Wind turbine gearbox lubrication filtration system, control method, and integrated filter

Abstract

Embodiments of the present application provide a wind turbine gearbox lubrication filtering system, a control method and an integrated filter. The wind turbine gearbox lubrication filtering system comprises an integrated filter, N-1 communication valves, a first oil sensor, a controller, etc. The integrated filter comprises a filter cartridge and N-stage filter layers. The filter cartridge is internally provided with the first-stage filter layer to the N-stage filter layer in the N-stage filter layers from inside to outside. Each stage of filter layers forms a columnar closed structure. The N-1 communication valves are used to communicate the oil pool and each liquid inlet. The first oil sensor is used to collect oil parameters. The controller controls the conduction and shutdown of each communication valve in the N-1 communication valves according to the oil parameters, so as to filter the lubricating oil according to the requirements. By using this scheme, the integrated filter of the wind turbine gearbox lubrication filtering system contains multiple stages of filter layers with different functions. The controller selects the corresponding filter layer according to the oil parameters collected by the first oil sensor, so as to adapt to different pollution conditions of the lubricating oil and ensure that the purified lubricating oil meets the standards.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a wind turbine gearbox lubrication and filtration system, control method, and integrated filter element. Background Technology

[0002] With the continuous development of society and the increasing demand for energy, wind energy, as a clean and renewable energy source, is receiving increasing attention from countries around the world. Wind turbine generators, also known as wind turbines, are the main equipment for generating electricity using wind energy.

[0003] The wind turbine gearbox is a crucial transmission component connecting the wind turbine rotor and the generator in a wind turbine generator set. During operation, the lubricating oil in the gearbox needs to be filtered. The filtered oil is used to lubricate the meshing and rotating parts such as the sun gear, planetary gears, planet carrier bearings, and high-speed shaft bearings, and to remove frictional heat. After absorbing heat, the lubricating oil flows back to the oil sump at the bottom of the gearbox, where it is recycled after impurities settle, achieving continuous circulating lubrication. Filtering of particulate matter in the lubricating oil is typically achieved through a filter element, which filters out solid impurities larger than a predetermined size.

[0004] However, the above-mentioned filter can only intercept solid particles larger than the preset size, and its purification function is singular and limited. Summary of the Invention

[0005] This application provides a wind turbine gearbox lubrication and filtration system, control method, and integrated filter element. The controller controls the opening and closing of each connecting valve according to the oil parameters collected by the first oil sensor, so as to control the oil to pass through the filter element layers with different functions, so as to achieve the purpose of filtering lubricating oil as needed, thereby ensuring that the particle size and moisture content in the filtered lubricating oil accurately meet the customer's specifications.

[0006] In a first aspect, embodiments of this application provide a wind turbine gearbox lubrication and filtration system, comprising: An integrated filter element includes a filter cartridge and N filter layers. The filter cartridge contains, from the inside to the outside, the first to the Nth filter layers. Each filter layer forms a columnar closed structure. An inlet is provided between the filter cartridge and the Nth filter layer, and between every two adjacent filter layers. The bottom of the columnar closed structure formed by the first filter layer has an outlet. N ≥ 2 and is an integer. There are N-1 connecting valves. The first output of the nth connecting valve is connected to the inlet of the (N-n+1)th stage filter element, and the second output of the nth connecting valve is connected to the input of the (n+1)th connecting valve. 1 < n < N-1 and is an integer. The input of the first connecting valve is connected to an oil sump for containing lubricating oil. The first output of the (N-1)th connecting valve is connected to the inlet of the second stage filter element, and the second output of the (N-1)th connecting valve is connected to the inlet of the first stage filter element. The first oil sensor is connected to the outlet of the oil tank; The controller is connected to the first oil sensor and each of the N-1 connecting valves, and is configured to control the opening and closing of each connecting valve in the N-1 connecting valves according to the oil parameters collected by the first oil sensor.

[0007] Secondly, embodiments of this application provide a control method, including: Based on the oil parameters collected by the first oil sensor, a filtration strategy is determined, and the filtration strategy is used to indicate the target filter layer in the N-stage filter layer. The filtration strategy is used to control the opening and closing of each of the N-1 connecting valves so that the lubricating oil is filtered through the target filter element layer.

[0008] Thirdly, embodiments of this application provide an integrated filter element, comprising: The filter cartridge consists of an N-stage filter element layer and an N-stage filter element layer. The filter cartridge contains, from the inside out, the first stage filter element layer to the Nth stage filter element layer. Each stage filter element layer forms a columnar closed structure. An inlet is provided between the filter cartridge and the Nth stage filter element layer, and between every two adjacent stages filter element layers. The bottom of the columnar closed structure formed by the first stage filter element layer has an outlet. N ≥ 2 and is an integer.

[0009] Fourthly, embodiments of this application provide a control device, including: The processing module is used to determine a filtration strategy based on the oil parameters collected by the first oil sensor, wherein the filtration strategy is used to indicate the target filter layer in the N-stage filter layer. The control module is used to control the opening and closing of each of the N-1 connecting valves according to the filtration strategy, so that the lubricating oil is filtered through the target filter element layer.

[0010] Fourthly, embodiments of this application provide an electronic device, including: a processor, a memory, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it causes the electronic device to implement the method described in the second aspect above or various possible implementations of the second aspect.

[0011] Fifthly, embodiments of this application provide a computer-readable storage medium storing computer instructions that, when executed by a processor, are used to implement the method described in the second aspect above or various possible implementations of the second aspect.

[0012] In a sixth aspect, embodiments of this application provide a computer program product comprising a computing program, wherein when the computer program is executed by a processor, it implements the method described in the sixth aspect above or in various possible implementations of the sixth aspect.

