Noise elimination and reduction device for gearbox of wind power cabin

Abstract

The invention is suitable for the related technical field of gear boxes, and provides a wind power cabin gear box noise elimination and reduction device which comprises a sensing layer, a control layer and an execution layer. The sensing layer comprises a piezoelectric type pressure sensor and a Hall type gear rotating speed sensor which are installed in a gear meshing area in a gear box. The control layer is an industrial-grade central controller with a PID adjusting function, the central controller is in communication connection with the sensing layer and the execution layer through a CAN bus, through cooperative arrangement of the sensing layer, the control layer and the execution layer, the problems that most of existing noise reduction devices are improved on sound insulation materials, the effect is not obvious enough, and the noise reduction effect is poor are solved. The noise cannot be reduced fundamentally, and certain limitation exists.

Description

Technical Field

[0001] This invention relates to the field of gearbox technology, specifically a noise reduction device for a wind turbine nacelle gearbox. Background Technology

[0002] With the global trend of energy structure transformation towards cleaner and renewable energy, wind power, as a technologically mature and widely commercialized new energy source, has become one of the core pillars for alleviating the shortage of traditional fossil fuels and reducing carbon emissions. As the wind power industry develops on a large scale, the single-unit capacity of wind turbines continues to increase. Currently, the capacity of mainstream onshore wind turbines has reached 4-6MW, and offshore wind turbines have even exceeded 15MW. While the larger size of the turbines has significantly improved power generation efficiency, it has also placed more stringent demands on the performance of core transmission components. The gearbox inside the wind turbine nacelle, as the core component for mechanical energy transmission and speed conversion, functions to convert the low-speed, high-torque mechanical energy captured by the wind turbine into the high-speed, low-torque power required by the generator through multi-stage gear meshing. It is the "power heart" that ensures stable power generation of the unit. However, during long-term high-load operation of the gearbox, due to factors such as mechanical structural characteristics, operating conditions, and manufacturing and assembly precision, high-intensity noise is inevitably generated, becoming one of the main noise sources in the wind turbine nacelle and even the entire wind farm.

[0003] Most existing noise reduction devices improve sound insulation materials, but the effect is not significant enough to reduce noise at its source, thus having certain limitations. Therefore, there is an urgent need to provide a noise reduction device for wind turbine nacelle gearboxes to overcome the shortcomings in current practical applications. Summary of the Invention

[0004] The purpose of this invention is to provide a noise reduction device for wind turbine nacelle gearboxes, which aims to solve the problems mentioned in the background art.

[0005] This invention is implemented as follows: a noise reduction device for a wind turbine nacelle gearbox, comprising:

[0006] Perception layer, control layer, and execution layer;

[0007] The sensing layer includes a piezoelectric pressure sensor and a Hall effect gear speed sensor installed in the gear meshing area inside the gearbox.

[0008] The control layer is an industrial-grade central controller with PID regulation function. The central controller communicates with the sensing layer and the execution layer via a CAN bus.

[0009] The execution layer includes a housing with a filter chamber for storing lubricating fluid. The filter chamber contains an electric heating wire and a cooling coil. The housing is also connected to a second circulation pipe and a first circulation pipe. The second circulation pipe and the first circulation pipe are respectively equipped with a first pump and a second pump. The output end of the first pump is connected to the filter chamber, and the input end of the second pump is connected to the filter chamber. The first circulation pipe and the second circulation pipe are also connected to the lubricating fluid inlet and the lubricating fluid outlet of the gearbox, respectively. The gearbox is also equipped with an ultrasonic atomizing nozzle that sprays lubricating fluid toward the gear meshing area, and the ultrasonic atomizing nozzle is connected to the lubricating fluid inlet.

[0010] As a further aspect of the present invention: the central controller can adjust the execution layer parameters in stages based on the operating condition data fed back from the sensing layer.

[0011] When the gear speed is <500r / min, the electric heating wire is controlled to heat the lubricating oil to reduce the viscosity to 150-200cSt, the output flow of the second pump is adjusted to 8-10L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 20μm to ensure that the lubricating oil quickly covers the tooth surface.

[0012] When the gear speed is 1500-3000 r / min, the cooling coil is controlled to maintain the lubricating oil viscosity at 80-120 cSt, the output flow of the second pump is adjusted to 15-18 L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 5-10 μm to form a uniform oil film to absorb the meshing impact energy.

