specified direction are generated using the lifting load calculation method described above; the torque arm structure and the rear housing structure in the gearbox model are simplified to generate a simplified gearbox model; the torque arm structure and the rear housing structure in the simplified gearbox model are connected, and the mesh of the torque arm structure and the rear housing structure in the simplified gearbox model is refined; the lifting loads of each lifting lug point in the specified direction in the gearbox coordinate system are applied to each lifting lug hole in the simplified gearbox model, and then the strength is checked to generate the strength check results of each lifting lug.

[0008] In this embodiment, the method for calculating the load on the lifting lugs during the wind turbine gearbox turning process includes: generating the coordinates of each lifting lug point, the coordinates of the gearbox center of mass, and the gearbox weight based on the gearbox model; wherein, the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear gearbox lifting lug point; generating the coordinates of each rotating lifting lug point and the coordinates of the rotating gearbox center of mass based on a preset rotation angle, the coordinates of each lifting lug point, and the coordinates of the gearbox center of mass; wherein, the coordinates of the rotating lifting lug point are the coordinates of the rotating rear gearbox lifting lug points; generating the unit vector of each rotating lifting rope based on the length of each lifting rope and the coordinates of each rotating lifting lug point; wherein, the length of each lifting rope is generated based on workshop hoisting information; and generating the lifting lug load of each lifting lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the rotating gearbox center of mass, and the unit vector of each rotating lifting rope. This scheme, by parametrically inputting a preset rotation angle and combining the known coordinates of the lifting lugs, the coordinates of the center of mass, and the length of the lifting rope, can continuously and dynamically calculate the precise load of each lifting lug point in its direction of force at any angle during the gearbox's overturning process. This scheme replaces the cumbersome process of traditionally requiring complex modeling and static analysis for each discrete angle, thus avoiding the risk of missing the true maximum dynamic load due to sampling analysis. It fundamentally improves the computational efficiency, accuracy, and completeness of the lifting lug load calculation, providing a reliable input for subsequent accurate strength verification.

[0009] In addition, the step of generating the coordinates of each rotating lifting lug point and the coordinates of the gearbox center of mass based on the preset rotation angle, the coordinates of each of the lifting lug points, and the coordinates of the gearbox center of mass includes: determining the rotation axis based on the coordinates of each of the torque arm lifting lug points; determining the initial angle between the rotation axis and the reference plane based on the rotation axis, the coordinates of each of the rear housing lifting lug points, and the coordinates of the gearbox center of mass; and generating the coordinates of each rotating lifting lug point and the coordinates of the gearbox center of mass based on the rotation angle, the initial angle, the coordinates of each of the rear housing lifting lug points, and the coordinates of the gearbox center of mass.

[0010] In addition, the step of generating a unit vector for each rotating suspension rope based on the length of each suspension rope and the coordinates of each rotating lug point includes: generating the coordinates of the upper end suspension point of each suspension rope based on the length of each suspension rope and the coordinates of each rotating lug point; and generating a unit vector for each rotating suspension rope based on the length of each suspension rope, the coordinates of each rotating lug point, and the coordinates of the upper end suspension point of each suspension rope.

[0011] In addition, each of the rotated suspension rope unit vectors includes a rotated X-axis suspension rope unit vector and a rotated Z-axis suspension rope unit vector; the step of generating the suspension lug load at each lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lug point, the coordinates of each rotated suspension lug point, the coordinates of the gearbox centroid after rotation, and the rotated suspension rope unit vectors includes: constructing a first force balance equation based on the suspension lug load at each lug point, the rotated X-axis suspension rope unit vectors, and the gearbox weight; and based on the suspension lug load at each lug point... A second force balance formula is constructed based on the load, coordinates of each torque arm lifting lug point, coordinates of each lifting lug point after rotation, coordinates of the center of mass of the gearbox after rotation, unit vectors of the X-axis lifting rope after rotation, and unit vectors of the Z-axis lifting rope after rotation. Based on the load relationships of the lifting lug loads at each lifting lug point and the second force balance formula, the first force balance equation is solved to generate the lifting lug loads at each lifting lug point. Based on the unit vectors of the lifting rope after rotation and the lifting lug loads at each lifting lug point, the lifting lug loads at each lifting lug point in a specified direction are generated.

[0012] In addition, the construction of the first force balance equation based on the lifting lug load at each of the lifting lug points, the unit vector of the rotating X-axis lifting rope, and the weight of the gearbox includes: based on a preset force balance equation. The first force balance equation is constructed; wherein, in the force balance equation, G is the gravity corresponding to the weight of the gearbox, and F1, F2, F3, and F4 are the lifting loads at each of the lifting lug points. , , and Let X be the unit vector of the suspension rope along the X-axis after rotation.