[0013] The wind turbine gearbox lubrication filtration system, control method, and integrated filter element provided in this application embodiment include an integrated filter element, N-1 connecting valves, a first oil sensor, and a controller. The integrated filter element comprises a filter cartridge and N filter layers. The filter cartridge contains, from the inside out, N filter layers, from the first to the Nth layer, each forming a columnar closed structure. N ≥ 2 and is an integer. The N-1 connecting valves connect the oil sump to each inlet. The first oil sensor collects oil parameters. The controller controls the opening and closing of each of the N-1 connecting valves based on the oil parameters to filter the lubricating oil as needed. Using this scheme, the integrated filter element of the wind turbine gearbox lubrication filtration system contains multiple filter layers with different functions. The controller selects the corresponding filter layer based on the oil parameters collected by the first oil sensor to adapt to different lubricating oil contamination conditions, ensuring that the purified lubricating oil meets standards. Meanwhile, the integrated filter element has a simple and compact structure, eliminating the need for multiple filters and helping to reduce the size and weight of the wind turbine gearbox. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1A This is a side view of the integrated filter element provided in the embodiment of this application; Figure 1B This is a top view of the integrated filter element provided in the embodiment of this application; Figure 2 This is a simplified top view of the integrated filter element provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the wind turbine gearbox lubrication and filtration system provided in the embodiments of this application; Figure 4 This is a flowchart of the control method provided in the embodiments of this application; Figure 5 A schematic diagram of the control device provided in the embodiments of this application; Figure 6 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application. Detailed Implementation

[0016] The wind turbine gearbox is a key transmission component in a wind turbine generator set, connecting the wind turbine rotor and the generator. It includes the planetary carrier, sun gear, and planetary gears. A sump for holding lubricating oil, also known as lubricating fluid, is typically located at the bottom of the gearbox. During operation, the gearbox's built-in oil pump draws lubricating oil from the sump, filters it through a filter, and then delivers it to the meshing and rotating parts such as the sun gear, planetary gears, planetary carrier bearings, and high-speed shaft bearings. After lubricating and absorbing heat from these parts, the lubricating oil returns to the sump, where impurities settle and the oil is recycled.

[0017] During the recycling process, wear and tear on internal components of the wind turbine gearbox generates particles of varying sizes. These particles disperse in the lubricating oil, causing contamination. Therefore, the contaminated lubricating oil needs to be filtered. Additionally, when the lubricating oil comes into contact with air, moisture from the humid air easily enters the lubricating oil, increasing its water content. Therefore, it is necessary to filter out the water from the lubricating oil.

[0018] Traditional solutions employ filter elements with fixed precision or function to filter contaminated lubricating oil. The filtered oil meets requirements for either water content or particulate size, but lacks real-time monitoring of the oil itself, making it difficult to guarantee filtration accuracy and effectiveness. Furthermore, the filter elements have a single function, unable to achieve multi-functional, multi-stage filtration, and cannot intelligently control the oil filtration effect. Additionally, traditional filter elements typically utilize glass fiber and steel wire skeletons to filter impurities; or they use wood fiber for separate water removal. These products are complex in structure, large in size, have short service life, single filtration function, and high replacement and maintenance costs.

[0019] Based on this, this application provides a wind turbine gearbox lubrication and filtration system, control method, and integrated filter element. The controller controls the opening and closing of each connecting valve according to the oil parameters collected by the first oil sensor, so as to control the oil to pass through the filter element layers with different functions, thereby achieving the purpose of filtering lubricating oil as needed, and thus ensuring that the particle size and moisture content in the filtered lubricating oil accurately meet the customer's specifications.

[0020] Figure 1A This is a side view of the integrated filter element provided in the embodiment of this application. Figure 1B This is a top view of the integrated filter element provided in the embodiment of this application. Please refer to... Figure 1A and Figure 1BThe integrated filter element 100 provided in this application embodiment includes a filter cartridge and N-stage filter layers. N is an integer greater than or equal to 2, and its value can be 2, 3, 4, 5, 7, etc., which are not limited in this application embodiment. Taking N=4 as an example, the N-stage filter layers include a first-stage filter layer 11, a second-stage filter layer 12, a third-stage filter layer 13, and a fourth-stage filter layer 14. These filter layers are disposed inside the filter cartridge 15, that is, the first-stage filter layer 11, the second-stage filter layer 12, the third-stage filter layer 13, and the fourth-stage filter layer 14 are disposed sequentially from the inside to the outside inside the filter cartridge 15, as shown in the figure of filter layers filled with horizontal lines, gray fill, dots, and diagonal lines, respectively.

[0021] In this embodiment, the filter cartridge 15 and the filter elements at each stage are manufactured through structural design and bonding process, forming a composite integrated filter element with comprehensive filtration function. The filter elements are made of materials such as permeable membranes, and the space between the filter elements ensures sufficient filtration. Each filter element has a certain thickness and is formed by integral baking, which ensures the structural strength of the product while eliminating the support skeleton of traditional filter elements, thereby reducing the volume and complexity of the integrated filter element.

[0022] Please refer to Figure 1A and Figure 1B The Nth filter layer is the water filtration layer; when N=4, the 4th filter layer is the water filtration layer. From the outside to the inside, the filtration precision decreases sequentially from the (N-1)th to the 1st filter layer, meaning the (N-1)th filter layer has the strongest filtration capacity and is the finest filtration layer; the (N-2)th filter layer has the next strongest filtration capacity, and so on, with the 1st filter layer having the weakest filtration capacity. In actual filtration, the choice of which filter layers to use depends on the level of contamination in the lubricating oil. For example, when the lubricating oil has a high water content, filter layers from the 1st to the Nth are selected, so that the lubricating oil passes through the Nth, N-1th, and so on, until the 1st filter layer.

[0023] In addition, during actual filtration, when a filter element is clogged, try to avoid using the clogged filter element. For example, if the (N-1)th filter element is clogged, then select all or part of the (N-2), (N-3), ..., (1)th filter elements as the target filter elements.

[0024] After filtration, the filtered lubricating oil flows out from outlet 10 and returns to the oil tank for recycling.

[0025] It should be noted that, although Figure 1A and Figure 1B The example described uses a cylindrical closed structure formed by the filter element layer. However, the embodiments of this application are not limited thereto; for example, the filter element layer can also be formed into a prismatic columnar closed structure.

[0026] This design incorporates multiple filter layers with different functions, allowing users to select the appropriate layer to suit various lubricant contamination conditions and ensure the purified lubricant meets standards. Furthermore, the integrated filter's simple and compact structure eliminates the need for multiple filters, contributing to a reduction in the size and weight of the wind turbine gearbox.