[0013] As a further aspect of the present invention: when the pressure sensor detects that the pressure fluctuation amplitude in the meshing area changes by more than ±0.4MPa within 1 second, the central controller controls the second pump 17 to increase the output flow rate to 20L / min within 100ms;

[0014] If the pressure fluctuation exceeds 3MPa, the lubricating oil viscosity is reduced by 10-20cSt in the cooling coil to enhance the oil film thickness.

[0015] As a further aspect of the present invention: the pressure sensor adopts a double-layer sealing structure, with an inner layer of nitrile rubber O-ring and an outer layer of anaerobic adhesive sealant;

[0016] The ultrasonic atomizing nozzle is made of 304 stainless steel.

[0017] As a further aspect of the present invention, it also includes a filtration system, the filtration system comprising:

[0018] A rotating shaft is installed inside the filter chamber, and a second motor for driving the rotating shaft is also provided at the bottom of the housing;

[0019] A filter cover for filtering lubricating fluid, the filter cover being fixedly installed on a rotating shaft, with the bottom of the filter cover fitting against the inner wall of the filter chamber.

[0020] As a further aspect of the present invention, the filtration system further includes a sewage discharge mechanism, which includes a cleaning component and a debris discharge component.

[0021] As a further aspect of the present invention: the impurity removal component includes:

[0022] A discharge port is provided on the side wall of the housing and communicates with the filter chamber. A sealing plate for sealing the discharge port is also slidably installed inside the side wall of the housing.

[0023] A collection box for collecting impurities is disposed on the side wall of the housing and arranged around the impurity discharge port;

[0024] And the drive components used to move the sealing plate.

[0025] As a further aspect of the present invention: the driving component includes an external gear ring rotatably mounted on the side wall of the box, the external gear ring being fixedly connected to the end of the sealing plate via a linkage rod, and the collection box is also provided with a motor, and a driving gear meshing with the external gear ring is fixedly mounted on the output shaft of the motor.

[0026] As a further aspect of the present invention: the cleaning and scraping assembly includes:

[0027] The slider is slidably mounted inside the rotating shaft, and the rotating shaft is provided with a spring for elastically supporting the slider.

[0028] A driven shaft is slidably mounted on a rotating shaft. The driven shaft is rotatably connected to the slider, and a protrusion is provided on the driven shaft. A slot is provided inside the rotating shaft for engaging with the protrusion.

[0029] A dispersion cover is fixedly installed on the driven shaft and is located below one input end of the pump.

[0030] A linkage sleeve is slidably mounted on the driven shaft. The linkage sleeve can rotate with the driven shaft, and a scraper that fits against the surface of the filter cover is also provided on the linkage sleeve.

[0031] The fixing strip is fixedly installed on the dispersion cover;

[0032] And a baffle for blocking the fixing strip, the baffle being fixedly installed on the inner wall of the filter chamber and located within the opening range of the discharge port.

[0033] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention achieves the triple function of "precise lubrication + damping vibration reduction + heat dissipation synergy" through innovative lubrication structure design, which reduces vibration excitation from the source of noise, and solves the pain points of poor heat dissipation and low reliability of traditional sound insulation technology.

[0034] By combining the perception layer, control layer, and execution layer, this approach avoids the problem that most existing noise reduction devices only improve sound insulation materials, resulting in insufficient effectiveness and an inability to reduce noise at its source, thus having certain limitations. Attached Figure Description

[0035] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0036] Figure 1 This is a diagram showing the working state of the present invention.

[0037] Figure 2 This is a schematic diagram of the structure of the present invention.

[0038] Figure 3 This is a schematic diagram of the structure of the present invention with the collection box hidden.

[0039] Figure 4 This is a schematic diagram of the internal structure of the box in this invention.

[0040] Figure 5 for Figure 4 A schematic diagram of the structure viewed from below.

[0041] Figure 6 This is a schematic diagram of the auxiliary impurity removal component in this invention.

[0042] Figure 7 This is a cross-sectional view of the connection between the rotating shaft and the driven shaft in this invention.

[0043] In the attached diagram: 1-Gearbox, 2-Circulation pipe one, 3-Box body, 4-External gear ring, 5-Motor one, 6-Collection box, 7-Circulation pipe two, 8-Drive gear, 9-Blocking plate, 10-Linkage rod, 11-Discharge port, 12-Pump one, 13-Baffle bar, 14-Dispersion cover, 15-Fixing bar, 16-Scraper, 17-Pump two, 18-Filter cover, 19-Rotating shaft, 20-Motor two, 21-Linkage sleeve, 22-Driven shaft, 23-Slider, 24-Spring, 25-Protruding strip. Detailed Implementation

[0044] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0046] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0047] The present invention will be further explained below with reference to specific embodiments.

