A wind turbine generator variable pitch gear ring detection device

Abstract

This utility model relates to the technical field of wind turbine generators, and in particular to a wind turbine pitch gear ring testing device, which can realize online multi-parameter testing of the pitch gear ring, improve testing efficiency and accuracy, reduce power generation loss, and ensure safe operation of the generator set. It includes a mounting base, a testing frame, a testing unit, a cleaning component, and a control unit. The testing frame is mounted on the mounting base, and both the testing unit and the cleaning component are mounted on the testing frame, with the cleaning component located in front of the testing unit along the rotation direction of the pitch gear ring. The control unit is connected to the testing unit and the cleaning component. The testing unit includes a displacement adjustment mechanism and a multi-parameter testing element. The displacement adjustment mechanism is mounted on the testing frame, and the multi-parameter testing element is mounted on the displacement adjustment mechanism, with the testing end of the multi-parameter testing element facing the pitch gear ring.

Description

Technical Field

[0001] This utility model relates to the technical field of wind turbine generators, and in particular to a wind turbine pitch gear ring detection device. Background Technology

[0002] In wind power generation, the pitch system of a wind turbine precisely controls the wind turbine's absorption of wind energy by adjusting the blade pitch angle (the angle between the blade and the rotor's plane of rotation). When wind speeds are low, the pitch system adjusts the pitch angle to a smaller angle, maximizing wind energy capture and ensuring efficient power generation. Conversely, when wind speeds exceed the rated value, the pitch angle increases, reducing the blade's surface area exposed to wind, thus limiting rotor speed and preventing damage from overload. Furthermore, when the turbine is shut down or encounters extreme weather, the pitch system can quickly adjust the blades to a feathered position (pitch angle close to 90°), aligning the blades with the wind direction to minimize wind load and ensure equipment safety.

[0003] A pitch control system typically consists of a drive unit, transmission mechanism, sensors, control system, and backup power supply. The output gear of the drive unit meshes with the gear ring of the transmission mechanism. As the drive unit operates, the output gear drives the gear ring to rotate, causing the blades to rotate around their own axis, thus adjusting the pitch angle. During wind turbine operation, the pitch gear ring is subjected to complex loads over long periods, making it prone to wear, cracks, and tooth surface fatigue. This can prevent the wind turbine blades from accurately adjusting their angle, affecting the turbine's power generation efficiency and potentially leading to safety accidents. Existing testing methods often involve manual inspection after shutdown or offline disassembly, which results in power generation losses. Furthermore, existing testing devices lack the multi-parameter detection capabilities for the pitch gear ring, making it difficult to comprehensively assess its operational status. Utility Model Content

[0004] In order to solve the above-mentioned technical problems, or at least partially solve the above-mentioned technical problems, this utility model provides a wind turbine pitch gear ring detection device.

[0005] This utility model discloses a wind turbine pitch gear ring testing device, comprising a mounting base, a testing frame, a testing unit, a cleaning component, and a control unit. The testing frame is mounted on the mounting base, and both the testing unit and the cleaning component are mounted on the testing frame, with the cleaning component located in front of the testing unit along the rotation direction of the pitch gear ring. The control unit is connected to the testing unit and the cleaning component. The testing unit includes a displacement adjustment mechanism and a multi-parameter testing element. The displacement adjustment mechanism is mounted on the testing frame, and the multi-parameter testing element is mounted on the displacement adjustment mechanism, with the testing end of the multi-parameter testing element facing the pitch gear ring. The cleaning component includes a cleaning bracket, a cleaning actuator, and a cleaning drive. The cleaning bracket is connected to the displacement adjustment mechanism via a connecting rod, the cleaning actuator is mounted on the cleaning bracket, and the output end of the cleaning drive is connected to the cleaning actuator, with the cleaning end of the cleaning actuator facing the pitch gear ring.