[0027] Optionally, when N=4, the N-stage filter layers, from the inside out, are the first-stage filter layer 11, the second-stage filter layer 12, the third-stage filter layer 13, and the fourth-stage filter layer 14, which are respectively: a coarse filter layer, a fine filter layer, an ultra-fine filter layer, and a water filter layer. The water filter layer is used to filter water in the lubricating oil. The coarse filter layer, the fine filter layer, and the ultra-fine filter layer are used to filter particles with sizes larger than a first size, a second size, and a third size, respectively, with the first size, the second size, and the third size decreasing sequentially.

[0028] Please refer to Figure 1A and Figure 1B An inlet is provided between each pair of adjacent filter cartridges, as shown in inlet 16, inlet 17, and inlet 18 in the figure. An inlet 19 is located between filter cartridge 15 and the fourth-stage filter cartridge 14. Furthermore, the bottom of the columnar closed structure formed by the first-stage filter cartridge 11 has an outlet 10. The inlet is the inlet of the filter cartridge closest to it. For example, inlet 19 is the inlet of the fourth-stage filter cartridge 14, inlet 18 is the inlet of the third-stage filter cartridge 13, inlet 17 is the inlet of the second-stage filter cartridge 12, and inlet 16 is the inlet of the first-stage filter cartridge 11.

[0029] When using the integrated filter element 100 to filter contaminated lubricating oil, if the lubricating oil has a high water content, the inlet 19 is selected. After entering through the inlet 19, the lubricating oil passes through the fourth filter element layer 14, the third filter element layer 13, the second filter element layer 12, and the first filter element layer 11 in sequence.

[0030] If the lubricating oil has a normal water content but is highly contaminated (i.e., has a high particulate matter content), then inlet 18 is selected. The lubricating oil passes sequentially through the third-stage filter layer 13, the second-stage filter layer 12, and the first-stage filter layer 11. The water-filtering layers remove water from the lubricating oil, reducing the water content to below the preset level. The third-stage filter layer 13 removes particles larger than the third size. After passing through the third-stage filter layer 13, all particles larger than the third size are removed. Subsequent passages through the second-stage filter layer 12 and the first-stage filter layer 11 can be considered as pass-through.

[0031] If the lubricating oil has a normal water content and is only slightly contaminated (i.e., low particulate matter content), then inlet 17 is selected. After entering the integrated filter element through inlet 17, the lubricating oil passes through the second-stage filter layer 12 and the first-stage filter layer 11 in sequence. After passing through the second-stage filter layer 12, all particles larger than the second size in the lubricating oil are filtered out. The subsequent passage through the first-stage filter layer 11 can be considered as pass-through.

[0032] If the lubricating oil has a normal water content and is only minimally contaminated (i.e., low particulate matter content), then inlet 16 is selected. The lubricating oil passes through the first-stage filter layer 11, where it is filtered. After passing through the first-stage filter layer 11, all particles larger than the first size in the lubricating oil are filtered out.

[0033] In the above embodiments, the first size, the second size, and the third size decrease sequentially. For example, the first size is 50 micrometers (μm), the second size is 10 μm, and the first size is 3 μm; or, for another example, the first size is 30 μm, the second size is 8 μm, and the first size is 3 μm.

[0034] This design incorporates multiple filter layers with different functions. When using ultra-fine filtration, it can trap particles larger than the third size; when using fine filtration, it can trap particles larger than the second size; and when using coarse filtration, it can trap particles larger than the first size. By flexibly selecting the filter layer according to the contamination level of the lubricating oil, it balances flow resistance and purification effect, effectively improving the cleanliness of the lubricating oil and achieving the goal of protecting all components of the wind turbine gearbox.

[0035] In this embodiment, the spacing between each filter layer can be flexibly set. In one embodiment, the spacing between each filter layer is the same; for example, please refer to... Figure 2 . Figure 2 This is a simplified top view of the integrated filter element provided in the embodiments of this application. Please refer to... Figure 2 The distance between the first-stage filter layer 11 and the second-stage filter layer 12 is d1, the distance between the second-stage filter layer 12 and the third-stage filter layer 13 is d2, the distance between the third-stage filter layer 13 and the fourth-stage filter layer 14 is d3, and the distance between the fourth-stage filter layer 14 and the filter cartridge 15 is d4, where d1=d2=d3=d4.

[0036] In another implementation, the spacing between two adjacent filter layers in the N-stage filter layer increases sequentially from the inside out.

[0037] Please refer to the following: Figure 1BThe further outward the filter layer, the greater its filtration efficiency, the smaller the minimum size of particles it can intercept, and the slower its filtration speed. Therefore, the distance between filter cartridge 15 and the Nth stage filter layer is the largest, followed by the distance between the Nth and N-1th stage filter layers, then the distance between the N-1th and N-2th stage filter layers, and so on, with the smallest distance between the 2nd and 1st stage filter layers. When N=4, d1 < d2 < d3 < d4.

[0038] This approach allows for the spacing between filter elements to be adjusted according to the filtration speed differences of each filter element, thus adapting to the flow characteristics of each filter element, stabilizing the lubricating oil filtration conditions, and ensuring the filtration effect.

[0039] Figure 3 This is a schematic diagram of the structure of the wind turbine gearbox lubrication and filtration system provided in this embodiment. Please refer to... Figure 3 The system includes an integrated filter element 100, N-1 connecting valves, a first oil sensor 200, and a controller 300. Taking N=4 as an example, the N-1 connecting valves include a first connecting valve 400, a second connecting valve 500, and a third connecting valve 600.

[0040] In this embodiment, the solenoid valve, such as a three-way valve, has one input terminal and two output terminals. The three-way valve has two operating positions: a left position and a right position. When the valve core of the three-way valve is in the right position, the input terminal and the first output terminal on the right are connected; when the valve core of the three-way valve is in the left position, the input terminal and the second output terminal on the left are connected.