[0013] In addition, the construction of a second force balance formula based on the lifting load of each lifting lug point, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the center of mass of the rotating gearbox, the unit vector of the rotating X-axis lifting rope, and the unit vector of the rotating Z-axis lifting rope includes: based on a preset force balance formula. Construct the second force balance formula; wherein, in the force balance formula, , , and Let X be the unit vector of the suspension rope along the X-axis after each rotation. , , and Let F1, F2, F3, and F4 be the unit vector of the Z-axis lifting rope after rotation, and let F1, F2, F3, and F4 be the lifting lug loads at each of the lifting lug points. and These are the X-axis and Z-axis coordinates of the centroid of the rotated gearbox, respectively. and These are the X-axis and Z-axis coordinates of the coordinates of each torque arm lug point. and These are the X-axis and Z-axis coordinates of the rotating lug points, respectively.

[0014] In addition, the lifting lugs include each torque arm lifting lug and each rear box lifting lug; the load relationship of the lifting lug loads of each of the lifting lugs is that the lifting lug loads of each of the torque arm lifting lugs are the same and the lifting lug loads of each of the rear box lifting lugs are the same. Attached Figure Description

[0015] One or more embodiments are illustrated by way of example with the corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0016] Figure 1 This is a flowchart illustrating a method for calculating the load of a lifting lug according to an embodiment of this application.

[0017] Figure 2 This is a schematic diagram of the measurement of the coordinates of the lifting lug point according to an embodiment of this application.

[0018] Figure 3 This is a flowchart illustrating a method for calculating the load of a lifting lug according to an embodiment of this application.

[0019] Figure 4 This is a schematic diagram of a turning and hoisting operation according to an embodiment of this application.

[0020] Figure 5 This is a flowchart illustrating a method for calculating the load of a lifting lug according to an embodiment of this application.

[0021] Figure 6 This is a flowchart illustrating a method for calculating the load of a lifting lug according to an embodiment of this application.

[0022] Figure 7 This is a schematic diagram showing the results of the lug load calculation method according to an embodiment of this application.

[0023] Figure 8 This is a flowchart illustrating the lug strength verification method according to an embodiment of this application.

[0024] Figure 9 This is a schematic diagram of a model of a lug strength verification method according to an embodiment of this application.

[0025] Figure 10This is a schematic diagram showing the results of the lug strength verification method according to an embodiment of this application.

[0026] Figure 11 This is a schematic diagram of the structure of an electronic device according to an embodiment of this application. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the various embodiments of this application will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been presented in the various embodiments of this application to facilitate the reader's better understanding of this application. However, the technical solutions claimed in this application can be implemented even without these technical details and with various changes and modifications based on the following embodiments. The division of the various embodiments below is for the convenience of description and should not constitute any limitation on the specific implementation of this application. The various embodiments can be combined with and referenced by each other without contradiction.

[0028] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0029] This application proposes a method for calculating the load on the lifting lugs during the turning process of a wind turbine gearbox. The method includes: generating the coordinates of each lifting lug point, the coordinates of the gearbox's center of mass, and the gearbox weight based on a gearbox model; wherein the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear gearbox lifting lug point; generating the coordinates of each rotating lifting lug point and the coordinates of the rotated gearbox's center of mass based on a preset rotation angle, the coordinates of each lifting lug point, and the coordinates of the gearbox's center of mass; wherein the coordinates of the rotating lifting lug points are the coordinates of the rear gearbox lifting lug points after rotation; generating unit vectors for each rotating lifting rope based on the length of each lifting rope and the coordinates of each rotating lifting lug point; wherein the length of each lifting rope is generated based on workshop lifting information; and generating the lifting lug load at each lifting lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the rotated gearbox's center of mass, and the unit vectors of each rotating lifting rope. This method can quickly, accurately, and comprehensively assess the load on the lifting lugs during continuous turning.

[0030] The following is a detailed description of the implementation details of the lifting lug load calculation method according to the embodiments of this application. The following content is only for the convenience of understanding and is not necessary for implementing this solution.

[0031] One embodiment of this application relates to a method for calculating the load on a lifting lug, applied in the process of wind turbine gearbox overturning, such as... Figure 1 As shown, the method for calculating the load of the lifting lug in this embodiment includes steps 110 to 140, and the specific content and implementation details of each step are as follows.

[0032] In step 110, based on the gearbox model, the coordinates of each lifting lug point, the coordinates of the gearbox center of mass, and the gearbox weight are generated; wherein, the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear housing lifting lug point.