[0006] Furthermore, the displacement adjustment mechanism includes a lateral adjustment module and a longitudinal adjustment module; the lateral adjustment module includes an adjustment slide rail, an adjustment slider, and a lateral adjustment drive component. The adjustment slide rail is fixed on the detection frame, the adjustment slider is slidably fitted on the adjustment slide rail, and the lateral adjustment drive component drives the adjustment slider to move; the longitudinal adjustment module includes a longitudinal adjustment drive component, a slide rod, a roller, and an elastic component. The longitudinal adjustment drive component is fixedly connected to the adjustment slider, the slide rod is connected to the output end of the longitudinal adjustment drive component, the roller is rotatably installed at the bottom of the slide rod, and the elastic component is sleeved on the outside of the slide rod.

[0007] Furthermore, the output end of the longitudinal adjustment drive is provided with a guide post, and the guide post is provided with a guide groove corresponding to the slide rod.

[0008] Furthermore, the multi-parameter detection components include a laser displacement sensor, an ultrasonic flaw detection sensor, and a visual inspection camera. All three are fixedly connected to the adjusting slider and arranged sequentially along the rotation direction of the pitch gear ring. The laser displacement sensor is located at the top of the guide groove.

[0009] Furthermore, the detection unit also includes an illumination element, which is fixedly connected to the adjustment slider and located on one side of the visual inspection camera, with its illumination direction facing the detection area.

[0010] Furthermore, the cleaning actuator includes a cleaning roller and removable bristles, with both ends of the cleaning roller rotatably connected to a cleaning bracket, and the removable bristles covering the outside of the cleaning roller.

[0011] Furthermore, the cleaning support and the cleaning roller form a semi-enclosed structure.

[0012] Furthermore, the cleaning components also include a collection box, an air extraction unit, and an air duct; the two sides of the collection box are connected to one end of the air extraction unit and one end of the air duct, respectively, and the other end of the air duct extends through the cleaning bracket to the side near the bristles.

[0013] In the above technical solution, the wind turbine pitch gear ring detection device provided by this utility model has the following beneficial effects:

[0014] 1. By setting up a cleaning component, the testing area of ​​the pitch gear ring can be cleaned before testing to avoid dust, oil and other impurities on the surface of the gear ring from interfering with the test results and improve the testing accuracy; the displacement adjustment mechanism in the testing unit can flexibly adjust the position of the cleaning component to ensure that the cleaning end and the pitch gear ring maintain a suitable cleaning distance.

[0015] 2. The multi-parameter detection component integrates laser displacement, ultrasonic flaw detection, and visual inspection functions, which can simultaneously acquire multiple parameters such as wear, cracks, and tooth surface fatigue of the gear ring, enabling a comprehensive assessment of the gear ring's operating status. The displacement adjustment mechanism in the detection unit can flexibly adjust the position of the multi-parameter detection component to ensure that the detection end maintains a suitable detection distance from the pitch gear ring.

[0016] 3. The control unit can coordinate the control of various components, improve the automation of the testing process, reduce the cost of manual intervention, ensure the safety and reliability of the testing process, and help to detect gear ring faults in a timely manner and take maintenance measures, thereby improving the power generation efficiency and operational safety of wind turbine units. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the embodiments will be briefly described below.

[0018] Figure 1 This is a schematic diagram of the structure of the utility model and the pitch gear ring. Figure 1 ;

[0019] Figure 2 This is a schematic diagram of the structure of the utility model and the pitch gear ring. Figure 2 ;

[0020] Figure 3 This is a schematic diagram of the structure of this utility model. Figure 1 ;

[0021] Figure 4 This is a schematic diagram of the structure of this utility model. Figure 2 ;

[0022] Figure 5 yes Figure 4 Schematic diagram of the structure of part AA;