[0041] In this embodiment, the first output terminal of the nth connecting valve is connected to the inlet of the (N-n+1)th stage filter element, and the second output terminal of the nth connecting valve is connected to the input terminal of the (n+1)th connecting valve, where 1 < n < N-1 and is an integer. For example, when N=4, the first output terminal of the second connecting valve is connected to the inlet 18 of the third stage filter element, and the second output terminal of the second connecting valve is connected to the input terminal of the third connecting valve.

[0042] Of the N-1 connecting valves, the input of the first connecting valve is connected to the oil sump, the first output of the first connecting valve is connected to the inlet of the Nth stage filter element, the first output of the (N-1)th connecting valve is connected to the inlet of the 2nd stage filter element, and the second output of the (N-1)th connecting valve is connected to the inlet of the 1st stage filter element. Continuing with the example of N=4, there are now 3 connecting valves: the first output of the first connecting valve is connected to the inlet 19 of the 4th stage filter element, the first output of the third connecting valve is connected to the inlet 17 of the 2nd stage filter element, and the second output of the third connecting valve is connected to the inlet 16 of the 1st stage filter element.

[0043] The first oil sensor 200 is positioned near the oil sump and is used to detect the pressure, cleanliness level, and water content of the lubricating oil. After selecting the inlet, the lubricating oil enters the integrated filter element through the selected inlet. The pressure of the lubricating oil is the input pressure of the filter element layer closest to the inlet, where the lubricating oil is about to flow in.

[0044] In this embodiment, the first oil sensor 200 integrates cleanliness level detection, moisture detection, and pressure detection. Cleanliness level detection is primarily based on particle diameter. When the lubricating oil sampling volume and detection conditions are consistent, a higher proportion of large particles indicates a lower cleanliness level for the lubricating oil. When detecting particle size, the controller utilizes the light source of the first oil sensor 200 itself to emit light, forming electrodes at both ends of the lubricating oil, and collects the resistance change of the sensing silicon wafer. This, combined with photoresistivity, enables the detection of lubricating oil particle size.

[0045] When detecting water content, the first oil sensor 200 uses the resistance method to measure the water content of the lubricating fluid. When detecting pressure, the first oil sensor 200 uses the piezoresistive method to measure the pressure at the oil sump outlet and simultaneously provides an early warning based on the pressure difference.

[0046] The controller 300 is used to determine a filtration strategy based on the cleanliness level, water content, and other parameters of the oil collected by the first oil sensor 200, and to control the opening and closing of each connecting valve according to the control strategy. The controller 300 can be a programmable logic controller (PLC), a system on chip (SoC), a microcontroller unit (MCU), a field programmable gate array (FPGA), etc., and the embodiments of this application are not limited thereto.

[0047] The controller 300 is communicatively connected to each connecting valve and the first oil sensor 200. The connection method can be wired or wireless, and this embodiment is not limited thereto. The controller 300 can send control commands to each connecting valve and interact with the first oil sensor 200, etc. In the figure, the dashed lines represent command and data transmission channels, and the solid lines represent lubricating oil transmission channels.

[0048] The wind turbine gearbox lubrication and filtration system provided in this application includes an integrated filter element, N-1 connecting valves, a first oil sensor, and a controller. The integrated filter element comprises a filter cartridge and N filter layers. From the inside to the outside, the N filter layers are arranged sequentially from the first to the Nth level, each forming a columnar closed structure. Inlets are provided between the filter cartridge and the Nth level filter layer, and between each adjacent filter layer. The bottom of the columnar closed structure formed by the first level filter layer has an outlet. N ≥ 2 and is an integer. The N-1 connecting valves connect the oil sump to each inlet. The first oil sensor collects oil parameters. The controller controls the opening and closing of each of the N-1 connecting valves based on the oil parameters to select a target filter layer from the N filter layers as needed, and uses the target filter layer to filter the lubricating oil. This design incorporates an integrated filter element in the wind turbine gearbox lubrication and filtration system, comprising multiple filter layers with different functions. The controller selects the appropriate filter layer based on oil parameters collected by the first oil sensor to adapt to varying lubricant contamination conditions, ensuring the purified lubricant meets standards. Furthermore, the integrated filter element has a simple and compact structure, eliminating the need for multiple filters and helping to reduce the size and weight of the wind turbine gearbox.

[0049] Optional, please refer to Figure 3 The aforementioned wind turbine gearbox lubrication and filtration system also includes a second oil sensor 700 connected to the outlet 10 of the filter cartridge 15. The controller 300 is further configured to determine the pressure difference between a first pressure collected by the first oil sensor 200 and a second pressure collected by the second oil sensor 700. When the pressure difference is less than a preset pressure difference, the controller 300 determines that the first filter element in the N-stage filter layers, which filters the lubricating oil first, is clogged. The first pressure is the pressure of the lubricating oil entering the first filter element layer, and the second pressure is the pressure of the lubricating oil flowing out of the outlet.

[0050] In this embodiment, the first oil sensor 200 and the second oil sensor are respectively located at one end near the oil tank and the other end near the outlet 10. These two oil sensors integrate particle size detection, moisture detection, and pressure detection, and can simultaneously and accurately measure the cleanliness level, water content, and pressure value of the lubricating oil. When the lubricating oil enters the integrated filter element 100 from the inlet, passes through each target filter element layer in sequence, and flows out from the outlet 10, the controller 300 acquires the first pressure collected by the first oil sensor 200 and the second pressure collected by the second oil sensor. Then, the controller 300 compares these two pressures. If the pressure difference is greater than a preset pressure difference, it indicates that the filter element layer closest to the inlet is blocked.

[0051] After identifying the clogged filter layer, the controller 300 determines the filtration strategy by selecting the target filter layer from the remaining filter layers in the N-stage filter layer list, excluding the clogged layer. The target filter layer is then used to filter the lubricating oil. For example, if N=4, the current filtration strategy is: the lubricating oil passes through the 4th, 3rd, 2nd, and 1st stage filter layers sequentially, with the 4th stage filter layer being the first to filter the lubricating oil. When the difference between the first and second pressures is less than a preset pressure difference, the controller 400 determines that the 4th stage filter layer is clogged and then selects the target filter layer from the 3rd, 2nd, and 1st stage filter layers.