[0048] Please see Figures 1-7 The present invention provides a noise reduction device for a wind turbine nacelle gearbox, comprising:

[0049] Perception layer, control layer, and execution layer;

[0050] The sensing layer includes a piezoelectric pressure sensor and a Hall effect gear speed sensor installed in the gear meshing area inside the gearbox 1. The pressure sensor has a range of 0-10MPa and a response frequency of ≥5kHz, and the speed sensor has a measurement range of 0-5000r / min.

[0051] The control layer is an industrial-grade central controller with PID regulation function. The central controller communicates with the sensing layer and the execution layer via a CAN bus.

[0052] The execution layer includes a housing 3, which has a filter chamber for storing lubricating fluid. The filter chamber contains an electric heating wire and a cooling coil. The housing 3 is also connected to a second circulation pipe 7 and a first circulation pipe 2. The second circulation pipe 7 and the first circulation pipe 2 are respectively equipped with a first pump 12 and a second pump 17. The output end of the first pump 12 is connected to the filter chamber, and the input end of the second pump 17 is connected to the filter chamber. The first circulation pipe 2 and the second circulation pipe 7 are also connected to the lubricating fluid inlet and lubricating fluid outlet of the gearbox 1, respectively. The gearbox 1 is also provided with an ultrasonic atomizing nozzle that sprays lubricating fluid toward the gear meshing area, and the ultrasonic atomizing nozzle is connected to the lubricating fluid inlet.

[0053] In the embodiments of the present invention, the innovative lubrication structure design achieves the triple function of "precise lubrication + damping vibration reduction + heat dissipation synergy", reducing vibration excitation from the source of noise and solving the pain points of poor heat dissipation and low reliability of traditional sound insulation technology. Compared with the prior art, the present invention avoids the problem that most existing noise reduction devices improve the sound insulation material, which is not effective enough and cannot reduce noise at the source, thus having certain limitations.

[0054] In one embodiment of the present invention, please refer to Figures 1-7 The central controller can adjust the execution layer parameters in stages based on the operating condition data fed back from the sensing layer.

[0055] When the gear speed is <500r / min, the electric heating wire is controlled to heat the lubricating oil to reduce the viscosity to 150-200cSt, the output flow of the pump 17 is adjusted to 8-10L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 20μm to ensure that the lubricating oil quickly covers the tooth surface and reduces dry friction noise during cold start.

[0056] When the gear speed is 1500-3000 r / min, the cooling coil is controlled to maintain the lubricating oil viscosity at 80-120 cSt, the output flow of the second pump 17 is adjusted to 15-18 L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 5-10 μm to form a uniform oil film. The elastic damping effect of the oil film absorbs the meshing impact energy and reduces high-frequency meshing noise.

[0057] When the pressure sensor detects a pressure fluctuation amplitude change exceeding ±0.4MPa within 1 second (corresponding to a torque fluctuation of ±20%) in the meshing area, the central controller controls the second pump 17 to increase the output flow rate to 20L / min within 100ms. If the pressure fluctuation amplitude exceeds 3MPa, the cooling coil is additionally controlled to reduce the lubricating oil viscosity by 10-20cSt to respond to sudden gear load changes, strengthen the oil film thickness, avoid direct contact between gear surfaces, suppress impact noise peaks, and protect gearbox 1, thus extending its service life. By optimizing the lubrication structure, vibration excitation of gears and bearings is directly reduced. Compared with traditional passive sound insulation technology, noise reduction is more thorough and there is no noise leakage problem. The lubricating oil circulation loop simultaneously achieves noise reduction and heat dissipation, avoiding the heat dissipation bottleneck of traditional soundproof enclosures and improving the operational reliability of gearbox 1.

[0058] The pressure sensor adopts a double-layer sealing structure, with an inner layer of nitrile rubber O-ring and an outer layer of anaerobic adhesive sealant.

[0059] The ultrasonic atomizing nozzle is made of 304 stainless steel.

[0060] In this embodiment, the second pump 17 can be a variable flow plunger pump.

[0061] In one embodiment of the present invention, please refer to Figures 1-7 It also includes a filtration system, the filtration system comprising:

[0062] Rotary shaft 19 is installed inside the filter chamber; a motor 20 for driving the rotating shaft 19 is also provided at the bottom of the housing 3.