[0033] Specifically, open the gearbox model in Creo software and check if the X-axis of the model coordinate system points from the RS side to the GS side and the positive direction of gravity is the X-axis. If not, the model coordinate system needs to be adjusted to meet the above conditions. The gearbox model can be a single gearbox model or other models containing gearbox models. The RS side refers to the side of the gearbox that connects to the low-speed shaft of the wind turbine impeller, and the GS side refers to the side of the gearbox that connects to the high-speed shaft of the generator. Ensuring that the X-axis points from the RS side to the GS side and the positive direction of gravity is the fundamental prerequisite for accurately performing spatial geometric transformations and static calculations during the calculation of the lifting lug load. This ensures that the data measured from the model can be seamlessly and correctly used for subsequent related calculations and finite element analysis.

[0034] Specifically, after the model coordinate system of the gearbox model is determined, such as Figure 2 As shown, the coordinates of each lifting lug point can be created in the gearbox model, and the gearbox center of mass coordinates and gearbox weight can be obtained by measuring the gearbox model. The measured data are then recorded in an Excel spreadsheet so that Excel can perform subsequent lifting lug load calculations based on this data. The coordinates of each lifting lug point are the coordinates of its center point, including the coordinates of each torque arm lifting lug point and each rear housing lifting lug point. The coordinates of each torque arm lifting lug point are... Figure 2 The coordinates of the two lug points where the X and Z coordinates are 0. Figure 2 The coordinates of the remaining lifting lugs are the coordinates of the lifting lugs of each rear box.

[0035] Specifically, after obtaining various relevant parameters based on the gearbox model and recording them in an Excel spreadsheet, the length of the lifting rope corresponding to each lifting lug point can also be obtained through the relevant lifting station information in the workshop and recorded in an Excel spreadsheet.

[0036] In step 120, based on the preset rotation angle, the coordinates of each lifting lug point and the coordinates of the gearbox centroid, the coordinates of each rotating lifting lug point and the coordinates of the gearbox centroid after rotation are generated; wherein, the coordinates of the rotating lifting lug points are the coordinates of the lifting lug points of the rear housing after rotation.

[0037] Specifically, the coordinates of each rotating lug point and the coordinates of the gearbox centroid mentioned in step 120 can be obtained as follows: Figure 3 The method shown includes: step 310, determining the rotation axis based on the coordinates of each torque arm lug point; step 320, determining the initial angle between the rotation axis and the reference plane based on the rotation axis, the coordinates of each rear housing lug point, and the coordinates of the gearbox center of mass; and step 330, generating the coordinates of each rotated rear lug point and the coordinates of the rotated rear gearbox center of mass based on the rotation angle, the initial angle, the coordinates of each rear housing lug point, and the coordinates of the gearbox center of mass.

[0038] Specifically, such as Figure 4 In the schematic diagram of the gearbox's tilting operation, the position of the torque arm lifting lug point (lifting point 1) remains basically unchanged during the tilting operation, while the position of the rear gearbox lifting lug point (lifting point 2) changes significantly. Therefore, based on the coordinates of the two torque arm lifting lug points in each lifting lug point coordinate system, a straight line connecting these two points can be determined as the axis of rotation. This axis of rotation physically corresponds to the hinge axis of the auxiliary tooling used to control the rotation of the gearbox during actual hoisting, and mathematically provides a unique and unchanging center line of rotation for the entire calculation.

[0039] Specifically, under the original placement posture of the gearbox, the geometric relationship between the coordinates of the rear housing lifting lug point and the coordinates of the gearbox centroid relative to the rotation axis is calculated for each lifting lug point. That is, the initial angle between the projection of the vector formed by each point and the rotation axis onto a selected reference plane (such as the XY plane perpendicular to the rotation axis) and a certain reference direction in the reference plane is determined. This initial angle defines the initial orientation of the rear housing lifting lug point and the centroid point before the rotation begins.

[0040] Specifically, once the rotation angle (i.e., the angle by which the gearbox flips over) is determined, since the rotation axis is fixed and the vertical distance from each point to the rotation axis remains unchanged during the rigid body rotation, the coordinates of the rear housing lifting lugs and the gearbox centroid can be calculated by superimposing the input rotation angle on the known initial angle and using standard spatial vector rotation transformation formulas (such as trigonometric functions).