[0052] For example, with N=4, the current filtration strategy is as follows: the lubricating oil passes through the second-stage filter layer and the first-stage filter layer in sequence, with the second-stage filter layer being the first to filter the lubricating oil. When the difference between the first and second pressures is less than the preset pressure difference, the controller 400 determines that the second-stage filter layer is clogged, and the lubricating oil is subsequently filtered using the first-stage filter layer.

[0053] In addition, once the integrated filter element 100 is found to have a clogged filter layer, the controller will simultaneously issue a clogging warning, making it easier for staff to replace the integrated filter element in a timely manner.

[0054] Using this approach, the controller identifies the clogged filter layer from the N-stage filter layer based on the pressure collected by the first and second oil sensors, thus preventing the subsequent use of the clogged filter layer to filter lubricating oil and improving the efficiency and effectiveness of lubricating oil filtration.

[0055] Optionally, in the above embodiments, when the Nth stage filter layer is a water filtration layer, a drain outlet is also provided at the bottom of the filter cartridge. The drain outlet is connected to a water collection device provided outside the filter cartridge for collecting the water filtered out by the water filtration layer.

[0056] In this embodiment, when a water-filtering layer exists, the Nth stage filter element is the water-filtering layer; that is, from the inside out, the last stage is the water-filtering layer. When no water-filtering layer exists, the Nth stage filter element is the filter element with the highest filtration accuracy, meaning that the Nth stage filter element can filter particles of the smallest size. The cleanliness level of the lubricating oil decreases significantly after passing through the Nth stage filter element, and the N-1th to the 1st stage are equivalent to permeable lubricating oil.

[0057] When a filter layer is present, the pore size of the filter layer's permeable membrane is designed to intercept large water molecules, allowing smaller oil molecules to pass through. Simultaneously, taking advantage of the difference in specific gravity between water and lubricating oil, the water flows to the bottom of the filter cartridge under gravity. Please refer to [reference needed]. Figure 1A and Figure 3A drain outlet is provided at the bottom of the filter cartridge 11, located next to the liquid inlet 19, or the liquid inlet 19 is located on the side wall of the filter cartridge 11, with the drain outlet located at or near the liquid inlet 19. Simultaneously, a water collection device is provided on the outside of the filter cartridge 11, which is connected to the drain outlet to collect water filtered by the filter layer. During the filtration process, the operator periodically or irregularly opens the drain outlet to release water, allowing the filter layer to circulate and filter lubricating oil, extending the service life of the integrated filter element while reducing filter element costs.

[0058] Based on the aforementioned integrated filter element and wind turbine gearbox lubrication filtration system, this application embodiment also provides a control method for controlling the wind turbine gearbox lubrication filtration system as described above. For example, please refer to... Figure 4 , Figure 4 This is a flowchart of a control method provided in an embodiment of this application. The controller described above is the executing entity of this control method, and this embodiment includes the following steps: 401. Based on the oil parameters collected by the first oil sensor, a filtration strategy is determined, wherein the filtration strategy is used to indicate the target filter layer in the N-stage filter layer.

[0059] Please refer to Figure 1A and Figure 3 The first oil sensor is positioned near the outlet of the oil tank. This sensor collects oil parameters, including but not limited to water content, cleanliness level, and initial pressure. When the lubricating oil in the oil tank is contaminated, during lubrication, the wind turbine gearbox's oil pump pressurizes the oil, which then flows into the gearbox's lubrication and filtration system. The oil first passes through the online-mounted first oil sensor 200, which analyzes the oil to obtain parameters and provides these parameters to the controller. The controller analyzes the particle size, water content, and cleanliness level of the lubricating oil, and, combined with filtration indicators, determines the filtration strategy. This strategy indicates which filter layers (N-stage filter layers) the lubricating oil needs to pass through, i.e., the target filter layers. When the number of target filter layers is greater than or equal to two, it indicates that the lubricating oil needs to undergo multiple filtration stages, i.e., it passes through each target filter layer sequentially. For example, if the target filter layer is all filter layers, then the lubricating oil passes through the Nth filter layer, the N-1th filter layer, ... the 1st filter layer in sequence; or if the target filter layer is the 1st filter layer, then only the 1st filter layer is used to filter the lubricating oil.

[0060] 402. Control the opening and closing of each of the N-1 connecting valves according to the filtration strategy, so that the lubricating oil is filtered through the target filter element layer.

[0061] After determining the filtration strategy, the controller controls the opening and closing of each of the N-1 connecting valves according to the strategy, ensuring that the lubricating oil flows sequentially through each target filter element layer. In other words, the controller determines which inlet the lubricating oil enters from based on the filtration strategy and controls the opening and closing of the connecting valves to ensure the lubricating oil enters from the determined inlet, thus allowing the lubricating oil to flow sequentially through each target filter element layer. Different filtration strategies correspond to different target filter elements.

[0062] The control method provided in this application involves a controller determining a filtration strategy for the target filter layer in the N-stage filter layer based on oil parameters collected by a first oil sensor. Then, the controller controls the opening and closing of each of the N-1 connecting valves according to the filtration strategy, allowing the lubricating oil to sequentially pass through each target filter layer. This approach automatically obtains oil parameters using the first oil sensor. Different oil parameters correspond to different lubricating oil filtration requirements. A filtration strategy is determined based on these different filtration requirements, and the corresponding target filter layer is selected based on the filtration strategy. This allows the lubricating oil to enter different filter layers as needed, adapting to different lubricating oil contamination conditions. This ensures that the purified lubricating oil meets quality standards while simultaneously reducing costs and improving efficiency.

[0063] Optionally, in the above embodiments, when the controller determines the filtration strategy based on the oil parameters collected by the first oil sensor, if the oil parameters include water content and the water content is greater than the preset water content, the target filter element layer is determined to include each of the N-stage filter element layers, and the lubricating oil sequentially passes through the Nth stage filter element layer to the 1st stage filter element layer.