[0063] A filter cover 18 for filtering lubricating fluid is fixedly installed on a rotating shaft 19, and the bottom of the filter cover 18 is in contact with the inner wall of the filter chamber.

[0064] The filtration system also includes a waste discharge mechanism, which includes a cleaning component and a debris removal component;

[0065] The impurity removal component includes:

[0066] A discharge port 11 is provided on the side wall of the housing 3 and communicates with the filter chamber. A sealing plate 9 for sealing the discharge port 11 is also slidably installed inside the side wall of the housing 3.

[0067] A collection box 6 for collecting impurities is provided on the side wall of the box body 3 and arranged around the impurity discharge port 11;

[0068] And the drive components used to move the sealing plate 9;

[0069] The driving component includes an external gear ring 4 rotatably mounted on the side wall of the housing 3. The external gear ring 4 is fixedly connected to the end of the sealing plate 9 through a linkage rod 10. The collection box 6 is also equipped with a motor 5, and a drive gear 8 that meshes with the external gear ring 4 is fixedly mounted on the output shaft of the motor 5.

[0070] The cleaning assembly includes:

[0071] The slider 23 is slidably mounted inside the rotating shaft 19, and the rotating shaft 19 is provided with a spring 24 for elastically supporting the slider 23;

[0072] A driven shaft 22 is slidably mounted on a rotating shaft 19. The driven shaft 22 is rotatably connected to a slider 23. A protrusion 25 is also provided on the driven shaft 22. A strip groove for engaging with the protrusion 25 is provided inside the rotating shaft 19.

[0073] Dispersion cover 14 is fixedly installed on driven shaft 22 and is located below the input end of pump 12;

[0074] A linkage sleeve 21 is slidably mounted on the driven shaft 22. The linkage sleeve 21 can rotate with the driven shaft 22, and a scraper 16 that is in contact with the surface of the filter cover 18 is also provided on the linkage sleeve 21.

[0075] Fixing strip 15, which is fixedly installed on the dispersion cover 14;

[0076] And a baffle 13 for blocking the fixing strip 15, the baffle 13 being fixedly installed on the inner wall of the filter chamber and located within the opening range of the discharge port 11.

[0077] In this embodiment, pump 12 draws lubricating fluid from gearbox 1 into the filter chamber. The lubricating fluid impacts the dispersion cover 14, causing it to press against the driven shaft 22, thus compressing the spring 24. During this process, the fixing strip 15, rotating with the dispersion cover 14, is not obstructed by the baffle strip 13. Motor 20, by driving the rotating shaft 19, rotates the filter cover 18, filtering impurities from the lubricating fluid. The rotating filter cover 18 disperses impurities under centrifugal force. The filtered lubricating fluid is then drawn out by pump 27 and introduced into gearbox 1 through circulation pipe 2, achieving lubricating fluid circulation. When gearbox 1 stops working, motor 5 uses the drive gear 8 to drive the external... When the toothed ring 4 rotates, the sealing plate 9 moves along with the outer toothed ring 4 via the linkage rod 10, causing the sealing plate 9 to stop blocking the discharge port 11. At the same time, the spring 24 pushes the slider 23 upward, causing the convex strip 25 to separate from the strip groove in the rotating shaft 19. At this time, the driven shaft 22 will not rotate with the rotating shaft 19. When the rotating shaft 19 drives the filter cover 18 to rotate, the impurities remaining on the filter cover 18 will push the scraper 16 to move synchronously until the fixed strip 15 is blocked by the baffle 13. Then the filter cover 18 continues to rotate, causing the impurities to be discharged through the discharge port 11 under the action of centrifugal force and the scraping action of the scraper 16, and enter the collection box 6. Impurity removal can improve the lubrication effect and reduce noise. When maintaining the wind turbine, the staff can clean the impurities in the collection box 6.

