A wind power bearing retainer with a metal skeleton and a manufacturing method thereof

Abstract

This invention provides a wind turbine bearing cage with a metal frame and its manufacturing method, comprising: a metal frame and a plastic-coated structure externally disposed on the metal frame; the metal frame includes side beams, end beams, and cross braces, wherein there are two side beams arranged in parallel; the end beams are disposed at both ends of the side beams and are connected to the side beams by a tenon and mortise structure; the cross braces are disposed between the two side beams and are connected to the side beams by an insertion joint, the cross braces are arranged parallel to the end beams, and a window is formed between the cross braces and the end beams; the plastic-coated structure includes a plastic coating layer and a pocket plastic layer, the pocket plastic layer being disposed on two opposite sides of the end beams and cross braces within the window, forming pockets for installing cylindrical rollers, and the plastic coating layer being disposed on other sides of the side beams and end beams. This invention solves the problem of deformation and cracking that easily occurs during high-speed rotation of existing injection-molded wind turbine bearing cages.

Description

Technical Field

[0001] This invention belongs to the field of wind turbine bearing technology, specifically relating to a wind turbine bearing cage with a metal skeleton and its manufacturing method. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] In the field of wind turbine bearing cage manufacturing, traditional injection molding processes present significant technical bottlenecks. Cage products made by direct injection molding of engineering plastics are prone to dimensional inaccuracies due to unstable material shrinkage during production. Furthermore, as the product thickness increases, internal porosity defects easily form, severely impacting material density and mechanical strength. These inherent defects make pure plastic cages susceptible to deformation, cracking, and other failures under the high load and high speed conditions of wind turbine operation, failing to meet the stringent requirements of wind turbine bearings for long lifespan and high reliability. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a wind turbine bearing cage with a metal skeleton and a manufacturing method thereof, which solves the problem that existing injection-molded wind turbine bearing cages are prone to deformation and cracking during high-speed rotation.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: In a first aspect, the present invention provides a wind turbine bearing cage with a metal frame, comprising: a metal frame and a plastic-coated structure disposed on the outside of the metal frame; the metal frame includes side beams, end beams, and cross braces, wherein there are two side beams arranged in parallel; the end beams are disposed at both ends of the side beams and are connected to the side beams by a tenon and mortise structure; the cross braces are disposed between the two side beams and are connected to the side beams by an insertion joint, the cross braces are arranged in parallel with the end beams, and a window is formed between the cross braces and the end beams; the plastic-coated structure includes a plastic coating layer and a pocket plastic layer, the pocket plastic layer is disposed on two opposite sides of the end beams and cross braces within the window to form pockets for mounting cylindrical rollers, and the plastic coating layer is disposed on other sides of the side beams and end beams.

[0006] As a further implementation, the side beams, end beams, and cross braces are all made of metal plates, and each side beam, end beam, and cross brace is provided with multiple through holes, which are distributed in a rectangular array.

[0007] As a further implementation, a plurality of first support columns are provided on the end beam, and the first support columns are located at the edge of the end beam.

[0008] As a further implementation, dovetail tenons are provided at both ends of the end beam, the length of the dovetail tenons is the same as the thickness of the side beam, the end of the side beam is provided with a mortise, a U-shaped groove is opened in the middle of the dovetail tenon of the end beam, a second support column is provided on the dovetail tenon, and a T-shaped limiting block is provided in the mortise of the side beam.

[0009] As a further implementation, the included angle between the sidewall of the dovetail tenon and the tenon shoulder is 60°~85°.

[0010] As a further implementation, the included angle between the sidewall of the tenon and the side of the side beam is 90°.

[0011] As a further implementation, two plug-in posts are provided at both ends of the cross brace, the length of the plug-in posts is equal to the thickness of the side beam, and a third support post is provided between the two plug-in posts; a plug-in hole is provided at the middle of the side beam corresponding to the position of the cross brace, a support hole is provided between the two plug-in holes, the plug-in posts are installed in the plug-in holes, and the third support post is installed in the support hole.

[0012] As a further implementation, the thickness of the plastic coating layer is 1.5-6mm, and the thickness of the plastic coating layer is equal to the length of the first support column and the second support column, respectively.

[0013] As a further implementation, the pockets formed by the pocket plastic layer are through holes, with one end of the pocket opening being larger than the other end opening; the opening arrangements of the pockets in adjacent windows are opposite.

[0014] Secondly, the present invention also provides a method for manufacturing a wind turbine bearing cage with a metal skeleton, comprising the following steps: Step 1: Cut the metal steel plate into side beams, end beams and cross braces according to the size requirements. After assembling the side beams, end beams and cross braces, press the side wall of the tenon into the side wall of the tenon to achieve riveting. Step 2: Place the assembled metal frame into the injection mold cavity, and inject the injection molding material into the injection mold cavity using an injection molding machine; Step 3: After injection molding is completed, the metal skeleton, plastic coating layer and pocket plastic layer are cooled to room temperature by air cooling.