[0064] In this embodiment, when the N-stage filter layer includes a water-filtering layer, the Nth filter layer is a water-filtering layer. When the target water-filtering layer includes a water-filtering layer, the controller controls the valve core of the first connecting valve to be in the right position, so that the input end of the first connecting valve and the first output end on the right are connected, and the second and third connecting valves are disconnected. Lubricating oil enters the integrated filter element from the inlet 19, and passes through the water-filtering layer and other filter layers of each stage used to filter out particulate matter in sequence. Taking N=4, the third-stage filter layer can filter particles larger than the third size, the second-stage filter layer can filter particles larger than the second size, and the first-stage filter layer can filter particles larger than the first size as an example, the third size is smaller than the second size and smaller than the first size. For example, the first size is 50μm, the second size is 10μm, and the third size is 3μm.

[0065] When lubricating oil with a water content greater than the preset water content enters the filter cartridge through the inlet 19, it passes through the fourth, third, second, and first stage filter layers in sequence. It then flows out through the outlet 10.

[0066] This approach, when used for lubricating oil with high water content, allows the oil to flow sequentially through a water filter layer and various filter elements. First, the water in the lubricating oil is removed, and then solid particles are intercepted. The purification of water and particles is completed step by step, thereby improving the filtration effect of the lubricating oil.

[0067] In this embodiment, the degree of contamination of the lubricating oil can be measured by its cleanliness level. A higher cleanliness level indicates a greater degree of contamination and dirtier the lubricating oil; conversely, a lower cleanliness level indicates a lower degree of contamination and cleaner the lubricating oil. Optionally, in the above embodiment, during the process of determining the filtration strategy based on the oil parameters collected by the first oil sensor, when the oil parameters include water content and cleanliness level, the controller determines the filtration strategy based on the cleanliness level. The following details how the controller determines the filtration strategy under different scenarios.

[0068] Situation a. The cleanliness of the lubricating oil is equal to or greater than the first threshold, indicating that the lubricating oil is severely contaminated.

[0069] When the moisture content is less than or equal to the preset moisture content and the cleanliness level is greater than the first threshold, the controller determines that the target filter layer includes all filter layers in the N-stage filter layers except for the water-filtering layer. Continuing with the example of N=4, the third-stage filter layer, the second-stage filter layer, and the first-stage filter layer can filter particles larger than 3μm, 10μm, and 50μm, respectively. The controller controls the valve core of the first connecting valve to be in the left position, so that the input end of the first connecting valve and the second output end on the left are connected; the valve core of the second connecting valve is in the right position, so that the input end of the second connecting valve and the first output end on the right are connected; the third connecting valve is disconnected, and lubricating oil enters from the inlet 18, flows sequentially through the third-stage filter layer, the second-stage filter layer, and the first-stage filter layer, and finally flows out from the outlet 10. The first threshold is, for example, a cleanliness level of 18, that is, when the cleanliness level is greater than 18, the lubricating oil flows sequentially through all filter layers except for the water-filtering layer.

[0070] Case b. The cleanliness level of the lubricating oil is less than or equal to the first threshold and greater than the second threshold. The lubricating oil is seriously contaminated, which is a normal filtration situation.

[0071] When the moisture content is less than or equal to the preset moisture content, and the cleanliness level is less than or equal to the first threshold and greater than the second threshold, the controller determines that the target filter layer includes all filter layers in the N-level filter layers except for the Nth and N-1th level filter layers. Continuing with the example of N=4, the 3rd, 2nd, and 1st level filter layers can filter particles larger than 3μm, 10μm, and 50μm, respectively. The controller controls the valve core of the 1st connecting valve to be in the left position, so that the input end of the 1st connecting valve and the second output end on the left are connected; the valve core of the 2nd connecting valve to be in the left position, so that the input end of the 2nd connecting valve and the second output end on the left are connected; the valve core of the 3rd connecting valve to be in the right position, so that the input end of the 3rd connecting valve and the first output end on the right are connected. Lubricating oil enters from the inlet 17, flows through the 2nd and 1st level filter layers in sequence, and finally flows out from the outlet 10. The first threshold is, for example, a cleanliness level of 18, and the second cleanliness level is, for example, 16. That is, when 16 < cleanliness level ≤ 18, the lubricating oil passes through the second-stage filter layer and the first-stage filter layer in sequence.

[0072] Case c. The cleanliness level of the lubricating oil is less than or equal to the second threshold, indicating that the lubricating oil is less contaminated.

[0073] When the oil parameters include water content and cleanliness level, if the water content is less than or equal to the preset water content and the cleanliness level is less than or equal to the second threshold, the target filter layer is determined to include the remaining filter layers in the N-stage filter layers, excluding the Nth, N-1th, and N-2th stage filter layers. Continuing with the example of N=4, the 3rd, 2nd, and 1st stage filter layers can filter particles larger than 3μm, 10μm, and 50μm, respectively. The controller controls the valve core of the first connecting valve to be in the left position, so that the input end of the first connecting valve and the second output end on the left are connected. The valve core of the second connecting valve is also in the left position, so that the input end of the second connecting valve and the second output end on the left are connected. The valve core of the third connecting valve is also in the left position, so that the input end of the third connecting valve and the second output end on the left are connected. Lubricating oil enters from the inlet 16, flows through the first-stage filter layer, and finally flows out from the outlet 10. The first threshold is, for example, a cleanliness level of 18, and the second cleanliness level is, for example, 16. That is, when 16 < cleanliness level ≤ 18, the lubricating oil passes through the first-stage filter layer.

[0074] This approach allows for the selection of target filter layers based on the cleanliness level of the lubricating oil, which has a low water content and only requires the removal of particulate matter. By controlling the opening and closing of the connecting valve, the controller guides the lubricating oil into the integrated filter element through different inlets, precisely matching the purification requirements and preventing the lubricating oil from flowing through unnecessary filter layers, thereby improving the filtration effect and efficiency of the lubricating oil.

[0075] Optionally, in the above embodiments, the opening and closing of each of the N connecting valves is controlled according to the filtration strategy, so that after the lubricating oil is filtered through the target filter element layer, the first cleanliness level collected by the first oil sensor and the second cleanliness level collected by the second oil sensor are compared. When the difference between the first cleanliness level and the second cleanliness level is less than a preset difference, the filtration strategy is adjusted; when the difference between the first cleanliness level and the second cleanliness level is greater than or equal to the preset difference, the filtration strategy is maintained.