[0041] Specifically, when calculating the coordinates of the lifting lug point and the center of mass of the gearbox after rotation, a stable and accurate rigid body rotation kinematic model is constructed by explicitly defining the actual torque arm lifting lug connection line as a mathematically fixed axis of rotation and calculating the initial angle between this axis and the reference plane. During the calculation, the complex spatial coordinate transformation is transformed into a deterministic calculation problem based on a fixed axis of rotation and a single rotation angle. This ensures the mathematical rigor, program repeatability, and high accuracy of the calculated coordinates of the lifting lug point and the center of mass after rotation at any turning angle. This provides a reliable and efficient geometric basis for subsequent dynamic load calculations and avoids load calculation distortion caused by coordinate transformation errors.

[0042] In step 130, a unit vector for each rotating lifting rope is generated based on the length of each lifting rope and the coordinates of each rotating lifting lug point; wherein, the length of each lifting rope is generated based on the workshop lifting information.

[0043] Specifically, the unit vectors of the rotating suspension ropes mentioned in step 130 can be adopted as follows: Figure 5 The method shown includes: step 510, generating the coordinates of the upper end of each suspension point of each suspension rope based on the length of each suspension rope and the coordinates of each rotational suspension lug point; step 520, generating the unit vector of each suspension rope after rotation based on the length of each suspension rope, the coordinates of each rotational suspension lug point and the coordinates of each upper end of each suspension rope.

[0044] Specifically, in actual hoisting, to ensure the stability of the hoisting structure, the hoisting rope should generally be as perpendicular as possible to the hoisting plane, or, according to the tooling design, the upper hoisting point should be located directly above the lower hoisting lug. Therefore, after knowing the coordinates of the hoisting lug point after rotation, combined with the length of the hoisting rope, the precise coordinates of the upper hoisting point in three-dimensional space can be calculated uniquely and definitively through spatial geometric relationships, so that the position of the hoisting point in the gearbox model is completely consistent with the actual hoisting station layout in the workshop.

[0045] Specifically, when the coordinates of the upper end of the suspension rope and the coordinates of the rotating lug point are both known, the spatial vector connecting these two points is uniquely determined. Dividing each coordinate component of this vector by the length of the suspension rope yields the unit vector of each rotated suspension rope. This unit vector can represent the direction of the tension in the suspension rope at a specific rotation angle.

[0046] Specifically, when calculating the unit vector of the lifting rope after rotation, the coordinates of the upper lifting point of the rope are uniquely and accurately deduced based on the actual rope length in the workshop and the dynamically changing coordinates of the lifting lugs, thus ensuring the physical accuracy of subsequent vector calculations. This process transforms fuzzy spatial direction estimation into rigorous calculation based on definite geometric relationships, eliminating load direction deviations caused by inaccurate assumptions about the lifting point positions, and ensuring that the final rope tension direction strictly corresponds to the actual lifting scenario.

[0047] In step 140, the lifting load of each lifting lug point in the specified direction is generated based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the gearbox centroid after rotation, and the unit vector of each rotating lifting rope.

[0048] Specifically, based on each rotated suspension rope unit vector, the rotated suspension rope unit vector is divided into suspension rope unit vectors in three directions: X-axis, Y-axis, and Z-axis, which are used for subsequent calculation of the lug load.

[0049] Specifically, the lifting lug loads at each lifting lug point mentioned in step 140 in the specified direction can be adopted as follows: Figure 6The method shown includes: Step 610, constructing a first force balance equation based on the lifting load at each lifting lug point, the unit vector of the X-axis lifting rope after rotation, and the weight of the gearbox; Step 620, constructing a second force balance formula based on the lifting load at each lifting lug point, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the centroid of the gearbox after rotation, the unit vectors of the X-axis lifting rope after rotation, and the unit vectors of the Z-axis lifting rope after rotation; Step 630, solving the first force balance equation based on the load relationship of the lifting load at each lifting lug point and the second force balance formula to generate the lifting load at each lifting lug point; Step 640, generating the lifting load at each lifting lug point in a specified direction based on the unit vector of the rotating lifting rope and the lifting load at each lifting lug point.

[0050] Specifically, in the X-axis direction, the tension of the lifting rope at each lifting lug point must be balanced with the weight of the gearbox. Based on this, a first force balance equation is constructed according to the lifting lug load at each lifting lug point, the unit vector of the X-axis lifting rope after rotation, and the weight of the gearbox, where G is the gravity corresponding to the weight of the gearbox, and F1, F2, F3, and F4 are the lifting lug loads at each lifting lug point. , , and Let X be the unit vector of the suspension rope along the X-axis after each rotation. The first force balance equation is as follows.