[0023] The attached diagram shows the following components: 1. Mounting base; 2. Detection frame; 3. Detection unit; 31. Displacement adjustment mechanism; 311. Lateral adjustment module; 3111. Adjustment slide rail; 3112. Adjustment slider; 3113. Lateral adjustment drive component; 312. Longitudinal adjustment module; 3121. Longitudinal adjustment drive component; 3122. Slide bar; 3123. Roller; 3124. Elastic component; 3125. Guide column; 3126. Guide groove; 32. Multi-parameter detection component; 321. Laser displacement sensor; 322. Ultrasonic flaw detection sensor; 323. Visual inspection camera; 33. Illumination component; 4. Cleaning assembly; 41. Cleaning bracket; 42. Cleaning actuator; 421. Cleaning roller; 422. Brush bristles; 43. Cleaning drive component; 44. Connecting rod; 45. Collection box; 46. Air extraction component; 47. Exhaust duct. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0025] like Figures 1 to 2As shown in the figure, a wind turbine pitch gear ring testing device according to an embodiment of the present invention includes a mounting base 1, a testing frame 2, a testing unit 3, a cleaning component 4, and a control unit. The testing frame 2 is fixedly mounted on the mounting base 1 by welding or connecting with connectors. The mounting base 1 can be fixed to the fixed structure of the wind turbine pitch system by magnetic attraction or mechanical clamping to ensure the stability of the overall device. The testing unit 3 and the cleaning component 4 are both arranged on the testing frame 2, and the cleaning component 4 is located in front of the testing unit 3 along the rotation direction of the pitch gear ring. This arrangement allows the cleaning component 4 to remove surface impurities before the testing unit 3 contacts the gear ring, avoiding impurities from interfering with the testing accuracy. The control unit is connected to the testing unit 3 and the cleaning component 4 and can be automated using a PLC controller. The detection unit 3 includes a displacement adjustment mechanism 31 and a multi-parameter detection element 32. The displacement adjustment mechanism 31 is mounted on the detection frame 2, and the multi-parameter detection element 32 is mounted on the displacement adjustment mechanism 31. The detection end of the multi-parameter detection element 32 faces the pitch gear ring. The displacement adjustment mechanism 31 can drive the multi-parameter detection element 32 to adjust its position, ensuring that the detection end maintains the optimal detection distance with the surface of the gear ring. The cleaning component 4 includes a cleaning bracket 41, a cleaning actuator 42, and a cleaning drive 43. The cleaning bracket 41 is connected to the displacement adjustment mechanism 31 through a connecting rod 44, enabling it to move synchronously with the detection unit 3. The cleaning actuator 42 is mounted on the cleaning bracket 41 and can be a geared motor. Its output end is connected to the cleaning actuator 42, driving the cleaning actuator 42 to rotate. The cleaning end of the cleaning actuator 42 faces the pitch gear ring. It is understandable that the mounting base 1 is rigidly connected to the fixed structure of the wind turbine, so the whole device maintains a fixed position in physical space. However, by linking the control unit with the pitch control system of the wind turbine, the dynamic adaptation of the detection position is achieved by using the rotational motion of the pitch gear ring generated by the pitching action of the blades, combined with the displacement adjustment mechanism 31. This enables the detection to cover the entire circumference of the pitch gear ring.

[0026] like Figure 3As shown, the displacement adjustment mechanism 31 includes a lateral adjustment module 311 and a longitudinal adjustment module 312. The lateral adjustment module 311 includes an adjustment slide rail 3111, an adjustment slider 3112, and a lateral adjustment drive component 3113. The adjustment slide rail 3111 is fixed on the detection frame 2, and the adjustment slider 3112 is slidably fitted on the adjustment slide rail 3111. The lateral adjustment drive component 3113 can be an electric telescopic rod or a servo motor combined with a ball screw, etc. Its output end is connected to the adjustment slider 3112, which can drive the adjustment slider 3112 to move along the length of the slide rail, thereby realizing the lateral position adjustment of the components connected to the adjustment slider 3112. The longitudinal adjustment module 312 includes a longitudinal adjustment drive 3121, a slide bar 3122, a roller 3123, and an elastic element 3124. The longitudinal adjustment drive 3121 is fixedly connected to the adjustment slider 3112, and the slide bar 3122 is connected to the output end of the longitudinal adjustment drive 3121. The longitudinal adjustment drive 3121 can be selected with the same or different structure as the transverse adjustment drive 3113 to realize the longitudinal position adjustment of the slide bar 3122. The roller 3123 is rotatably mounted on the bottom of the slide bar 3122 and can contact the end face of the gear ring to achieve guiding and positioning. The elastic element 3124 can be a compression spring, which is sleeved on the outside of the slide bar 3122 to provide buffer pressure for the roller 3123 and ensure longitudinal fit stability.