[0076] Please refer to Figure 3 A second oil sensor 700 is installed at one end of the outlet 10. For a description of the second oil sensor 700, please refer to the description of the first oil sensor 200 above; it will not be repeated here. The only difference between these two oil sensors is their placement. During lubricant filtration, the controller obtains a first cleanliness level from the first oil sensor 200 and a second cleanliness level from the second oil sensor 700. The first cleanliness level is the cleanliness level of the lubricant before filtration, and the second cleanliness level is the cleanliness level of the lubricant after filtration. If the difference between these two cleanliness levels is less than a preset difference, it indicates poor filtration performance, and the filtration strategy needs to be readjusted. Continuing with N=4 as an example, assuming the original filtration strategy was that the lubricant passed through the second-stage filter layer and the first-stage filter layer sequentially, the adjusted filtration strategy would be: passing through the third-stage filter layer, the second-stage filter layer, and the first-stage filter layer sequentially. If the difference between the two cleanliness levels is greater than or equal to the preset difference, it indicates good filtration performance, and the current filtration strategy should continue to be used to filter the lubricant.

[0077] This approach involves real-time tracking of changes in the composition of lubricating oil before and after filtration, comparing the cleanliness levels of the lubricating oil before and after filtration, and dynamically adjusting the filtration strategy based on the difference. This timely optimization of the filtration strategy enables intelligent control of the filtration strategy, thereby ensuring the effectiveness of lubricating oil filtration.

[0078] Optionally, in the above embodiments, during the process of the controller determining the filtration strategy based on the oil parameters collected by the first oil sensor, the target filter layer is determined from the remaining filter layers in the N-stage filter layers excluding the clogged filter layer based on the oil parameters collected by the first oil sensor and the clogged filter layer, so as to obtain the filtration strategy.

[0079] In this embodiment, the first oil sensor 200 and the second oil sensor 700 integrate cleanliness level detection, moisture detection, and pressure detection. The controller can determine the pressure difference based on the first pressure collected by the first oil sensor and the second pressure collected by the second oil sensor, and identify the clogged filter layer from the N-stage filter layers based on the pressure difference. When the target filter layer includes only the first-stage filter layer, if the pressure difference is less than a preset pressure difference, the controller determines that the first-stage filter layer is clogged and issues a prompt message to remind the user to replace the integrated filter element. When the target filter layer includes two or more filter layers, if the pressure difference is less than a preset pressure difference, the controller determines that the first filter layer that filters the lubricating oil first is clogged. The first pressure is the pressure of the lubricating oil entering the first filter layer, and the second pressure is the pressure of the lubricating oil flowing out of the outlet. After identifying the clogged filter layer, the target filter layer is selected from the non-clogged filter layers when making subsequent filtration strategy decisions. Taking N=5 as an example, when the 4th stage filter layer is clogged, the controller selects the target filter layer from the 3rd, 2nd, and 1st stage filter layers. For example, the 2nd and 1st stage filter layers can be selected as the target filter layers.

[0080] The decision-making filtration strategy adopted by this approach is to eliminate the blockage of the filter element layer, ensure continuous filtration of lubricating oil, and improve the system's fault tolerance.

[0081] The following are embodiments of the apparatus described in this application, which can be used to execute the embodiments of the method described in this application. For details not disclosed in the apparatus embodiments of this application, please refer to the embodiments of the method described in this application.

[0082] Figure 5 This is a schematic diagram of a control device provided in an embodiment of this application. The control device 500 includes a processing module 51 and a control module 52.

[0083] Processing module 51 is used to determine a filtration strategy based on the oil parameters collected by the first oil sensor, wherein the filtration strategy is used to indicate the target filter layer in the N-stage filter layer. The control module 52 is used to control the opening and closing of each of the N-1 connecting valves according to the filtration strategy, so that the lubricating oil is filtered through the target filter element layer.

[0084] In one feasible implementation, the processing module 51 is used to determine that the target filter element layer includes each of the N-stage filter element layers when the oil parameters include water content and the water content is greater than a preset water content, and the lubricating oil sequentially passes through the Nth stage filter element layer to the 1st stage filter element layer.

[0085] In one feasible implementation, the processing module 51 is configured to: when the oil parameters include water content and cleanliness level, determine that the target filter element layer includes all filter elements except the water-filtering layer in the N-level filter elements if the water content is less than or equal to the preset water content and the cleanliness level is greater than a first threshold; when the oil parameters include water content and cleanliness level, determine that the target filter element layer includes all filter elements except the Nth and N-1th level filter elements in the N-level filter elements if the water content is less than or equal to the preset water content and the cleanliness level is less than or equal to the first threshold and greater than a second threshold; and when the oil parameters include water content and cleanliness level, determine that the target filter element layer includes all filter elements except the Nth, N-1th, and N-2th level filter elements in the N-level filter elements if the water content is less than or equal to the preset water content and the cleanliness level is less than or equal to the second threshold.

[0086] In one feasible implementation, after the control module 52 controls the opening and closing of each of the N connecting valves according to the filtration strategy, so that the lubricating oil is filtered through the target filter layer, the processing module 51 is further used to compare the first cleanliness level collected by the first oil sensor and the second cleanliness level collected by the second oil sensor; when the difference between the first cleanliness level and the second cleanliness level is less than a preset difference, the filtration strategy is adjusted.

[0087] In one feasible implementation, the processing module 51 is used to determine the clogged filter layer from the N-stage filter layers; and based on the oil parameters collected by the first oil sensor and the clogged filter layer, to determine the target filter layer from the remaining filter layers in the N-stage filter layers excluding the clogged filter layer, so as to obtain the filtration strategy.

[0088] The control device provided in this application embodiment can execute the actions of the controller in the above embodiment. Its implementation principle and technical effect are similar, and will not be described again here.

[0089] Figure 6 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device 600 includes: Processor 61 and memory 62; The memory 62 stores computer instructions and test data; The processor 61 executes the computer instructions stored in the memory 62, causing the processor 61 to perform the control method described above.