[0051]

[0052] Specifically, during the gearbox flipping process, after rotating through a certain angle, the gearbox will not rotate around the Y-axis. Therefore, the gearbox can be considered to be in torque equilibrium in the XZ plane. By taking the moments about the center of mass using the loads at the torque arm lifting lugs and the rear housing lifting lugs, the second force equilibrium formula can be obtained; where... , , and Let X be the unit vector of the suspension rope along the X-axis after each rotation. , , and Let F1, F2, F3, and F4 be the unit vectors of the lifting rope along the Z-axis after each rotation, and let F1, F2, F3, and F4 be the lifting lug loads at each lug point. and These are the X-axis and Z-axis coordinates of the centroid of the gearbox after rotation. and These are the X-axis and Z-axis coordinates of each torque arm lug point, respectively. and These are the X-axis and Z-axis coordinates of each rotating lug point, respectively; the constructed second force equilibrium formula is as follows.

[0053]

[0054] Specifically, the two equations above are insufficient to directly solve for the four unknown loads. Therefore, a simplified relationship needs to be introduced based on the actual overturning conditions: the gearbox's center of mass deviates slightly from the Y-axis, and in the calculation, the loads F1 and F2 on the two suspension ropes on the torque arm side are assumed to be the same, as are the loads F3 and F4 on the two suspension ropes on the rear housing side, i.e.: as well as Substituting these values ​​into the above equation reduces the number of unknowns to two, allowing us to solve the two equations simultaneously to obtain the loads F1, F2, F3, and F4 for each lifting lug.

[0055] Specifically, the calculated loads F1, F2, F3, and F4 for each lifting lug are the total loads of that lug. For strength verification, it is necessary to know the force components in the X, Y, and Z directions. Therefore, the final step is to multiply each lug load by its corresponding unit vector of the lifting rope (inclusive of the X, Y, and Z directions), thereby generating the force components of that lifting lug point in each specified coordinate axis direction. These components are the final loads that can be directly input into finite element software and applied to the lifting lug holes for accurate stress analysis. Specifically, the calculation of the entire lifting lug load is presented in an Excel spreadsheet as follows: Figure 7 As shown, when performing calculations, the corresponding rope length, coordinates of each lifting lug point, coordinates of the gearbox centroid, weight of the gearbox, and corresponding rotation angle are entered into an Excel spreadsheet to obtain the lifting lug load at each lifting lug point in the specified direction. This reduces the consumption of computational resources and shortens the calculation time.

[0056] Specifically, when calculating the load on each lifting lug point, the complex three-dimensional dynamic force analysis is transformed into a deterministic mathematical model that can be directly solved using known geometric parameters and vectors. Force balance ensures that the overall force cancels out gravity, and moment balance around a specified axis ensures the stability of the box's posture during tilting, thus guaranteeing the completeness of the mechanical model and the uniqueness of the solution in principle. Combined with a reasonable simplification of the lifting lug load relationships, this scheme makes the originally cumbersome iterative calculations or calculations relying on complex finite element software streamlined, programmable, efficient, and reliable. This allows for the rapid and accurate output of the dynamic load components of the lifting lugs in all directions, providing a direct and reliable input for strength verification.

[0057] In this embodiment, the method for calculating the load on the lifting lugs during the wind turbine gearbox turning process includes: generating the coordinates of each lifting lug point, the coordinates of the gearbox center of mass, and the gearbox weight based on the gearbox model; wherein, the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear gearbox lifting lug point; generating the coordinates of each rotating lifting lug point and the coordinates of the rotating gearbox center of mass based on a preset rotation angle, the coordinates of each lifting lug point, and the coordinates of the gearbox center of mass; wherein, the coordinates of the rotating lifting lug point are the coordinates of the rotating rear gearbox lifting lug points; generating the unit vector of each rotating lifting rope based on the length of each lifting rope and the coordinates of each rotating lifting lug point; wherein, the length of each lifting rope is generated based on workshop hoisting information; and generating the lifting lug load of each lifting lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the rotating gearbox center of mass, and the unit vector of each rotating lifting rope. This scheme, by parametrically inputting a preset rotation angle and combining the known coordinates of the lifting lugs, the coordinates of the center of mass, and the length of the lifting rope, can continuously and dynamically calculate the precise load of each lifting lug point in its direction of force at any angle during the gearbox's overturning process. This scheme replaces the cumbersome process of traditionally requiring complex modeling and static analysis for each discrete angle, thus avoiding the risk of missing the true maximum dynamic load due to sampling analysis. It fundamentally improves the computational efficiency, accuracy, and completeness of the lifting lug load calculation, providing a reliable input for subsequent accurate strength verification.

[0058] The following is a detailed description of the implementation details of the lug strength verification method according to the embodiments of this application. The following content is only for the convenience of understanding and is not necessary for implementing this solution.