[0078] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A noise reduction device for a wind turbine nacelle gearbox, comprising a sensing layer, a control layer, and an execution layer, characterized in that, The sensing layer includes a piezoelectric pressure sensor and a Hall effect gear speed sensor installed in the gear meshing area inside the gearbox. The control layer is an industrial-grade central controller with PID regulation function. The central controller communicates with the sensing layer and the execution layer via a CAN bus. The execution layer includes a housing with a filter chamber for storing lubricating fluid. The filter chamber contains an electric heating wire and a cooling coil. The housing is also connected to a second circulation pipe and a first circulation pipe. The second circulation pipe and the first circulation pipe are respectively equipped with a first pump and a second pump. The output end of the first pump is connected to the filter chamber, and the input end of the second pump is connected to the filter chamber. The first circulation pipe and the second circulation pipe are also connected to the lubricating fluid inlet and the lubricating fluid outlet of the gearbox, respectively. The gearbox is also equipped with an ultrasonic atomizing nozzle that sprays lubricating fluid toward the gear meshing area, and the ultrasonic atomizing nozzle is connected to the lubricating fluid inlet.

2. The wind turbine nacelle gearbox noise reduction device according to claim 1, characterized in that, The central controller can adjust the execution layer parameters in stages based on the operating condition data fed back from the sensing layer: When the gear speed is <500r / min, the electric heating wire is controlled to heat the lubricating oil to reduce the viscosity to 150-200cSt, the output flow of the second pump is adjusted to 8-10L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 20μm to ensure that the lubricating oil quickly covers the tooth surface. When the gear speed is 1500-3000 r / min, the cooling coil is controlled to maintain the lubricating oil viscosity at 80-120 cSt, the output flow of the second pump is adjusted to 15-18 L / min, and the ultrasonic atomizing nozzle sprays with a particle size of 5-10 μm to form a uniform oil film to absorb the meshing impact energy.

3. The wind turbine nacelle gearbox noise reduction device according to claim 2, characterized in that, When the pressure sensor detects that the pressure fluctuation amplitude in the meshing area changes by more than ±0.4MPa within 1 second, the central controller controls the second pump 17 to increase the output flow rate to 20L / min within 100ms. If the pressure fluctuation exceeds 3MPa, the lubricating oil viscosity is reduced by 10-20cSt in the cooling coil to enhance the oil film thickness.

4. The wind turbine nacelle gearbox noise reduction device according to claim 1, characterized in that, The pressure sensor adopts a double-layer sealing structure, with an inner layer of nitrile rubber O-ring and an outer layer of anaerobic adhesive sealant. The ultrasonic atomizing nozzle is made of 304 stainless steel.

5. The wind turbine nacelle gearbox noise reduction device according to claim 1, characterized in that, It also includes a filtration system, which comprises: A rotating shaft is installed inside the filter chamber, and a second motor for driving the rotating shaft is also provided at the bottom of the housing; A filter cover for filtering lubricating fluid, the filter cover being fixedly installed on a rotating shaft, with the bottom of the filter cover fitting against the inner wall of the filter chamber.

6. The wind turbine nacelle gearbox noise reduction device according to claim 5, characterized in that, The filtration system also includes a waste discharge mechanism, which includes a cleaning component and a debris removal component.

7. The wind turbine nacelle gearbox noise reduction device according to claim 6, characterized in that, The impurity removal component includes: A discharge port is provided on the side wall of the housing and communicates with the filter chamber. A sealing plate for sealing the discharge port is also slidably installed inside the side wall of the housing. A collection box for collecting impurities is disposed on the side wall of the housing and arranged around the impurity discharge port; And the drive components used to move the sealing plate.

8. The wind turbine nacelle gearbox noise reduction device according to claim 7, characterized in that, The driving component includes an external gear ring rotatably mounted on the side wall of the box. The external gear ring is fixedly connected to the end of the sealing plate through a linkage rod. The collection box is also equipped with a motor, and a drive gear that meshes with the external gear ring is fixedly mounted on the output shaft of the motor.

9. The wind turbine nacelle gearbox noise reduction device according to claim 7, characterized in that, The cleaning assembly includes: The slider is slidably mounted inside the rotating shaft, and the rotating shaft is provided with a spring for elastically supporting the slider. A driven shaft is slidably mounted on a rotating shaft. The driven shaft is rotatably connected to the slider, and a protrusion is provided on the driven shaft. A slot is provided inside the rotating shaft for engaging with the protrusion. A dispersion cover is fixedly installed on the driven shaft and is located below one input end of the pump. A linkage sleeve is slidably mounted on the driven shaft. The linkage sleeve can rotate with the driven shaft, and a scraper that fits against the surface of the filter cover is also provided on the linkage sleeve. The fixing strip is fixedly installed on the dispersion cover; And a baffle for blocking the fixing strip, the baffle being fixedly installed on the inner wall of the filter chamber and located within the opening range of the discharge port.

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