[0090] The specific implementation process of processor 61 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0091] Optionally, the electronic device 600 also includes a communication component 63. The processor 61, memory 62, and communication component 63 can be connected via a bus 64.

[0092] This application also provides a computer-readable storage medium storing computer instructions, which, when executed by a processor, are used to implement the control method described above.

[0093] This application also provides a computer program product, which includes a computer program that, when executed by a processor, implements the control method described above.

[0094] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the application disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0095] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A wind turbine gearbox lubrication and filtration system, characterized in that, include: An integrated filter element includes a filter cartridge and N filter layers. The filter cartridge contains, from the inside to the outside, the first to the Nth filter layers. Each filter layer forms a columnar closed structure. An inlet is provided between the filter cartridge and the Nth filter layer, and between every two adjacent filter layers. The bottom of the columnar closed structure formed by the first filter layer has an outlet. N ≥ 2 and is an integer. There are N-1 connecting valves. The first output of the nth connecting valve is connected to the inlet of the (N-n+1)th stage filter element, and the second output of the nth connecting valve is connected to the input of the (n+1)th connecting valve. 1 < n < N-1 and is an integer. The input of the first connecting valve is connected to an oil sump for containing lubricating oil. The first output of the (N-1)th connecting valve is connected to the inlet of the second stage filter element, and the second output of the (N-1)th connecting valve is connected to the inlet of the first stage filter element. The first oil sensor is connected to the outlet of the oil tank; The controller is connected to the first oil sensor and each of the N-1 connecting valves, and is configured to control the opening and closing of each connecting valve in the N-1 connecting valves according to the oil parameters collected by the first oil sensor.

2. The system according to claim 1, characterized in that, Also includes: The second oil sensor is connected to the outlet of the filter cartridge; The controller is further configured to determine the pressure difference between the first pressure collected by the first oil sensor and the second pressure collected by the second oil sensor, and when the pressure difference is less than a preset pressure difference, to determine that the first filter layer in the N-stage filter layer that filters the lubricating oil first is blocked, the first pressure is the pressure of the lubricating oil entering the first filter layer, and the second pressure is the pressure of the lubricating oil flowing out from the outlet.

3. The system according to claim 1, characterized in that, When N=4, the N-stage filter layer consists of, from the inside out: a coarse filter layer, a fine filter layer, an ultrafine filter layer, and a water filter layer. The water filter layer is used to filter water in the lubricating oil. The coarse filter layer, the fine filter layer, and the ultrafine filter layer are used to filter particles larger than the first size, the second size, and the third size, respectively, with the first size, the second size, and the third size decreasing sequentially.

4. The system according to any one of claims 1 to 3, characterized in that, From the inside out, the spacing between two adjacent filter layers in the N-stage filter layer increases sequentially.

5. The system according to any one of claims 1 to 3, characterized in that, When the Nth stage filter element is a water filtration layer, a drain outlet is also provided at the bottom of the filter cartridge. The drain outlet is connected to a water collection device located outside the filter cartridge and is used to collect the water filtered out by the water filtration layer.

6. A control method, characterized in that, The method for controlling the lubrication and filtration system of a wind turbine gearbox as described in any one of claims 1 to 6 includes: Based on the oil parameters collected by the first oil sensor, a filtration strategy is determined, and the filtration strategy is used to indicate the target filter layer in the N-stage filter layer. The filtration strategy is used to control the opening and closing of each of the N-1 connecting valves so that the lubricating oil is filtered through the target filter element layer.

7. The method according to claim 6, characterized in that, The step of determining the filtration strategy based on the oil parameters collected by the first oil sensor includes: When the oil parameters include water content and the water content is greater than the preset water content, the target filter element layer is determined to include each of the N-stage filter element layers, and the lubricating oil sequentially passes through the Nth stage filter element layer to the 1st stage filter element layer.

8. The method according to claim 6, characterized in that, The step of determining the filtration strategy based on the oil parameters collected by the first oil sensor includes: When the oil parameters include water content and cleanliness level, if the water content is less than or equal to the preset water content and the cleanliness level is greater than the first threshold, it is determined that the target filter element layer includes the remaining filter elements in the N-level filter element layer except for the water filtration layer. When the oil parameters include water content and cleanliness level, when the water content is less than or equal to the preset water content and the cleanliness level is less than or equal to the first threshold and greater than the second threshold, it is determined that the target filter element layer includes the remaining filter elements in the N-level filter elements except for the Nth-level filter element layer and the N-1th-level filter element layer. When the oil parameters include water content and cleanliness level, if the water content is less than or equal to the preset water content and the cleanliness level is less than or equal to the second threshold, the target filter element layer is determined to include the remaining filter elements in the N-level filter elements except for the Nth-level filter element layer, the N-1th-level filter element layer and the N-2th-level filter element layer.

9. The method according to any one of claims 6 to 8, characterized in that, The step of controlling the opening and closing of each of the N connecting valves according to the filtration strategy, so that the lubricating oil is filtered through the target filter element layer, further includes: Compare the first cleanliness level collected by the first oil sensor with the second cleanliness level collected by the second oil sensor; When the difference between the first cleanliness level and the second cleanliness level is less than a preset difference, the filtration strategy is adjusted.

10. The method according to any one of claims 6 to 8, characterized in that, The step of determining the filtration strategy based on the oil parameters collected by the first oil sensor includes: Identify the clogged filter layer from the N-stage filter layer; Based on the oil parameters collected by the first oil sensor and the clogged filter layer, the target filter layer is determined from the remaining filter layers in the N-stage filter layers excluding the clogged filter layer, so as to obtain the filtration strategy.

11. An integrated filter element, characterized in that, include: The filter cartridge consists of an N-stage filter element layer and an N-stage filter element layer. The filter cartridge contains, from the inside out, the first stage filter element layer to the Nth stage filter element layer. Each stage filter element layer forms a columnar closed structure. An inlet is provided between the filter cartridge and the Nth stage filter element layer, and between every two adjacent stages filter element layers. The bottom of the columnar closed structure formed by the first stage filter element layer has an outlet. N ≥ 2 and is an integer.

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