[0027] To limit the radial wobble of the slide bar 3122, such as Figure 5 As shown, the output end of the longitudinal adjustment drive 3121 is provided with a guide post 3125, and the guide post 3125 is provided with a guide groove 3126 corresponding to the slide rod 3122; the cooperation between the guide post 3125 and the guide groove 3126 can provide precise guidance for the longitudinal movement of the slide rod 3122 and improve the stability of the longitudinal adjustment.

[0028] like Figure 5As shown, the multi-parameter detection component 32 includes a laser displacement sensor 321, an ultrasonic flaw detection sensor 322, and a visual inspection camera 323. All three are fixedly connected to the adjusting slider 3112 and arranged sequentially along the rotation direction of the pitch gear ring. The laser displacement sensor 321 is located at the top of the guide groove 3126. The roller 3123 at the bottom of the slider 3122 is always in contact with the end face of the gear ring. When there is end face runout of the gear ring, the slider 3122 will slide up and down along the guide groove 3126. At this time, the laser displacement sensor 321 can simultaneously detect the displacement change at the top of the slider 3122. The system uses an ultrasonic flaw detector 322 to indirectly measure the distance to the tooth ring surface, thereby detecting the amount of tooth surface wear. The ultrasonic flaw detector 322 emits high-frequency ultrasonic waves to the tooth ring surface. When the ultrasonic waves propagate inside the tooth ring, they will be reflected or refracted when they encounter defects such as cracks and fatigue layers. After receiving the reflected signals, the sensor analyzes the time, amplitude and other characteristics of the signals to determine the location and size of the defects. The visual inspection camera 323 acquires optical images of the tooth ring surface through the lens and analyzes the appearance defects of the tooth surface by combining image processing algorithms. The three together realize the comprehensive detection of defects on the surface and inside of the tooth ring.

[0029] To optimize visual inspection results, such as Figure 5 As shown, the detection unit 3 also includes an illumination element 33, which is fixedly connected to the adjustment slider 3112 and located on one side of the visual inspection camera 323. Its illumination direction is towards the detection area. The illumination element 33 can use a ring light to provide a uniform and stable lighting environment, avoid and eliminate the problem of uneven image brightness caused by ambient light interference, ensure that the visual inspection camera 323 can clearly capture the detailed features of the tooth surface, and improve the accuracy of surface defect identification.

[0030] like Figure 5 As shown, the cleaning actuator 42 includes a cleaning roller 421 and detachable bristles 422. The two ends of the cleaning roller 421 are rotatably connected to the cleaning bracket 41. The detachable bristles 422 are wrapped around the outside of the cleaning roller 421 using Velcro or snap fasteners for easy periodic cleaning or replacement. During cleaning, the bristles 422 rotate synchronously with the cleaning roller 421. Dynamic cleaning is achieved through the flexible contact between the bristles 422 and the tooth surface, effectively removing dust, oil, rust, and other impurities adhering to the tooth surface without damaging it.

[0031] To prevent dust from being stirred up during the cleaning process, the cleaning bracket 41 and the cleaning roller 421 form a semi-enclosed structure to prevent impurities from spreading to the cleaned area or the detection area and causing secondary pollution, thereby improving the stability of the cleaning effect.

[0032] To achieve clean waste collection, such as Figure 2As shown, the cleaning component 4 also includes a collection box 45, an air extraction component 46, and an air duct 47. The two sides of the collection box 45 are connected to one end of the air extraction component 46 and one end of the air duct 47, respectively. The other end of the air duct 47 extends through the cleaning bracket 41 to the side near the bristles 422. The air extraction component 46 creates negative pressure in the cleaning area through the air duct 47, which can immediately suck away dust and debris raised during the cleaning process, preventing impurities from re-attaching to the tooth surface after being suspended. The collection box 45 can centrally store the sucked-in impurities, which can be cleaned periodically, preventing impurities from scattering randomly and causing secondary pollution, thus maintaining a clean testing environment.

[0033] The above are all preferred embodiments of this utility model, and are not intended to limit the scope of protection of this utility model. Therefore, all equivalent changes made to the structure, shape and principle of this utility model should be covered within the scope of protection of this utility model.