[0015] Compared with the prior art, the advantages and positive effects of this invention are: This invention includes a metal frame and a plastic-coated structure on the outside of the metal frame. The metal frame withstands the impact of the rollers under high-speed operation, speed changes, or loads, preventing excessive deformation or breakage of the cage. The plastic-coated structure is relatively soft and self-lubricating, reducing wear on the roller surface. The end beams and side beams are connected by a mortise and tenon structure, which makes the structure stable and effectively transmits and disperses stress at the beam ends, ensuring the stability and dimensional accuracy of the overall shape of the cage. A window is formed between the cross brace and the end beam, enhancing the integrity of the two parallel side beams and creating two windows for mounting cylindrical rollers. The plastic-coated structure includes a plastic coating layer and a pocket plastic layer. The pocket plastic layer is located on the two opposite sides of the end beam and cross brace within the window, forming pockets. The pocket shape is directly molded within the window formed by the metal frame to accommodate and isolate the cylindrical rollers. Compared to metal, the perforated plastic coating is softer and self-lubricating, reducing wear on the roller surface and lowering rolling resistance. It also possesses elasticity, absorbing minor impacts and vibrations between the rollers and the cage, further reducing noise. The plastic coating is applied to the other sides of the side and end beams, covering their outer surfaces and isolating the metal skeleton from the environment, improving its corrosion resistance. Simultaneously, it reduces friction and noise, achieving both self-lubrication and noise reduction. The metal skeleton solves the problems of insufficient strength and easy creep of pure plastic cages under high speed and heavy loads; the plastic coating structure enables the cage to achieve friction reduction, noise reduction, and corrosion resistance, giving it both high strength and rigidity, as well as excellent surface functional properties.

[0016] The side beams, end beams, and cross braces of this invention are all made of metal plates. Each side beam, end beam, and cross brace has multiple through holes arranged in a rectangular array. This allows the injection molding material to pass through the through holes, weaving the metal skeleton and the plastic-coated structure together and preventing peeling between the plastic-coated structure and the metal skeleton. The end beams are equipped with multiple first support columns located at their edges. These first support columns provide clearance for the injection molding material to flow within the mold cavity. After the injection molding material has cured, the ends of the first support columns are flush with the surface of the plastic-coated structure. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0018] Figure 1 This is a schematic diagram of the wind turbine bearing cage structure with a metal skeleton according to the present invention.

[0019] Figure 2 This is a schematic diagram of the metal skeleton structure of the present invention.

[0020] Figure 3 This is a schematic diagram of the end beam structure of the present invention.

[0021] Figure 4 This is a schematic diagram of the side beam structure of the present invention.

[0022] Figure 5 This is a schematic diagram of the cross brace structure of the present invention.

[0023] In the diagram: 1. Metal frame; 2. Plastic coating layer; 3. Pocket plastic coating layer; 4. Pocket; 5. Side beam; 6. End beam; 7. Cross brace; 8. First support column; 9. Tenon; 10. Second support column; 11. U-shaped groove; 12. Through hole; 13. Mortise and tenon; 14. T-shaped limiting block; 15. Insertion hole; 16. Support hole; 17. Insertion column; 18. Third support column. Detailed Implementation

[0024] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0025] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof. Example 1 This embodiment provides a wind turbine bearing cage with a metal frame, such as... Figures 1-5As shown, the structure includes: a metal frame 1 and a plastic-coated structure on the outside of the metal frame 1. The metal frame 1 bears the centrifugal force, inertial force, and contact force of the rollers under high-speed operation, speed change, or load impact, preventing excessive deformation or breakage of the cage. The plastic-coated structure is relatively soft and self-lubricating, reducing wear on the roller surface and lowering rolling resistance. The metal frame 1 includes side beams 5, end beams 6, and cross braces 7. There are two side beams 5, arranged in parallel. The end beams 6 are located at both ends of the side beams 5 and are connected to the side beams 5 by a mortise and tenon structure. The mortise and tenon connection between the side beams 5 and the end beams 6 makes the structure stable and can effectively transfer and distribute the force at the beam ends. Stress is applied to ensure the stability and dimensional accuracy of the overall shape of the cage. The cross brace 7 is positioned between the two side beams 5 and is connected to the side beams 5 by an insertion connection. The cross brace 7 is arranged parallel to the end beam 6, and a window is formed between the cross brace 7 and the end beam 6. This enhances the integrity of the two parallel side beams 5 and also forms two windows for installing cylindrical rollers. The plastic coating structure includes a plastic coating layer 2 and a pocket plastic layer 3. The pocket plastic layer 3 is positioned on the two opposite sides of the end beam 6 and the cross brace 7 within the window, forming pockets 4. The pockets 4 are directly molded into the shape of pockets within the window formed by the metal frame to accommodate and isolate cylindrical rollers. The perforated plastic layer 3 is softer and self-lubricating than metal, reducing wear on the roller surface and lowering rolling resistance. It also possesses elasticity, absorbing minor impacts and vibrations between the rollers and the cage, further reducing noise. The plastic coating layer 2 is applied to the other sides of the side beams 5 and end beams 6, covering their outer surfaces and isolating the metal frame 1 from the environment, thus improving its corrosion resistance. Simultaneously, it reduces friction and noise, achieving self-lubrication and noise reduction. The metal frame 1 solves the problems of insufficient strength and easy creep of pure plastic cages under high speed and heavy load. The plastic coating structure enables the cage to achieve friction reduction, noise reduction, and corrosion resistance, giving it both high strength and high rigidity, as well as excellent surface functional properties.