[0059] One embodiment of this application relates to a method for verifying the strength of a lifting lug, applied during the overturning process of a wind turbine gearbox, such as... Figure 8 As shown, the lug strength verification method of this embodiment includes steps 810 to 840, and the specific content and implementation details of each step are as follows.

[0060] In step 810, the lifting load of each lifting lug point in the specified direction is transformed into a coordinate system to obtain the lifting load of each lifting lug point in the specified direction in the gearbox coordinate system; wherein, the lifting load of each lifting lug point in the specified direction is generated using the lifting load calculation method described above.

[0061] Specifically, since the previous calculation of the lifting lug load was completed in different local coordinate systems during the gearbox rotation process, this step transforms all the lifting lug loads to a unique and fixed initial coordinate system of the gearbox through coordinate transformation.

[0062] Specifically, the coordinate system transformation of the lifting lug load at each lifting lug point in the specified direction is performed using the three coordinate system transformation formulas shown below; where FTx F Ty and F Tz These represent the loads on each lifting lug along the X, Y, and Z axes of the gearbox coordinate system. , and Let X be the unit vector of the lifting rope on the X-axis, Y-axis, and Z-axis after rotation, F1 be the lifting load of the lifting rope at the lifting lug point in the corresponding direction, and θ be the gearbox flip angle.

[0063]

[0064]

[0065]

[0066] In step 820, the torque arm structure and rear housing structure in the gearbox model are simplified to generate a simplified gearbox model.

[0067] Specifically, such as Figure 9 As shown, after entering the Creo model, the gearbox model is opened and greatly simplified. Only the torque arm and rear housing structure that directly participate in the force are retained, and all features unrelated to the strength of the lifting lug are removed. This greatly reduces the geometric complexity and size of the model. The opened gearbox model can be a single gearbox model or other models that contain gearbox models.

[0068] In step 830, the torque arm structure and the rear housing structure in the simplified gearbox model are connected, and the mesh of the torque arm structure and the rear housing structure in the simplified gearbox model is refined.

[0069] Specifically, in the simplified gearbox model, the two components are simulated with fixed constraints at the connection point, and the mesh is refined for the critical stress areas of the lug and its surroundings, while a coarser mesh is used in non-critical areas. This minimizes the total number of meshes and computation time while ensuring the accuracy of the calculation results.

[0070] In step 840, the lifting loads of each lifting lug point in the gearbox coordinate system in the specified direction are applied to each lifting lug hole in the simplified gearbox model, and then the strength is checked to generate the strength check results of each lifting lug.

[0071] Specifically, the lifting load F at each lifting lug point in the specified direction is... Tx F Ty and F TzThe load is applied as a concentrated force or bearing force to the corresponding lifting lug position in the simplified gearbox model. This method uses the inertial release principle for calculation, eliminating the need for complex and difficult-to-determine physical constraints on the model, and relying solely on the balance between the load itself and the inertial force for the solution. This simplifies and unifies the analysis setup, avoiding stress distortion caused by improper constraint settings. After submitting the calculation, the stress and deformation results of the lifting lug can be obtained in a very short time. By comparing with the allowable strength of the material, reliable lifting lug strength verification results can be quickly generated. The load type in the X direction is Force, and the load in the YZ direction is bearing load. The lifting lug strength verification results are as follows: Figure 10 As shown.

[0072] Specifically, the strength verification result of each lifting lug is the Mises stress of each lifting lug. It is determined whether the Mises stress of the lifting lug is less than the yield strength of the lifting lug. If it is less, it means that the current lifting lug structure is safe and can be put into production. If it is greater than the yield strength, it needs to be further evaluated by the strain criterion. If it passes the strain criterion evaluation, it proves that the current lifting lug design meets the design requirements and can be put into production. If it fails the strain criterion evaluation, it proves that the current lifting lug design does not meet the design requirements and the lifting lug needs to be redesigned and re-verified. Among them, the strain criterion evaluation adopted in this embodiment is a commonly used strain criterion evaluation method in the prior art.

[0073] The beneficial effects of the implementation method described in this application include: by decoupling and connecting "load calculation" and "strength verification", the standardization and efficiency of the safety assessment process are maximized. First, dynamic loads are uniformly transformed to the initial coordinate system, ensuring the consistency of load direction under all working conditions, which facilitates accurate comparative analysis and identification of dangerous working conditions. Second, by significantly simplifying the complex gearbox model (retaining only the key load-bearing structure and removing nonlinear elements) and only refining the mesh in key areas such as the lifting lugs, the model size and computational complexity are greatly reduced while ensuring calculation accuracy. Finally, the calculation load is directly applied using the inertial release principle, avoiding the complex boundary constraint problems that are difficult to accurately simulate in traditional methods. This allows for accurate strength verification of a single working condition within minutes, providing a complete solution for quickly and reliably assessing the safety of lifting operations.