Claims

1. A wind turbine pitch gear ring testing device, characterized in that, The system includes a mounting base (1), a testing frame (2), a testing unit (3), a cleaning component (4), and a control unit. The testing frame (2) is mounted on the mounting base (1), and the testing unit (3) and the cleaning component (4) are both mounted on the testing frame (2). The cleaning component (4) is located in front of the testing unit (3) along the rotation direction of the pitch gear ring. The control unit is connected to the testing unit (3) and the cleaning component (4). The testing unit (3) includes a displacement adjustment mechanism (31) and a multi-parameter testing element (32). The displacement adjustment mechanism (31) is mounted on the testing unit. On the frame (2), the multi-parameter detection element (32) is mounted on the displacement adjustment mechanism (31), and the detection end of the multi-parameter detection element (32) faces the pitch gear ring; the cleaning component (4) includes a cleaning bracket (41), a cleaning actuator (42) and a cleaning drive (43), the cleaning bracket (41) is connected to the displacement adjustment mechanism (31) through a connecting rod (44), the cleaning actuator (42) is mounted on the cleaning bracket (41), the output end of the cleaning drive (43) is connected to the cleaning actuator (42), and the cleaning end of the cleaning actuator (42) faces the pitch gear ring.

2. The wind turbine pitch gear ring testing device as described in claim 1, characterized in that, The displacement adjustment mechanism (31) includes a lateral adjustment module (311) and a longitudinal adjustment module (312); the lateral adjustment module (311) includes an adjustment slide rail (3111), an adjustment slider (3112), and a lateral adjustment drive (3113). The adjustment slide rail (3111) is fixed on the detection frame (2), the adjustment slider (3112) is slidably fitted on the adjustment slide rail (3111), and the lateral adjustment drive (3113) drives the adjustment slider (3112) to move. The longitudinal adjustment module (312) includes a longitudinal adjustment drive (3121), a slide bar (3122), a roller (3123), and an elastic element (3124). The longitudinal adjustment drive (3121) is fixedly connected to the adjustment slider (3112). The slide bar (3122) is connected to the output end of the longitudinal adjustment drive (3121). The roller (3123) is rotatably mounted on the bottom of the slide bar (3122). The elastic element (3124) is sleeved on the outside of the slide bar (3122).

3. The wind turbine pitch gear ring testing device as described in claim 2, characterized in that, The output end of the longitudinal adjustment drive (3121) is provided with a guide post (3125), and the guide post (3125) is provided with a guide groove (3126) corresponding to the slide rod (3122).

4. The wind turbine pitch gear ring testing device as described in claim 3, characterized in that, The multi-parameter detection component (32) includes a laser displacement sensor (321), an ultrasonic flaw detection sensor (322), and a visual inspection camera (323). All three are fixedly connected to the adjusting slider (3112) and arranged sequentially along the rotation direction of the pitch gear ring. The laser displacement sensor (321) is located at the top of the guide groove (3126).

5. The wind turbine pitch gear ring testing device as described in claim 4, characterized in that, The detection unit (3) also includes an illumination element (33), which is fixedly connected to the adjustment slider (3112) and located on one side of the visual inspection camera (323), with its illumination direction facing the detection area.

6. The wind turbine pitch gear ring testing device as described in claim 1, characterized in that, The cleaning actuator (42) includes a cleaning roller (421) and detachable bristles (422). The two ends of the cleaning roller (421) are rotatably connected to the cleaning bracket (41), and the detachable bristles (422) cover the outside of the cleaning roller (421).

7. The wind turbine pitch gear ring testing device as described in claim 6, characterized in that, The cleaning support (41) and the cleaning roller (421) form a semi-enclosed structure.

8. The wind turbine pitch gear ring testing device as described in claim 6, characterized in that, The cleaning assembly (4) also includes a collection box (45), an air extraction component (46), and an air duct (47); the two sides of the collection box (45) are respectively connected to one end of the air extraction component (46) and one end of the air duct (47), and the other end of the air duct (47) extends through the cleaning bracket (41) to the side near the bristles (422).

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