[0026] As a further implementation, the side beams 5, end beams 6, and cross braces 7 are all made of metal plates, and each of the side beams 5, end beams 6, and cross braces 7 is provided with multiple through holes 12, which are distributed in a rectangular array. This allows the injection molding material to pass through the through holes 12, weaving the metal skeleton 1 and the plastic-coated structure together, thus preventing the plastic-coated structure from peeling off from the metal skeleton 1.

[0027] As a further implementation, the end beam 6 is provided with a plurality of first support columns 8, which are located at the edges of the end beam 6. The first support columns 8 are used to retain gaps for the flow of injection molding material when the metal skeleton 1 is placed into the mold cavity. After the injection molding material is cured, the ends of the first support columns 8 are flush with the surface of the plastic-coated structure.

[0028] As a further implementation, dovetail tenons 9 are provided at both ends of the end beam 6. The length of the dovetail tenons 9 is the same as the thickness of the side beam 5. The end of the side beam 5 is provided with a mortise 13. The mortise 13 and the dovetail tenons 9 can be used to fix the side beam 5 and the end beam 6 in the width direction of the cage. A U-shaped groove 11 is opened in the middle of the dovetail tenon 9 of the end beam 6. A second support column 10 is provided on the dovetail tenon 9. A T-shaped limiting block 14 is provided in the mortise 13 of the side beam 5. The T-shaped limiting block 14 is installed in the U-shaped groove 11. By providing the T-shaped limiting block 14 at the end of the side beam 5 and cooperating with the U-shaped groove 11, the movement of the end beam 6 along the length direction of the cage can be prevented.

[0029] As a further implementation, the included angle between the side wall of the dovetail tenon 9 and the tenon shoulder is 60°~85°.

[0030] The angle between the side wall of the mortise 13 and the side of the side beam 5 is 90°. The reason for setting the angle between the side wall of the mortise 13 and the side of the side beam 5 to 90° is that the end of the side beam 5 is provided with a T-shaped limiting block 14. Therefore, the side beam 5 cannot move along the sliding direction of the tenon 9 during the assembly of the side beam 5 and the end beam 6. Setting the angle between the side wall of the mortise 13 and the side of the side beam 5 to 90° allows the tenon 9 to be inserted into the mortise 13 along the thickness direction of the side beam 5. Then, the tenon 9 and the mortise 13 are riveted together by pressing and hammering.

[0031] As a further implementation, two insertion posts 17 are provided at both ends of the cross brace 7. The length of the insertion post 17 is equal to the thickness of the side beam 5. A third support post 18 is provided between the two insertion posts 17. An insertion hole 15 is provided at the middle of the side beam 5 corresponding to the position of the cross brace 7. A support hole 16 is provided between the two insertion holes 15. The insertion posts 17 are installed in the insertion holes 15, and the third support post 18 is installed in the support hole 16.

[0032] As a further implementation, the thickness of the plastic coating layer 2 is 1.5-6mm, and the thickness of the plastic coating layer 2 is equal to the length of the first support column 8 and the second support column 10. After the injection molding material is cured, the ends of the first support column 8 and the second support column 10 are flush with the surface of the plastic coating structure.

[0033] As a further implementation, the pocket 4 formed by the pocket plastic layer 3 is a through hole 12, and the opening at one end of the pocket 4 is larger than the opening at the other end; the opening arrangement of the pockets 4 in adjacent windows is opposite, so that the entry direction of two adjacent cylindrical rollers when they are installed into the cage is opposite, which can effectively avoid the problem of excessive gap between the cage and the cylindrical roller caused by local wear of the pockets 4 of the cage.