[0074] Meanwhile, the core of the lifting lug load calculation method and lifting lug strength verification method mentioned in this application is based on rigid body mechanics and vector operations. Its technical process can be extended to the design and verification of lifting lugs for all large structural components (such as large machine bases, pressure vessels, and bridge segments) that require dynamic turning and hoisting.

[0075] The steps described above are for clarity only. In practice, they can be combined into one step or some steps can be split into multiple steps. As long as they include the same logical relationship, they are all within the scope of protection of this application. Adding insignificant modifications or introducing insignificant designs to the algorithm or process, but without changing the core design of the algorithm and process, are also within the scope of protection of this application.

[0076] Furthermore, the examples mentioned in the above embodiments can be freely combined, and any combination can be understood as an implementation method. The terms "implementation method" or "example" appearing in various locations in the specification do not necessarily refer to the same implementation method, nor are they independent or alternative implementation methods mutually exclusive with other implementation methods. Those skilled in the art will understand that the implementation methods described herein can be combined with other implementation methods.

[0077] Another embodiment of this application relates to an electronic device, such as... Figure 11 As shown, it includes at least one processor 1110; and a memory 1120 communicatively connected to at least one processor 1110; wherein the memory 1120 stores instructions that can be executed by at least one processor 1110, and the instructions are executed by at least one processor 1110 to enable at least one processor 1110 to execute the implementation of the above-described lifting lug load calculation method or lifting lug strength verification method.

[0078] The memory and processor are connected via a bus, which can include any number of interconnecting buses and bridges, connecting various circuits of one or more processors and memories. The bus can also connect various other circuits such as peripherals, voltage regulators, and power management circuits. A bus interface provides an interface between the bus and the transceiver. The transceiver can be a single component or multiple components, such as multiple receivers and transmitters, providing a unit for communicating with various other devices over a transmission medium. Data processed by the processor is transmitted over the wireless medium via an antenna, which further receives data and transmits it back to the processor.

[0079] The processor manages the bus and general processing, and also provides various functions, including timing, peripheral interfaces, voltage regulation, power management, and other control functions. Memory is used to store data used by the processor during operation.

[0080] This application also relates to a computer-readable storage medium storing a computer program. When executed by a processor, the computer program implements the embodiments corresponding to the above-described lug load calculation method or lug strength verification method.

[0081] That is, those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a device (which may be a microcontroller, chip, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0082] Those skilled in the art will understand that the above embodiments are specific implementations of this application, and in practical applications, various changes can be made in form and detail without departing from the spirit and scope of this application.

Claims

1. A method for calculating the load on a lifting lug, characterized in that, When applied to the overturning process of wind turbine gearboxes, the method includes: Based on the gearbox model, the coordinates of each lifting lug point, the coordinates of the gearbox center of mass, and the gearbox weight are generated; wherein, the coordinates of each lifting lug point include the coordinates of each torque arm lifting lug point and the coordinates of each rear housing lifting lug point; Based on the preset rotation angle, the coordinates of each of the lifting lug points, and the coordinates of the gearbox centroid, the coordinates of each rotating lifting lug point and the coordinates of the rotating gearbox centroid are generated; wherein, the coordinates of the rotating lifting lug points are the coordinates of the rear lifting lug points after rotation; Based on the length of each hoisting rope and the coordinates of each rotating lifting lug point, a unit vector for each rotating hoisting rope is generated; wherein, the length of each hoisting rope is generated based on workshop hoisting information; Based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the gearbox centroid after rotation, and the unit vector of each rotating lifting rope, the lifting lug load of each lifting lug point in the specified direction is generated.

2. The method for calculating the load on the lifting lug according to claim 1, characterized in that, The process of generating the coordinates of each rotating lug point and the coordinates of the gearbox centroid after rotation, based on a preset rotation angle, the coordinates of each of the aforementioned lug points, and the coordinates of the gearbox centroid, includes: The rotation axis is determined based on the coordinates of each torque arm lug point. Based on the rotation axis, the coordinates of each of the rear housing lifting lug points, and the coordinates of the gearbox centroid, the initial angle between the rotation axis and the reference plane is determined; Based on the rotation angle, the initial angle, the coordinates of each of the rear housing lifting lug points, and the coordinates of the gearbox centroid, the coordinates of each of the rotated rear lifting lug points and the coordinates of the rotated gearbox centroid are generated.