[0034] Example 2 This embodiment provides a method for manufacturing a wind turbine bearing cage with a metal skeleton 1, including the following steps: Step 1: Cut the metal steel plate into side beams 5, end beams 6 and cross braces 7 according to the size requirements. Deburr and clean the side beams 5, end beams 6 and cross braces 7, and grind or spray the key contact surfaces. After assembling the side beams 5, end beams 6 and cross braces 7, press the side wall of the tenon 13 onto the side wall of the tenon 9, so that the tenon 13 undergoes plastic deformation, tightly wraps and bites the side wall of the tenon 9, thereby realizing the riveting. Step 2: Place the assembled metal skeleton 1 into the injection mold cavity, and inject the injection molding material into the injection mold cavity through the injection molding machine. The injection molding machine injects the molten engineering plastic into the mold cavity under high pressure. The plastic melt completely covers the preset part of the metal skeleton 1. After cooling, a solid pocket plastic layer 3 and a plastic coating layer 2 are formed. Step 3: After injection molding, the metal skeleton 1, plastic coating layer 2 and pocket plastic layer 3 are cooled to room temperature by air cooling. First, rapid cooling is performed to set the plastic surface, and then the whole is cooled slowly and evenly to eliminate the internal stress caused by the difference in shrinkage rate between the metal and the plastic, and to prevent deformation and cracking.

[0035] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A wind turbine bearing cage with a metal frame, characterized in that, include: A metal frame and a plastic-coated structure on the outside of the metal frame; the metal frame includes side beams, end beams, and cross braces. There are two side beams arranged in parallel. The end beams are located at both ends of the side beams and are connected to the side beams by mortise and tenon joints. The cross braces are located between the two side beams and are connected to the side beams by interlocking joints. The cross braces are arranged parallel to the end beams, forming a window between them. The plastic-coated structure includes a plastic coating layer and a pocket plastic coating layer. The pocket plastic coating layer is located on two opposite sides of the end beams and cross braces within the window, forming pockets for installing cylindrical rollers. The plastic coating layer is located on the other sides of the side beams and end beams.

2. The wind turbine bearing cage with a metal frame as described in claim 1, characterized in that, The side beams, end beams, and cross braces are all made of metal plates, and each side beam, end beam, and cross brace has multiple through holes arranged in a rectangular array.

3. A wind turbine bearing cage with a metal frame as described in claim 2, characterized in that, The end beam is provided with a plurality of first support columns, which are located at the edge of the end beam.

4. A wind turbine bearing cage with a metal frame as described in claim 3, characterized in that, The end beam is provided with dovetail tenons at both ends, the length of the dovetail tenons is the same as the thickness of the side beam, the end of the side beam is provided with a mortise, the middle of the dovetail tenon of the end beam is provided with a U-shaped groove, a second support column is provided on the dovetail tenon, and a T-shaped limiting block is provided in the mortise of the side beam.

5. A wind turbine bearing cage with a metal frame as described in claim 4, characterized in that, The angle between the sidewall of the dovetail tenon and the shoulder is 60°~85°.

6. A wind turbine bearing cage with a metal frame as described in claim 4, characterized in that, The angle between the side wall of the tenon and the side of the side beam is 90°.

7. A wind turbine bearing cage with a metal frame as described in claim 6, characterized in that, Two insertion posts are provided at both ends of the cross brace. The length of the insertion post is equal to the thickness of the side beam. A third support post is provided between the two insertion posts. An insertion hole is provided at the middle of the side beam corresponding to the position of the cross brace. A support hole is provided between the two insertion holes. The insertion post is installed in the insertion hole, and the third support post is installed in the support hole.

8. A wind turbine bearing cage with a metal frame as described in claim 7, characterized in that, The thickness of the plastic coating layer is 1.5-6mm, and the thickness of the plastic coating layer is equal to the length of the first support column and the second support column, respectively.

9. A wind turbine bearing cage with a metal frame as described in claim 8, characterized in that, The pockets formed by the pocket plastic layer are through holes, and the opening at one end of the pocket is larger than the opening at the other end; the openings of the pockets in adjacent windows are arranged in opposite ways.

10. A method for manufacturing a wind turbine bearing cage with a metal frame as described in any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Cut the metal steel plate into side beams, end beams and cross braces according to the size requirements. After assembling the side beams, end beams and cross braces, press the side wall of the tenon into the side wall of the tenon to achieve riveting. Step 2: Place the assembled metal frame into the injection mold cavity, and inject the injection molding material into the injection mold cavity using an injection molding machine; Step 3: After injection molding is completed, the metal skeleton, plastic coating layer and pocket plastic layer are cooled to room temperature by air cooling.

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