3. The method for calculating the load on the lifting lug according to claim 1, characterized in that, The process of generating unit vectors for each rotating suspension rope based on the length of each rope and the coordinates of each rotating lug point includes: Based on the length of each suspension rope and the coordinates of each rotating lug point, the coordinates of the upper suspension point of each suspension rope are generated. Based on the length of each suspension rope, the coordinates of each rotating lug point, and the coordinates of each suspension rope's upper end point, a unit vector for each rotating suspension rope is generated.

4. The method for calculating the load on the lifting lug according to claim 1, characterized in that, Each of the rotated suspension rope unit vectors includes each rotated X-axis suspension rope unit vector and each rotated Z-axis suspension rope unit vector; The step of generating the lifting load of each lifting lug point in a specified direction based on the gearbox weight, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the gearbox centroid after rotation, and the unit vector of each rotating lifting rope includes: Based on the lifting lug load at each lifting lug point, the unit vector of the rotating X-axis lifting rope at each lifting lug point, and the weight of the gearbox, a first force balance equation is constructed. Based on the lifting load of each lifting lug point, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the centroid of the gearbox after rotation, the unit vectors of the X-axis lifting rope after rotation, and the unit vectors of the Z-axis lifting rope after rotation, a second force balance formula is constructed. Based on the load relationship of the lifting lug loads at each of the lifting lug points and the second force balance formula, the first force balance equation is solved to generate the lifting lug loads at each of the lifting lug points; Based on the unit vector of each rotating suspension rope and the lug load of each lug point, the lug load of each lug point in the specified direction is generated.

5. The method for calculating the load on the lifting lug according to claim 4, characterized in that, The first force balance equation is constructed based on the lifting lug load at each of the lifting lug points, the unit vector of the rotating X-axis lifting rope, and the weight of the gearbox, including: Based on the pre-set force balance equation Construct the first force equilibrium equation; In the force balance equation, G represents the gravity corresponding to the weight of the gearbox, and F1, F2, F3, and F4 represent the lifting loads at each of the lifting lug points. , , and Let X be the unit vector of the suspension rope along the X-axis after rotation.

6. The method for calculating the load on the lifting lug according to claim 4, characterized in that, The second force balance formula is constructed based on the lifting load at each lifting lug point, the coordinates of each torque arm lifting lug point, the coordinates of each rotating lifting lug point, the coordinates of the centroid of the gearbox after rotation, the unit vector of the X-axis lifting rope after rotation, and the unit vector of the Z-axis lifting rope after rotation, including: Based on the preset force balance formula Construct the second force equilibrium formula; In the force balance formula, , , and Let X be the unit vector of the suspension rope along the X-axis after rotation. , , and Let F1, F2, F3, and F4 be the unit vector of the Z-axis lifting rope after rotation, and let F1, F2, F3, and F4 be the lifting lug loads at each of the lifting lug points. and These are the X-axis and Z-axis coordinates of the centroid of the rotated gearbox, respectively. and These are the X-axis and Z-axis coordinates of the coordinates of each torque arm lug point. and These are the X-axis and Z-axis coordinates of the rotating lug points, respectively.

7. The method for calculating the load on the lifting lug according to claim 4, characterized in that, The lifting lugs include each torque arm lifting lug and each rear box lifting lug; The load relationship of the lifting lugs at each of the lifting lug points is that the lifting lugs at each of the torque arm lifting lug points are the same, and the lifting lugs at each of the rear box lifting lug points are the same.

8. A method for verifying the strength of a lifting lug, characterized in that, When applied to the overturning process of wind turbine gearboxes, the method includes: The coordinate system transformation process is performed on the lifting lug load of each lifting lug point in the specified direction to obtain the lifting lug load of each lifting lug point in the specified direction in the gearbox coordinate system; wherein, the lifting lug load of each lifting lug point in the specified direction is generated using the lifting lug load calculation method according to any one of claims 1-7; The torque arm structure and rear housing structure in the gearbox model are simplified to generate a simplified gearbox model. Connect the torque arm structure and the rear housing structure in the simplified gearbox model, and perform mesh refinement processing on the torque arm structure and the rear housing structure in the simplified gearbox model; After applying the lifting load of each lifting lug point in the gearbox coordinate system in the specified direction to each lifting lug hole in the simplified gearbox model, a strength check is performed to generate the strength check results of each lifting lug.

9. An electronic device, characterized in that, include: At least one processor; as well as, A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor, which enables the at least one processor to perform the lug load calculation method as described in any one of claims 1 to 7 or the lug strength verification method as described in claim 8.

10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the lug load calculation method as described in any one of claims 1 to 7 or the lug strength verification method as described in claim 8.

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